PWM controller with automatic low battery power reduction circuit and lighting device incorporating the controller

• US 6,870,329 B2
• Filed: 01/16/2003
• Issued: 03/22/2005
• Est. Priority Date: 04/26/2002
• Status: Expired due to Term

• Current Assignee: Vector Products Incorporated (Stanley Black & Decker, Inc.)
• Original Assignee: Vector Products Incorporated (Stanley Black & Decker, Inc.)
• Inventors: Shum, Henry, Krieger, Michael, Randolph, Bruce
• Primary Examiner(s): TRAN, THUY V
• Application Number:
  US10/345,154
• Publication Number:
  US 20030201734A1
• Time in Patent Office: 796 Days
• Field of Search: 315/295, 315/291, 315/362, 315/307, 315/DIG.7, 307/106, 307/130, 307/116, 307/125
• US Class Current: 315/295
• CPC Class Codes: H05B 39/047 with pulse width modulation from a DC power source
• CPC Class Codes: H05B 41/2853 against abnormal power supply conditions
• CPC Class Codes: Y02B 20/00 Energy efficient lighting technologies, e.g. halogen lamps or gas discharge lamps

Abstract

A controller for controlling a voltage applied to a load from a power source includes a square wave producing circuit for connection in the circuit with the battery and the lamp. The square wave producing circuit produces a variable duty cycle square wave for controlling application of power to the load in accordance with the duty cycle of the square wave. The square wave producing circuit has a control input for varying the duty cycle of the square wave in response to a voltage at the control input. A voltage varying circuit is connected to the power source for producing a selectively variable voltage that is fed to the control input of the square wave producing circuit for selectively adjusting the duty cycle of the square wave. A low voltage detection circuit is connected to the power source and coupled to the control input of the square wave producing circuit for automatically producing a voltage that decreases the duty cycle of the square wave when the battery voltage decreases to or below a predetermined level.

Claims

1. A control circuit for a load, comprising:

a square wave generator producing a square wave output, a duty cycle of the square wave output being controllable by a control input of the square wave generator, the square wave output being coupled to the load, wherein the square wave generator comprises a comparator circuit having a threshold level set by the control input;

a low voltage detection circuit for monitoring a voltage level of a power source and providing a control signal to the control input of the square wave generator, to thereby decrease the duty cycle of the square wave output when the voltage level of the power source decreases below a predetermined level; and

a triangular wave oscillator producing a triangle wave signal, wherein the triangle wave signal is provided as input to the square wave generator for comparison to the threshold level by the comparator circuit.

2. A control circuit for a load, comprising:

a square wave generator producing a square wave output, a duty cycle of the square wave output being controllable by a control input of the square wave generator, the square wave output being coupled to the load; and

a low voltage detection circuit for monitoring a voltage level of a power source and providing a control signal to the control input of the square wave generator, to thereby decrease the duty cycle of the square wave output when the voltage level of the power source decreases below a predetermined level; and

manual control means for varying the control signal input to the control input of the square wave generator.

3. The control circuit of claim 2, wherein the manual control means comprises a potentiometer.

4. The control circuit of claim 2, wherein the manual control means comprises:

a plurality of transistors;

a plurality of resistor means, corresponding in number to the plurality of transistors, each having a different value, and each coupled to a different one of the plurality of transistors; and

a selector switch coupled to select one or none of the plurality of transistors to be conductive.

5. The control circuit of claim 4, further comprising:

an integrated circuit coupled to the selector switch, wherein one or none of the plurality of transistors is enabled to conduct by an output of the integrated circuit generated in response to use of the selector switch.

6. The control circuit of claim 5, wherein the integrated circuit comprises a decade counter.

7. The control circuit of claim 5, wherein the integrated circuit includes a reset input coupled to reset the integrated circuit upon any one of power-up, low power source voltage, and use of the selector switch to turn off the load, wherein the reset of the integrated circuit results in power to the load being cut off and the control circuit entering a power conservation mode.

8. The control circuit of claim 2, wherein the manual control means comprises:

a selector switch; and

an integrated circuit coupled to the selector switch to vary the control signal input to the control input of the square wave generator among a plurality of discrete levels.

9. The control circuit of claim 8, wherein the manual control means further comprises:

at least two Level resistors, each having a first terminal coupled to a corresponding different output of the integrated circuit, each level resistor having a resistance different from each of the other level resistors; and

a common resistor having one terminal coupled to a second terminal of each of the level resistors another terminal coupled to ground;

wherein a point at which the level resistors are coupled to the common resistor is also coupled to the control input of the square wave generator, and wherein the integrated circuit controls the level of the control signal input to the control input of the square wave generator by selecting an output coupled to one of the level resistors or to none of the level resistors.

10. The control circuit of claim 9, further comprising:

a number of diodes equal in number to the at least two level resistors, wherein each of the level resistors is coupled to the common resistor via one of the diodes.

11. The control circuit of claim 8, wherein the integrated circuit includes a reset input coupled to reset the circuit upon any one of power-up, low power source voltage, and use of the selector switch to turn off the load, wherein the reset mode results in power to the load being cut off and the integrated circuit entering an initial state.

