Abstract:
Methods and apparatus are provided for operating very high pressure short arc mercury discharge lamps primarily used for projection applications. The method includes controlling an alternating lamp current supplied to the lamp at a constant RMS value. In some embodiments, the lamp current is adjusted to a new constant RMS value to maintain lamp power between an upper power limit and a lower power limit. In other embodiments, lamp cooling is adjusted to maintain a wall temperature of the arc tube below a softening temperature.

Description:
FIELD OF THE INVENTION  
       [0001]     This invention relates to arc discharge lamps and, more particularly, to methods and apparatus for operating very high pressure short arc mercury discharge lamps primarily used for projection applications.  
       BACKGROUND OF THE INVENTION  
       [0002]     Very high pressure discharge lamps include an arc tube containing an inert gas, mercury vapor, and two electrodes positioned at opposite ends of the arc tube. An arc discharge is established in the arc tube by supplying an electrical current to the electrodes. The very high pressure discharge lamp is typically utilized for projection applications, where the optical system requires point-like light sources. To achieve such optical performance, the arc length must be on the order of 1.0-1.5 millimeters. The lamps typically include an arc tube constructed of heat resistant and optical transparent material such as quartz, tungsten electrodes, mercury vapor and an inert starting gas. The electrodes are constructed of a tungsten rod with a tungsten coil attached to one end.  
         [0003]     Typically, the electrode tip in very high pressure discharge lamps reaches temperatures close to or even above the melting point of tungsten. This is necessary to prevent movement of the point of arc attachment to the electrode, also called the arc root. However, if the electrodes become too cold, the molten tip solidifies and collapses to a relatively flat surface. The arc attachment becomes unstable, leading to sudden arc movement or jumping. Moreover, the distance between electrodes increases, thereby reducing the performance of the light collecting optics. On the other hand, if the electrodes become too hot, the molten region increases, leading to a meltback condition where the distance between electrodes increases, thereby reducing the performance of the light collecting optics. Moreover, during the meltback, increased amounts of tungsten are evaporated from the electrodes and deposited on the arc tube walls, leading to poor lamp maintenance. Therefore, the operation of very high pressure discharge lamps needs to be optimized in order to achieve the most beneficial electrode temperature.  
         [0004]     A problem in establishing the optimal temperature for the two electrodes of a discharge lamp may arise when the lamp current is varied. Such a situation occurs as the lamp voltage increases. To maintain constant power conditions, prior arc ballast circuitry reduces the lamp current. As a result, the tip temperature of one electrode is reduced such that the tip starts to solidify. Upon solidification, the tip of the electrode diminishes, leading to a larger arc gap and therefore, a larger lamp voltage. The current supply to the lamp decreases and the electrode tip temperature is further reduced. The process continues until the electrode surface becomes flat. Arc instability may then occur.  
         [0005]     Furthermore, a very high pressure discharge lamp is usually mounted in a reflector, which changes the thermal environment of the arc tube. One end of the lamp, and thus one electrode, may be hotter than the other end. In typical applications, very high pressure discharge lamps are operated with forced air cooling, which is usually directed to both sides of the lamp or to the upper side of the lamp. Depending on the configuration of the cooling airflow, different lamp performance is achieved.  
         [0006]     During the lifetime of a discharge lamp, the structure of the electrodes may change due to tungsten transport from the tip of the electrode. In cases where one of the electrodes has started to melt back, its ability to conduct heat from the electrode tip changes, and the flattening process may accelerate, leading to early lamp failure. Using preshaped electrodes cannot compensate for most of these asymmetries, because they are unpredictable. Different electrode shapes require additional devices to permit proper mounting of the lamp in the system in which it is employed.  
         [0007]     Techniques and circuits for operating high pressure discharge lamps are disclosed in U.S. Pat. No. 5,608,294, issued Mar. 4, 1997 to Derra et al.; U.S. Pat. No. 6,232,725, issued May 15, 2001 to Derra et al.; U.S. Pat. No. 6,239,556, issued May 29, 2001 to Derra et al.; and International Publication No. WO 2004/002200, published Dec. 31, 2003. All of the known prior art techniques have had one or more drawbacks and disadvantages.  
         [0008]     Accordingly, there is a need for methods and apparatus for operating very high pressure discharge lamps with improved performance and lifetime.  
       SUMMARY OF THE INVENTION  
       [0009]     According to a first aspect of the invention, a method is provided for operating a high pressure discharge lamp. The method comprises controlling an alternating lamp current supplied to the lamp at a constant RMS value, and adjusting the lamp current to a new RMS value to prevent power supplied to the lamp from exceeding an upper power limit. The lamp current is maintained constant at the new RMS value.  
