LED lighting system with a multiple mode current control dimming strategy

U.S. Provisional Application No. 60/909,458, entitled “Ballast for Light Emitting Diode Light Sources,” inventor John L. Melanson, and filed on Apr. 1, 2007 describes exemplary methods and systems and is incorporated by reference in its entirety. Referred to herein as “Melanson I”.

U.S. patent application Ser. No. 12/047,249, entitled “Ballast for Light Emitting Diode Light Sources,” inventor John L. Melanson, and filed on Mar. 12, 2008 describes exemplary methods and systems and is incorporated by reference in its entirety. Referred to herein as “Melanson II”.

U.S. patent application Ser. No. 12/047,269, entitled “Lighting System with Power Factor Correction Control Data Determined from a Phase Modulated Signal,” inventor John L. Melanson, and filed on Mar. 12, 2008 describes exemplary methods and systems and is incorporated by reference in its entirety. Referred to herein as “Melanson III”.

U.S. patent application Ser. No. 11/695,024, entitled “Lighting System with Lighting Dimmer Output Mapping,” inventors John L. Melanson and John Paulos, and filed on Apr. 1, 2007 describes exemplary methods and systems and is incorporated by reference in its entirety. Referred to herein as “Melanson IV”.

U.S. patent application Ser. No. 11,864,366, entitled “Time-Based Control of a System having Integration Response,” inventor John L. Melanson, and filed on Sep. 28, 2007 describes exemplary methods and systems and is incorporated by reference in its entirety. Referred to herein as Melanson V.

U.S. patent application Ser. No. 11/967,269, entitled “Power Control System Using a Nonlinear Delta-Sigma Modulator with Nonlinear Power Conversion Process Modeling,” inventor John L. Melanson, and filed on Dec. 31, 2007 describes exemplary methods and systems and is incorporated by reference in its entirety. Referred to herein as Melanson VI.

U.S. patent application Ser. No. 11/967,271, entitled “Power Factor Correction Controller with Feedback Reduction,” inventor John L. Melanson, and filed on Dec. 31, 2007 describes exemplary methods and systems and is incorporated by reference in its entirety. Referred to herein as Melanson VII.

U.S. patent application Ser. No. 11/967,273, entitled “System and Method with Inductor Flyback Detection Using Switch Date Charge Characteristic Detection,” inventor John L. Melanson, and filed on Dec. 31, 2007 describes exemplary methods and systems and is incorporated by reference in its entirety. Referred to herein as Melanson VIII.

U.S. patent application Ser. No. 11/967,275, entitled “Programmable Power Control System,” inventor John L. Melanson, and filed on Dec. 31, 2007 describes exemplary methods and systems and is incorporated by reference in its entirety. Referred to herein as Melanson IX.

U.S. patent application Ser. No. 11/967,272, entitled “Power Factor Correction Controller With Switch Node Feedback”, inventor John L. Melanson, and filed on Dec. 31, 2007 describes exemplary methods and systems and is incorporated by reference in its entirety. Referred to herein as Melanson X.

1. Field of the Invention

The present invention relates in general to the field of electronics and lighting, and more specifically to a system and method related to controlling an active light emitting diode current using a multiple mode dimming strategy.

2. Description of the Related Art

Commercially practical incandescent light bulbs have been available for over 100 years. However, other light sources show promise as commercially viable alternatives to the incandescent light bulb. LEDs are becoming particularly attractive as main stream light sources in part because of energy savings through high efficiency light output and environmental incentives such as the reduction of mercury.

LEDs are semiconductor devices and are driven by direct current. The lumen output intensity (i.e. brightness) of the LED approximately varies in direct proportion to the current flowing through the LED. Thus, increasing current supplied to an LED increases the intensity of the LED and decreasing current supplied to the LED dims the LED, i.e. decreases the brightness of the LED. Current can be modified by either directly reducing the direct current level to the white LEDs or by reducing the average current through duty cycle modulation.

Dimming a light source saves energy when operating a light source and also allows a user to adjust the intensity of the light source to a desired level. Many facilities, such as homes and buildings, include light source dimming circuits (referred to herein as “dimmers”).

FIG. 1 depicts an LED lighting system 100 that supplies power to light emitting diodes (LEDs) 102 and dims the LEDs 102 in accordance with a dimming level indicated by the phase modulated signal V Φ . The voltage source 104 supplies an alternating current (AC) input voltage V IN . The dimmer 106 is, for example, a phase cut dimmer that generates phase delays in the input voltage V IN to generate a phase modulated input signal. Full, diode bridge rectifier 108 rectifies the input voltage V IN to generate the phase modulated signal V Φ . The voltage source 104 is, for example, a public utility, and the input voltage V DIM is, for example, a 60 Hz/120 V voltage in the United States of America or a 50 Hz/230 V voltage in Europe. The phase delays indicate dimming levels. Generally, as the phase delays increase, the dimming level decreases, i.e. as the phase delays increase, the dimming level indicates a lower brightness level for LEDs 102 . The Background sections of Melanson I, Melanson II, and Melanson III, describe examples of dimmer 106 .

