Controllable-load circuit for use with a load control device

• US 9,220,133 B2
• Filed: 11/19/2010
• Issued: 12/22/2015
• Est. Priority Date: 11/20/2009
• Status: Active Grant

• Current Assignee: Lutron Technology Company LLC
• Original Assignee: Lutron Electronics Company Incorporated (Lutron Electronics)
• Inventors: Salvestrini, Christopher James, Bedell, Ryan S., Harte, Matthew V.
• Primary Examiner(s): D A, Minh
• Assistant Examiner(s): YANG, AMY X
• Application Number:
  US12/950,079
• Publication Number:
  US 20110121744A1
• Time in Patent Office: 1,859 Days
• Field of Search: 315/291, 315/312, 315/246, 315/307, 315/308
• US Class Current: 1/1
• CPC Class Codes: H02M 1/082 with digital control
• CPC Class Codes: H02M 5/2576 with digital control
• CPC Class Codes: H05B 45/10 Controlling the intensity of the light
• CPC Class Codes: H05B 45/14 using electrical feedback from LEDs or from LED modules
• CPC Class Codes: H05B 45/3725 Switched mode power supply [SMPS]
• CPC Class Codes: H05B 45/44 with an active control inside an LED matrix
• CPC Class Codes: H05B 47/175 by remote control

Abstract

A load control device for controlling the amount of power delivered from an AC power source to an electrical load is operable to conduct enough current through a thyristor of a connected dimmer switch to exceed rated latching and holding currents of the thyristor. The load control device comprises a controllable-load circuit operable to conduct a controllable-load current through the thyristor of the dimmer switch. The load control device disables the controllable-load circuit when the phase-control voltage received from the dimmer switch is a reverse phase-control waveform. When the phase-control voltage received from the dimmer switch is a forward phase-control waveform, the load control device is operable to decrease the magnitude of the controllable-load current so as to conduct only enough current as is required in order to exceed rated latching and holding currents of the thyristor.

Claims

1. A load control device for controlling the amount of power delivered from an AC power source to an electrical load, the load control device adapted to be coupled to the AC power source through a dimmer switch, the load control device comprising:

a load control circuit adapted to be coupled to the electrical load for controlling the amount of power delivered to the electrical load;

a controller coupled to the load control circuit for controlling the amount of power delivered to the electrical load in response to a conduction period of a phase-control voltage received from the dimmer switch; and

a controllable-load circuit coupled to the controller, the controllable-load circuit configured to conduct a controllable-load current from the AC power source through the dimmer switch, the controllable-load circuit configured to maintain the magnitude of the controllable-load circuit constant for at least a portion of each half-cycle of the AC power source;

wherein the controller is configured to monitor the conduction period of the phase-control voltage and to cause the controllable-load circuit to decrease the magnitude of the controllable-load current from an initial magnitude in a first half-cycle to a decreased magnitude in a second subsequent half-cycle, such that the conduction period of the phase-control voltage when the controllable-load current has the decreased magnitude in the second half-cycle is the same as when the controllable-load current has the initial magnitude in the first half-cycle.

2. The load control device of claim 1, wherein the decreased magnitude is less than the initial magnitude and greater than approximately zero amps.

3. The load control device of claim 2, wherein the controller is configured to monitor the conduction period of the phase-control voltage after the magnitude of the controllable-load current has been decreased to the decreased magnitude in the second half-cycle and to further decrease the magnitude of the controllable-load current by an increment in a third half-cycle if the conduction period of the phase-control voltage has not changed.

4. The load control device of claim 3, wherein the controller is configured to increase the magnitude of the controllable-load current by the increment in a fourth half-cycle if the conduction period of the phase-control voltage has changed.

5. The load control device of claim 1, wherein the decreased magnitude is approximately zero amps.

6. The load control device of claim 5, wherein the controller is configured to monitor the conduction period of the phase-control voltage after the magnitude of the controllable-load current has been decreased to approximately zero amps and to increase the magnitude of the controllable-load current in a subsequent half-cycle back to the initial magnitude if the conduction period of the phase-control voltage has changed.