12. A control circuit for a load, comprising:

a square wave generator producing a square wave output, a duty cycle of the square wave output being controllable by a control input of the square wave generator, the square wave output being coupled to the load; and

a low voltage detection circuit for monitoring a voltage level of a power source and providing a control signal to the control input of the square wave generator, to thereby decrease the duty cycle of the square wave output when the voltage level of the power source decreases below a predetermined level, wherein the low voltage detection circuit comprises a control transistor, wherein the control transistor is gradually turned off as the voltage level of the power source decreases below the predetermined level.

13. A control circuit for a load, comprising:

a square wave generator producing a square wave output, a duty cycle of the square wave output being controllable by a control input of the square wave generator, the square wave output being coupled to the load; and

a low voltage detection circuit for monitoring a voltage level a power source and providing a control signal to the control input of the square wave generator, to thereby decrease the duty cycle of the square wave output when the voltage level of the power source decreases below a predetermined level; and

a transistor coupled to the square wave generator and arranged so as to permit and shut off input to the square wave generator.

14. The control circuit of claim 13, further comprising:

an integrated circuit having an output coupled to the transistor to control the transistor to permit and shut off input to the square wave generator.

15. The control circuit of claim 14, comprising:

a selector switch coupled to the integrated circuit;

wherein the integrated circuit includes a reset input; and

wherein the reset input is connected so that the integrated circuit resets when at least one of a low power condition, a power-up condition, or a manual turn-off condition occurs.

16. The control circuit of claim 15, wherein, when the integrated circuit resets, the integrated circuit output coupled to the transistor causes the transistor to shut off input to the square wave generator.

17. A control circuit for a load, comprising:

a square wave generator producing a square wave output, a duty cycle of the square wave output being controllable by a control input of the square wave generator, the square wave output being coupled to the load, wherein the square wave generator comprises a timer circuit; and

a low voltage detection circuit for monitoring a voltage level of a power source and providing a control signal to the control input of the square wave generator, to thereby decrease the duty cycle of the square wave output when the voltage level of the power source decreases.

18. A method of controlling a load, comprising the steps of:

producing a controllable variable duty cycle square wave for controlling application of power to the load in accordance with the duty cycle of the square wave;

detecting when the voltage of a power source decreases to a predetermined level and upon such detection automatically producing a voltage that decreases the duty cycle of the square wave used for controlling application of power to the load; and

manually controlling the duty cycle of the square wave to control the intensity of the load.

19. A method of controlling a load, comprising the steps of:

producing a controllable variable duty cycle square wave for controlling application of power to the load in accordance with the duty cycle of the square wave; and

detecting when the voltage of a power source decreases to a predetermined level and upon such detection automatically producing a voltage that decreases the duty cycle of the square wave used for controlling application of power to the load, wherein the step of producing the controllable variable duty cycle square wave comprises the steps of;

providing a fixed frequency triangular wave; and

comparing the triangular wave to a threshold voltage, thereby producing the square wave.

20. The method of claim 19, wherein the voltage that decreases the duty cycle of the square wave, produced by the detecting step, determines the threshold voltage.

21. The method of claim 20, further comprising the step of:

manually adjusting the voltage that decreases the duty cycle of the square wave, produced by the detecting step, so as to manually adjust the threshold voltage.

22. A pulse-width modulation (PWM)-based lamp control circuit comprising:

a square wave generator for producing a square wave output, a duty cycle of the square wave output being controllable by a control input of the square wave generator, the square wave output being coupled to the lamp, wherein the square wave generator comprises a comparator circuit having a threshold level set by the control input;

a low voltage detection circuit for monitoring a voltage level of a power source and providing a control signal to the control input of the square wave generator, to thereby decrease the duty cycle of the square wave output when the voltage level of the power source decreases below a predetermined level; and

a triangular wave oscillator producing a triangle wave signal, wherein the triangle wave signal is provided as input to the square wave generator for comparison to the threshold level by the comparator circuit.

23. A pulse-width modulation (PWM)-based lamp control circuit comprising:

a square wave generator for producing a square wave output, a duty cycle of the square wave output being controllable by a control input of the square wave generator, the square wave output being coupled to the lamp;

a low voltage detection circuit for monitoring a voltage level of a power source and providing a control signal to the control input of the square wave generator, to thereby decrease the duty cycle of the square wave output when the voltage level of the power source decreases below a predetermined level; and

manual control means for varying the control signal input from the low voltage detection circuit to the control input of the square wave generator.

24. The control circuit of claim 23, wherein the manual control means comprises a potentiometer.

25. The control circuit of claim 23, wherein the manual control means comprises:

a plurality of transistors;

a plurality of resistor means, corresponding in number to the plurality of transistors, each having a different value, and each coupled to a different one of the plurality of transistors; and

a selector switch coupled to select one or none of the plurality of transistors to be conductive.

26. The control circuit of claim 25, further comprising:

an integrated circuit coupled to the selector switch, wherein one or none of the plurality of transistors is enabled to conduct by an output of the integrated circuit generated in response to use of the selector switch.

