Load control device for high-efficiency loads

• US 9,343,998 B2
• Filed: 01/28/2015
• Issued: 05/17/2016
• Est. Priority Date: 11/25/2009
• Status: Active Grant

• Current Assignee: Lutron Technology Company LLC
• Original Assignee: Lutron Electronics Company Incorporated (Lutron Electronics)
• Inventors: Newman, Robert C. Jr., Salvestrini, Christopher J., Harte, Matthew V.
• Primary Examiner(s): Laxton, Gary L
• Application Number:
  US14/607,442
• Publication Number:
  US 20150146465A1
• Time in Patent Office: 475 Days
• Field of Search: 323/235, 323/237, 323/239, 323/905
• US Class Current: 1/1
• CPC Class Codes: H02M 7/06 using discharge tubes without control electrode or semiconductor devices without control electrode
• CPC Class Codes: H02M 7/155 using semiconductor devices only
• CPC Class Codes: H02M 7/217 using semiconductor devices only
• CPC Class Codes: H05B 39/04 Controlling
• CPC Class Codes: H05B 39/044 continuously H05B39/042 takes precedence
• CPC Class Codes: H05B 39/048 with reverse phase control
• CPC Class Codes: H05B 41/3924 by phase control, e.g. using a triac H05B41/3922 takes precedence
• 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 45/315 Reverse phase-control circuits
• CPC Class Codes: H05B 45/37 Converter circuits
• CPC Class Codes: H05B 47/10 Controlling the light source
• CPC Class Codes: H05B 47/19 via wireless transmission
• CPC Class Codes: Y02B 20/00 Energy efficient lighting technologies, e.g. halogen lamps or gas discharge lamps
• CPC Class Codes: Y02B 20/30 Semiconductor lamps, e.g. solid state lamps [SSL] light emitting diodes [LED] or organic LED [OLED]
• CPC Class Codes: Y10S 323/905 Lamp dimmer structure

Abstract

A two-wire load control device (such as, a dimmer switch) for controlling power delivered from an AC power source to an electrical load (such as, a high-efficiency lighting load) includes a thyristor coupled between the source and the load, a first circuit coupled between a first main terminal and a gate terminal of the thyristor to conduct current through the gate terminal, a second circuit coupled between the first main terminal and a second main terminal of the thyristor to conduct current through the load when the thyristor is non-conductive, and a control circuit configured to individually control the first and second circuits. The control circuit renders the first circuit conductive to conduct a pulse of current through the gate terminal to render the thyristor conductive at a firing time, and allows the first circuit to conduct at least one other pulse of current through the gate terminal after the firing time.

Claims

1. A load control device for controlling power delivered from an AC power source to an electrical load, the load control device comprising:

a thyristor adapted to be electrically coupled between the AC power source and the electrical load, the thyristor having first and second main terminals through which current can be conducted to energize the electrical load and a gate terminal through which current can be conducted to render the thyristor conductive between the first and second main terminals;

a first circuit electrically coupled between the first main terminal of the thyristor and the gate terminal of the thyristor to conduct current through the gate terminal of the thyristor;

a second circuit electrically coupled between the first and second main terminals of the thyristor to conduct current through the electrical load when the thyristor is non-conductive; and

a control circuit configured to individually control the first and second circuits to be conductive and non-conductive, the control circuit configured to render the first circuit conductive to conduct a pulse of current through the gate terminal of the thyristor at a firing time during a present half-cycle of the AC power source to render the thyristor conductive, the control circuit configured to control the first circuit to allow the first circuit to conduct at least one other pulse of current through the gate terminal of the thyristor after the firing time during the present half-cycle;

wherein the control circuit is configured to render the first circuit non-conductive before the end of the present half-cycle to prevent any further pulses of current from being thereafter conducted through the gate terminal of the thyristor during the present half-cycle, the control circuit being further configured to control the second circuit to conduct current through the electrical load after the first circuit is rendered non-conductive.

2. The load control device of claim 1, wherein the first circuit includes a gate coupling circuit and a controllable switching circuit electrically coupled in series between the first main terminal of the thyristor and the gate terminal of the thyristor for conducting current through the gate terminal of the thyristor when the gate coupling circuit and the controllable switching circuit are conductive.

3. The load control device of claim 2, wherein the second circuit includes the gate coupling circuit and a resistor, the gate coupling circuit electrically coupled between the first main terminal of the thyristor and the controllable switching circuit, the resistor electrically coupled between the second main terminal of the thyristor and the junction of the gate coupling circuit and the controllable switching circuit, the resistor configured to conduct current through the electrical load when the thyristor is non-conductive.

4. The load control device of claim 3, wherein the gate coupling circuit comprises two MOS-gated transistors electrically coupled in anti-series connection between the first main terminal and the gate terminal of thyristor.

5. The load control device of claim 4, wherein the control circuit is configured to generate a single drive signal for controlling the gate coupling circuit, the gate coupling circuit comprising a control input electrically coupled to receive the single drive signal from the control circuit.

6. The load control device of claim 5, wherein the gate coupling circuit is configured such that the control input conducts an average current of less than one microamp to maintain the gate coupling circuit conductive between the firing time and the end of the present half-cycle.

7. The load control device of claim 5, wherein the gate coupling circuit is configured to conduct through the control input an amount of current appropriate to charge input capacitances of gate terminals of the MOS-gated transistors when the MOS-gated transistors are rendered conductive at the firing time.

8. The load control device of claim 4, wherein the control circuit is configured to generate two drive signals and to apply the two drive signals to respective ones of the MOS-gated transistors to independently control the MOS-gated transistors.