7. The load control device of claim 1, further comprising a communications circuit coupled to the controller.

8. The load control device of claim 7, wherein the controller is further configured to determine a total number of load control devices coupled to the dimmer switch and receiving the phase-control voltage.

9. The load control device of claim 8, wherein the controller is further configured to transmit a query message and to receive a query response message via the communications circuit to determine the total number of load control devices coupled to the dimmer switch.

10. The load control device of claim 9, wherein the decreased magnitude of the controllable-load current is equal to a maximum magnitude divided by the total number of load control devices coupled to the dimmer switch.

11. The load control device of claim 7, wherein the controller is configured to transmit a first digital message before decreasing the magnitude of the controllable-load current and to transmit a second digital message after decreasing the magnitude of the controllable-load current.

12. The load control device of claim 1, wherein when the controller is configured to cause the controllable-load circuit to decrease the magnitude of the controllable-load current from the initial magnitude to the decreased magnitude, the controller further configured to control the load control circuit to deliver a constant amount of power to the electrical load.

13. A load control system for controlling the amount of power delivered from an AC power source to an electrical load, the load control system comprising:

a load control device adapted to be coupled to the electrical load for controlling the amount of power delivered to the electrical load; and

a dimmer switch comprising a thyristor coupled in series electrical connection between the AC power source and the load control device, the thyristor characterized by a rated holding current and configured to conduct a load current from the AC power source to the load control device, the dimmer switch configured to generate a phase-control voltage that is provided to the load control device to enable the load control device to adjust the amount of power being delivered to the electrical load in response to a conduction period of the phase-control voltage;

wherein the load control device is configured to conduct a controllable-load current from the AC power source through the thyristor of the dimmer switch, the load control device configured to maintain the magnitude of the controllable-load current constant for at least a portion of each half-cycle of the AC power source, the load control device configured to decrease the magnitude of the controllable-load current from an initial magnitude in a first half-cycle to a decreased magnitude in a second subsequent half-cycle, such that the decreased magnitude of the load current conducted through the thyristor in the second half-cycle exceeds the rated holding current.

14. A load control system for controlling the amount of power delivered from an AC power source to first and second electrical loads, the load control system comprising:

a first load control device adapted to be coupled to the first electrical load for controlling the amount of power delivered to the first electrical load;

a second load control device adapted to be coupled to the second electrical load for controlling the amount of power delivered to the second electrical load; and

a dimmer switch comprising a thyristor coupled in series electrical connection between the AC power source and the first and second load control devices, the thyristor characterized by a rated holding current and configured to conduct a load current from the AC power source to the first and second load control devices, the dimmer switch configured to generate a phase-control voltage that is provided to the first and second load control device to enable the first and second load control devices to adjust the amount of power being delivered to the respective electrical loads in response to a conduction period of the phase-control voltage;

wherein the load control devices are configured to conduct respective controllable-load currents from the AC power source through the thyristor of the dimmer switch, the load control devices configured to maintain the magnitude of each controllable-load current constant for at least a portion of each half-cycle of the AC power source, the load control devices each configured to adjust the magnitude of the respective controllable-load current from an initial magnitude in a first half-cycle to a decreased magnitude in a second subsequent half-cycle, such that a total magnitude of the respective controllable-load currents exceeds the rated holding current when the controllable-load currents have the respective decreased magnitudes in the second half-cycle.

15. The load control system of claim 14, wherein the first load control device is configured to adjust the magnitude of its respective controllable-load current from the initial magnitude to a minimum magnitude;

and

the second load control device is configured to adjust the magnitude of its respective controllable-load current from an initial magnitude to a first magnitude greater than the minimum magnitude, such that the total magnitude of the respective controllable-load currents exceeds the rated holding current of the thryristor.

16. The load control system of claim 15, wherein the minimum magnitude is approximately zero amps.

17. The load control system of claim 14, wherein the first and second load control devices are coupled to a communication link.

18. The load control system of claim 17, wherein the first and second load control devices are configured to determine a total number of load control devices in the load control system.

19. The load control system of claim 18, wherein the decreased magnitude of the respective controllable-load current is equal to a maximum magnitude divided by the total number of load control devices.

