A high power density dimming power supply and its control method

Abstract

This invention relates to the field of dimming power supply technology, and discloses a high power density dimming power supply and its control method. The dimming power supply includes a housing and a control circuit board disposed within the housing. The control circuit board is equipped with control circuitry. The control circuitry includes a rectifier filter circuit, a power factor correction circuit, a DC-DC power conversion circuit, an output control circuit, and a main control circuit. The DC-DC power conversion circuit adopts a soft-switching circuit architecture, with an operating frequency set above 110kHz. The control circuit board includes a main board and multiple sub-boards mounted on the main board. The power factor correction circuit operates at a frequency above 75kHz in continuous conduction mode; or, in critical conduction mode, the operating frequency near the zero-crossing point is not limited, and when the voltage is above 1 / 2 of the AC peak, the operating frequency of the power factor correction circuit is set above 75kHz. This dimming power supply can increase power density without increasing size.

Description

Technical Field

[0001] This invention relates to the field of dimming power supply technology, specifically to a high power density dimming power supply and its control method. Background Technology

[0002] As people's living standards improve, their demands for lighting are also constantly increasing, requiring lighting adjustments in various life scenarios. Most lighting adjustments involve a dimmer or dimming system sending a dimming command to a dimming power supply. Upon receiving the dimming signal, the power supply adjusts its output to change the brightness, color temperature, or color of the light. This method is cumbersome in terms of wiring, requiring a dimmer or dimming system and a matching dimming power supply. For example, if the dimmer is 0-10V, the matching power supply must also be 0-10V. To address these technical issues, some manufacturers have developed products that integrate the power supply and dimmer within a housing the size of a dimmer switch. However, these products generally use conventional technology, employing silicon MOSFETs and operating at frequencies around 40-70kHz, resulting in relatively low power consumption, typically not exceeding 100W, which is insufficient for higher-power applications. Summary of the Invention

[0003] In order to overcome the shortcomings of the prior art, the purpose of this invention is to provide a high power density dimming power supply, which can improve the power density of the dimming power supply, thereby increasing the output power of the power supply without increasing the product size, and meeting the needs of high power applications.

[0004] To solve the above problems, the technical solution adopted by the present invention is as follows: A high power density dimming power supply includes a housing and a control circuit board. The housing includes a control panel and a rear housing. The control circuit board is disposed within the space enclosed by the control panel and the rear housing. The control panel is provided with control devices, and the control circuit board is provided with a control circuit. The rear housing is provided with input terminals and output terminals. The control circuit includes a rectifier and filter circuit, a power factor correction circuit, a DC-to-DC power conversion circuit, an output control circuit, and a main control circuit. The input terminal of the rectifier and filter circuit is connected to the mains power through the input terminal. The output terminal of the rectifier and filter circuit is electrically connected to the input terminal of the power factor correction circuit. The output terminal of the power factor correction circuit is electrically connected to the input terminal of the DC-to-DC power conversion circuit. The output terminal of the DC-to-DC power conversion circuit is electrically connected to the input terminal of the output control circuit. The DC-to-DC power conversion circuit supplies power to the main control circuit. The output terminal of the output control circuit is electrically connected to the lamp load through the output terminal. The output control circuit is controlled by the main control circuit. The control device is electrically connected to the main control circuit. The DC-to-DC power conversion circuit adopts a soft-switching circuit architecture. The operating frequency of the DC-to-DC power conversion circuit is set above 110KHz. The control circuit board includes a main board and multiple sub-boards mounted on the main board. The electronic components in the control circuit are distributed on the main board and the sub-boards. The operating frequency of the power factor correction circuit in continuous conduction mode is above 75KHz; or, in critical conduction mode, the operating frequency of the power factor correction circuit is not limited near the zero crossing point, and when the voltage is above 1 / 2 of the peak value of the AC current, the operating frequency of the power factor correction circuit is set above 75KHz.

[0005] Compared to existing technologies, the advantages of this invention are as follows: by increasing the operating frequency of the DC-to-DC power conversion circuit and the power factor correction circuit, the volume of the magnetic components in these circuits is reduced, thereby increasing the power density and output power of the power supply. Simultaneously, this dimming power supply further enhances its power density by employing a three-dimensional control circuit board assembly composed of a daughter board and a motherboard, fully utilizing the space within the casing. This dimming power supply can increase the output power of the product without increasing its size, making it suitable for high-power applications.