9. The load control device of claim 8, wherein the control circuit is configured to render both of the MOS-gate transistors conductive at the firing time, the control circuit being further configured to render a first one of the MOS-gated transistors non-conductive prior to the end of the present half-cycle to block current at the beginning of the next half-cycle, and to render a second one of the MOS-gated transistors non-conductive after the end of the present half-cycle to conduct current through the electrical load until the end of the present half-cycle.

10. The load control device of claim 8, wherein the gate coupling circuit comprises two control inputs for receiving the respective drive signals from the control circuit, the gate coupling circuit being configured to conduct through each of the control inputs an amount of current appropriate to charge an input capacitance of a gate terminal of the respective MOS-gated transistor when the MOS-gated transistors are rendered conductive at the firing time.

11. The load control device of claim 4, wherein the control circuit comprises a microprocessor and a power supply configured to generate a DC supply voltage to power the microprocessor so that the control circuit is able to render the MOS-gated transistors of the gate coupling circuit conductive.

12. The load control device of claim 4, wherein the MOS-gated transistors comprise MOSFETs or IGBTs.

13. The load control device of claim 3, wherein the control circuit is configured to control the gate coupling circuit to allow the gate coupling circuit to conduct the at least one other pulse of current between the firing time and a second time that occurs after the firing time and before the end of the present half-cycle, the control circuit being configured to render the controllable switching circuit non-conductive at the second time in order to prevent the gate coupling circuit from conducting another pulse of current to thereby allow the thyristor to become non-conductive.

14. The load control device of claim 13, wherein the gate coupling circuit is electrically coupled to conduct current through the electrical load when the thyristor becomes non-conductive after the second time.

15. The load control device of claim 3, wherein the control circuit is configured to render the controllable switching circuit conductive and to control the gate coupling circuit to conduct the pulse of current through the gate terminal of the thyristor at the firing time to render the thyristor conductive, the control circuit being configured to control the gate coupling circuit to allow the gate coupling circuit to conduct the at least one other pulse of current through the gate terminal of the thyristor after the firing time during the present half-cycle, the control circuit being further configured to render the controllable switching circuit non-conductive before the end of the present half-cycle to prevent any further pulses of current from being thereafter conducted through the gate terminal of the thyristor during the present half-cycle.

16. The load control device of claim 15, wherein the thyristor is able to commutate off after the control circuit renders the controllable switching circuit non-conductive, the control circuit being further configured to maintain the controllable switching circuit non-conductive until at least the beginning of the next half-cycle of the AC power source, thereby assuring that the thyristor remains non-conductive for the remainder of the present half-cycle after the thyristor commutates off.

17. The load control device of claim 3, wherein the load control device arranged such that a combination of the thyristor and the gate coupling circuit is able conduct current through the electrical load independent of a rated holding current of the thyristor.

18. The load control device of claim 1, wherein the control circuit is configured to control the first and second circuits to prevent the thyristor from being rendered conductive again after the first circuit is rendered non-conductive until the end of the present half-cycle.

19. The load control device of claim 1, wherein the control circuit is configured to control the first and second circuits to ensure that the thyristor remains non-conductive for the remainder of the present half-cycle after the thyristor commutates off.

20. A load control device for controlling power delivered from an AC power source to an electrical load, the load control device comprising:

a thyristor adapted to be electrically coupled between the AC power source and the electrical load, the thyristor having first and second main terminals through which current can be conducted to energize the electrical load and a gate terminal through which current can be conducted to render the thyristor conductive between the first and second main terminals;

a semiconductor-switch circuit comprising a semiconductor switch electrically coupled between the first and second main terminals of the thyristor; and

a control circuit configured to render the thyristor conductive in response to a pulse of current conducted through the gate terminal of the thyristor at a firing time during a present half-cycle of the AC power source, the control circuit being configured to maintain the thyristor conductive by allowing the gate terminal of the thyristor to conduct at least one other pulse of current between the firing time and a second time that occurs before the end of the present half-cycle, the control circuit being further configured to allow the thyristor to become non-conductive by preventing the gate terminal of the thyristor from conducting further pulse of current between the second time and the end of the present half-cycle;

wherein the control circuit is configured to render the semiconductor switch of the semiconductor-switch circuit conductive and non-conductive, the control circuit configured to control the semiconductor switch of the semiconductor-switch circuit to allow the semiconductor switch to conduct current through the electrical load when the thyristor is non-conductive.

21. The load control device of claim 20, wherein the semiconductor-switch circuit comprises a gate coupling circuit electrically coupled to the gate terminal of the thyristor to conduct current through the gate terminal.

22. The load control device of claim 21, further comprising:

a controllable switching circuit electrically coupled in series between the gate coupling circuit and the gate terminal of the thyristor and configured to conduct current through the gate terminal of the thyristor;

wherein the control circuit is configured to render the controllable switching circuit conductive and to control the gate coupling circuit to conduct the pulse of current through the gate terminal of the thyristor at the firing time to render the thyristor conductive, the control circuit being configured to control the gate coupling circuit to allow the gate coupling circuit to conduct the at least one other pulse of current through the gate terminal of the thyristor again after the firing time during the present half-cycle, the control circuit being further configured to render the controllable switching circuit non-conductive before the end of the present half-cycle to prevent any further pulses of current from being thereafter conducted through the gate terminal of the thyristor during the present half-cycle.

23. The load control device of claim 21, wherein the gate coupling circuit comprises two MOS-gated transistors electrically coupled in anti-series connection between the first main terminal of the thyristor and the gate terminal of thyristor.

24. The load control device of claim 21, wherein the semiconductor-switch circuit comprises a resistor electrically coupled to the gate coupling circuit, the series combination of the gate coupling circuit and the resistor electrically coupled in parallel with the first and second main terminals of the thyristor, whereby a path is provided for current to flow through the electrical load after the thyristor becomes non-conductive during the present half-cycle.