LED-BASED EMERGENCY LIGHTING EQUIPMENT AND METHODOLOGY

• US 20170250569A1
• Filed: 05/17/2017
• Published: 08/31/2017
• Est. Priority Date: 08/29/2011
• Status: Active Grant

• Current Assignee: Hubbell Lighting Incorporated (Hubbell, Inc.)
• Original Assignee: Hubbell, Inc.
• Inventors: Han, Lei, Lane, John Evan
• Granted Patent: US 10,794,555 B2
• Time in Patent Office: Days
• CPC Class Codes: F21S 9/022 Emergency lighting devices
• CPC Class Codes: F21V 21/30 Pivoted housings or frames
• CPC Class Codes: F21V 29/507 of means for protecting lighting devices from damage, e.g. housings
• CPC Class Codes: F21V 29/74 with fins or blades
• CPC Class Codes: F21Y 2115/10 Light-emitting diodes [LED]
• CPC Class Codes: H02J 2207/20 Charging or discharging characterised by the power electronics converter
• CPC Class Codes: H02J 7/0013 acting upon several batteries simultaneously or sequentially H02J7/1423 takes precedence
• CPC Class Codes: H02J 7/0071 with a programmable schedule
• CPC Class Codes: H02J 7/00712 the cycle being controlled or terminated in response to electric parameters
• CPC Class Codes: H02J 7/00714 in response to battery charging or discharging current
• CPC Class Codes: H02J 7/02 for charging batteries from ac mains by converters
• CPC Class Codes: H02J 7/04 Regulation of charging current or voltage
• CPC Class Codes: H02J 9/061 for DC powered loads
• CPC Class Codes: H03K 5/24 the characteristic being amplitude
• CPC Class Codes: H05B 45/56 involving measures to prevent abnormal temperature of the LEDs

Abstract

Systems and methods provide LED-based emergency lighting utilizing AC-DC switch mode power conversion technology, NiMH battery technology, and emergency lighting lamps that use high power white LEDs as the emergency lighting source. A low voltage microprocessor based circuit design reduces the battery input voltage for the unit to a nominal level of 2.4VDC. The microprocessor executes a pulse charging algorithm to lower battery maintenance mode power consumption levels and extend the useful life of the battery. Brownout detection technology does not require the determination of the AC input voltage level or transmission of the brownout detection signal to the secondary side of the circuit. A rechargeable battery is charged by a charge current selectively set to a bulk charge value, a trickle charge high value, or a trickle charge low value based on sampling of the voltage of the rechargeable battery and the charge current.

Claims

1. An emergency lighting system comprising:

an AC-DC switch mode power converter;

a brown-out detection circuit for detecting a change in AC voltage and determining a brown-out state by reference to preset threshold values;

a rechargeable battery;

a charger circuit for charging said battery and operatively coupled to said AC-DC switch mode power converter;

at least one LED lighting source powered by said battery upon determination of said brown-out state; and

a microprocessor powered by said battery and executing a pulse charging algorithm to selectively change said battery power consumption levels and control said charger circuit for selectively charging said battery.

2. The system of claim 1, wherein said microprocessor is powered by said battery upon determination of said brown-out state.

3. The system of claim 1, wherein said microprocessor executes said pulse charging algorithm to lower battery maintenance mode power consumption levels.

4. The system of claim 2, wherein said microprocessor is powered by said battery at a level of about 3 Volts Direct Current (VDC) or less.

5. The system of claim 1, wherein said microprocessor comprises a general purpose microcontroller integrating DC-DC controller operational requirements and AC line loss detection, said AC line loss detection being indicative of said change in AC voltage for determining said brown-out state.

6. The system of claim 1, wherein said pulse charging algorithm supports multiple charging modes for said battery including at least one of a maintenance charge state and a bulk charge state.

7. The system of claim 6, wherein said executing said pulse charging algorithm comprises an initialization state including

disabling battery charging,

resetting a status of said rechargeable battery to indicate that said rechargeable battery is not fully charged, and

resetting a charger fault delay time, a battery fault delay time, a battery absent delay time.

