Configurable load control device for light-emitting diode light sources

• US 8,492,988 B2
• Filed: 06/11/2010
• Issued: 07/23/2013
• Est. Priority Date: 10/07/2009
• Status: Active Grant

• Current Assignee: Lutron Technology Company LLC
• Original Assignee: Lutron Electronics Company Incorporated (Lutron Electronics)
• Inventors: Nuhfer, Matthew W., Shearer, Thomas M., Chitta, Venkatesh, Biery, Ethan Charles, Iyer, Kartik
• Primary Examiner(s): Chang, Daniel D
• Application Number:
  US12/813,989
• Publication Number:
  US 20110080111A1
• Time in Patent Office: 1,138 Days
• Field of Search: 315/246, 315/254, 315/297, 315/209.R, 315/212, 315/291
• US Class Current: 315/246
• 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 configurable light-emitting diode (LED) driver is adapted to control a plurality of different LED light sources, which may be rated to operate using different load control techniques, different dimming techniques, and different magnitudes of load current and voltage. The LED driver comprises a power converter circuit for generating a DC bus voltage, and an LED drive circuit for receiving the bus voltage and adjusting either the magnitude of the current conducted through the LED light source or the magnitude of the voltage across the LED light source. The LED driver is operable to dim the LED light source using either a pulse-width modulation technique or a constant current reduction technique, and may be configured using a programming device and a personal computer.

Claims

1. 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;

an LED drive circuit operable to receive the bus voltage and to control both the magnitude of a load current conducted through the LED light source and the magnitude of a load voltage produced across the LED light source, the LED drive circuit comprising a linear regulator including a regulation transistor adapted to be coupled in series with the led LED light source; and

a control circuit coupled to the LED drive circuit for adjusting the magnitude of the load voltage produced across the LED light source when operating in a voltage load control mode, the control circuit operatively coupled to the linear regulator of the LED drive circuit for controlling the linear regulator to adjust the magnitude of the load current conducted through the LED light source when operating in a current load control mode.

2. The LED driver of claim 1, wherein the control circuit is coupled to the power converter circuit for adjusting the magnitude of the bus voltage.

3. The LED driver of claim 2, wherein the power converter circuit comprises a flyback converter including a flyback transformer, a flyback switching transistor coupled in series with a primary winding of the flyback transformer, and a flyback controller for controlling the flyback switching transistor to be conductive and non-conductive to generate the bus voltage across a secondary winding of the flyback transformer, the flyback controller powered by a first low-voltage DC supply voltage.

4. The LED driver of claim 3, wherein the secondary winding of the flyback transformer comprises a center tap that produces a center tap voltage, the power converter comprising a first power supply operable to receive the center tap voltage and to generate a second low-voltage DC supply voltage at an output when the center tap voltage is above a cutover voltage.

5. The LED driver of claim 4, wherein the power converter further comprises a second power supply having an output coupled to the output of the first power supply, the second power supply operable to receive the bus voltage and to generate the second DC supply voltage when the center tap voltage is below approximately the cutover voltage.

6. The LED driver of claim 5, wherein the power converter further comprises a linear regulator operable to receive the second DC supply voltage and to generate a third low-voltage DC supply voltage for powering the control circuit.

7. The LED driver of claim 3, wherein the power converter comprises a flyback power supply coupled to a supply winding of the flyback transformer and operable to generate the first DC supply voltage.

8. The LED driver of claim 7, wherein the power converter comprises a startup power supply operable to receive the rectified voltage and to generate the first DC supply voltage before the flyback controller starts up.

9. The LED driver of claim 8, wherein the startup power supply comprises a cat-ear power supply.

10. The LED driver of claim 3, wherein the power converter comprises a buck-boost flyback converter.

11. The LED driver of claim 2, wherein the control circuit is operable to control the regulation transistor into the saturation region, and to adjust the magnitude of the bus voltage to thus control the magnitude of the load voltage produced across the LED light source when operating in the voltage load control mode.

12. The LED driver of claim 11, 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 when operating in the voltage load control mode.