Switching power supply 110 utilizes switching power converter technology to convert the phase modulated signal V Φ into an output voltage V OUT . The output voltage V OUT is sufficient to bias the LEDs 102 . Switching power supply 110 also supplies an LED current i LED to illuminate the LEDs 102 .

Current controller 112 controls active and average values of LED current i LED by controlling the conductivity of n-channel field effect transistor (FET) Q 1 . Current controller 112 generates a gate control signal C G0 to charge and discharge a gate of FET Q 1 . The control signal C G0 has two relevant frequencies, an active frequency and a duty cycle modulated frequency. During an active period of LED current i LED , the control signal C G0 has an active frequency in the range of, for example, 20 kHz to 500 kHz. As described subsequently in more detail, the duty cycle modulated frequency is less than the active frequency. The active period of LED current i LED is the period of time when the average value of LED current i LED equals i FULL . The time period for this average is, for example, one or a few (such as 3-5) periods of the active frequency.

When the control signal C G0 is a logical “one”, FET Q 1 conducts, i.e. is “ON”, and when the control signal C G0 is a logical “zero”, FET Q 1 is nonconductive, i.e. is “OFF”. When the FET Q 1 is “ON”, diode D 1 is reversed bias and, LED current i LED flows through the LEDs 102 and charges inductor L 1 . When FET Q 1 is “OFF”, the voltage across inductor L 1 changes polarity, and diode D 1 creates a current path for the LED current i LED . The inductor L 1 is chosen so as to store enough energy to maintain an approximately constant active value of LED current i LED when MOSFET Q 1 is “OFF”. Capacitor C 1 helps “smooth” LED current i LED . As subsequently explained in more detail, the active value of the LED current i LED is the average LED current i LED when the current control system 112 is active, i.e. during the active period of LED current i LED . The LED current i LED includes a ripple 201 due to, for example, the charging and discharging of inductor L 1 . The frequency of the ripple 201 is the active frequency. It is desirable, for LED efficiency, to keep the LED current relatively constant, to reduce heating effects.

FIG. 2 depicts a graphical representation 200 of the LED current i LED for various dimming levels indicated by the phase modulated signal V Φ . Referring to FIGS. 1 and 2 , when the phase modulated signal V Φ indicates a full dimming level, i.e. full brightness for LEDs 102 , current controller 112 controls the LED current i LED so that the active value of LED current i LED is continuous and constant over time and equals i FULL , as indicated by LED current i LED waveform 202 . “i FULL ” represents the active value of LED current i LED that causes the LEDs 102 to illuminate at full brightness.

The current controller 112 uses feedback information from feedback signal LEDi sense to sense the active value of LED current i LED . The feedback signal LEDi sense represents a voltage V fb across sense resistor R SENSE . The voltage V fb represents LED current i LED when FET Q 1 is ON. Thus, from the feedback signal LEDi sense, the current controller 112 obtains the value of LED current i LED and can adjust the duty cycle of control signal C G0 — FULL to maintain the active value of LED current i LED at the full active value i FULL during the active period of LED current i LED . As subsequently explained in more detail, the control signal C G0 — FULL is also duty cycle modulated at the duty cycle modulation frequency in response to dimming levels indicated by phase modulated signal V Φ to generate control signal C G0 .

To determine the dimming level indicated by phase modulated signal V Φ , comparator 114 compares the phase modulated signal V Φ with a phase delay detection reference signal V DET . The value of phase delay detection reference signal V DET is set to detect an edge of any phase delays in the phase modulated signal V Φ . Generally, the edge of any phase delays during each cycle of phase modulated signal V Φ results in a voltage increase in phase modulated signal V Φ . Thus, generally, the value of phase delay detection reference signal V DET is set low enough, so that the output of comparator 114 changes from a logical 0 to a logical 1 when a rising edge associated with an end to a phase delay is detected and changes to a logical 0 if a phase delay is detected during a cycle of phase modulated signal V Φ .

Comparator 114 generates a duty cycle modulated enable signal EN at the duty cycle modulation frequency. The duty cycle of enable signal EN corresponds to the dimming level indicated by phase modulated signal V Φ . The current controller 112 responds to the enable signal EN by duty cycle modulating the control signal C G0 so that the average value, i LED — AVG , of LED current i LED varies in accordance with dimming levels indicated by the phase modulated signal V Φ . Modulator 116 represents a logical representation of utilizing the enable signal EN to generate a duty cycle modulated control signal C G0 . The enable signal EN represents one input signal to AND gate 118 , and control signal C G0 — FULL represents another input signal to AND gate 118 . The AND gate 118 is exemplary. In typical applications, the function of the AND gate 118 is integrated into the logic of the controller 112 . Control signal C G0 — FULL corresponds to control signal C G0 during the active period of LED current i LED . When the enable signal EN is a logical 1, the control signal C G0 equals the control signal C G0 — FULL . When the enable signal EN is a logical 0, the control signal C G0 equals 0. Thus, the control signal C G0 is duty cycle modulated to generate the control signal C G0 — FULL and is duty cycle modulated in response to the phase modulated signal V Φ .

