Closed-loop load control circuit having a wide output range

• US 8,466,628 B2
• Filed: 06/11/2010
• Issued: 06/18/2013
• Est. Priority Date: 10/07/2009
• Status: Active Grant

• Current Assignee: Lutron Technology Company LLC
• Original Assignee: Lutron Electronics Company Incorporated (Lutron Electronics)
• Inventors: Shearer, Thomas M., Nuhfer, Matthew W., Chitta, Venkatesh, Iyer, Kartik, Hoerter, Nicholas A., Taipale, Mark S.
• Primary Examiner(s): Chang, Daniel D
• Application Number:
  US12/814,026
• Publication Number:
  US 20110080112A1
• Time in Patent Office: 1,103 Days
• Field of Search: 315/209.R, 315/210, 315/186, 315/219, 315/291, 315/313, 323/273
• US Class Current: 315/209.R
• CPC Class Codes: H05B 45/10 Controlling the intensity of the light
• CPC Class Codes: H05B 45/12 using optical feedback
• CPC Class Codes: H05B 45/18 using temperature feedback
• CPC Class Codes: H05B 45/3725 Switched mode power supply [SMPS]
• CPC Class Codes: H05B 45/385 using flyback topology
• CPC Class Codes: H05B 45/397 Current mirror circuits
• CPC Class Codes: H05B 45/44 with an active control inside an LED matrix
• CPC Class Codes: H05B 47/155 Coordinated control of two or more light sources
• CPC Class Codes: Y02B 20/30 Semiconductor lamps, e.g. solid state lamps [SSL] light emitting diodes [LED] or organic LED [OLED]

Abstract

A load control circuit, such as a light-emitting diode (LED) driver, for controlling the amount of power delivered to an electrical load, such as an LED light source, comprises a regulation transistor adapted to be coupled in series with the load, and a feedback circuit coupled in series with the regulation transistor, whereby the load control circuit is able to control the magnitude of a load current conducted through the load from a minimum load current to a maximum load current, which is at least approximately one thousand times larger than the minimum load current. The feedback circuit generates at least one load current feedback signal representative of the magnitude of the load current. The regulation transistor operates in the linear region to control the magnitude of the load current conducted through the load in response to the magnitude of the load current determined from the load current feedback signal.

Claims

1. A load control circuit for controlling the amount of power delivered to an electrical load, the load control circuit comprising:

a regulation transistor adapted to be coupled in series with the load to control the magnitude of a load current conducted through the load, so as to control the amount of power delivered to the load; and

a feedback circuit coupled in series with the regulation transistor and operable to generate a first load current feedback signal representative of the magnitude of the load current;

wherein the regulation transistor operates in the linear region in response to the magnitude of the load current determined from the first load current feedback signal, such that the load control circuit is able to control the magnitude of the load current conducted through the load from a minimum load current to a maximum load current, the maximum load current at least approximately one thousand times larger than the minimum load current.

2. The load control circuit of claim 1, further comprising:

a control circuit operatively coupled to the regulation transistor for controlling the regulation transistor to operate in the linear region to thus adjust the magnitude of the load current through the load in response to the first load current feedback signal.

3. The load control circuit of claim 2, wherein the feedback circuit generates a second load current feedback signal representative of the magnitude of the load current, the first and second load current feedback signals characterized by respective first and second gains applied to the magnitude of the load current, the first gain different than the second gain, the control circuit operable to determine the magnitude of the load current in response to both the first and second load current feedback signals.

4. The load control circuit of claim 3, wherein the control circuit only uses the first load current feedback signal to determine the magnitude of the load current when the magnitude of the second load current feedback signal is greater than a first threshold voltage, and only uses the second load current feedback signal to determine the magnitude of the load current when the magnitude of the second load current feedback signal is less than a second threshold voltage.

5. The load control circuit of claim 4, wherein the control circuit combines the first and second load current feedback signals to determine the magnitude of the load current when the magnitude of the second load current feedback signal is between the first and second threshold voltages.

6. The load control circuit of claim 5, wherein the control circuit uses a weighted sum of the first and second load current feedback signals to determine the magnitude of the load current when the magnitude of the second load current feedback signal is between the first and second threshold voltages.

