A Novel Boost Converter Based LED Driver Chip Targeting Mobile Applications

abstract: A novel integrated constant current LED driver design on a single chip is developed in this dissertation. The entire design consists of two sections. The first section is a DC-DC switching regulator (boost regulator) as the frontend power supply; the second section is the constant current LED driver system. In the first section, a pulse width modulated (PWM) peak current mode boost regulator is utilized. The overall boost regulator system and its related sub-cells are explained. Among them, an original error amplifier design, a current sensing circuit and slope compensation circuit are presented. In the second section – the focus of this dissertation – a highly accurate constant current LED driver system design is unveiled. The detailed description of this highly accurate LED driver system and its related sub-cells are presented. A hybrid PWM and linear current modulation scheme to adjust the LED driver output currents is explained. The novel design ideas to improve the LED current accuracy and channel-to-channel output current mismatch are also explained in detail. These ideas include a novel LED driver system architecture utilizing 1) a dynamic current mirror structure and 2) a closed loop structure to keep the feedback loop of the LED driver active all the time during both PWM on-duty and PWM off-duty periods. Inside the LED driver structure, the driving amplifier with a novel slew rate enhancement circuit to dramatically accelerate its response time is also presented.Dissertation/ThesisDoctoral Dissertation Electrical Engineering 201

Design Techniques of Highly Integrated Hybrid-Switched-Capacitor-Resonant Power Converters for LED Lighting Applications

The Light-emitting diodes (LEDs) are rapidly emerging as the dominant light source given their high luminous efficacy, long lift span, and thanks to the newly enacted efficiency standards in favor of the more environmentally-friendly LED technology. The LED lighting market is expected to reach USD 105.66 billion by 2025. As such, the lighting industry requires LED drivers, which essentially are power converters, with high efficiency, wide input/output range, low cost, small form factor, and great performance in power factor, and luminance flicker. These requirements raise new challenges beyond the traditional power converter topologies. On the other hand, the development and improvement of new device technologies such as printed thin-film capacitors and integrated high voltage/power devices opens up many new opportunities for mitigating such challenges using innovative circuit design techniques and solutions. Almost all electric products needs certain power delivery, regulation or conversion circuits to meet the optimized operation conditions. Designing a high performance power converter is a real challenge given the market’s increasing requirements on energy efficiency, size, cost, form factor, EMI performance, human health impact, and so on. The design of a LED driver system covers from high voltage AC/DC and DC/DC power converters, to high frequency low voltage digital controllers, to power factor correction (PFC) and EMI filtering techniques, and to safety solutions such as galvanic isolation. In this thesis, we study design challenges and present corresponding solutions to realize highly integrated and high performance LED drivers combining switched-capacitor and resonant converters, applying re-configurable multi-level circuit topology, utilizing sigma delta modulation, and exploring capacitive galvanic isolation. A hybrid switched-capacitor-resonant (HSCR) LED driver based on a stackable switched-capacitor (SC) converter IC rated for 15 to 20 W applications. Bulky transformers have been replaced with a SC ladder to perform high-efficiency voltage step-down conversion; an L-C resonant output network provides almost lossless current regulation and demonstrates the potential of capacitive galvanic isolation. The integrated SC modules can be stacked in the voltage domain to handle a large range of input voltage ranges that largely exceed the voltage limitation of the medium-voltage-rated 120 V silicon technology. The LED driver demonstrates > 91% efficiency over a rectified input DC voltage range from 160 VDC to 180 VDC with two stacked ICs; using a stack of four ICs > 89.6% efficiency is demonstrated over an input range from 320 VDC to 360 VDC . The LED driver can dim its output power to around 10% of the rated power while maintaining >70% efficiency with a PWM controlled clock gating circuit. Next, the design of AC main rectifier and inverter front end with sigma delta modulation is described. The proposed circuits features a pair of sigma delta controlled multilevel converters. The first is a multilevel rectifier responsible for PFC and dimming. The second is a bidirectional multilevel inverter used to cancel AC power ripple from the DC bus. The system also contains an output stage that powers the LEDs with DC and provides for galvanic isolation. Its functional performance indicates that integrated multilevel converters are a viable topology for lighting and other similar applications