For example, referring to LED current i LED waveform 204 , when the phase modulated signal V Φ indicates a ¾ dimming level, the duty cycle of enable signal EN is 0.75. The enable signal EN causes the current controller 112 to duty cycle modulate the control signal C G0 with the same duty cycle as enable signal EN so that time period T ACTIVE — 3/4 /T equals 0.75. Thus, the active period of LED current i LED equals T ACTIVE — 3/4 for each period T of phase modulated signal V Φ while the phase modulated signal V Φ indicates a ¾ dimming level. Period T represents a duty cycle modulated period, and the duty cycle modulated frequency equals 1/T. The average LED current i LED — AVG equals i FULL (the active value of LED current i LED ) times the duty cycle of enable signal EN. For a ¾ dimming level, the average LED current i LED — AVG equals 0.75·i FULL . During the inactive period of LED current i LED , i.e. between the end of the active period T ACTIVE — 3/4 and the beginning of the next period of phase modulated signal V Φ , the LED current i LED is zero.

Referring to LED current i LED waveform 206 , when the phase modulated signal V Φ indicates a ⅛ dimming level, the duty cycle of enable signal EN is 0.125. The enable signal EN causes the current controller 112 to duty cycle modulate the control signal C G0 with the same duty cycle as enable signal EN so that time period T ACTIVE — 1/8 /T equals 0.125. Thus, the active period of LED current i LED equals T ACTIVE — 1/8 for each period T of phase modulated signal V Φ while the phase modulated signal V Φ indicates a ⅛ dimming level. The average LED current i LED — AVG equals i FULL times the duty cycle of enable signal EN. For a ⅛ dimming level, the average LED current i LED — AVG equals 0.125·i FULL . During the inactive period of LED current i LED , i.e. between the end of the active period T ACTIVE — 1/8 and the beginning of the next period of phase modulated signal V Φ , the LED current i LED is zero.

FIG. 3 depicts a graphical relationship 300 between each dimming level indicated by phase modulated signal V Φ and the LED current i LED , the enable signal EN, and the average value of LED current i LED , i LED — AVG . The current controller 112 maintains the active value of LED current i LED at i FULL for all dimming levels. The duty cycle of the enable signal EN varies from 0 to 1.0 as the dimming level varies from 0, i.e. LEDs 102 OFF, to full intensity, i.e. LEDs 102 at full brightness. By modulating the LED current i LED in accordance with the enable signal EN, the LED average current i LED — AVG varies as the dimming level varies.

During inactive periods of LED current i LED , the LEDs 102 can noticeably flicker, especially at lower dimming levels when the LED current i LED is inactive for longer periods of time during each period of phase modulated signal V Φ . Additionally, the high active value i FULL of LED current i LED causes inductor L 1 to generate more noise and heat during the active period relative to a lower value of LED current i LED . Furthermore, generally, LED lighting system 100 operates less efficiently with higher values of active current value of LED current i LED . Additionally, dimming the LEDs 102 as described with reference to FIGS. 1-3 can cause color variations in the output light of the LEDs 102 .

In one embodiment of the present invention, a light emitting diode (LED) lighting system includes a controller to control current in an LED. The controller includes components to respond to a dimming level input to control an active value of the LED current. For a first set of dimming levels, the active value varies between a full active value and an intermediate active value of the LED current. For a second set of dimming levels, the LED current is duty cycle modulated.

In another embodiment of the present invention, a method of controlling an LED lighting system includes receiving a dimmer signal indicating a dimming level and controlling an active value of a current in an LED in response to the dimming level. Controlling the active value of the LED current includes, for a first set of dimming levels, varying the active value between a full active value and an intermediate active value of the LED current and, for a second set of dimming levels, duty cycle modulating the LED current.

In a further embodiment of the present invention, an apparatus for controlling an LED lighting system includes means for receiving a dimmer signal indicating a dimming level. The apparatus further includes means for controlling an active value of a current in an LED in response to the dimming level. The means for controlling the active value of the LED current includes, for a first set of dimming levels, means for varying the active value between a full active value and an intermediate active value of the LED current and, for a second set of dimming levels, means for duty cycle modulating the LED current.

The present invention may be better understood, and its numerous objects, features and advantages made apparent to those skilled in the art by referencing the accompanying drawings. The use of the same reference number throughout the several figures designates a like or similar element.

FIG. 1 (labeled prior art) depicts an LED lighting system.

FIG. 2 (labeled prior art) depicts a graphical representation of LED current in the LED lighting system of FIG. 1 for various dimming levels.

FIG. 3 (labeled prior art) depicts a graphical relationship between dimming levels and an LED current and an enable signal for the LED lighting system of FIG. 1 .

FIG. 4 depicts an LED lighting system having a dimming strategy module to vary and modulate an active LED current i LED in response to varying dimming levels.

FIG. 5 depicts a dimming strategy representation.

