Illumination device and method for determining a maximum lumens that can be safely produced by the illumination device to achieve a target chromaticity

• US 9,237,623 B1
• Filed: 01/26/2015
• Issued: 01/12/2016
• Est. Priority Date: 01/26/2015
• Status: Active Grant

• Current Assignee: Lutron Technology Company LLC
• Original Assignee: Ketra, Inc. (Lutron Electronics)
• Inventors: Lewis, Jason, Bocock, Ryan Matthew, Savage, Joseph, Luu, Jivan James, Knapp, David
• Primary Examiner(s): Vu, Jimmy
• Application Number:
  US14/604,881
• Time in Patent Office: 351 Days
• Field of Search: 315/185.R, 315/291, 315/307, 315/308, 315/312, 315/360, 315/362
• US Class Current: 1/1
• CPC Class Codes: H05B 45/10 Controlling the intensity of the light
• CPC Class Codes: H05B 45/18 using temperature feedback
• CPC Class Codes: H05B 45/3725 Switched mode power supply [SMPS]
• CPC Class Codes: H05B 45/375 using buck topology
• CPC Class Codes: H05B 45/385 using flyback topology
• CPC Class Codes: H05B 45/46 having LEDs disposed in parallel lines
• CPC Class Codes: H05B 47/19 via wireless transmission
• CPC Class Codes: H05B 47/195 the transmission using visible or infrared light

Abstract

An illumination device and methods are provided herein for avoiding over-current and over-power conditions in one or more power converters included within the illumination device. The illumination device may generally include a plurality of light emitting diode (LED) chains, a driver circuit, at least one power converter, and a control circuit. The LED chains may produce illumination for the illumination device at a chromaticity consistent with a chromaticity setting. The power converter(s) may be coupled for powering the LED chains, and may each comprise a maximum safe current level or a maximum safe power level, which varies with temperature. The control circuit may be configured for determining a maximum lumens value that can be safely produced by all LED chains at a predetermined safe temperature to achieve the chromaticity setting without exceeding the maximum safe current level or the maximum safe power level of the power converter(s) at the predetermined safe temperature.

Claims

1. An illumination device, comprising:

a plurality of light emitting diode (LED) chains configured to produce illumination for the illumination device at a chromaticity consistent with a chromaticity setting;

a driver circuit coupled for generating and supplying a respective drive current to each of the plurality of LED chains for producing the illumination;

a plurality of power converters coupled for supplying power to the driver circuit, wherein the power converters each comprise a maximum safe current level or a maximum safe power level, which varies with temperature; and

a control circuit configured for determining a maximum lumens value that is safely producible by all LED chains at a predetermined safe temperature to achieve the chromaticity setting without exceeding the maximum safe current level or the maximum safe power level of the power converters at the predetermined safe temperature.

2. The illumination device as recited in claim 1, further comprising an interface coupled for receiving the chromaticity setting.

3. The illumination device as recited in claim 1, further comprising a storage medium coupled for storing the chromaticity setting.

4. The illumination device as recited in claim 1, wherein the control circuit is configured to determine the maximum lumens value by:

determining, for each LED chain, a lumen proportion needed from each LED chain to achieve the chromaticity setting at the predetermined safe temperature;

determining, for each LED chain, a relative lumens needed from the LED chain to achieve the lumen proportion determined for the LED chain, assuming only one of the plurality of LED chains is driven with a maximum drive current;

calculating, for each LED chain, a ratio of the relative lumens determined for the LED chain over a maximum lumen output for the LED chain;

determining, for each LED chain, an actual lumens needed from the LED chain to achieve the chromaticity setting at the predetermined safe temperature by dividing the relative lumens needed from the LED chain by a largest of the calculated ratios; and

summing the actual lumens needed from each LED chain to determine the maximum lumens value that is producible by all LED chains at the predetermined safe temperature to achieve the chromaticity setting.

5. The illumination device as recited in claim 4, wherein the control circuit is configured to determine the lumen proportions needed from each LED chain to achieve the chromaticity setting at the predetermined safe temperature by:

determining, for each LED chain, chromaticity values that are expected for the LED chain using a forward voltage calibrated for the LED chain at the predetermined safe temperature, the respective drive current supplied to the LED chain, a table of stored calibration values correlating forward voltage and drive current to chromaticity at a plurality of different temperatures, and one or more interpolation techniques; and

calculating the lumen proportions needed from each LED chain to achieve the chromaticity setting at the predetermined safe temperature using the expected chromaticity values.

6. The illumination device as recited in claim 4, wherein the control circuit is further configured to determine the maximum lumens value by:

determining, for each LED chain, a drive current needed to produce the actual lumens needed from the LED chain to achieve the chromaticity setting at the predetermined safe temperature;

estimating a total power drawn by all LED chains combined at the predetermined safe temperature;

generating a scale factor; and

applying the scale factor to the maximum lumens value.

7. The illumination device as recited in claim 6, wherein the control circuit is configured to determine, for each LED chain, the drive current needed to produce the actual lumens by using a forward voltage calibrated for the LED chain at the predetermined safe temperature, the actual lumens determined for the LED chain, a table of stored calibration values correlating forward voltage and drive current to lumens at a plurality of different temperatures, and one or more interpolation techniques.