8. The system of claim 7, wherein said executing said pulse charging algorithm further comprises

if a charge current of said charger circuit is greater than a current threshold value for longer than a first time period, shifting to a state indicative of a fault condition of said charger circuit, and shifting to said initialization state after waiting for said charger fault delay time;

and

if said charge current of said charger circuit is less than or equal to said current threshold value, sampling and storing a charge current amplifier output offset, and shifting to a check cell state.

9. The system of claim 8, wherein said check cell state comprises

if a voltage of said rechargeable battery is higher than a voltage threshold value for longer than a second time period, shifting to a state indicative of a fault condition of said rechargeable battery, and shifting to said initialization state after waiting for said battery fault delay time;

and

if said voltage of said rechargeable battery is less than or equal to said voltage threshold value, shifting to said bulk charge state.

10. The system of claim 9, wherein said voltage threshold value is proportional to a number of cells of said rechargeable battery.

11. The system of claim 9, wherein said bulk charge state comprises

setting a charge current to a bulk charge value;

and

enabling charging of said rechargeable battery by said charge current via said charger circuit.

12. The system of claim 11, wherein said bulk charge state further comprises

if said voltage of said rechargeable battery is lower than a low voltage threshold value for longer than a third time period, disabling said charger circuit and shifting to said state indicative of said fault condition of said rechargeable battery;

and

shifting to said initialization state after waiting for said battery fault delay time.

13. The system of claim 11, wherein said bulk charge state further comprises

if said voltage of said rechargeable battery is higher than said voltage threshold value and said charge current of said charger circuit is less than said current threshold value for longer than said second time period, shifting to a state indicative of an absence of said rechargeable battery;

and

shifting to said initialization state after waiting for said battery absent delay time.

14. The system of claim 11, wherein said bulk charge state further comprises

if said voltage of said rechargeable battery is higher than said voltage threshold value and said charge current of said charger circuit is greater than said current threshold value for longer than said second time period, shifting to said state indicative of said fault condition of said rechargeable battery;

and

shifting to said initialization state after waiting for said battery fault delay time.

15. The system of claim 11, wherein said bulk charge state further comprises

if said voltage of said rechargeable battery is greater than or equal to a low voltage threshold value and less than or equal to said voltage threshold value and said charge current of said charger circuit is outside a certain range of said bulk charge value for longer than a fourth time period, shifting to said state indicative of said fault condition of said charger circuit;

and

shifting to said initialization state after waiting for said charger fault delay time.

16. The system of claim 15, wherein said certain range is within about +/−

10% of said bulk charge value.

17. The system of claim 11, wherein said bulk charge state further comprises

if said voltage of said rechargeable battery is greater than or equal to a low voltage threshold value and less than or equal to said voltage threshold value and said charge current of said charger circuit is within a certain range of said bulk charge value, checking at bulk charge check time intervals a duration of said bulk charge state;

and

if said duration of said bulk charge state is greater than or equal to a bulk charge time expiration period, shifting to a trickle charge low state.

18. The system of claim 17, wherein said bulk charge time expiration period is about 10 hours and said certain range is within about +/−

10% of said bulk charge value.

19. The system of claim 17, wherein each of said bulk charge check time intervals is about 1 millisecond.

20. The system of claim 17, wherein said trickle charge low state further comprises

disabling said charger circuit;

if said voltage of said rechargeable battery is lower than said trickle charge threshold value for a fifth time period, shifting to said state indicative of said fault condition of said rechargeable battery; and

shifting to said initialization state after waiting for said battery fault delay time.

21. The system of claim 20, wherein said trickle charge threshold value is proportional to a number of cells of said rechargeable battery.

22. The system if claim 17, wherein said trickle charge low state further comprises

if said voltage of said rechargeable battery is higher than said voltage threshold value for longer than said second time period, shifting to said state indicative of said fault condition of said rechargeable battery;

and

shifting to said initialization state after waiting for said battery fault delay time.

23. The system of claim 17, wherein said trickle charge low state further comprises

if said charge current of said charger circuit is greater than said current threshold value for longer than said first time period, shifting to said state indicative of said fault condition of said charger circuit;

and

shifting to said initialization state after waiting for said charger fault delay time.