Integrated circuits for efficient power delivery using pulse-width-modulation

Circuits and architectures for efficient power delivery have become crucial in emerging smart systems. Switching power amplifiers (PA) are very attractive for such applications, because they exhibit better efficiency compared to linear PA designs, due to saturated operation. Switching PAs also allow for utilization of deep submicron CMOS technologies, due to which these designs can be easily integrated with digital circuits, and can benefit from process scaling, in performance as well as in area. Pulse-width-modulation (PWM) is commonly used with switching PAs. A PWM signal typically employs a high-frequency switching pulse waveform as a carrier signal, wherein the pulse-width or duty-cycle of each pulse is modulated by a given low-frequency input signal. The carrier frequency can vary from several kHz to GHz, and is typically determined by the target application. In this thesis, efficient power-delivery circuits that use PWM with switching class-D stages are presented. Advanced circuit techniques, as well as architectures for PWM are proposed to enhance efficiency and circumvent the limitations of conventional architectures. A digitally-intensive transmitter using RF-PWM with a class-D PA is described in the first part of the thesis. The use of carrier switching for alleviating the dynamic range limitation that can be observed in classical RF-PWM implementations is introduced. The approach employs the full carrier frequency for half of the amplitude range, and the second harmonic of half of the carrier frequency, for the remainder of the amplitude range. This concept not only allows the transmitter to drive modulated signals with large peak-to-average power ratio (PAPR), but also improves the back-off efficiency due to reduced switching losses in the half carrier-frequency mode. A glitch-free phase selector is proposed that removes the deleterious glitches that can occur at the input data transitions. The phase-selector also prevents D flip-flop setup-and-hold time violations. The transmitter has been implemented in a 130-nm CMOS process. The measured peak output power and power-added-efficiency (PAE) are 25.6 dBm and 34%, respectively. While driving 802.11g 20-MHz 64-QAM OFDM signals, the average measured output power is 18.3 dBm and the PAE is 16%, with an EVM of -25.5 dB. The second part of the thesis describes a high-speed driver that provides a PWM output using a class-D PA. A PLL-based architecture is employed which eliminates the requirement for a precise ramp or triangular signal generator, and a high-speed comparator, which are typically used for PWM generation. Multi-level signaling is proposed to enhance back-off as well as peak efficiency, which is critical for signals with high PAPR. A differential, folded PWM scheme is introduced to achieve highly linear operation. 3-level operation is achieved without the requirement for additional supply source or sink paths, while 5-level operation is achieved with additional supply source and sink paths, compared to 2-level operation. The PWM driver has been implemented in a 130-nm CMOS process and can operate with a switching frequency of 40-to-170 MHz. For 2/3/5-level PA operation, with a 500 kHz sinusoidal input and 60 MHz switching frequency, the measured THD is -61/-62/-53 dB and corresponding efficiency is 71/83/86% with 175/200/220 mW output power level, respectively. Performance has also been verified for 2/3-level PA operation with a high PAPR signal with 500 kHz bandwidth. While intended as a general purpose amplifier, the approach is well-suited for applications such as power-line communications (PLC). The final part of the thesis introduces an efficient buck/buck-boost reconfigurable LED driver that supports PWM and PFM operation. The driver is based on peak current control. Rectified sin as well as sin² functions are employed in the reference signal to improve the power factor (PF) and total harmonic distortion (THD) of the buck and buck-boost converters. The design ensures that the peak of the inductor current maintains a constant level that is invariant for different AC line voltages. The operating mode of the design can be changed between PWM and PFM. The LED driver has been implemented in a 130-nm CMOS process. PF and THD are improved when the proposed reference is employed, and peak PF and lowest THD are 0.995/0.983/0.996 and 7.8/6.2/3.5% for the buck (PWM), buck (PFM), buck-boost (PFM) cases, respectively. The corresponding peak efficiency for the three cases is 88/92/91%, respectively.Electrical and Computer Engineerin

Variable Spurious Noise Mitigation Techniques in Hysteretic Buck Converters

This work proposes a current-mode hysteretic buck converter with a spur-free constant-cycle frequency-hopping controller that fully eliminates spurs from the switching noise spectrum irrespective of variations in the switching frequency and operating conditions. As a result, the need for frequency regulation loops to ensure non-varying switching frequency (i.e. fixed spurs location) in hysteretic controllers is eliminated. Moreover, compared to frequency regulation loops, the proposed converter offers the advantage of eliminating mixing and interference altogether due to its spur-free operation, and thus, it can be used to power, or to be integrated within noise-sensitive systems while benefiting from the superior dynamic performance of its hysteretic operation. The proposed converter uses dual-sided hysteretic band modulation to eliminate the inductor current imbalance that results from frequency hopping along with the output voltage transients and low-frequency noise floor peaking associated with it. Moreover, a feedforward adaptive hysteretic band controller is proposed to reduce variations in the switching frequency with the input voltage, and an all-digital soft-startup circuit is proposed to control the in-rush current without requiring any off-chip components. The converter is implemented in a 0.35-õm standard CMOS technology and it achieves 92% peak efficiency

Using an LED as a sensor and visible light communication device in a smart illumination system