         [0010]     According to a second aspect of the invention, a lamp system comprises a high pressure discharge lamp, a power circuit for supplying alternating current to the lamp, and a controller configured to control the lamp current at a constant RMS value and to adjust the lamp current to a new RMS value to prevent power supplied to the lamp from exceeding an upper power limit. The lamp current is maintained constant at the new RMS value.  
         [0011]     According to a third aspect of the invention, a method is provided for operating a high pressure discharge lamp including an arc tube. The method comprises controlling an alternating current supplied to the lamp at a constant RMS value, and adjusting lamp cooling to maintain a wall temperature of the arc tube below a softening temperature.  
         [0012]     According to a fourth aspect of the invention, a lamp system comprises a high pressure discharge lamp including an arc tube, a power circuit for supplying alternating current to the lamp, a cooling source directed at the lamp, and a controller configured to control the lamp current at a constant RMS value and to adjust the cooling source to maintain a wall temperature of the arc tube below a softening temperature.  
         [0013]     According to a fifth aspect of the invention, a method is provided for operating a high pressure discharge lamp. The method comprises controlling an alternating lamp current supplied to the lamp at a constant RMS value, and adjusting the lamp current to a new RMS value to maintain lamp power between an upper power limit and a lower power limit. The lamp current is maintained constant at the new RMS value.  
         [0014]     According to a sixth aspect of the invention, a lamp system comprises a high pressure discharge lamp, a power circuit for supplying alternating current to the lamp and a controller configured to control the lamp current at a constant RMS value and to adjust the lamp current to a new RMS value to maintain lamp power between an upper power limit and a lower power limit. The lamp current is maintained constant at the new RMS value.  
         [0015]     According to a seventh aspect of the invention, a method is provided for operating a high pressure discharge lamp. The method comprises controlling an alternating lamp current supplied to the lamp at a constant RMS value; and increasing the lamp current to a new RMS value in response to a prescribed value of lamp voltage and maintaining the lamp current constant at the new RMS value.  
         [0016]     According to an eighth aspect of the invention, a lamp system comprises a high pressure discharge lamp; a power circuit for supplying alternating lamp current to the lamp; and a controller configured to control the lamp current at a constant RMS value, to increase the lamp current to a new RMS value in response to a prescribed value of lamp voltage and to maintain the lamp current constant at the new RMS value. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0017]     For a better understanding of the present invention, reference is made to the accompanying drawings, which are incorporated herein by reference and in which:  
         [0018]      FIG. 1  is a schematic block diagram of a lamp system in accordance with a first embodiment of the invention;  
         [0019]      FIG. 2  illustrates an electrode condition for stable arc root attachment;  
         [0020]      FIG. 3  illustrates a flat electrode tip which exhibits flicker conditions;  
         [0021]      FIG. 4  is a graph of lamp power, lamp voltage and lamp current as a function of time and illustrates current control in accordance with embodiments of the invention;  
         [0022]      FIG. 4A  is a flow chart of a process for lamp control in accordance with embodiments of the invention;  
         [0023]      FIG. 5  is a graph of relative light output (RLO) of a discharge lamp as a function of time for flicker and flicker-free operation;  
         [0024]      FIG. 6  is a graph of lamp power, lamp voltage and lamp current as a function of time and illustrates current control in accordance with embodiments of the invention;  
         [0025]      FIG. 7  is a schematic block diagram of a prior art lamp reflector and forced air cooling assembly;  
         [0026]      FIG. 8  is a schematic block diagram of a lamp system in accordance with a second embodiment of the invention;  
         [0027]      FIG. 9  is a graph of cooling rate, lamp power, lamp voltage and lamp current as a function of time and illustrates current control and cooling control in accordance with embodiments of the invention;  
         [0028]      FIG. 9A  is a flow chart of a process for lamp control in accordance with embodiments of the invention;  
         [0029]      FIG. 10  is a graph of lamp voltage and lamp power as a function of time in accordance with a prior art constant power control technique;  
         [0030]      FIG. 11  is a graph of lamp voltage and lamp power as a function of time in accordance with embodiments of the invention; and  
         [0031]      FIG. 12  is a graph of lamp voltage and lamp power as a function of time in accordance with embodiments of the invention. 
     
    
     DETAILED DESCRIPTION  
       [0032]     A schematic block diagram of a lamp system in accordance with a first embodiment of the invention is shown in  FIG. 1 . The lamp system includes a very high pressure discharge lamp  10  and an electronic power supply  20 . Discharge lamp  10  is mounted in a reflector  12 . One end  22  of discharge lamp  10  is secured in a neck  24  of reflector  12 . The reflector  12  is enclosed by a transparent member  26 .  