13. The LED driver of claim 11, wherein the control circuit is operable to measure the magnitude of the load voltage generated across the LED light source.

14. The LED driver of claim 11, wherein the control circuit is operable to measure the magnitude of the bus voltage and the magnitude of the voltage generated across the linear regulator, the control circuit further operable to calculate the magnitude of the load voltage generated across the LED light source by subtracting the magnitude of the voltage generated across the linear regulator from the magnitude of the bus voltage.

15. The LED driver of claim 2, wherein the control circuit is operable to control the regulation transistor to operate in the linear region to thus control the magnitude of the load current conducted through the LED light source when operating in the current load control mode.

16. The LED driver of claim 15, wherein the control circuit is operable to control the regulation transistor using a constant current reduction technique to adjust the intensity of the LED light source when operating in the current load control mode.

17. The LED driver of claim 15, 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 when operating in the current load control mode.

18. The LED driver of claim 1, further comprising:

a communication circuit coupled to the control circuit, such that the control circuit is operable to receive a digital message including at least one parameter for the LED driver.

19. The LED driver of claim 18, wherein the parameter defines whether the control circuit should operate in the current load control mode or in the voltage load control mode.

20. The LED driver of claim 19, wherein the control circuit begins to operate in the current load control mode in response to the parameter, the parameter further defining a target current to which the control circuit will control the magnitude of the load current.

21. The LED driver of claim 19, wherein the control circuit begins to operate in the voltage load control mode in response to the parameter, the parameter further defining a target voltage to which the control circuit will control the magnitude of the load voltage.

22. The LED driver of claim 1, wherein the control circuit is coupled to the power converter circuit for adjusting the magnitude of the bus voltage to thus control the magnitude of the load voltage produced across the LED light source when operating in the voltage load control mode.

23. The LED driver of claim 22, wherein the control circuit is operable to control the LED drive circuit using a pulse-width modulation technique to adjust the intensity of the LED light source when operating in the voltage load control mode.

24. An LED driver for driving an LED light source including at least one LED, the LED driver comprising:

a first circuit receiving a rectified AC voltage and providing a DC bus voltage;

a second circuit receiving said DC bus voltage and producing one of a load current through said LED light source or a load voltage across said LED light source;

a control circuit having a first control input from said first circuit and a second control input from said second circuit and further having a first control output provided to said first circuit and a second control output provided to said second circuit;

said first control input comprising a signal related to said DC bus voltage;

said first control output comprising a control signal for controlling said first circuit to deliver a desired DC bus voltage;

said second control input comprising a signal related to either or both the load current provided by said second circuit through said LED light source and said load voltage provided by said second circuit to said LED light source;

said second control output comprising a control signal to regulate either or both said load current to said LED light source and said load voltage provided to said LED light source;

wherein said second circuit comprises a linear regulator circuit having a power semiconductor device adapted to be coupled in series with said LED light source;

wherein said second circuit comprises a drive circuit operable by said control circuit in either a voltage control mode or a current control mode; and

wherein when said second circuit is operating in said current control mode, said power semiconductor device is operated in a linear region by said control circuit providing said second control output to control said power semiconductor device into said linear region.

25. The LED driver of claim 24, wherein said control circuit further comprises a dimming signal input and a dimming output, said dimming output controlling said power semiconductor device to dim said LED light source by reducing the average load current to said LED light source.

26. The LED driver of claim 25, wherein said dimming signal input comprises a phase control dimming signal provided by a phase control dimmer circuit.

27. The LED driver of claim 25, wherein when said second circuit is operated in said voltage control mode, said dimming output comprises a DC level signal to reduce said load current supplied to said LED light source.

28. The LED driver of claim 24, wherein said first control output controls said first circuit to set said DC bus voltage to a predetermined voltage above said load voltage whereby said power semiconductor device can control said load current to said LED light source to a desired load current.