FIG. 6 depicts an exemplary LED current i LED graphical representation for various dimming levels.

FIG. 7 depicts an exemplary LED current waveforms for dimming levels within a first set of dimming levels.

FIG. 8 depicts an exemplary LED current waveforms for dimming levels within a second set of dimming levels.

FIG. 9 depicts an exemplary, logical representation of an LED lighting system controller.

FIG. 10 depicts an LED lighting system that includes an analog current control system.

A light emitting diode (LED) lighting system includes a controller to control current in one or more LEDs in response to a dimming level input. The LED lighting system implements a dimming strategy having two modes of operation that allow the LED lighting system to dim the LEDs using an active value of an LED current less than a full value of the LED current while maintaining continuous conduction mode operation. In an active value varying mode of operation, the controller varies an active value of the LED current for a first set of dimming levels. In an active value, duty cycle modulation mode of operation, the controller duty cycle modulates an active value of the LED current for a second set of dimming levels. In at least one embodiment, the active value of the LED current varies from a full active value to an intermediate active value as dimming levels decrease.

In at least one embodiment, upon reaching the intermediate active value, the controller modulates a duty cycle of the LED current with the LED current at the intermediate active value during an active period to achieve a full range of dimming while reducing the peak LED current. Thus, the LED lighting system is generally more efficient than conventional LED lighting systems because the LED lighting system utilizes a lower LED current. In at least one embodiment, the intermediate active value of the LED current is set to operate an inductor coupled to each LED in continuous conduction mode to eliminate complexities involved with operating the inductor in discontinuous conduction mode. Additionally, the inductor generally generates less noise than the inductor in a conventional dimming system that maintains the LED current at a full active value during an active period of the LED current.

Additionally, in at least one embodiment, the inactive period of the LED current for the present LED lighting system has a shorter duration than the inactive period of the LED current in a conventional LED lighting system, such as lighting system 100 , for a particular dimming level. Thus, the present LED lighting system exhibits less flicker for a particular dimming level.

FIG. 4 depicts an LED lighting system 400 that includes a current control system 402 to control the LED current i LED . The LED lighting system 400 also includes a dimming strategy module 404 to vary and modulate an active value of LED current i LED in response to varying dimming levels and in accordance with a dimming strategy described subsequently in more detail. In at least one embodiment, the LED lighting system 400 also includes the voltage source 104 , dimmer 106 , rectifier 108 , and switching power supply 110 , which operate as previously described.

The current control system 402 includes a current controller 406 to generate a duty cycle modulated gate control signal C G1 to control conductivity of FET Q 1 and, thus, control LED current i LED . Control signal C G1 charges and discharges a gate of FET Q 1 . A logical 1 value of control signal C G1 causes FET Q 1 to conduct and draws LED current i LED through LEDs 102 and inductor L 1 , and a logical 0 value of controls signal C G1 causes FET Q 1 to be non-conductive. FET Q 1 represents one embodiment of a switch and can be replaced by any type of switch.

In at least one embodiment, the LED lighting system 400 dims the LEDs 102 in conformity with a dimming level input generated by a dimmer such as phase cut dimmer 106 . The number of LEDs 102 is a matter of choice. LEDs 102 can be replaced by a single LED. The LED lighting system 400 can receive dimmer signals indicating dimming levels from LEDs 102 from any type of dimmer. For example, dimmer 106 can be omitted, and LED lighting system 400 can include a dimmer, such as digital dimmer 408 or a dimmer having a direct current (DC) dimming control voltage (not shown). In at least one embodiment, the digital dimmer 408 is a digital addressable lighting interface (DALI) compatible dimmer. Digital dimmer 408 is depicted with “dashed” lines because generally LED lighting system 400 includes one dimmer or another but not two dimmers. Thus, in at least one embodiment, digital dimmer 408 is a substitute for dimmer 106 and phase delay detector 410 . The dimmers, such as dimmer 106 and digital dimmer 408 , receive inputs, either manually or automatically, that set the dimming level values to be output by the dimmers.

In at least one embodiment, the current controller 406 responds to a dimming level input and generates the control signal C G1 in accordance with a dimming strategy that, in at least one embodiment, includes two modes of operation. In an active value varying mode of operation, the current controller 406 varies an active value of the LED current i LED in conformity with the dimming level for a first set of dimming levels. In an active value, duty cycle modulation mode of operation, the current controller 406 modulates a duty cycle of an active value of the LED current i LED in conformity with the dimming level for a second set of dimming levels.

To determine which of the two modes of operation to use in generating the LED current i LED , LED lighting system 400 first detects a dimming level for LEDs 102 . When LED lighting system 400 includes dimmer 106 , the LED lighting system 400 also includes a phase delay detector 410 to detect phase delays in the phase modulated signal V Φ . The phase delay detector 410 generates a phase delay signal (Φ, and the phase delays represented by the digital phase delay signal Φ represent dimming levels. Melanson III describes an exemplary embodiment of phase delay detector 410 .