20. The load control system of claim 19, wherein the initial magnitude of the respective controllable-load current is equal to the maximum magnitude.

21. The load control system of claim 17, wherein the first load control device is configured to transmit a first digital message before adjusting the magnitude of its respective controllable-load current from the initial magnitude to the decreased magnitude and a second digital message after adjusting the magnitude of its respective controllable-load current from the initial magnitude to the decreased magnitude.

22. The load control system of claim 21, wherein the second load control device is configured to adjust the magnitude of its respective controllable-load current from the initial magnitude to the decreased magnitude in response to receiving the second digital message from the first load control device.

23. A controllable-load circuit for drawing a selected current from a power source comprising:

a first semiconductor switch having a control input coupled to the power source;

a first impedance forming circuit connected in series with the first semiconductor switch across the power source, the first impedance forming circuit including a first input for selecting between at least two impedances to be connected in series with the first semiconductor switch;

a control circuit having an output coupled to said first input for selecting the selected impedance; and

a second circuit coupled to said first semiconductor switch for monitoring the power source and for increasing the impedance to current flowing from said power source through said first semiconductor switch at a selected voltage level of said power source, thereby to reduce the current through said first semiconductor switch;

wherein said power source comprises an alternating current source, said control circuit configured to control the impedance of said impedance forming circuit to automatically control the current through said first semiconductor switch to be at a predefined level, said control circuit configured to control the impedance of said first impedance forming circuit for each half-cycle of the alternating current source;

further wherein the controllable-load circuit is coupled across the power source providing power to a driver circuit driving an LED light source.

24. The controllable-load circuit of claim 23, wherein the power source comprises a source of rectified alternating current.

25. The controllable-load circuit of claim 24, wherein the rectified alternating current has a phase control component.

26. The controllable-load circuit of claim 25, wherein the phase control component comprises one of a forward phase control or a reverse phase control.

27. The controllable-load circuit of claim 26, wherein said control circuit is operable to determine whether said rectified alternating current comprises a forward phase control component or a reverse phase control component.

28. The controllable-load circuit of claim 27, wherein the control circuit monitors said power source to determine if a voltage of said power source is above a predefined voltage level for a predefined time to determine if said power source includes a forward phase component or a reverse phone component.

29. The controllable-load circuit of claim 25, wherein the control circuit controls the impedance of said first impedance forming circuit to set the current through said first semiconductor switch at the predefined level by determining if a conduction period of the phase control component is within a predefined value.

30. The controllable-load circuit of claim 29, wherein said control circuit determines a steady state value of the conduction period by determining if the conduction period remains constant for a predetermined number of half cycles of said rectified alternating current, and if so, sets the determined conduction period as the steady state conduction period.

31. The controllable-load circuit of claim 30, wherein to automatically control the current through the first semiconductor switch to the predefined level, the control circuit implements the steps of:

a) decreasing the current through the first semiconductor switch by controlling the first impedance forming circuit to incrementally increase the impedance of said impedance forming circuit;

b) determining the present conduction period in the next half cycle of said rectified alternating current;

c) determining a conduction period adjustment value as a function of said steady state conduction period and the present conduction period;

d) determining if the conduction period adjustment value is less than or equal to a predefined conduction period adjustment value threshold;

e) incrementing a within tolerance counter if the conduction period adjustment value is less than the predefined conduction period adjustment value threshold and incrementing an outside tolerance counter if the conduction period adjustment value is greater than the predefined conduction period adjustment value threshold;

f) determining if the within tolerance counter equals or exceeds a within tolerance maximum value and if so checking to determine if the current through the first semiconductor switch equals a predefined minimum value and if not, decreasing the current through the first semiconductor switch by controlling the first impedance forming circuit to incrementally increase the impedance of said impedance forming circuit and repeating steps b-f; and

g) if the within tolerance counter is less than the within tolerance maximum value, determining if the outside tolerance counter equals or exceeds a maximum value for the outside tolerance counter and if not, repeating steps b-f, and if equal to the maximum value, controlling the first impedance forming circuit to incrementally decrease the impedance of said impedance forming circuit to incrementally increase the current through said first semiconductor switch.