[0006] The aforementioned high power density dimming power supply has multiple slots or soldering vias on the motherboard, and one end of the daughterboard has a conductive contact that matches the slot or a soldering pad that matches the soldering via. The daughterboard achieves electrical connection with the motherboard by inserting the conductive contact into the slot or by soldering.

[0007] In the aforementioned high power density dimming power supply, the MOS transistor in the power factor correction circuit is a third-generation semiconductor gallium nitride MOS transistor.

[0008] The aforementioned high power density dimming power supply uses third-generation gallium nitride MOS transistors in its DC-DC power conversion circuit.

[0009] In the aforementioned high power density dimming power supply, the coils of the boost inductor in the power factor correction circuit and the transformer in the DC-DC power conversion circuit are both made of multi-strand wire with a diameter of less than 0.1 mm.

[0010] The aforementioned high power density dimming power supply uses an active bridge rectifier circuit for its rectifier and filter circuit.

[0011] The aforementioned high power density dimming power supply includes a switch and a dimming controller.

[0012] A control method for the aforementioned high power density dimming power supply controls the operating frequency of the DC-to-DC power conversion circuit to be above 110 kHz, and controls the operating frequency of the power factor correction circuit to be above 75 kHz when the power factor correction circuit is operating in continuous conduction mode; when the power factor correction circuit is operating in critical conduction mode, the minimum operating frequency near the zero crossing point is not limited, and the operating frequency of the power factor correction circuit is controlled to be above 75 kHz when the voltage is above 1 / 2 of the peak voltage of the AC power.

[0013] The present invention will now be described in further detail with reference to the accompanying drawings and specific embodiments. Attached Figure Description

[0014] Figure 1 This is a schematic diagram of the high power density dimming power supply according to an embodiment of the present invention;

[0015] Figure 2 This is a schematic diagram of the control circuit board according to an embodiment of the present invention;

[0016] Figure 3 This is a schematic block diagram of the control circuit according to an embodiment of the present invention.

[0017] Explanation of icon numbers:

[0018] 100 Outer casing, 110 Control panel, 111 Switch, 112 Slide bar, 120 Rear casing, 200 Control circuit board, 210 Main board, 220 Sub-board. Detailed Implementation

[0019] The embodiments of the present invention are described in detail below, with reference to... Figures 1 to 3This invention provides a high power density dimming power supply, including a housing 100 and a control circuit board 200. The housing 100 includes a control panel 110 and a rear housing 120, and the control circuit board 200 is disposed within the space enclosed by the control panel 110 and the rear housing 120. The control panel 110 is equipped with controllers, the control circuit board 200 is equipped with control circuitry, and the rear housing 120 is equipped with input terminals and output terminals. The control circuitry includes a rectifier and filter circuit, a power factor correction circuit, a DC-to-DC power conversion circuit, an output control circuit, and a main control circuit. The input terminal of the rectifier and filter circuit is electrically connected to the mains power supply via its input terminal, and its output terminal is electrically connected to the input terminal of the power factor correction circuit. This is used to eliminate electromagnetic interference in the input mains power and to rectify the AC power into pulsating DC power before inputting it to the power factor correction circuit. The output terminal of the power factor correction circuit is connected to the input terminal of the DC-to-DC power conversion circuit to reduce current harmonics, thereby providing a more stable DC power supply to the DC-to-DC power conversion circuit. The output terminal of the DC-to-DC power conversion circuit and the output control circuit are used to step up and down the input stable DC power to generate a stable DC power of the required voltage value to power the output control circuit and the main control circuit. The output control circuit is controlled by the main control circuit. The output terminal of the output control circuit is electrically connected to the lamp load through the output terminal. The controller is electrically connected to the main control circuit. Under the control of the main control circuit, the output control circuit controls the power output to the lamp load according to the controller or an external dimming signal to enable the lamp to emit the required illumination. The DC-to-DC power conversion circuit adopts a soft-switching circuit architecture, and its operating frequency is set above 110KHz. The control circuit board 200 includes multiple sub-boards 220 mounted on the main board 210. The electronic components of the control circuit are distributed on the main board 210 and the sub-boards 220. The power factor correction circuit operates at a frequency above 75kHz in continuous conduction mode; or, when the power factor correction circuit is in critical conduction mode, the operating frequency near the zero-crossing point is not restricted, and when the voltage is above 1 / 2 of the peak value of the AC current, the operating frequency of the power correction circuit is set above 75kHz.