In at least one embodiment, the LED lighting system 400 also includes an optional mapping system and filter 411 to map the dimming levels indicated by the phase delay signal Φ to predetermined digital values of dimming signal D V . Melanson IV describes an exemplary mapping system and filter 420 that maps values of dimming signal D V to perceived light levels. The LED lighting system 400 receives the dimming signal D V as a dimming level input. In at least one embodiment, LED lighting system 400 omits the mapping system and filter 411 , and the dimming strategy module 404 receives the phase delay signal Φ as a direct, digital dimmer signal input having values indicating dimming levels.

FIG. 5 depicts a dimming strategy representation 500 , which represents one embodiment of a dimming strategy of dimming strategy module 404 ( FIG. 4 ) having the two modes of operation and a resulting average LED current i LED . Referring to FIGS. 4 and 5 , the dimming strategy module 404 receives the dimming signal D V and generates two signals, i TARGET and EN V , whose values are based on the dimming level indicated by dimming signal D V . The LED current target signal i TARGET is an input signal to current control system 402 and represents a scaled target value for an active value of LED current i LED . Enable value signal EN V represents a value indicating a duty cycle of enable signal EN, which also represents a duly cycle of the LED current i LED during the active value, duty cycle modulation mode of operation. The enable signal EN is an input to current control system 402 .

The dimming levels are divided into a first set of dimming levels DLS 1 and a second set of dimming levels DLS 2 . In at least one embodiment, the first set of dimming levels DLS 1 range from a changeover dimming level DL CO to a full intensity dimming level DL FULL , and the second set of dimming levels DLS 2 range from OFF to the changeover dimming level DL CO . The changeover dimming level DL CO is a matter of design choice and, as described subsequently in more detail, preferably corresponds to a value of i TARGET that avoids operating inductor L 1 in discontinuous conduction mode. The dimming level strategy module 404 causes the current control system 402 to operate in the active value varying mode of operation for the first set of dimming signals and in the duty cycle modulation mode of operation for the second set of dimming signals.

In at least one embodiment, as depicted in i TARGET waveform 504 , in the active value varying mode of operation for the first set of dimming levels DLS 1 , the target signal i TARGET equals the value of dimming signal D V and, thus, directly tracks the dimming levels indicated by dimming signal D V . As depicted in enable waveform 504 , the value of enable value signal EN V is set so that the enable signal EN is a logical 1 and does not affect the generation of control signal C G1 in the active value varying mode of operation. Thus, in at least one embodiment, in the active value varying mode of operation, the current control system 402 does not duty cycle modulate the active value of LED current i LED . The digital target signal i TARGET is converted to an analog signal i TARGET (t) by digital-to-analog converter (DAC) 412 . Comparator 414 compares the signal i TARGET (t) with feedback signal LEDi sense and generates a comparison signal V COMP representing the comparison between the signal i TARGET (t) with feedback signal LEDi sense . The feedback signal LEDi sense represents a value of LED current i LED when FET Q 1 conducts.

In at least one embodiment, LEDi sense represents the feedback voltage V fb across sense resistor R SENSE . The current i LEDsense represents the LED current i LED when FET Q 1 conducts. The feedback signal LEDi sense and target signal i TARGET are scaled so that if the comparison signal V COMP indicates that the feedback signal LEDi sense is greater than the target signal i TARGET , then current control system 402 decreases the average value of LED current i LED . If the comparison signal V COMP indicates that the feedback signal LEDi sense is less than the target signal i TARGET , then current control system 402 increases the average value of LED current i LED . Since the value of target signal i TARGET tracks the dimming levels indicated by dimming signal D V for the first set of dimming levels, the value of the comparison signal V COMP causes the current control system 402 to control the LED current i LED so that the average value of the LED current i LED dims LEDs 102 to a dimming level indicated by dimming signal D V .

During the active value varying mode of operation, the current controller 406 receives the comparison signal V COMP and generates a control signal C G1 that causes the active value of LED current i LED to vary in accordance with the dimming levels indicated by the dimming signal D V for the first set of dimming levels DLS 1 . Melanson V describes at least one embodiment of generating control signal C G1 to cause the active value of LED current i LED to vary in accordance with the dimming levels. During an active period of LED current i LED , the control signal C G1 has an active frequency greater than or equal to 20 kHz, such as in the range of 20 kHz to 500 kHz. As described subsequently in more detail, the duty cycle modulated frequency is less than the active frequency. The active period of LED current i LED is the period of time when the average value of LED current i LED equals i FULL . The time period for this average is, for example, one or a few (such as 3-5) periods of the active frequency. During an active period of LED current i LED , the control signal C G1 varies between logical 1 and logical 0. In at least one embodiment, the active period of LED current i LED is a period of time when the control signal C G1 is switching at the 20-500 kHz rate, stated in another way, the active period of LED current i LED is a period of time when the active value of LED current i LED is not approximately zero. In at least one embodiment, the current control system 402 and LED current i LED are inactive only during the active value, duty cycle modulation mode or operation. In at least one embodiment, the inactive period corresponds to a period of time when enable signal EN is 0 and the control signal C G1 is not switching at the active frequency. The LED current i LED in the LEDs 102 during the transition from an active period to an inactive period, and vice versa, is generally not well controlled. By reducing the active value of the LED current i LED during the active value, duty cycle modulation mode or operation, the uncertainty of this effect is reduced.