24. The system of claim 17, wherein said trickle charge low state further comprises

if said current of said charger circuit is less than or equal to said current threshold value, checking at trickle charge low check time intervals a duration of said trickle charge low state;

and

if said duration of said trickle charge low state is greater than or equal to a trickle charge low time expiration period, shifting to a trickle charge high state.

25. The system of claim 24, wherein said trickle charge high state comprises

setting said charge current to a trickle charge high value;

enabling charging of said rechargeable battery by said charge current via said charger circuit;

if said voltage of said rechargeable battery is lower than a low voltage threshold value for longer than a third time period, disabling said charger circuit and shifting to said state indicative of said fault condition of said rechargeable battery; and

shifting to said initialization state after waiting for said battery fault delay time.

26. The system of claim 24, wherein said trickle charge high state further comprises

if said voltage of said rechargeable battery is higher than said voltage threshold value and said charge current of said charger circuit is less than said current threshold value for longer than said second time period, shifting to a state indicative of an absence of said rechargeable battery;

and

shifting to said initialization state after waiting for said battery absent delay time.

27. The system of claim 24, wherein said trickle charge high state further comprises

if said voltage of said rechargeable battery is higher than said voltage threshold value and said charge current of said charger circuit is greater than said current threshold value for longer than said second time period, shifting to said state indicative of said fault condition of said rechargeable battery;

and

shifting to said initialization state after waiting for said battery fault delay time.

28. The system of claim 24, wherein said trickle charge high state further comprises

if said voltage of said rechargeable battery is greater than or equal to a low voltage threshold value and less than or equal to said voltage threshold value and said charge current of said charger circuit is outside a certain range of said trickle charge high value for longer than a fourth time period, shifting to said sate indicative of said fault condition of said charger circuit;

and

shifting to said initialization state after waiting for said charger fault delay time.

29. The system of claim 28, wherein said certain range is within about +/−

10% of said trickle charge high value.

30. The system of claim 24, wherein said trickle charge high state further comprises

if said voltage of said rechargeable battery is greater than or equal to a low voltage threshold value and less than or equal to said voltage threshold value and said charge current of said charger circuit is within a certain range of said trickle charge high value, checking at trickle charge high check time intervals a duration of said trickle charge high state;

and

if said duration of said trickle charge high state is greater than or equal to a trickle charge high time expiration period, shifting to said trickle charge low state.

31. The system of claim 7, wherein said executing said pulse charging algorithm further comprises

if AC power is absent, shifting to an emergency state;

and

when the AC power is restored, resetting said battery charger state and starting said charger circuit from said initialization state.

32. The system of claim 9, wherein said executing said bulk charge state further comprises

checking said voltage of said rechargeable battery, storing peak values of said voltage, and calculating a delta V/delta t value of said voltage;

if said delta V/delta t value is less than or equal to about zero for a first conditional time period, shifting to a trickle charge low state; and

if during a second conditional time period said delta V/delta t value is not less than or equal to about zero for said first conditional time period, shifting to said trickle charge low state,

wherein V is said voltage of said rechargeable battery, and t is time.

33. The system of claim 1, wherein said charger circuit comprises an AC-DC switch-mode fly-back converter.

34. The system of claim 10, wherein said voltage threshold value is about 1.65V multiplied by N, where N is equal to a number of cells of said rechargeable battery.

35. The system of claim 21, wherein said trickle charge threshold value is about 1.2 V multiplied by N, where N is equal to a number of cells of said rechargeable battery.

36. The system of claim 1, wherein said preset threshold values include a threshold voltage level and an internal brown-out threshold value, said AC voltage has a first nominal input voltage value or a second nominal input voltage value, and said brown-out detection circuit includes

a voltage sensing circuit sensing said AC voltage, said voltage sensing circuit including an output outputting a reference direct current (DC) voltage proportional said AC voltage,

a first circuit responsive to said output of said voltage sensing circuit, said first circuit including a first output outputting a first voltage value when said AC voltage is below said threshold voltage level and a second voltage value when said AC voltage is above said threshold level, and

a second circuit responsive to said first output of said first circuit, said second circuit including a second output outputting a second control signal indicative of said determination of said brown-out state based on said first or second voltage value output of said first circuit and said internal brown-out threshold value.