29. The LED driver of claim 24, wherein said first circuit comprises a switching mode power supply.

30. The LED driver of claim 29, wherein said first circuit comprises a flyback switching converter having a transformer providing DC isolation between said rectified AC signal and said second circuit.

31. The LED driver of claim 24, further comprising a communication circuit coupled to said control circuit for communicating with a communication bus.

32. The LED driver of claim 24, further comprising a memory coupled to said control circuit for storing either or both said desired load voltage when said second circuit is operated in said voltage control mode and said desired load current when said second circuit is operated in said current control mode.

33. An LED driver for driving an LED light source including at least one LED, the LED driver comprising:

a first circuit receiving a rectified AC voltage and providing a DC bus voltage;

a second circuit receiving said DC bus voltage and producing one of a load current through said LED light source or a load voltage across said LED light source;

a control circuit having a first control input from said first circuit and a second control input from said second circuit and further having a first control output provided to said first circuit and a second control output provided to said second circuit;

said first control input comprising a signal related to said DC bus voltage;

said first control output comprising a control signal for controlling said first circuit to deliver a desired DC bus voltage;

said second control input comprising a signal related to either or both the load current provided by said second circuit through said LED light source and said load voltage provided by said second circuit to said LED light source;

said second control output comprising a control signal to regulate either or both said load current to said LED light source and said load voltage provided to said LED light source;

wherein said second circuit comprises a linear regulator circuit having a power semiconductor device adapted to be coupled in series with said LED light source;

wherein said second circuit is operable by said control circuit in either a voltage control mode or a current control mode;

wherein said control circuit further comprises a dimming signal input and a dimming output, said dimming output controlling said power semiconductor device to dim said LED light source by reducing the average load current to said LED light source;

wherein said dimming signal input comprises a phase control dimming signal provided by a phase control dimmer circuit; and

wherein said phase control dimmer circuit provides an AC voltage signal to a rectifier circuit, said rectifier circuit providing said rectified AC voltage having said phase control dimming signal, further comprising a phase-control input circuit receiving said rectified AC voltage and providing said dimming signal input as an output signal to said control circuit, said phase-control input circuit detecting said phase control dimming signal of said rectified AC voltage and converting said phase control dimming signal to a DC level dimming signal.

34. An LED driver for driving an LED light source including at least one LED, the LED driver comprising:

a first circuit receiving a rectified AC voltage and providing a DC bus voltage;

a second circuit receiving said DC bus voltage and producing one of a load current through said LED light source or a load voltage across said LED light source;

a control circuit having a first control input from said first circuit and a second control input from said second circuit and further having a first control output provided to said first circuit and a second control output provided to said second circuit;

said first control input comprising a signal related to said DC bus voltage;

said first control output comprising a control signal for controlling said first circuit to deliver a desired DC bus voltage;

said second control input comprising a signal related to either or both the load current provided by said second circuit through said LED light source and said load voltage provided by said second circuit to said LED light source;

said second control output comprising a control signal to regulate either or both said load current to said LED light source and said load voltage provided to said LED light source;

wherein said second circuit comprises a linear regulator circuit having a power semiconductor device adapted to be coupled in series with said LED light source;

wherein said second circuit is operable by said control circuit in either a voltage control mode or a current control mode;

wherein when said second circuit is operated in said current control mode, said power semiconductor device is operated in a linear region by said control circuit providing said second control output to control said power semiconductor device into said linear region;

wherein said control circuit further comprises a dimming signal input and a dimming output, said dimming output controlling said power semiconductor device to dim said LED light source by reducing the average load current to said LED light source; and

wherein said dimming output comprises a dimming PWM signal, said dimming PWM signal controlling an on time of said power semiconductor device to control said average current to said LED light source.