FIG. 6 depicts an exemplary LED current i LED waveforms 600 of current i LED at various dimming levels. Referring to FIGS. 4 and 6 , as control signal C G1 causes FET Q 1 to switch ON and OFF, the inductor L 1 charges and discharges. Charging and discharging inductor L 1 is at least one cause for the ripple 602 in LED current i LED . The ripple 602 has a period T CG1 , which is the same as the period of control signal C G1 during the active period. The active frequency equals 1/T CG1 . The peak-to-peak value of ripple 602 depends upon the particular components of LED lighting system 400 such as the values of inductor L 1 and capacitor C 1 . In at least one embodiment, the peak-to-peak value of ripple 602 is 200 mA, and the full active value i FULL of LED current i LED is 400 mA. The LED current i LED waveforms 600 assume little filtering by capacitor C 1 so that the switching behavior of current control system 402 and LED current i LED can be better understood. In typical applications, capacitor C 1 would provide more smoothing to reduce the peak-to-peak voltage of ripple 602 .

Current controller 406 decreases the active value of LED current i LED in conformity with decreasing dimming levels indicated by dimming signal D V . The LED current i LED waveform 604 depicts no dimming (i.e. full brightness of LEDs 102 ), and the active value of LED current i LED equals the full active value i FULL . At a ½ dimming level, the active value of LED current i LED decreases to approximately ½ of the full active value i FULL as depicted in LED current i LED waveform 606 . At a ¼ dimming level, the active value of LED current i LED decreases to approximately ¼ of the full active value i FULL as depicted in LED current i LED waveform 608 . At a ⅛ dimming level, the active value of LED current i LED decreases to approximately ⅛ of the full active value i FULL as depicted in LED current i LED waveform 610 . As long as the LED current i LED is above zero for the entire period T CG1 of control signal C G1 , the inductor L 1 operates in continuous conduction mode (CCM). However, at the ⅛ dimming level, the ripple 602 of LED current i LED causes to drop to zero amps during a portion of the period T CG1 of control signal C G1 . When the LED current i LED drops to zero, the inductor L 1 begins operating in discontinuous conduction mode. Thus, at some value of LED current i LED conforming to a dimming level between ¼ dimming level and ⅛ dimming level, the operation of inductor L 1 changes from CCM to DCM.

With a 400 mA full active value and a 200 mA peak-to-peak ripple value, in the active value varying mode of operation, the LED current i LED can vary by an approximately 4:1 ratio before the inductor L 1 begins operating in discontinuous conduction mode (DCM). Operating inductor L 1 in DCM can be difficult and can require more complicated algorithms to ensure that the light intensity of LEDs 102 conforms to a dimming level indicated by dimming signal D V . For example, when operating in DCM to accurately dim LEDs 102 , current controller 406 typically requires data indicating a precise operational frequency of control signal C G1 and typically requires data indicating a precise inductance value of the inductor L 1 . Precise data indicating the operational frequency can be difficult to acquire if the operational frequency is derived from an imprecise source, such as a resistor-capacitor (RC) based oscillator. Precise data indicating the inductance value of inductor L 1 can be difficult to acquire because inductor values in LED light sources 204 can vary by, for example, 20% of a specified value. Thus, imprecise operational parameter data typically indicates the development and execution of more complicated algorithms and processing by current controller 406 to accurately dim the LEDs 102 .

Referring to FIGS. 4 and 5 , for dimming levels in the set of dimming levels DLS 1 , the average LED current i LED varies in linear proportion to the value of signal i TARGET . To avoid operating inductor L 1 in DCM, dimming strategy module 404 causes current controller 406 to operate in the active value, duty cycle modulation mode of operation when the dimming level indicated by dimming signal D V indicates dimming levels at or below the changeover dimming level DL CO , i.e. within the set of dimming levels DLS 2 . When the dimming strategy module 404 detects a dimming level within the set of dimming levels DLS 2 , the dimming strategy module 404 maintains the target signal i TARGET at a value corresponding to an LED current i LED greater than or equal to a minimum active value and less than the full active value i FULL . In at least one embodiment, the dimming strategy module 404 detects which set a dimming level belongs to by comparing the dimming level indicated by dimming signal D V with the changeover dimming level DL CO . The intermediate active value of the LED current i LED is, in at least one embodiment, an active value less than the full active value i FULL that ensures inductor L 1 will operate in CCM. A lower active value of LED current i LED is preferable to, for example, increase the efficiency and decrease the noise of LED lighting system 400 by decreasing the current in inductor L 1 . Flicker of LEDs 102 is also reduced at low dimming levels, i.e. low brightness levels of LEDs 102 .