7. The load control circuit of claim 6, wherein weighting factors of the weighted sum of the first and second load current feedback signals are functions of the magnitude of the second load current feedback signal.

8. The load control circuit of claim 6, wherein weighting factors of the weighted sum of the first and second load current feedback signals are functions of the amount of elapsed time since the magnitude of the second load current feedback signal transitioned across either of the first and second threshold voltages.

9. The load control circuit of claim 4, wherein the second gain is greater than the first gain.

10. The load control circuit of claim 9, wherein the first gain is approximately one.

11. The load control circuit of claim 4, wherein the control circuit combines the first and second load current feedback signals to determine the magnitude of the load current when the magnitude of the second load current feedback signal is between first and second threshold voltages.

12. The load control circuit of claim 2, wherein the feedback circuit comprises an adjustable-gain feedback circuit coupled in series with the regulation FET and operable to generate a load current feedback signal representative of the average magnitude of the load current, the adjustable-gain feedback circuit comprising first and second resistors coupled in series with the regulation FET, and a gain-adjustment transistor coupled across the second resistor, the control circuit coupled to the adjustable-gain feedback circuit for controlling the gain-adjustment transistor to be conductive and non-conductive, such that the series combination of the first and second resistors is coupled in series with the regulation FET when the gain-adjustment transistor is non-conductive, and only the first resistor is coupled in series with the regulation FET when the gain-adjustment transistor is conductive, the control circuit rendering the gain-adjustment transistor non-conductive when the magnitude of the load current is less than a threshold current.

13. The load control circuit of claim 12, wherein the control circuit is operable to:

generate a current control signal for controlling the regulation transistor to operate in the linear region to thus control the magnitude of the load current conducted through the load;

detect that the magnitude of the load current is less than the threshold current;

subsequently pause controlling the regulation transistor in response to the magnitude of the load current;

adjust the magnitude of the current control signal by a predetermined amount;

subsequently wait for a first delay time; and

render the gain-adjustment transistor non-conductive at the end of the first delay time.

14. The load control circuit of claim 13, wherein the control circuit is further operable to wait for a second delay time after rendering the gain-adjustment transistor non-conductive, and resume controlling the regulation transistor in response to the magnitude of the load current at the end of the second delay time.

15. The load control circuit of claim 14, further comprising:

a filter circuit coupled in series between the control circuit and a gate of the regulation transistor, the filter circuit operable to receive the current control signal from the control circuit, the filter circuit referenced to a source of the regulation transistor.

16. The load control circuit of claim 12, wherein the control circuit is operable to control the regulation transistor using a pulse-width modulation technique to adjust the amount of power delivered to the load, the control circuit rendering the gain-adjustment transistor non-conductive and conductive during a valley of the pulse-width modulated load current when the instantaneous magnitude of the load current is approximately zero amps.

17. An LED driver for controlling an LED light source, the LED driver comprising:

a power converter circuit operable to receive a rectified AC voltage and to generate a DC bus voltage;

a LED drive circuit operable to receive the bus voltage and to control the magnitude of a load current conducted through the LED light source, the LED drive circuit comprising a feedback circuit operable to generate first and second load current feedback signals representative of the magnitude of the load current, the first and second load current feedback signals characterized by respective first and second gains applied to the magnitude of the load current, the first gain different than the second gain; and

a control circuit operable to combine the first and second load current feedback signals, the control circuit operatively coupled to the LED drive circuit for controlling the magnitude of the load current through the load in response to both the first and second load current feedback signals, such that the LED drive circuit is able to control the magnitude of the load current conducted through the load from a minimum load current to a maximum load current.

18. The LED driver of claim 17, wherein the control circuit uses only the first load current feedback signal to determine the magnitude of the load current when the magnitude of the second load current feedback signal is greater than a first threshold voltage, and uses only the second load current feedback signal to determine the magnitude of the load current when the magnitude of the second load current feedback signal is less than a second threshold voltage.

19. The LED driver of claim 18, wherein the control circuit combines the first and second load current feedback signals to determine the magnitude of the load current when the magnitude of the second load current feedback signal is between the first and second threshold voltages.