The need for more efficient illumination systems has led to the proliferation of Solid-State Lighting (SSL) systems, which offer optimized power consumption. SSL systems are comprised of LED devices which are intrinsically fast devices and permit very fast light modulation. This, along with the congestion of the radio frequency spectrum has paved the path for the emergence of Visible Light Communication (VLC) systems. VLC uses free space to convey information by using light modulation. Notwithstanding, as VLC systems proliferate and cost competitiveness ensues, there are two important aspects to be considered. State-of-the-art VLC implementations use power demanding PAs, and thus it is important to investigate if regular, existent Switched-Mode Power Supply (SMPS) circuits can be adapted for VLC use. A 28 W buck regulator was implemented using a off-the-shelf LED Driver integrated circuit, using both series and parallel dimming techniques. Results show that optical clock frequencies up to 500 kHz are achievable without any major modification besides adequate component sizing. The use of an LED as a sensor was investigated, in a short-range, low-data-rate perspective. Results show successful communication in an LED-to-LED configuration, with enhanced range when using LED strings as sensors. Besides, LEDs present spectral selective sensitivity, which makes them good contenders for a multi-colour LED-to-LED system, such as in the use of RGB displays and lamps. Ultimately, the present work shows evidence that LEDs can be used as a dual-purpose device, enabling not only illumination, but also bi-directional data communication

Hybrid monolithic integration of high-power DC-DC converters in a high-voltage technology

The supply of electrical energy to home, commercial, and industrial users has become ubiquitous, and it is hard to imagine a world without the facilities provided by electrical energy. Despite the ever increasing efficiency of nearly every electrical application, the worldwide demand for electrical power continues to increase, since the number of users and applications more than compensates for these technological improvements. In order to maintain the affordability and feasibility of the total production, it is essential for the distribution of the produced electrical energy to be as efficient as possible. In other words the loss in the power distribution is to be minimized. By transporting electrical energy at the maximum safe voltage, the current in the conductors, and the associated conduction loss can remain as low as possible. In order to optimize the total efficiency, the high transportation voltage needs to be converted to the appropriate lower voltage as close as possible to the end user. Obviously, this conversion also needs to be as efficient, affordable, and compact as possible. Because of the ever increasing integration of electronic systems, where more and more functionality is combined in monolithically integrated circuits, the cost, the power consumption, and the size of these electronic systems can be greatly reduced. This thorough integration is not limited to the electronic systems that are the end users of the electrical energy, but can also be applied to the power conversion itself. In most modern applications, the voltage conversion is implemented as a switching DC-DC converter, in which electrical energy is temporarily stored in reactive elements, i.e. inductors or capacitors. High switching speeds are used to allow for a compact and efficient implementation. For low power levels, typically below 1 Watt, it is possible to monolithically implement the voltage conversion on an integrated circuit. In some cases, this is even done on the same integrated circuit that is the end user of the electrical energy to minimize the system dimensions. For higher power levels, it is no longer feasible to achieve the desired efficiency with monolithically integrated components, and some external components prove indispensable. Usually, the reactive components are the main limiting factor, and are the first components to be moved away from the integrated circuit for increasing power levels. The semiconductor components, including the power transistors, remain part of the integrated circuit. Using this hybrid approach, it is possible in modern converterapplications to process around 60 Watt, albeit limited to voltages of a few Volt. For hybrid integrated converters with an output voltage of tens of Volt, the power is limited to approximately 10 Watt. For even higher power levels, the integrated power transistors also become a limiting factor, and are replaced with discrete power devices. In these discrete converters, greatly increased power levels become possible, although the system size rapidly increases. In this work, the limits of the hybrid approach are explored when using so-called smart-power technologies. Smart-power technologies are standard lowcost submicron CMOS technologies that are complemented with a number of integrated high-voltage devices. By using an appropriate combination of smart-power technologies and circuit topologies, it is possible to improve on the current state-of-the-art converters, by optimizing the size, the cost, and the efficiency. To determine the limits of smart-power DC-DC converters, we first discuss the major contributing factors for an efficient energy distribution, and take a look at the role of voltage conversion in the energy distribution. Considering the limitations of the technologies and the potential application areas, we define two test-cases in the telecommunications sector for which we want to optimize the hybrid monolithic integration in a smart-power technology. Subsequently, we explore the specifications of an ideal converter, and the relevant properties of the affordable smart-power technologies for the implementation of DC-DC converters. Taking into account the limitations of these technologies, we define a cost function that allows to systematically evaluate the different potential converter topologies, without having to perform a full design cycle for each topology. From this cost function, we notice that the de facto default topology selection in discrete converters, which is typically based on output power, is not optimal for converters with integrated power transistors. Based on the cost function and the boundary conditions of our test-cases, we determine the optimal topology for a smart-power implementation of these applications. Then, we take another step towards the real world and evaluate the influence of parasitic elements in a smart-power implementation of switching converters. It is noticed that the voltage overshoot caused by the transformer secondary side leakage inductance is a major roadblock for an efficient implementation. Since the usual approach to this voltage overshoot in discrete converters is not applicable in smart-power converters due to technological limitations, an alternative approach is shown and implemented. The energy from the voltage overshoot is absorbed and transferred to the output of the converter. This allows for a significant reduction in the voltage overshoot, while maintaining a high efficiency, leading to an efficient, compact, and low-cost implementation. The effectiveness of this approach was tested and demonstrated in both a version using a commercially available integrated circuit, and our own implementation in a smart-power integrated circuit. Finally, we also take a look at the optimization of switching converters over the load range by exploiting the capabilities of highly integrated converters. Although the maximum output power remains one of the defining characteristics of converters, it has been shown that most converters spend a majority of their lifetime delivering significantly lower output power. Therefore, it is also desirable to optimize the efficiency of the converter at reduced output current and output power. By splitting the power transistors in multiple independent segments, which are turned on or off in function of the current, the efficiency at low currents can be significantly improved, without introducing undesirable frequency components in the output voltage, and without harming the efficiency at higher currents. These properties allow a near universal application of the optimization technique in hybrid monolithic DC-DC converter applications, without significant impact on the complexity and the cost of the system. This approach for the optimization of switching converters over the load range was demonstrated using a boost converter with discrete power transistors. The demonstration of our smart-power implementation was limited to simulations due to an issue with a digital control block. On a finishing note, we formulate the general conclusions and provide an outlook on potential future work based on this research

