Patent Publication Number: US-2015077016-A1

Title: Controller

Description:
FIELD OF THE DISCLOSED TECHNOLOGY 
     The present invention relates to a controller and particularly, but not exclusively to a controller for controlling the optical output of at least one light emitting diode. 
     BACKGROUND 
     The optical output from an LED will vary over its useful lifetime and as such the perception of the light output will also vary. 
     DETAILED DESCRIPTION OF EMBODIMENTS OF THE DISCLOSED TECHNOLOGY 
     We have now devised a controller for controlling the optical output of at least one light emitting diode. 
     In accordance with the present invention as seen from a first aspect, there is provided a controller for controlling the optical output of at least one light emitting diode, 
     the controller comprising a control unit and a power supply unit for supplying power to the at least one light emitting diode, 
     the control unit being arranged to receive as input, first and second signals which are representative of the operating characteristics of the at least one light emitting diode, 
     and which is further arranged to control the power output from the power supply unit to the at least one light emitting diode in dependence of the first and second signals, wherein 
     the first signal is representative of the current within the at least one light emitting diode and the second signal is representative of the temperature of the at least one light emitting diode. 
     The provision of two feedback loops enables the control unit to monitor and adjust the optical output of the light emitting diode and to provide for an energy saving lighting system, without compromising the visual perception of the optical output. 
     Preferably, the control unit further receives as input a third signal which is representative of the time and a fourth signal which is representative of ambient lighting conditions. 
     The third signal is preferably generated by a clock which is arranged to monitor the time, such as the time of day and/or month and/or year, for example. The fourth signal is preferably generated by a sensor which senses ambient lighting conditions. 
     The controller is preferably arranged to control the optical output of a plurality of light emitting diodes. 
     The controller is preferably powered by an alternating current mains supply. The power unit preferably receives as input a rectified direct current supply which is obtained from the alternating current mains supply. 
     The power supply to the controller and the power unit is preferably first regulated to minimise any voltage spikes. 
     In accordance with the present invention as seen from a second aspect, there is provided an energy saver light emitting diode (LED) power supply system composed and realized as shown in the description with the elements represented in the drawing with the exposed automatic controls and features, comprising: 
     an overvoltage suppression section to cut the voltage transient peaks of the AC grid; a Graetz Schottky diode bridge for the efficient high voltage AC\DC conversion; a ripple filter to obtain a stable DC voltage; an high efficiency resonant DC/DC buck converter for an efficient DC\ DC conversion; a power unit that regulates efficiently voltage and current on the LED module; a control unit to manage automatically the other sections and to performs protection and energy saving operations; a LED module to convert efficiently the electrical energy supplied by the power unit into light energy. 
     In accordance with the present invention as seen from a third aspect, there is provided a method of controlling the optical output of at least one light emitting diode, the method comprising the steps of: 
     providing electrical power to the at least one light emitting diode to cause the light emitting diode to produce an optical output; 
     generating a first signal which is representative of the current passing through the at least one light emitting diode; 
     generating a second signal which is representative of the temperature of the at least one light emitting diode; 
     adjusting the electrical power supply to the at least one light emitting diode in dependence of the first and second signals. 
     In accordance with the present invention as seen from a fourth aspect, there is provided a lighting system comprising an array of light emitting diodes and at least one controller of the first or second aspect. 
     An embodiment of the present invention will now be described by way of example only and with reference to the accompanying drawing, which illustrates an electronic circuit comprising a controller according to the described embodiment of the present invention. 
     Referring to the drawing, there is illustrated an electronic circuit  10  comprising a controller  20  for controlling the optical output of an array of light emitting diodes (LED) (not shown) housed within an LED module  30 . The LED&#39;s are powered using a power unit  21  which receives as input a control signal from a control unit  22  and a power supply from a power modulation system  40 . 
     The power modulation system  40  comprises a Graetz diode bridge  41  which receives an alternating current input from the mains  50 , for example. The ac supply to the diode bridge  41  however, is first passed through a voltage suppression circuit  42  which is arranged to remove any voltage spikes which appear from the mains  42  above a threshold value, and a fuse  43 , such as a self restoring fuse, which is arranged to isolate the power modulation system  40  from the mains  50  in the event that the mains input voltage far exceeds the average voltage. 
     The diode bridge  41  comprises four Schottky diodes  41   a - d  which are arranged to minimize the voltage drop across the diode bridge  41 , and thus minimize electrical power dissipation in the diode bridge  41 . 
     The diode bridge  41  is arranged to generate a rectified voltage which is subsequently passed through a ripple filter  44  comprising a capacitor and resistor (not shown) arranged in a parallel configuration. The capacitors (not shown) of the filter  44  comprise a low equivalent series resistance (ESR) to withstand any peaks in the current, and comprise a working temperature range which ensures a long filter lifetime. The ripple filter  44  is arranged to smooth the oscillating waveform from the diode bridge  41  and generate a substantially constant voltage, which is subsequently passed to a buck converter  45 . 
     The buck converter is arranged to step-down the direct current voltage supply from the filter  44  to a useful voltage for powering the power unit  21  of the controller  20 . The buck converter  45  regulates the output voltage to the power unit  21  to produce a stable, constant voltage, and incorporates over-current protection, short-circuit protection and over-voltage protection circuitry to protect the power unit  21  from spurious voltages from the mains supply  50 . 
     The power unit  21  is arranged to power the LED&#39;s of the LED module  30 . The power unit  21  is arranged to generate a low frequency pulse width modulation of the voltage output from the resonant converter  45 , to modulate the energy to transfer to the LED module  30 . In order to minimise winding power losses associated with the converter  45 , the converter  45  operates without the mean value inductor-capacitor (L-C) filter (not shown), which is commonly used in buck converters, without affecting LED lifetime. This is because the LED&#39;s (not shown) of the module  30  are capable of withstanding the peak forward current surges. 
     The mean value of the voltage across the LED module  30  can be expressed as: 
     