20. The LED driver of claim 19, wherein the control circuit uses a weighted sum of the first and second load current feedback signals to determine the magnitude of the load current when the magnitude of the second load current feedback signal is between the first and second threshold voltages.

21. The LED driver of claim 20, wherein the weighting factors of the weighted sum of the first and second load current feedback signals are functions of the magnitude of the second load current feedback signal.

22. The LED driver of claim 20, wherein the weighting factors of the weighted sum of the first and second load current feedback signals are functions of the amount of elapsed time since the magnitude of the second load current feedback signal transitioned across either of the first and second threshold voltages.

23. The LED driver of claim 17, wherein the LED drive circuit further comprises a regulation transistor adapted to be coupled in series with the load to control the magnitude of the load current conducted through the load, the control circuit operatively coupled to the regulation transistor for controlling the regulation transistor to operate in the linear region to thus adjust the magnitude of the load current through the load in response to the first load current feedback signal.

24. The LED driver of claim 23, wherein the feedback circuit comprises an adjustable-gain feedback circuit coupled in series with the regulation FET and operable to generate a load current feedback signal representative of the magnitude of the load current, the adjustable-gain feedback circuit comprising first and second resistors coupled in series with the regulation FET, and a gain-adjustment transistor coupled across the second resistor, the control circuit coupled to the adjustable-gain feedback circuit for controlling the gain-adjustment transistor to be conductive and non-conductive, such that the series combination of the first and second resistors is coupled in series with the regulation FET when the gain-adjustment transistor is non-conductive, and only the first resistor is coupled in series with the regulation FET when the gain-adjustment transistor is conductive, the control circuit rendering the gain-adjustment transistor non-conductive when the magnitude of the load current is less than a threshold current.

25. The LED driver of claim 24, wherein the control circuit is operable to:

generate a current control signal for controlling the regulation transistor to operate in the linear region to thus control the magnitude of the load current conducted through the LED light source;

detect that the magnitude of the load current is less than the threshold current;

subsequently pause controlling the regulation transistor in response to the magnitude of the load current;

adjust the magnitude of the current control signal by a predetermined amount;

subsequently wait for a first delay time; and

render the gain-adjustment transistor non-conductive at the end of the first delay time.

26. The LED driver of claim 23, wherein the control circuit is operable to control the regulation transistor using a pulse-width modulation technique to adjust the intensity of the LED light source, the control circuit rendering the gain-adjustment transistor non-conductive and conductive during a valley of the pulse-width modulated load current when the instantaneous magnitude of the load current is approximately zero amps.

27. The LED driver of claim 17, wherein the maximum load current is at least approximately one thousand times larger than the minimum load current.

28. A load control circuit for controlling the amount of power delivered to an electrical load, the load control circuit comprising:

a regulation transistor adapted to be coupled in series with the load to control the magnitude of a load current conducted through the load, so as to control the amount of power delivered to the load;

a feedback circuit coupled in series with the regulation transistor and operable to generate first and second load current feedback signals representative of the magnitude of the load current, the first and second load current feedback signals characterized by respective first and second gains with respect to the magnitude of the load current, the first gain different than the second gain; and

a control circuit operable to combine the first and second load current feedback signals to determine the magnitude of the load current in response to both the first and second load current feedback signals, the control circuit operatively coupled to the regulation transistor for controlling the regulation transistor to operate in the linear region to thus adjust the magnitude of the load current through the load in response to the magnitude of the load current determined from the first and second load current feedback signals.

29. The load control circuit of claim 28, wherein the control circuit uses only the first load current feedback signal to determine the magnitude of the load current when the magnitude of the second load current feedback signal is greater than a first threshold voltage, and uses only the second load current feedback signal to determine the magnitude of the load current when the magnitude of the second load current feedback signal is less than a second threshold voltage.

30. The load control circuit of claim 29, wherein the control circuit combines the first and second load current feedback signals to determine the magnitude of the load current when the magnitude of the second load current feedback signal is between the first and second threshold voltages.