37. A brown-out detection apparatus comprising:

a voltage sensing circuit sensing an input AC voltage, said input AC voltage having a first nominal input voltage value or a second nominal input voltage value, said voltage sensing circuit including an output outputting a reference DC voltage proportional said input AC voltage;

a first circuit responsive to said output of said voltage sensing circuit, said first circuit including a first output outputting a first voltage value when said input AC voltage is below a threshold voltage level and a second voltage value when said input AC voltage is above said threshold level; and

a second circuit responsive to said first output of said first circuit, said second circuit including a second output outputting a second control signal indicative of a brown-out condition of said input AC voltage based on said first or second voltage value output of said first circuit and an internal brown-out threshold value.

38. The apparatus of claim 37, wherein said threshold voltage level has a value above a high line condition for said first nominal input voltage value of said input AC voltage and below a low line condition for said second nominal input voltage value of said input AC voltage.

39. The apparatus of claim 38, wherein said first nominal value of said input AC voltage is about 120 Volts, and said second nominal value of said input AC voltage is about 277 Volts.

40. The apparatus of claim 37, wherein said voltage sensing circuit includes a full wave rectifying circuit for rectifying said input AC voltage and outputting a bulk DC voltage, and said reference DC voltage is proportional said bulk DC voltage.

41. The apparatus of claim 40, further comprising a first voltage divider circuit receiving said bulk DC voltage and outputting said reference DC voltage,

said first circuit including a first integrated circuit and a second voltage divider circuit, said first integrated circuit outputting a first control signal based on said reference DC voltage and said threshold voltage level, and

said second voltage divider circuit responsive to said first control signal selectively outputting said first voltage value or said second voltage value.

42. The apparatus of claim 41, wherein said second circuit includes a second integrated circuit having a fly-back control circuit selectively turned on or off based on said internal brown-out threshold value and in response to said first or second voltage value output of said second voltage divider circuit.

43. The apparatus of claim 41, wherein said internal brown-out threshold value is based on characteristics of said fly-back control circuit.

44. A brown-out detection method comprising:

sensing an input AC voltage having a first nominal input voltage value or a second nominal input voltage value;

outputting a reference DC voltage proportional said input AC voltage;

outputting in response to said reference DC voltage a first voltage value when said input AC voltage is below a threshold voltage level, or a second voltage value when said input AC voltage is above said threshold level; and

outputting a second control signal indicative of a brown-out condition of said input AC voltage based on said first or second voltage value and an internal brown-out threshold value.

45. The method of claim 44, wherein said threshold voltage level has a value above a high line condition for said first nominal input voltage value of said input AC voltage and below a low line condition for said second nominal input voltage value of said input AC voltage.

46. The method of claim 44, further comprising:

configuring a voltage sensing circuit for said sensing said input AC voltage, said voltage sensing circuit including an output for said outputting of said reference DC voltage proportional said input AC voltage;

configuring a first circuit connected to said output of said voltage sensing circuit, said first circuit including a first output for said outputting of said first voltage value when said input AC voltage is below said threshold voltage level and said second voltage value when said input AC voltage is above said threshold level; and

configuring a second circuit responsive to said first output of said first circuit, said second circuit including a second output for said outputting of said second control signal indicative of said brown-out condition of said input AC voltage based on said first or second voltage value output of said first circuit and said internal brown-out threshold value.

47. The method of claim 46, wherein said voltage sensing circuit includes a full wave rectifying circuit for rectifying said input AC voltage and outputting a bulk DC voltage, and said reference DC voltage is proportional said bulk DC voltage.

48. The method of claim 47, further comprising configuring a first voltage divider circuit receiving said bulk DC voltage and outputting said reference DC voltage,

said first circuit including a first integrated circuit and a second voltage divider circuit,

said first integrated circuit outputting a first control signal based on said reference DC voltage and said threshold voltage level, and

said second voltage divider circuit responsive to said first control signal selectively outputting said first voltage value or said second voltage value.

49. The method of claim 48, wherein said second circuit includes a second integrated circuit having a fly-back control circuit selectively turned on or off based on said internal brown-out threshold value and in response to said first or second voltage value output of said second voltage divider circuit.

50. The method of claim 48, wherein said internal brown-out threshold value is based on characteristics of said fly-back control circuit.