       
         
           
             
               V 
               M 
             
             = 
             
               
                 1 
                 T 
               
                
               
                 
                   ∫ 
                   0 
                   T 
                 
                  
                 
                   
                     V 
                      
                     
                       ( 
                       t 
                       ) 
                     
                   
                    
                   
                       
                   
                    
                   
                      
                     t 
                   
                 
               
             
           
         
       
     
     where V(t) is the impulse signal with variable duty cycle and with peak value equal to the output voltage of the buck converter  45 . 
     The voltage output from the power unit  21  is controlled by a switch (not shown), such as a metal oxide semiconductor field effect transistor (MOSFET), which comprises a low drain-source resistance when arranged in the ON state. The switching frequency of the MOSFET (not shown) must be a maximum of 3-4 kHz to ensure a high efficiency and to reduce any voltage stresses on the LED&#39;s (not shown) of the module  30 . 
     The power modulation system  40  is also arranged to power the control unit  22 . The output from the fuse  43  and the voltage suppression circuit  42  is passed through a current transformer  46  and then rectified and filtered using circuit  47  to produce a substantially stable uniform voltage. The output from the circuit  47  is subsequently passed to a voltage regulator  48  which further stabilizes the voltage supply to the control unit  22 , such that the control unit  22  can maintain control of the entire electronic circuit  10  and perform operations such as modifying the power supply to the buck converter  45  and disabling a power factor correction of the buck converter  45  to increase conversion efficiency at low output current. 
     The control unit  22  comprises a microprocessor (not shown), or any other kind of programmable integrated circuit such as a field programmable gate array (FPGA), which is capable of controlling the power unit  21  in generating a pulse width modulated (PWM) signal. In this way the amount of power transferred to the LED module  30  is proportional to the duty cycle (D) of the PWM signal generated by the power unit  21 . Upon increasing the duty cycle, more power will be delivered to the LED&#39;s (not shown) within the module  30  per voltage period. 
     When the mean value of the output current is equal to the nominal value of LED module  30  operating output current, the condition D&lt;1, must be satisfied. This is because the human eye is more sensitive to the peak of light intensity than the mean value, while power consumption is proportional to the mean value of the current absorbed. In this way, it is possible to obtain a better visual perception using less electrical power. 
     The control unit  22  is arranged to set the duty cycle value following a control algorithm which has input values relating to the current within the LED&#39;s (not shown) of the module  30  as determined by a current sensor  23 , the temperature of the LED&#39;s (not shown) as determined by a temperature sensor  24 , ambient light intensity as determined by a light sensor  25 , and a time signal, such as the time of day and/or time of year, as generated by a clock  26 . 
     The signal from the current sensor  23  is necessary for regulating the current flow within the LED&#39;s (not shown) and for short-circuit protection of the power unit  21 . The current signal from the LED module  30 , is further passed through a low pass filter  27  to generate an average current signal which is passed to the control unit  22 . Accordingly, when the mean value of the current flowing in the LED module  30  deviates outside a pre-defined range, the control unit  22  is arranged to adjust the duty cycle applied to the power unit  21  to vary the “ON” time during the voltage period and thus vary the current which is output therefrom. 
