PWM controller with automatic low battery power reduction circuit and lighting device incorporating the controller

• US 7,196,482 B2
• Filed: 10/20/2004
• Issued: 03/27/2007
• Est. Priority Date: 04/26/2002
• Status: Expired due to Term

• Current Assignee: Vector Products Incorporated (Stanley Black & Decker, Inc.)
• Original Assignee: Vector Products Incorporated (Stanley Black & Decker, Inc.)
• Inventors: Krieger, Michael, Randolph, Bruce, Shum, Henry
• Primary Examiner(s): TRAN, THUY V
• Application Number:
  US10/968,076
• Publication Number:
  US 20050067983A1
• Time in Patent Office: 888 Days
• Field of Search: 315/295, 315/291, 315/362, 315/307, 315/DIG.7, 315/299, 315/301, 315/308, 307/106, 307/130, 307/116, 307/125
• US Class Current: 315/291
• CPC Class Codes: H05B 39/047 with pulse width modulation from a DC power source
• CPC Class Codes: H05B 41/2853 against abnormal power supply conditions
• CPC Class Codes: Y02B 20/00 Energy efficient lighting technologies, e.g. halogen lamps or gas discharge lamps

Abstract

A controller for controlling a voltage applied to a load from a power source includes a square wave producing circuit for connection in the circuit with the battery and the lamp. The square wave producing circuit produces a variable duty cycle square wave for controlling application of power to the load in accordance with the duty cycle of the square wave. The square wave producing circuit has a control input for varying the duty cycle of the square wave in response to a voltage at the control input. A voltage varying circuit is connected to the power source for producing a selectively variable voltage that is fed to the control input of the square wave producing circuit for selectively adjusting the duty cycle of the square wave. A low voltage detection circuit is connected to the power source and coupled to the control input of the square wave producing circuit for automatically producing a voltage that decreases the duty cycle of the square wave when the battery voltage decreases to or below a selected level. The selected level may be set according to a value of at least one impedance within the low voltage detection circuit.

Claims

1. A control circuit for a load, comprising:

a square wave generator producing a square wave output, a duty cycle of the square wave output being controllable by a control input of the square wave generator, the square wave output being coupled to the load; and

a low voltage detection circuit for monitoring a voltage level of a power source and providing a control signal to the control input of the square wave generator, to thereby decrease the duty cycle of the square wave output when the voltage level of the power source decreases below a selected level.

2. The control circuit of claim 1, wherein the square wave generator comprises a comparator circuit having a threshold level set by the control input.

3. The control circuit of claim 2, further comprising:

a triangular wave oscillator producing a triangle wave signal, wherein the triangle wave signal is provided as input to the square wave generator for comparison to the threshold level by the comparator circuit.

4. The control circuit of claim 1, further comprising:

manual control means for varying the control signal input to the control input of the square wave generator.

5. The control circuit of claim 1, wherein the low voltage detection circuit comprises a control transistor, wherein the control transistor is gradually turned off as the voltage level of the power source decreases below the selected level.

6. The control circuit of claim 1, further comprising a switching means to which the square wave output is provided, to thereby control application of power to the load.

7. The control circuit of claim 1, further comprising a transistor coupled to the square wave generator and arranged so as to permit and shut off input to the square wave generator.

8. The control circuit of claim 1, further comprising:

a switching circuit having a terminal connected between the power source and the load and directly connected to a biasing resistor at an output of the square wave generator.

9. The control circuit of claim 1, wherein said low voltage detection circuit comprises at least one impedance, and wherein said selected level is selected according to at least one value of said at least one impedance.

10. The control circuit according to claim 9, wherein said at least one impedance includes at least two resistors, at least two of said resistors being connected in series, wherein values of said at least two of said resistors are chosen to determine said selected level.

11. The control circuit of claim 1, wherein a decrease in said duty cycle comprises a gradual decrease in duty cycle over a majority of a range of the voltage level of said power source below said selected level.