In at least one embodiment, the minimum active value of the LED current i LED is the lowest active value of LED current i LED that ensures CCM operation of inductor L 1 and below the full active value i FULL . In at least one embodiment, the intermediate active value of LED current i LED is set just above the minimum active value of LED current i LED to provide an operating margin to ensure CCM operation of inductor L 1 . In at least one embodiment, the intermediate active value of LED current i LED is 0.25·i FULL for an LED current i LED having a peak-to-peak ripple 602 equal to 50% of the full active value i FULL .

As depicted in FIG. 5 , when the dimming level indicated by dimming signal D V indicates a dimming level within the set of dimming levels DLS 2 , the target signal i TARGET is held constant at the intermediate active value of LED current i LED , which is for example, 0.25. So that LED current i LED is able to decrease below an active value corresponding to a ¼ dimming level, the current controller 406 generates a control signal C G1 to duty cycle modulate the LED current i LED for dimming levels in the set of dimming levels DLS 2 .

Referring to FIGS. 4 and 5 , to duty cycle modulate the LED current i LED during the active value, duty cycle modulation mode of operation, the dimming strategy module 404 generates an enable value EN V between 0 and 1. In at least one embodiment, the value of enable value EN V =[(dimming level)/(i TARGET /i TARGET — FULL )], where i TARGET — FULL is the value of the target signal i TARGET corresponding to a full value i FULL of LED current i LED . In at least one embodiment, the signal i TARGET is scaled so that i TARGET — FULL equals 1, and the value of enable value EN V =[(dimming level)/i TARGET ]. For the set of dimming levels DLS 2 , the average LED current i LED tracks the product of the enable value EN V and the target signal i TARGET .

In at least one embodiment, the enable value EN V is a digital value that is converted into a duty cycle modulated enable signal EN by duty cycle modulator 416 . In at least one embodiment, duty cycle modulator 416 is a pulse width modulator. In another embodiment, duty cycle modulator 416 is a delta-sigma modulator. A delta-sigma modulator varies the value of enable signal EN over time; however, the average value of enable signal EN equals the enable value EN V . The delta-sigma modulator version of duty cycle modulator 416 can be any delta-sigma modulator such as any first order or multi-order delta-sigma modulator described in, for example, Understanding Delta - Sigma Data Converters by Schreier and Temes, IEEE Press, 2005, ISBN 0-471-46585-2 or as available from Cirrus Logic Inc. of Austin, Tex., U.S.A. Delta-sigma duty cycle modulation allows for lower flicker of LEDs 102 than PWM modulation at the lower rates.

Referring to FIGS. 4 and 5 , during the active value, duty cycle modulation mode of operation, dimming strategy module 404 generates a target signal i TARGET corresponding to the intermediate active LED current i LED current for the active value, duty cycle modulation mode of operation as, for example, depicted in i TARGET waveform 501 . The dimming strategy module 404 also generates an enable signal EN as previously described and as, for example, depicted in enable waveform 504 . With the target signal i TARGET fixed, the current controller 406 generates a duty cycle modulated control signal C G1 corresponding to the dimming level indicated in the set of dimming levels DLS 2 . Duty cycle modulating the control signal C G1 also duty cycle modulates the LED current i LED . Thus, in at least one embodiment, the average LED current i LED conforms to the full range of dimming levels from OFF to full intensity as indicated in by the average LED current i LED versus dimming level waveform 502 .

FIG. 7 depicts exemplary LED current i LED waveforms 700 for dimming levels within the set of dimming levels DLS 1 greater than the changeover dimming level DL CO . For a full dimming level, the active value of LED current i LED equals i FULL For ¾ dimming level, the active value of LED current i LED equals ¾·i FULL . For a ¼ dimming level, the active value of LED current i LED equals the exemplary intermediate active value of ¼·i FULL . Referring to FIGS. 5 and 7 , the average LED current i LED conforms to the dimming level indicated by the dimming signal D V throughout the dimming levels in the set of dimming levels DLS 1 without causing inductor L 1 to enter DCM. In at least one embodiment, the active value of LED current i LED can be varied over time so that the average active value of LED current i LED equals the active value of LED current i LED depicted in waveforms 700 in order to, for example, spread the spectrum of the switching frequency of FET Q 1 .

FIG. 8 depicts exemplary LED current i LED waveforms 800 for dimming levels within the set of dimming levels DLS 2 . In the embodiment of waveforms 800 , the intermediate active value of LED current i LED is i FULL /4. For a ⅛ dimming level, the duty cycle (T ON — 1/2 /T) of enable signal EN is set by dimming strategy module 404 to 0.5 so that average LED current i LED equals 0.5·(intermediate active value of LED current i LED )=0.5·(i FULL /4). Thus, the value of LED current i LED equals the active value i FULL /4 for ½ of the period of enable signal EN for a dimming level of ⅛. For a 1/16 dimming level, the duty cycle (T ON — 1/4 /T) of enable signal EN is set by dimming strategy module 404 to 0.25 so that average LED current i LED equals 0.25·(intermediate active value of LED current i LED )=0.25·(i FULL /4). Thus, the value of LED current i LED equals the active value i FULL /4 for ¼ of the period of enable signal EN for a dimming level of 1/16. In at least one embodiment, the period of enable signal EN equals the period of the phase modulated signal V Φ . In general, in the active value, duty cycle varying mode of operation, the average LED current i LED equals the duty cycle (T ON /T) of the enable signal EN times the active value of LED current i LED . Period T ON represents the active period of LED current i LED and current control system 402 , and T-T ON represents an inactive period for each period T of enable signal EN. 1/T represents the duty cycle modulation frequency of control signal C G1 and LED current i LED .