27. The control circuit of claim 26, wherein the integrated circuit comprises a decade counter.

28. The control circuit of claim 26, wherein the integrated circuit includes a reset input coupled to reset the integrated circuit upon any one of power-up, low power source voltage, and use of the selector switch to turn off the load, wherein the reset of the integrated circuit results in power to the load being cut off and the control circuit entering a power conservation mode.

29. The control circuit of claim 23, wherein the manual control means comprises:

a selector switch; and

an integrated circuit coupled to the selector switch to vary the control signal input to the control input of the square wave generator among a plurality of discrete levels.

30. The control circuit of claim 29, wherein the manual control means further comprises:

at least two level resistors, each having a first terminal coupled to a corresponding a different output of the integrated circuit, each level resistor having a resistance different from each of the other level resistors; and

a common resistor having one terminal coupled to a second terminal of each of the level resistors another terminal coupled to ground;

wherein a point at which the level resistors are coupled to the common resistor is also coupled to the control input of the square wave generator, and wherein the integrated circuit controls the level of the control signal input to the control input of the square wave generator by selecting an output coupled to one of the level resistors or to none of the level resistors.

31. The control circuit of claim 30, further comprising:

a number of diodes equal in number to the at least two level resistors, wherein each of the level resistors is coupled to the common resistor via one of the diodes.

32. The control circuit of claim 29, wherein the integrated circuit includes a reset input coupled to reset the integrated circuit upon any one of power-up, low power source voltage, and use of the selector switch to turn off the load, wherein the reset mode results in power to the load being cut off and the integrated circuit entering an initial state.

33. A pulse-width modulation (PWM)-based lamp control circuit comprising:

a square wave generator for producing a square wave output, a duty cycle of the square wave output being controllable by a control input of the square wave generator, the square wave output being coupled to the lamp;

a low voltage detection circuit for monitoring a voltage level of a power source and providing a control signal to the control input of the square wave generator, to thereby decrease the duty cycle of the square wave output when the voltage level of the power source decreases below a predetermined level, wherein the low voltage detection circuit comprises a control transistor, wherein the control transistor is gradually turned off as the voltage level of the power source decreases below the predetermined level.

34. A pulse-width modulation (PWM)-based lamp control circuit comprising:

a square wave generator for producing a square wave output, a duty cycle of the square wave output being controllable by a control input of the square wave generator, the square wave output being coupled to the lamp;

a low voltage detection circuit for monitoring a voltage level of a power source and providing a control signal to the control input of the square wave generator, to thereby decrease the duty cycle of the square wave output when the voltage level of the power source decreases below a predetermined level; and

a transistor coupled to the square wave generator and arranged so as to permit and shut off input to the square wave generator.

35. The control circuit of claim 34, further comprising:

an integrated circuit having an output coupled to the transistor to control the transistor to permit and shut off input to the square wave generator.

36. The control circuit of claim 35, further comprising:

a selector switch coupled to the integrated circuit;

wherein the integrated circuit includes a reset input; and

wherein the reset input is arranged so that the integrated circuit resets when at least one of a low power condition, a power-up condition, or a manual turn-off condition occurs.

37. The control circuit of claim 36, wherein, when the integrated circuit resets, the integrated circuit output coupled to the transistor causes the transistor to shut off input to the square wave generator.

38. A pulse-width modulation (PWM)-based lamp control circuit composing:

a square wave generator for producing a square wave output, a duty cycle of the square wave output being controllable by a control input of the square wave generator, the square wave output being coupled to the lamp, wherein the square wave generator comprises a timer circuit;

a low voltage detection circuit for monitoring a voltage level of a power source and providing a control signal to the control input of the square wave generator, to thereby decrease the duty cycle of the square wave output when the voltage level of the power source decreases below a predetermined level.

39. A control circuit for a load, comprising:

a square wave generator producing a square wave output, a duty cycle of the square wave output being controllable by a control input of the square wave generator, the square wave output being coupled to the load; and

a low voltage detection circuit for monitoring a voltage level of a power source and providing a control signal to the control input of the square wave generator, to thereby decrease the duty cycle of the square wave output when the voltage level of the power source decreases below a predetermined level, wherein said predetermined level is less than or equal to about 80%.

40. A method of controlling a load, comprising the steps of:

producing a controllable variable duty cycle square wave for controlling application of power to the load in accordance with the duty cycle of the square wave;

detecting when a voltage of a power source decreases to a predetermined level and upon such detection automatically producing a voltage that decreases the duty cycle of the square wave used for controlling application of power to the, wherein said predetermined level is less than or equal to about 80%.

41. A pulse-width modulation (PWM)-based lamp control circuit comprising:

a square wave generator for producing a square wave output, a duty cycle of the square wave output being controllable by a control input of the square wave generator, the square wave output being coupled to the lame, wherein the square wave generator comprises a comparator circuit having a threshold level set by the control input;

a low voltage detection circuit for monitoring a voltage level of a power source and providing a control signal to the control input of the square wave generator, to thereby decrease the duty cycle of the square wave output when the voltage level of the power source decreases below a predetermined level, wherein said predetermined level is less than or equal to about 80%.