         [0033]     Very high pressure discharge lamps typically include an arc tube  30  constructed of a heat resistant and optically transparent material, such as quartz. Tungsten electrodes  32  and  34  are mounted at opposite ends of arc tube  30 , and the interior volume of arc tube  30  contains mercury vapor and an inert starting gas. Each of electrodes  32  and  34  includes a tungsten rod  40  having a tungsten coil  42  attached to one end, as shown schematically in  FIGS. 2 and 3 . Electrodes  32  and  34  are separated by an electrode distance, called the arc length. To achieve a desired optical performance, the arc length is on the order of 1.0-1.5 millimeters. The electrodes are affixed to opposite ends of arc tube  30  by press pinching. The electrodes are connected by appropriate electrical wiring to respective output terminals O 1  and O 2  of electronic power supply  20 .  
         [0034]     Electronic power supply  20  includes a power circuit  50 , an ignition circuit  52  and a controller  54 . When input terminals I 1  and  12  of electronic power supply  20  are connected to an AC voltage supply, power circuit  50  generates an alternating current having successive periods of alternate polarity and of predetermined shape. By way of example, the alternating current may be a square wave. However, the alternating current is not limited as to wave shape. Ignition circuit  52  ensures lamp starting.  
         [0035]     Controller  54  senses the operation of discharge lamp  10  and controls lamp current in accordance with embodiments of the invention. The controller  54  includes a lamp current sensor  60 , a lamp voltage sensor  62  and a control circuit  64 . Lamp current sensor  60  senses a lamp current value and provides outputs to power circuit  50  and control circuit  64 . Lamp voltage sensor  62  senses a lamp voltage value at the output of power circuit  50  and provides a voltage value to control circuit  64 . Control circuit  64  controls power circuit  50  in this embodiment. Control circuit  64  computes lamp power and maintains lamp power within specified limits as described below. Power circuit  50  maintains a constant value of RMS lamp current, with changes to new constant values of RMS lamp current in response to changes in lamp operation. The lamp current is an alternating current, having successive periods of alternate polarity and of predetermined shape. The RMS (root mean square) value of the alternating current is maintained constant over extended periods of time, its value depending on lamp operation as described below.  
         [0036]     When discharge lamp  10  is energized, the tips of electrodes  32  and  34  typically reach temperatures close to or even above the melting point of tungsten. Such operating temperatures are necessary to prevent movement of the point of arc attachment to the electrode, also called the arc root. As shown in  FIG. 2 , when the electrode has a rounded tip  70 , the arc root  72  of arc  74  remains at a fixed position. However, if the electrode temperature becomes too low, the molten tip solidifies and collapses to a relatively flat surface  80  as shown in  FIG. 3 . Then, arc root  72  may move on flat surface  80 , causing the lamp to flicker. Unexpectedly, it was discovered that by maintaining a controlled constant RMS value of lamp current I lmp , it is possible to substantially preserve the round shape of the electrode tip over an extended period of time, regardless of lamp voltage changes.  
         [0037]      FIG. 4  illustrates a lamp control routine in accordance with embodiments of the invention. Lamp power P lmp , lamp voltage V lmp  and lamp current I lmp  are plotted as a function of time in  FIG. 4 . Initially, it is assumed that lamp power, lamp voltage and lamp current are at nominal values. In this case, the lamp current I lmp  is controlled at a constant RMS value I lmp1 . In response to lamp changes, the lamp RMS current can be changed to a new constant RMS value. When the lamp voltage increases to a prescribed value of V lmp2 , the lamp current is increased to a level I lmp2  and is maintained at a constant RMS value of I lmp2  until a further change in lamp conditions. This routine ensures the electrode tips are maintained in a molten state with a rounded tip. In discharge lamps of this type, lamp voltage and electrode spacing increase with time. By increasing the RMS current when the lamp voltage increases to the prescribed value of V lmp2 , the voltage increase process may be slowed down or reversed. The prescribed value of V lmp2  at which the RMS current is increased may be defined by equation (1) below, but is not limited to this value. 
   V   lmp2   ≅V   lmp nom ·½·[ P   lmp hi   /P   lmp nom ]  (1)  
 where V lmp nom =nominal lamp voltage, 
 
         [0038]     P lmp hi =upper power limit, typically 120% of rated lamp power, and  
         [0039]     P lmp nom =nominal lamp power.  