12. A method of controlling a load, comprising:

producing a controllable variable duty cycle square wave for controlling application of power to the load in accordance with a duty cycle of the square wave; and

detecting when a voltage of a power source decreases to a selected level, and upon such detection automatically producing a voltage that decreases the duty cycle of the square wave used for controlling application of power to the load.

13. The method of claim 12, further comprising the step of:

manually controlling the duty cycle of the square wave to control an intensity of the load.

14. The method of claim 12, wherein the step of producing the controllable variable duty cycle square wave comprises the steps of:

providing a fixed frequency triangular wave; and

comparing the triangular wave to a threshold voltage, thereby producing the square wave.

15. The method of claim 14, wherein the voltage that decreases the duty cycle of the square wave, produced by the detecting step, determines the threshold voltage.

16. The method of claim 15, further comprising:

manually adjusting the voltage that decreases the duty cycle of the square wave, produced by the detecting step, so as to manually adjust the threshold voltage.

17. The method of claim 12, further comprising:

controlling a current flow through the load using a timer circuit that acts as a control signal generator.

18. The method of claim 12, further comprising:

selecting electrical component values to determine said selected level.

19. The method of claim 12, wherein said automatically producing a voltage that decreases the duty cycle of the square wave used for controlling application of power to the load comprises:

automatically producing a voltage that produces a gradual decrease in the duty cycle of the square wave used for controlling application of power to the load over a majority of a range of voltages of said power source below said selected level.

20. A pulse-width modulation (PWM)-based lamp control circuit comprising:

a square wave generator for producing a square wave output, a duty cycle of the square wave output being controllable by a control input of the square wave generator, the square wave output being coupled to a lamp; and

a low voltage detection circuit for monitoring a voltage level of a power source and providing a control signal to the control input of the square wave generator, to thereby decrease the duty cycle of the square wave output when the voltage level of the power source decreases below a selected level.

21. The control circuit of claim 20, wherein the square wave generator comprises a comparator circuit having a threshold level set by the control input.

22. The control circuit of claim 21, further comprising:

a triangular wave oscillator producing a triangle wave signal, wherein the triangle wave signal is provided as input to the square wave generator for comparison to the threshold level by the comparator circuit.

23. The control circuit of claim 20, further comprising:

manual control means for varying the control signal input from the low voltage detection circuit to the control input of the square wave generator.

24. The control circuit of claim 20, wherein the low voltage detection circuit comprises a control transistor, wherein the control transistor is gradually turned off as the voltage level of the power source decreases below the selected level.

25. The control circuit of claim 20, further comprising a switching means to which the square wave output is provided, to thereby control application of power to the lamp.

26. The control circuit of claim 25, wherein the switching means comprises a transistor, said control circuit further comprising:

a biasing resistor connected between a terminal of the power source and a base of the transistor.

27. The control circuit of claim 20, further comprising a transistor coupled to the square wave generator and arranged so as to permit and shut off input to the square wave generator.

28. A DC-powered lamp comprising the control circuit of claim 20 and further comprising:

a cold-cathode fluorescent lamp, controlled independently of the control circuit of claim 20.

29. The control circuit of claim 20, wherein the square wave generator comprises a timer circuit.

30. The control circuit of claim 20, further comprising:

a switching circuit having a terminal connected between the power source and the load and directly connected to a biasing resistor at an output of the square wave generator.

31. The control circuit of claim 20, wherein said low voltage detection circuit comprises at least one impedance, and wherein said selected level is selected according to at least one value of said at least one impedance.

32. The control circuit according to claim 31, wherein said at least one impedance includes at least two resistors, at least two of said resistors being connected in series, wherein values of said at least two of said resistors are chosen to determine said selected level.

33. The control circuit of claim 20, wherein a decrease in said duty cycle comprises a gradual decrease in duty cycle over a majority of a range of the voltage level of said power source below said selected level.