Doctor of Philosophy

dissertationMicroelectromechanical systems (MEMS) resonators on Si have the potential to replace the discrete passive components in a power converter. The main intention of this dissertation is to present a ring-shaped aluminum nitride (AlN) piezoelectric microreson

Time-Domain/Digital Frequency Synchronized Hysteresis Based Fully Integrated Voltage Regulator

abstract: Power management integrated circuit (PMIC) design is a key module in almost all electronics around us such as Phones, Tablets, Computers, Laptop, Electric vehicles, etc. The on-chip loads such as microprocessors cores, memories, Analog/RF, etc. requires multiple supply voltage domains. Providing these supply voltages from off-chip voltage regulators will increase the overall system cost and limits the performance due to the board and package parasitics. Therefore, an on-chip fully integrated voltage regulator (FIVR) is required. The dissertation presents a topology for a fully integrated power stage in a DC-DC buck converter achieving a high-power density and a time-domain hysteresis based highly integrated buck converter. A multi-phase time-domain comparator is proposed in this work for implementing the hysteresis control, thereby achieving a process scaling friendly highly digital design. A higher-order LC notch filter along with a flying capacitor which couples the input and output voltage ripple is implemented. The power stage operates at 500 MHz and can deliver a maximum power of 1.0 W and load current of 1.67 A, while occupying 1.21 mm2 active die area. Thus achieving a power density of 0.867 W/mm2 and current density of 1.377 A/mm2. The peak efficiency obtained is 71% at 780 mA of load current. The power stage with the additional off-chip LC is utilized to design a highly integrated current mode hysteretic buck converter operating at 180 MHz. It achieves 20 ns of settling and 2-5 ns of rise/fall time for reference tracking. The second part of the dissertation discusses an integrated low voltage switched-capacitor based power sensor, to measure the output power of a DC-DC boost converter. This approach results in a lower complexity, area, power consumption, and a lower component count for the overall PV MPPT system. Designed in a 180 nm CMOS process, the circuit can operate with a supply voltage of 1.8 V. It achieves a power sense accuracy of 7.6%, occupies a die area of 0.0519 mm2, and consumes 0.748 mW of power.Dissertation/ThesisDoctoral Dissertation Electrical Engineering 201

Design Space Evaluation for Resonant and Hard-charged Switched Capacitor Converters

USB Power Delivery enables a fixed ratio converter to operate over a wider range of output voltages by varying the input voltage. Of the DC/DC step-down converters powered from this type of USB, the hard-charged Switched Capacitor circuit is of interest to industry for its potential high power density. However implementation can be limited by circuit efficiency. In fully resonant mode, the efficiency can be improved while also enabling current regulation. This expands the possible applications into battery chargers and eliminates the need for a two-stage converter.In this work, the trade-off in power loss and area between the hard-charged and fully resonant switched capacitor circuit is explored using a technique that remains agnostic to inductor technology. The loss model for each converter is presented as well as discussion on the restrained design space due to parasitics in the passive components. The results are validated experimentally using GaN-based prototype converters and the respective design spaces are analyzed