31. The load control circuit of claim 30, wherein the control circuit uses a weighted sum of the first and second load current feedback signals to determine the magnitude of the load current when the magnitude of the second load current feedback signal is between the first and second threshold voltages.

32. The load control circuit of claim 31, wherein the weighting factors of the weighted sum of the first and second load current feedback signals are functions of the magnitude of the second load current feedback signal.

33. The load control circuit of claim 31, wherein the weighting factors of the weighted sum of the first and second load current feedback signals are functions of the amount of elapsed time since the magnitude of the second load current feedback signal transitioned across either of the first and second threshold voltages.

34. The load control circuit of claim 30, wherein the second gain is greater than the first gain.

35. The load control circuit of claim 34, wherein the first gain is approximately one.

36. The load control circuit of claim 28, wherein the control circuit combines the first and second load current feedback signals to determine the magnitude of the load current when the magnitude of the second load current feedback signal is between first and second threshold voltages.

37. The load control circuit of claim 28, where the load control circuit is able to control the amount of power delivered to the load from a minimum load current to a maximum load current, the maximum load current at least approximately one thousand times larger than the minimum load current.

38. A load control circuit for controlling the amount of power delivered to an electrical load, the load control circuit comprising:

a regulation transistor adapted to be coupled in series with the load to control the magnitude of a load current conducted through the load, so as to control the amount of power delivered to the load;

an adjustable-gain feedback circuit coupled in series with the regulation FET and operable to generate a load current feedback signal representative of the magnitude of the load current, the adjustable-gain feedback circuit comprising first and second resistors coupled in series with the regulation FET, and a gain-adjustment transistor coupled across the second resistor;

a control circuit operatively coupled to the regulation transistor for controlling the regulation transistor to thus adjust the magnitude of the load current through the load, the control circuit further coupled to the adjustable-gain feedback circuit for rendering the gain-adjustment transistor conductive and non-conductive, such that the series combination of the first and second resistors is coupled in series with the regulation FET when the gain-adjustment transistor is non-conductive, and only the first resistor is coupled in series with the regulation FET when the gain-adjustment transistor is conductive; and

wherein the control circuit is operable to;

generate a current control signal for controlling the regulation transistor to operate in the linear region to thus control the magnitude of the load current conducted through the load;

detect that the magnitude of the load current is less than the threshold current;

subsequently pause controlling the regulation transistor in response to the magnitude of the load current;

adjust the magnitude of the current control signal by a predetermined amount;

subsequently wait for a first delay time; and

render the gain-adjustment transistor non-conductive at the end of the first delay time.

39. The load control circuit of claim 38, wherein the control circuit is further operable to wait for a second delay time after rendering the gain-adjustment transistor non-conductive, and resume controlling the regulation transistor in response to the magnitude of the load current at the end of the second delay time.

40. The load control circuit of claim 39, further comprising:

a filter circuit coupled in series between the control circuit and a gate of the regulation transistor, the filter circuit operable to receive the current control signal from the control circuit, the filter circuit referenced to a source of the regulation transistor.

41. The load control circuit of claim 38, wherein the control circuit is operable to control the regulation transistor using a pulse-width modulation technique to adjust the amount of power delivered to the load, the control circuit rendering the gain-adjustment transistor non-conductive and conductive during a valley of the pulse-width modulated load current when the instantaneous magnitude of the load current is approximately zero amps.

42. The load control circuit of claim 38, wherein the regulation transistor comprises a FET.

43. The load control circuit of claim 38, where the load control circuit is able to control the amount of power delivered to the load from a minimum load current to a maximum load current, the maximum load current at least approximately one thousand times larger than the minimum load current.

44. A method of controlling the amount of power delivered to an electrical load, the method comprising:

controlling the magnitude of a load current conducted through the load, so as to control the amount of power delivered to the load;

generating first and second load current feedback signals representative of the magnitude of the load current, the first and second load current feedback signals characterized by respective first and second gains applied to the magnitude of the load current, the first gain different than the second gain;

combining the first and second load current feedback signals;

calculating the magnitude of the load current in response to combining both the first and second load current feedback signals; and

adjusting the magnitude of the load current in response to the calculated magnitude of the load current determined from the first and second load current feedback signals.