35. An LED driver for driving an LED light source including at least one LED, the LED driver comprising:

a first circuit receiving a rectified AC voltage and providing a DC bus voltage;

a second circuit receiving said DC bus voltage and producing one of a load current through said LED light source or a load voltage across said LED light source;

a control circuit having a first control input from said first circuit and a second control input from said second circuit and further having a first control output provided to said first circuit and a second control output provided to said second circuit;

said first control input comprising a signal related to said DC bus voltage;

said first control output comprising a control signal for controlling said first circuit to deliver a desired DC bus voltage;

said second control input comprising a signal related to either or both the load current provided by said second circuit through said LED light source and said load voltage provided by said second circuit to said LED light source;

said second control output comprising a control signal to regulate either or both said load current to said LED light source and said load voltage provided to said LED light source;

wherein said second circuit comprises a linear regulator circuit having a power semiconductor device adapted to be coupled in series with said LED light source;

wherein said second circuit is operable by said control circuit in either a voltage control mode or a current control mode;

wherein when said second circuit is operated in said current control mode, said power semiconductor device is operated in a linear region by said control circuit providing said second control output to control said power semiconductor device into said linear region;

wherein said control circuit further comprises a dimming signal input and a dimming output, said dimming output controlling said power semiconductor device to dim said LED light source by reducing the average load current to said LED light source;

wherein said dimming output comprises a dimming PWM signal, said dimming PWM signal controlling an on time of said power semiconductor device to control said average current to said LED light source; and

further comprising a second semiconductor device controlled by said dimming PWM signal, whereby said second semiconductor device turns off said power semiconductor device to turn off said load current to said LED light source for a predetermined time determined by a duty cycle of said dimming PWM signal thereby to dim said LED light source.

36. An LED driver for driving an LED light source including at least one LED, the LED driver comprising:

a first circuit receiving a rectified AC voltage and providing a DC bus voltage;

a second circuit receiving said DC bus voltage and producing one of a load current through said LED light source or a load voltage across said LED light source;

a control circuit having a first control input from said first circuit and a second control input from said second circuit and further having a first control output provided to said first circuit and a second control output provided to said second circuit;

said first control input comprising a signal related to said DC bus voltage;

said first control output comprising a control signal for controlling said first circuit to deliver a desired DC bus voltage;

said second control input comprising a signal related to either or both the load current provided by said second circuit through said LED light source and said load voltage provided by said second circuit to said LED light source;

said second control output comprising a control signal to regulate either or both said load current to said LED light source and said load voltage provided to said LED light source;

wherein said second circuit comprises a linear regulator circuit having a power semiconductor device adapted to be coupled in series with said LED light source;

wherein said second circuit is operable by said control circuit in either a voltage control mode or a current control mode;

wherein when said second circuit is operated in said current control mode, said power semiconductor device is operated in a linear region by said control circuit providing said second control output to control said power semiconductor device into said linear region; and

wherein said second control output comprises a PWM signal, said second circuit further comprising a filter circuit receiving said second control output from said control circuit, said filter circuit providing a filtered signal to said power semiconductor device to control said power semiconductor device in said linear region to regulate said load current to said desired load current.

37. An LED driver for driving an LED light source including at least one LED, the LED driver comprising:

a first circuit receiving a rectified AC voltage and providing a DC bus voltage;

a second circuit receiving said DC bus voltage and producing one of a load current through said LED light source or a load voltage across said LED light source;

a control circuit having a first control input from said first circuit and a second control input from said second circuit and further having a first control output provided to said first circuit and a second control output provided to said second circuit;

said first control input comprising a signal related to said DC bus voltage;

said first control output comprising a control signal for controlling said first circuit to deliver a desired DC bus voltage;

said second control input comprising a signal related to either or both the load current provided by said second circuit through said LED light source and said load voltage provided by said second circuit to said LED light source;

said second control output comprising a control signal to regulate either or both said load current to said LED light source and said load voltage provided to said LED light source; and

wherein said second circuit comprises a linear regulator circuit having a power semiconductor device adapted to be coupled in series with said LED light source;

wherein said second circuit is operable by said control circuit in either a voltage control mode or a current control mode;

wherein said first circuit comprises a switching mode power supply; and

wherein said first circuit comprises a flyback switching converter having a transformer providing DC isolation between said rectified AC signal and said second circuit;

further wherein said first control output comprises a PWM signal.