         [0040]     When the discharge lamp is operated with a conventional constant power ballast, the electrical power supplied to the lamp is substantially the product of the RMS values of lamp voltage and lamp current. As the lamp RMS voltage increases, the lamp RMS current is decreased proportionally to maintain the lamp power constant. Consequently, the electrode tip temperature decreases and the molten tip region starts to solidify and contract. The electrode surface becomes flat and the arc root attachment becomes unstable, leading to lamp flicker. The flicker and flicker-free modes of lamp operation may be assessed by measuring lamp relative light output (RLO). A photodiode positioned in front of the lamp reflector was utilized to quantify the light output. Typical signal traces are illustrated in  FIG. 5 . Large fluctuations of the RLO are indicative of arc jumping or flicker.  
         [0041]     In another embodiment of the lamp control routine shown in  FIG. 4 , if the lamp power increases to an upper power limit P lmp hi , typically 180 watts for 150 watts nominal lamp power or 120% of the rated lamp power, lamp current is decreased to a new constant RMS level I lmp3 , such that the lamp power does not exceed the upper power limit for the lamp. The upper power limit P lmp hi  may be specified relative to the rated lamp power. Thus, in the above example an upper power limit of 180 watts is 120% of the rated lamp power or 30 watts above the rated lamp power.  
         [0042]     In a further embodiment of the lamp control routine as shown in  FIG. 4 , if the lamp power decreases to a lower power limit P lmp lo , typically 120 watts for 150 watts nominal lamp power or 80% of the rated lamp power, lamp current is increased to a new constant RMS level I lmp4  so that the lamp power does not decrease below the lower power limit for the lamp.  
         [0043]     The reaction of the discharge lamp to changes in RMS current is typically relatively slow. Thus, control circuit  64  preferably implements a delay following a change in RMS current before another change in RMS current can occur. The delay permits the discharge lamp to stabilize in response to the new operating conditions. The delay may be on the order of 25 to 50 hours, for example.  
         [0044]     A flow chart of a control process implemented by controller  54  in the embodiments of  FIGS. 1 and 4  is shown in  FIG. 4A . In step  82 , lamp current I lmp  is controlled at a constant RMS value. Initially, the lamp current may be controlled at a nominal value. In step  84 , the lamp voltage V lmp  is compared with a prescribed value V lmp2 , such as the value given by equation (1) above. The prescribed value V lmp2  of lamp voltage is typically higher than the nominal lamp voltage and indicates that the electrode spacing has increased over its nominal value. If the lamp voltage V lmp  exceeds the prescribed value V lmp2 , the lamp current I lmp  is increased to a new RMS value I lmp2  in step  86 . The process then returns to step  82  and the lamp current I lmp  is maintained constant at the new RMS value. As noted above, the reaction of the discharge lamp to changes in RMS current is typically relatively slow. Accordingly, the controller  54  may implement a delay on the order of 25 to 50 hours before another comparison of lamp voltage V lmp  with the prescribed value V lmp2 .  
         [0045]     In step  88 , the lamp power P lmp  is compared to the upper power limit P lmp-hi . If the lamp power P lmp  is equal to or greater than the upper power limit, the lamp current I lmp  is decreased to lamp current I lmp3  in step  90 . The process then returns to step  82  and the lamp current is maintained constant at the new RMS value I lmp3 . In step  92 , the lamp power P lmp  is compared with the lower power limit P lmp-lo . If the lamp power P lmp  is less than or equal to the lower power limit, the lamp current I lmp  is increased to a new RMS value I lmp4  in step  94 . The process then returns to step  82  and the lamp current is maintained constant at the new RMS value I lmp4 . In the case where the lamp voltage does not exceed the prescribed value V lmp2  and the lamp power remains between the upper and lower power limits, the lamp current is maintained constant at the present RMS value in step  82 .  
         [0046]     A further embodiment of the lamp control routine is illustrated in  FIG. 6 , where lamp power, lamp voltage and lamp current are plotted as a function of time. When the lamp voltage increases to a level V lmp5 , which corresponds to the upper power limit P lmp hi , typically 180 watts for 150 watts nominal lamp power or 120% of the rated lamp power, the lamp current is decreased to a new constant RMS level I lmp5 , such that the lamp operates within a desired range of the rated power.  
         [0047]     The lamp current may be adjusted (increased or decreased) from one constant RMS value to a new constant RMS value continuously or in one or more steps. In one example, the lamp current is adjusted in increments of 1-2% of the lamp current to avoid an abrupt change in light output. Preferably, the lamp current is adjusted, based on known characteristics of the lamp, to bring the lamp power from the upper or lower power limit to or near the rated lamp power.  