32. The controllable-load circuit of claim 31, wherein the conduction period adjustment value comprises a value expressed as the absolute value of the difference between the determined present conduction period and the steady state conduction period as a percentage of the steady state conduction period.

33. The controllable-load circuit of claim 25, wherein the phase control component is generated by a phase control circuit including a thyristor series connected with the first semiconductor switch, and wherein the predefined level of the current through the first semiconductor switch minimally exceeds both a latching current and a holding current of said thyristor.

34. The controllable-load circuit of claim 23, wherein the second circuit comprises a first transistor coupled to the control input of said first semiconductor switch and a second transistor in series with the first transistor, the second transistor having a control input coupled to receive a voltage from said power source and to turn on at the selected voltage level to thereby cause current to be diverted away from the control input of said first semiconductor switch to cause said first semiconductor switch to enable a linear region of operation.

35. The controllable-load circuit of claim 23, wherein the power source comprises the output of a load control device including a series thyristor having a latching current and holding current, and said control circuit automatically adjusting said impedance of said impedance forming circuit to a value that insures said predefined level of the current through the first semiconductor switch is minimally adequate to maintain the latching current and holding current through said thyristor.

36. The controllable-load circuit of claim 23, wherein the first impedance forming circuit comprises a plurality of parallel connected series circuits each comprising a resistance and a controlled semiconductor switch, each controlled semiconductor switch having an input for selection by said control circuit, whereby one or more impedances can be disposed in series with said first semiconductor switch to generate a plurality of incrementally different current values through said first semiconductor switch.

37. A controllable-load circuit for drawing a selected current from a power source comprising:

a first semiconductor switch having a control input coupled to the power source;

a first impedance forming circuit connected in series with the first semiconductor switch across the power source, the first impedance forming circuit including a first input for selecting between at least two impedances to be connected in series with the first semiconductor switch;

a control circuit having an output coupled to said first input for selecting the selected impedance, said control circuit configured to control the impedance of said impedance forming circuit to automatically control the current through said first semiconductor switch to be at a predefined level;

a second circuit coupled to said first semiconductor switch for monitoring the power source and for increasing the impedance to current flowing from said power source through said first semiconductor switch at a selected voltage level of said power source, thereby to reduce the current through said first semiconductor switch;

wherein the power source comprises a source of rectified alternating current having a phase control component, the phase control component comprising one of a forward phase control component or a reverse phase control component, said control circuit configured to determine whether said rectified alternating current comprises a forward phase control component or a reverse phase control component, said control circuit further configured to render the first semiconductor switch conductive when there is a forward phase control component and to render the first semiconductor switch nonconductive when there is a reverse phase control component.

38. The controllable-load circuit of claim 37, wherein said control circuit is configured to sample the voltage of the power source and increment a first counter each time the voltage of the power source exceeds a noise level threshold to keep track of a number of samples.

39. The controllable-load circuit of claim 38, wherein, if the voltage of the power source exceeds a noise level superimposed thereon, the control circuit increments a second counter each time the voltage of the power source exceeds a predefined voltage level and checks to determine if the number of samples equals a predefined number of samples.

40. The controllable-load circuit of claim 39, wherein the control circuit increments a third counter each time the number of samples equals the predefined number of samples to keep track of the number of half cycles of said rectified alternating current and checks said second counter to determine if said second counter equals or exceeds a predefined count value of said second counter.

41. The controllable-load circuit of claim 40, wherein, if the count of said second counter does not equal or exceed said second counter predefined count value, the third counter is checked to determine if the third counter count equals a predefined third counter count and if not resets said first counter and further wherein if said second counter count equals or exceeds said second counter predefined count value, a fourth counter is incremented, said third counter count is checked to determine if it equals said predefined third counter count value and, if not said first counter is reset and if it equals said predefined third counter count value, checks the fourth counter count value to determine if it equals or exceeds a predefined fourth counter count value, and if so, said control circuit determines that the phase control component is a forward phase control component and enables said controllable-load circuit and if not, determines that said phase control component is a reverse phase control component and disables said controllable-load circuit.