FIG. 9 depicts an exemplary, logical representation of an LED lighting system controller 900 . Controller 900 includes current controller 902 , and current controller 902 represents one embodiment of current controller 406 . Controller 900 is depicted “logically” and can be physically implemented in any of a variety of ways. One of the components of current controller 902 is processor 904 . Processor 904 includes an input to receive the comparison signal V COMP , and processor 904 generates signal C G — ACTIVE . In at least one embodiment, processor 904 generates signal C G — ACTIVE in the same manner as Melanson V describes generating a control signal to control a switch such as FET Q 1 . FIG. 9 depicts an AND gate 906 with respective inputs for enable signal EN and signal C G — ACTIVE . The AND gate 906 is exemplary, and in general, the AND function of AND gate 906 is merged into the implementation of the current control system 402 . For the set of dimming levels DLS 1 during the active value varying mode of operation, the enable signal EN equals 1, thus, the control signal C G1 equals the signal C G — ACTIVE . For the set of dimming levels DLS 2 during the active value, duty cycle modulation mode of operation, the current controller 902 duty cycle modulates the control signal C G1 in accordance with the logical value of enable signal EN to generate duty cycle modulated control signal C G1 . Thus, when the enable signal EN equals logical 1, the control signal C G1 equals signal C G — ACTIVE , and when the enable signal EN equals 0, the control signal C G1 equals 0.

In at least one embodiment, the controller 900 also includes a power factor correction (PFC) controller 908 . The PFC controller 908 processes feedback signals representing the phase modulated signal V Φ and the output voltage V OUT of switching power supply 110 to generate a power factor correction control signal CS 1 . The control signal CS 1 controls a switch (not shown) in switching power supply 110 to control power factor correction and the output voltage V OUT of switching power converter 110 as, for example, described in Melanson VI, VII, VIII, IX, and X.

FIG. 10 depicts an LED lighting system 1000 that includes a linear current control system 1002 . The linear current control system 1002 controls a linear LED current i LED by varying an active value of the LED current i LED for a first set of dimming levels and duty cycle modulating an intermediate active value of LED current i LED for a second set of dimming levels. Because the LED lighting system 1000 does not include an inductor L 1 , ripple 602 ( FIG. 6 ) is not present in LED current i LED . Thus, the intermediate active value of LED current i LED is a matter of design choice. In at least one embodiment, the intermediate active value of LED current i LED for LED lighting system 1000 is set between 10% and 90% of the full active value i FULL . In at least one embodiment, the dimming levels in the first set are dimming levels corresponding to dimming levels generated by an LED current i LED between the intermediate active value and the full active value i FULL . The dimming levels in the second set represent all the dimming levels not in the first set.

When the enable signal EN is a logical 1, switch 1004 conducts, and the analog target signal i TARGET (t) is compared by operational amplifier 1006 to the feedback signal LEDi sense . The operational amplifier 1006 drives the base control signal C B higher if the voltage value of i TARGET (t) is higher than the value of feedback signal LEDi sense to cause the transistor Q 2 to conduct more LED current i LED . In at least one embodiment, transistor Q 2 is a bipolar junction transistor (BJT) or an insulated gate bipolar junction transistor. The operational amplifier 1006 drives the base control signal C B lower if the voltage value of i TARGET (t) is lower than the value of feedback signal LEDi sense to cause transistor Q 2 to conduct less LED current i LED . The enable signal EN causes the linear current control system 1002 to duty cycle modulate the active value of LED current i LED for the second set of dimming levels.

In at least one embodiment, the LED lighting system 400 of FIG. 4 includes an auxiliary power supply (not shown), such as a +15V to +20 V power supply, to provide sufficient power to logic and drive components of LED lighting system 400 other than, for example, the dimmer 106 , the switching power supply 110 , and LEDs 102 . In at least one embodiment, the auxiliary power supply (not shown) provides power to the current control system 402 , the phase delay detector 410 , the mapping system/filter 411 , the digital dimmer 408 , the dimming strategy module 404 , the duty cycle modulator 416 , and the DAC 412 .

Thus, the LED lighting systems 400 and 1000 control LED current i LED in one or more LEDs 102 in response to a dimming level input. The LED lighting systems 400 and 1000 implement respective dimming strategies having two modes of operation that allow the LED lighting system to dim the LEDs using an active value of LED current i LED less than a full value of the LED current i LED .

Although the present invention has been described in detail, it should be understood that various changes, substitutions and alterations can be made hereto without departing from the spirit and scope of the invention as defined by the appended claims.