     When the mean value of the current flowing in the LED module  30  exceeds a maximum permitted current value for example, the control unit  22  is arranged to generate a signal which causes the power unit  21  to switch to the OFF state. The current sensor  23  is of an electromagnetic inductive type to reduce losses associated with sensors comprising amperometric resistive shunts, thereby increasing the efficiency at which electrical power is converted to optical output from the LED&#39;s (not shown). The current sensor  23  may comprise a transducer (not shown) comprising a wire winding formed on a ferromagnetic ring (not shown), which must be crossed by one of the two wires (not shown) of the LED module  30 . 
     The temperature sensor  24  which monitors the temperature of the LED&#39;s (not shown), is mounted on a circuit board (not shown) of the LED module  30  and is arranged to generate a signal to the control unit  22  which is representative of the temperature of the circuit board (not shown), and thus the LED&#39;s (not shown). When the temperature of the LED module  30  deviates outside a pre-defined range, for example above 60° C., the control unit  22  decreases the duty cycle of the signal which is applied to the power unit  21  in proportion to the deviation in the temperature of the LED&#39;s outside the pre-defined range, to vary the mean value of the current which is output from the power unit  21 , and thus the temperature of the LED module  30 . This kind of temperature control is required to extend LED lifetime and to make the LED&#39;s (not shown) operate near the point of maximum device efficiency. This is because LED luminous efficiency is inversely proportional to the temperature of the LED, and so by keeping this temperature as low as possible, the LED efficiency can be held at its maximum value. 
     When the temperature of the LED module  30  exceeds the maximum operating temperature of the LED employed, the control unit  22  is arranged to generate a signal causing the power unit  21  to switch OFF the power supply to the module  30 , and thus protect the LED&#39;s (not shown). 
     The light sensor signal is required when, for example, there is a need to lower the output light intensity of the LED module  30 , thereby saving an additional amount of energy. The output from the light sensor  25  may be sensitive to an external command, such as a remote control signal or a signal from a resistive potentiometer or a trimmer (not shown), for example. The signal from the light sensor  25  may be a binary serial signal or an analogue signal which is sampled by the control unit  22 . The signal from the light sensor  25  comprises information relating to the variation in duty cycle of the PWM signal which is required to realise the reduction in electrical power supply to the module  30 . 
     The real time clock  26  is arranged to monitor the current time and is arranged to deliver time and day information to the control unit  22 , so as to affect the light output in accordance with the time of day for example. The clock  26  is powered by a battery (not shown) and generates a serial signal with an interface protocol which is recognized by the control unit  22 , such that the control unit  22  can provide for a gradual or stepped change in output light intensity. 
     The LED&#39;s (not shown) within the LED module  30  are arranged in an electrical parallel arrangement of rows of LED&#39;s (not shown), with the LED&#39;s (not shown) of each row being arranged in an electrical series configuration. The number of LED&#39;s (not shown) in series in each row must be more than ten, to reduce power losses due to electrical Ohmic conduction and to improve the efficiency of the buck converter  45 . This is because the converter  45  provides an increased efficiency when the output voltage is higher and the output current is lower. 
     The LED module  30  comprises a further row comprising a series arrangement of a resistor (not shown) and a Zener diode (not shown). The row comprising the resistor (not shown) and the Zener diode (not shown) is arranged in parallel to the rows of LED&#39;s (not shown) and must be connected such that the cathode of the Zener diode (not shown) is coupled to the anode of the LED (not shown). This scheme is helpful as a passive over-voltage LED protection circuit, but is essential, when one or more LED&#39;s of a series is interrupted or defectively soldered, for example. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1  shows a high level block diagram of a device of an embodiment of the disclosed technology.