42. A load control device for controlling the amount of power delivered from an AC power source to an electrical load, the load control device adapted to be coupled to the AC power source through a dimmer switch, the load control device comprising:

a load control circuit adapted to be coupled to the electrical load for controlling the amount of power delivered to the electrical load;

a controller coupled to the load control circuit for controlling the amount of power delivered to the electrical load in response to a phase-control voltage received from the dimmer switch; and

a controllable-load circuit coupled to the controller, the controllable-load circuit operable to conduct a controllable-load current from the AC power source through the dimmer switch;

wherein the controller is operable to determine whether the phase-control voltage comprises a forward phase-control waveform or a reverse phase-control waveform, the controller operable to operate in a first mode when the phase-control voltage is a forward phase-control waveform, and to operate in a second mode when the phase-control voltage is a reverse phase-control waveform;

wherein the controller is operable to enable the controllable-load circuit, such that the controllable-load circuit conducts the controllable load current through the dimmer switch when the controller is operating in the first mode, the controller further operable to disable the controllable-load circuit, such that the controllable-load circuit does not conduct the controllable-load current through the dimmer switch when the controller is operating in the second mode; and

wherein a magnitude of the controllable load current conducted by the controllable-load circuit through the dimmer switch exceeds at least one of a rated latching current or a rated holding current of the dimmer switch.

43. The load control device of claim 42, wherein the controller monitors a magnitude of the phase-control voltage received from the dimmer switch to determine whether the phase-control voltage is a forward phase-control waveform or a reverse phase-control waveform.

44. The load control device of claim 43, wherein the control circuit compares the magnitude of the phase-control voltage to a voltage threshold after detecting a voltage transition of the phase-control voltage to determine whether the phase-control voltage is a forward phase-control waveform or a reverse phase-control waveform, the controller determining that the phase-control voltage is a forward phase-control waveform if the magnitude of the phase-control voltage is consistently larger than the voltage threshold.

45. An LED driver for controlling the amount of power delivered from an AC power source to an LED light source, the LED driver adapted to be coupled to the AC power source through a dimmer switch, the LED driver comprising:

a bus capacitor for storing a DC bus voltage;

an LED drive circuit coupled to the bus capacitor for receiving the DC bus voltage and adapted to be coupled to the LED light source for controlling the amount of power delivered to the LED light source;

a controller coupled to the LED drive circuit for controlling the amount of power delivered to the LED light source to control the intensity of the LED light source in response to a phase-control voltage received from the dimmer switch; and

a controllable-load circuit coupled to the controller, the controllable-load circuit operable to conduct a controllable-load current from the AC power source through the dimmer switch;

wherein the controller is operable to determine whether the phase-control voltage comprises a forward phase-control waveform or a reverse phase-control waveform, the controller operable to enable the controllable-load circuit, such that the controllable-load circuit conducts the controllable-load current through the dimmer switch when the phase-control voltage is a forward phase-control waveform, the controller further operable to disable the controllable-load circuit, such that the controllable-load circuit does not conduct the controllable-load current through the dimmer switch when the phase-control voltage is a reverse phase-control waveform.

46. The LED driver of claim 45, wherein the controller is further operable to decrease a magnitude of the controllable-load current from an initial magnitude to a decreased magnitude when the controllable-load circuit is enabled.

47. The LED driver of claim 46, wherein the decreased magnitude of the controllable-load current conducted by the controllable-load circuit through the dimmer switch exceeds at least one of a rated latching current or a rated holding current of the dimmer switch.

48. The LED driver of claim 47, wherein the controller is operable to monitor a conduction period of the phase-control voltage after the magnitude of the controllable-load current has been decreased to the decreased magnitude and to further decrease the magnitude of the controllable-load current by an increment if the conduction period of the phase-control voltage has not changed.

49. The LED driver of claim 48, wherein the controller is operable to increase the magnitude of the controllable-load current by the increment if the conduction period of the phase-control voltage has changed.

50. The LED driver of claim 46, wherein when the controller decreases the magnitude of the controllable-load current from the initial magnitude to the decreased magnitude, the controller is further operable to control the LED drive circuit to deliver a constant amount of power to the LED light source.