         [0048]     Depending on operating power and projector system fixturing, very high pressure discharge lamps operate at high temperatures. Accordingly, cooling techniques are employed to extend the useful life of the lamp system. A typical prior art arrangement is shown in  FIG. 7 . Forced air cooling devices  100  and  102  are mounted external to reflector  12 . This cooling may be directed to both sides of reflector  12  or to the upper side of reflector  12 .  
         [0049]     A block diagram of a lamp system incorporating lamp cooling control in accordance with a further embodiment of the invention is shown in  FIG. 8 . Like elements in  FIGS. 1 and 8  have the same reference numerals. Cooling devices  100  and  102  are controlled by drive circuits  110  and  112 , respectively, which in turn are controlled by control circuit  64 . The amount of controlled cooling is adjusted such that the maximum wall temperature of the arc tube  30  is maintained below the softening temperature of the arc tube material. This softening temperature is defined as the temperature at which a solid material starts losing its rigidity and starts transforming into a plastic or liquid state.  
         [0050]     A lamp control routine in accordance with a further embodiment of the invention is illustrated in  FIG. 9 . Lamp cooling rate, lamp power, lamp voltage and lamp current are plotted as a function of time. As the lamp power increases to upper power limit P lmp hi , the RMS value of lamp current is maintained constant at a level I lmp6 . To prevent overheating of the lamp and decreased lamp life, the cooling rate is increased. When the cooling rate is increased, the lamp voltage drops and the lamp power thus drops, as shown in  FIG. 9 .  
         [0051]     When the material used for arc tube  30  is quartz, the critical temperature is not to exceed the devitrification point. This temperature is lower than the softening temperature and is the temperature at which quartz starts becoming opaque and loses optical transmission, typically around 1000° C.  
         [0052]     A flow chart of a lamp control process implemented by controller  54  in the embodiments of  FIGS. 8 and 9  is shown in  FIG. 9A . In step  200 , the lamp current I lmp  is controlled at a constant RMS value. Initially, the lamp current may be controlled at a nominal value. In step  202 , the lamp power P lmp  is compared with an upper power limit P lmp-hi  and a lower power limit P lmp-lo . If the lamp power is between the upper and lower power limits, lamp cooling by cooling devices  100  and  102  ( FIG. 8 ) is maintained at its present value in step  204 . If the lamp power P lmp  is determined in step  206  to be less than or equal to the lower power limit P lmp-lo , the lamp cooling is decreased in step  208 . If the lamp power P lmp  is determined in step  210  to be equal to or greater than the upper power limit P lmp-hi , a determination is made in step  212  as to whether the lamp cooling is at maximum value. If the lamp cooling is not at maximum value, lamp cooling is increased in step  214 , by controlling cooling devices  100  and  102 . If lamp cooling is  20  determined in step  212  to be at maximum value, the lamp current I lmp  is decreased to a new RMS value in step  216 . Following steps  204 ,  208 ,  214  and  216 , the process returns to step  200  and the lamp current I lmp  is maintained at a constant RMS value. The control process shown in  FIG. 9A  and described above has a relatively slow time constant, since the lamp system is relatively slow to react to changes in lamp cooling and lamp current.  
         [0053]      FIG. 10  illustrates experimental graphs of the lamp voltage and lamp power versus time in accordance with the prior art technique of constant power. As the lamp voltage increases or decreases with time, lamp power is maintained constant near lamp nominal power (typically within 1-2%).  
         [0054]      FIG. 11  illustrates experimental graphs of the lamp voltage and lamp power versus time in accordance with embodiments of the invention. As the lamp voltage increases or decreases and lamp current RMS value is maintained constant and, because the electrical power supplied to the lamp is substantially the product of RMS values of lamp voltage V lmp  and lamp current I lmp , lamp power increases or decreases accordingly. However, lamp power is not permitted to drop below 120 W (for a 150 W nominal lamp power) or 80% of the rated lamp power.  
         [0055]      FIG. 12  illustrates experimental graphs of the lamp voltage and lamp power versus time in accordance with embodiments of the invention. As the lamp voltage increases with time and lamp current RMS value is maintained constant and, because the electrical power supplied to the lamp is substantially the product of RMS values of lamp voltage V lmp  and lamp current I lmp , lamp power increases accordingly. However, lamp power is not permitted to exceed 180 W (for a 150 W nominal lamp power) or 120% of the rated lamp power.  
         [0056]     Having thus described several aspects of at least one embodiment of this invention, it is to be appreciated various alterations, modifications, and improvements will readily occur to those skilled in the art. Such alterations, modifications, and improvements are intended to be part of this disclosure, and are intended to be within the spirit and scope of the invention. Accordingly, the foregoing description and drawings are by way of example only.