8. The illumination device as recited in claim 6, wherein the control circuit is configured to estimate the total power drawn by all LED chains combined at the predetermined safe temperature by:

estimating, for each LED chain, a power drawn by the LED chain by multiplying the drive current needed from the LED chain to produce the actual lumens with a forward voltage value estimated for that drive current at the predetermined safe temperature; and

summing the estimated power drawn by all LED chains.

9. The illumination device as recited in claim 6, wherein the control circuit is configured to generate the scale factor by:

determining the maximum safe power level and the maximum safe current level of the power converters at the predetermined safe temperature;

calculating a ratio of the maximum safe power level at the predetermined safe temperature over the total power estimated at the predetermined safe temperature;

calculating, for each LED chain, a ratio of the maximum safe current level at the predetermined safe temperature over the drive current determined for the LED chain at the predetermined safe temperature; and

using a smallest of the calculated ratios to generate the scale factor.

10. The illumination device as recited in claim 9, further comprising a storage medium coupled for storing a relationship of saturation current versus temperature for each of the power converters, and wherein the control circuit is configured to determine the maximum safe power level and the maximum safe current level of the power converters at the predetermined safe temperature by linearly interpolating between the stored relationships.

11. The illumination device as recited in claim 6, further comprising an interface coupled for receiving the chromaticity setting, and wherein the control circuit is configured to determine a new maximum lumens value whenever a new chromaticity setting is received by the interface.

12. A method for adjusting a maximum lumens value associated with an illumination device comprising a plurality of light emitting diode (LED) chains and a plurality of power converters configured for powering the LED chains, the method comprising:

detecting a chromaticity setting set for the illumination device;

determining a maximum lumens value that is safely producible by all LED chains at a predetermined safe temperature to achieve the chromaticity setting, so as not to exceed a maximum safe power level or a maximum safe current level associated with the power converters at a predetermined safe temperature; and

adjusting the maximum lumens value upon detecting a change in the chromaticity setting.

13. The method as recited in claim 12, wherein said determining a maximum lumens value comprises:

determining, for each LED chain, a lumen proportion needed from each LED chain to achieve the chromaticity setting at the predetermined safe temperature;

determining, for each LED chain, a relative lumens needed from the LED chain to achieve the lumen proportion determined for the LED chain, assuming only one of the plurality of LED chains is driven with a maximum drive current;

calculating, for each LED chain, a ratio of the relative lumens determined for the LED chain over a maximum lumen output for the LED chain;

determining, for each LED chain, an actual lumens needed from the LED chain to achieve the chromaticity setting at the predetermined safe temperature by dividing the relative lumens needed from the LED chain by a largest of the calculated ratios; and

summing the actual lumens needed from each LED chain to determine the maximum lumens value that is safely producible by all LED chains at the predetermined safe temperature to achieve the chromaticity setting.

14. The method as recited in claim 13, wherein said determining the lumen proportions needed from each LED chain to achieve the chromaticity setting at the predetermined safe temperature comprises:

determining drive currents presently supplied to each LED chain;

determining, for each LED chain, chromaticity values that are expected for the LED chain using a forward voltage calibrated for the LED chain at the predetermined safe temperature, the drive current presently supplied to the LED chain, a table of stored calibration values correlating forward voltage and drive current to chromaticity at a plurality of different temperatures, and one or more interpolation techniques; and

calculating the lumen proportions needed from each LED chain to achieve the chromaticity setting at the predetermined safe temperature using the expected chromaticity values.

15. The method as recited in claim 13, wherein said determining a maximum lumens value further comprises:

determining, for each LED chain, a drive current needed to produce the actual lumens needed from the LED chain to achieve the chromaticity setting at the predetermined safe temperature;

estimating a total power drawn by all LED chains combined at the predetermined safe temperature;

generating a scale factor; and

applying the scale factor to the maximum lumens value.

16. The method as recited in claim 15, wherein said determining, for each LED chain, the drive current needed to produce the actual lumens comprises using a forward voltage calibrated for the LED chain at the predetermined safe temperature, the actual lumens determined for the LED chain, a table of stored calibration values correlating forward voltage and drive current to lumens at a plurality of different temperatures, and one or more interpolation techniques to determine the drive current.

17. The method as recited in claim 15, wherein said estimating the total power drawn by all LED chains combined at the predetermined safe temperature comprises:

estimating, for each LED chain, a power drawn by the LED chain by multiplying the drive current needed from the LED chain to produce the actual lumens with a forward voltage value estimated for that drive current at the predetermined safe temperature; and

summing the estimated power drawn by all LED chains.

18. The method as recited in claim 15, wherein said generating a scale factor comprises:

determining the maximum safe power level and the maximum safe current level of the power converters at the predetermined safe temperature;

calculating a ratio of the maximum safe power level at the predetermined safe temperature over the estimated total power;

calculating, for each LED chain, a ratio of the maximum safe current level at the predetermined safe temperature over the drive current needed for the LED chain to produce the actual lumens;

using a smallest of the calculated ratios to generate the scale factor.

19. The method as recited in claim 18, wherein said determining the maximum safe power level and the maximum safe current level of the power converters at the predetermined safe temperature comprises linearly interpolating between saturation current versus temperature relationships or values stored within the illumination device for each of the power converters.