45. The method of claim 44, further comprising:

using only the first load current feedback signal to determine the magnitude of the load current when the magnitude of the second load current feedback signal is greater than a first threshold voltage; and

using only the second load current feedback signal to determine the magnitude of the load current when the magnitude of the second load current feedback signal is less than a second threshold voltage.

46. The method of claim 45, wherein calculating the magnitude of the load current in response to combining both the first and second load current feedback signals further comprises combining the first and second load current feedback signals when the magnitude of the second load current feedback signal is between the first and second threshold voltages.

47. The method of claim 46, wherein combining the first and second load current feedback signals further comprises using a weighted sum of the first and second load current feedback signals to determine the magnitude of the load current when the magnitude of the second load current feedback signal is between the first and second threshold voltages.

48. The method of claim 47, wherein the weighting factors of the weighted sum of the first and second load current feedback signals are functions of the magnitude of the second load current feedback signal.

49. The method of claim 47, wherein the weighting factors of the weighted sum of the first and second load current feedback signals are functions of the amount of elapsed time since the magnitude of the second load current feedback signal transitioned across either of the first and second threshold voltages.

50. The method of claim 45, wherein the second gain is greater than the first gain.

51. The method of claim 50, wherein the first gain is approximately one.

52. A method of controlling the amount of power delivered to an electrical load, the method comprising:

controlling the magnitude of a load current conducted through the load by controlling a regulation transistor coupled so as to conduct the load current to operate in the linear region, so as to control the amount of power delivered to the load;

conducting the load current through first and second series-connected resistors;

generating a load current feedback signal across the series-connected resistors, the load current feedback signal representative of the magnitude of the load current;

the load current feedback signal comprising a first load current feedback signal developed across a first resistor and a second load current feedback signal developed across both resistors in series;

calculating the magnitude of the load current in response to both load current feedback signals;

adjusting the magnitude of the load current in response to the magnitude of the load current determined from the first and second load current feedback signals;

controlling a gain-adjustment transistor coupled across the second resistor to be conductive, such that the first load current feedback signal is generated from only the first resistor;

generating a current control signal for controlling the regulation transistor to operate in the linear region to thus control the magnitude of the load current conducted through the load;

detecting that the magnitude of the load current is less than the threshold current;

subsequently pausing controlling the regulation transistor in response to the magnitude of the load current;

adjusting the magnitude of the current control signal by a predetermined amount;

subsequently waiting for a first delay time; and

rendering the gain-adjustment transistor non-conductive at the end of the first delay time,

such that the load current feedback signal is generated across the series combination of the first and second resistors.

53. The method of claim 52, further comprising:

waiting for a second delay time after rendering the gain-adjustment transistor non-conductive; and

resuming controlling the regulation transistor in response to the magnitude of the load current at the end of the second delay time.

54. The method of claim 52, further comprising:

controlling the regulation transistor using a pulse-width modulation technique to adjust the amount of power delivered to the load; and

rendering the gain-adjustment transistor non-conductive and conductive during a valley of the pulse-width modulated load current when the instantaneous magnitude of the load current is approximately zero amps.

55. A load control circuit for controlling the amount of power delivered to an electrical load, the load control circuit comprising:

a regulation transistor adapted to be coupled in series with the load to control the magnitude of a load current conducted through the load, so as to control the amount of power delivered to the load;

a control circuit operatively coupled to the regulation transistor, the control circuit generating a current control signal for controlling the regulation transistor to operate in the linear region to thus adjust the magnitude of the load current through the load and

an adjustable-gain feedback circuit coupled in series with the regulation transistor and operable to generate a load current feedback signal representative of the magnitude of the load current, the adjustable-gain feedback circuit characterized by a first gain and characterized by a second gain;

wherein the control circuit is operable to;

control the adjustable-gain feedback circuit to be characterized by the first gain;

detect that the magnitude of the load current is less than a threshold current;

subsequently pause controlling the regulation transistor in response to the magnitude of the load current;

adjust the magnitude of the current control signal by a predetermined amount;

subsequently wait for a first delay time; and

control the adjustable-gain feedback circuit to be characterized by the second gain.