[0020] This high-power-density dimming power supply reduces the size of the magnetic components in the DC-DC power conversion circuit and power factor correction circuit by increasing their operating frequencies, thereby increasing the overall power density of the dimming power supply. The DC-DC power conversion circuit employs a soft-switching circuit architecture to further reduce losses. The control circuit board 200 uses a three-dimensional circuit board structure consisting of a main board 210 and a daughter board 220, which fully utilizes the space within the housing 100, further increasing the power density of the dimming power supply. This high-power-density dimming power supply can increase the output power to over 100W without increasing the product size, and even reach over 200W in some applications, to adapt to high-power application scenarios.

[0021] Understandably, in some embodiments, the MOSFETs in the power factor correction circuit and the DC-DC power conversion circuit are third-generation gallium nitride (GaN) MOSFETs, which helps reduce switching losses and further reduce product size and heat generation, thereby further improving the product's power density. The rectifier and filter circuit should preferably use an active bridge rectifier circuit to further reduce losses, minimize heat dissipation, and improve rectification efficiency, thus further increasing the product's power density. The DC-DC power conversion circuit can use soft-switching circuit architectures such as LLC, AHB, or ACF. The boost inductor of the power factor correction circuit and the transformer coil of the DC-DC power conversion circuit should preferably be made of multi-strand wire with a diameter of less than 0.1 mm to reduce the skin effect, further reduce losses, and increase power density.

[0022] In some embodiments, to facilitate the connection between the daughter board 220 and the motherboard 210, the motherboard 210 is provided with multiple slots, and one end of the daughter board 220 is provided with conductive contacts that match the slots of the motherboard 210. The daughter board 220 achieves electrical connection with the motherboard 210 by inserting the conductive contacts into the corresponding slots. In some embodiments, the daughter board 220 and the motherboard 210 can also be connected by soldering. The motherboard 210 is provided with several soldering vias, and one end of the daughter board 220 is provided with soldering pads corresponding to the soldering vias. It is understood that in some embodiments, the output terminals can be configured to have two or more channels to meet the requirements of the US CLASS2 standard, or to achieve color temperature and brightness adjustment.

[0023] Understandably, the main control circuit typically uses PWM signals to control the output control circuit. The control components include switch 111 and a dimming controller, which can be a slider 112, push rod, knob, button, or touchscreen. (See reference...) Figure 1In this embodiment, the control device includes a switch 111 and two sliders 112. The switch 111 is used to control the on / off state of the lamp load, and the two sliders 112 are used to adjust the color temperature and brightness of the lamp respectively.

[0024] The control method for a high-power-density dimming power supply in this invention sets the operating frequency of the DC-to-DC power conversion circuit to above 110kHz and the operating frequency of the power factor correction circuit operating in continuous conduction mode to above 75kHz; or, it does not limit the operating frequency of the power factor correction circuit operating in critical conduction mode near the zero-crossing point, and sets the operating frequency of the power factor correction circuit to above 75kHz when the voltage is above 1 / 2 of the peak voltage. This reduces the size of the magnetic components in the DC-to-DC power conversion circuit and the power factor correction circuit, thereby increasing the power density of the dimming power supply. This increases the output power of the product to over 100W without increasing the product size, making the product suitable for high-power applications. It is understood that the power factor correction circuit can determine whether it is near the zero-crossing point by judging whether the voltage value is below a preset threshold.

[0025] It should be noted that in the description of this invention, any descriptions of orientation, such as up, down, front, back, left, right, etc., indicating orientation or positional relationships, are based on the orientation or positional relationships shown in the accompanying drawings. They are only for the purpose of facilitating the description of this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, be constructed or operated in a specific orientation, and should not be construed as a limitation of this invention.

[0026] In the description of this invention, "several" means one or more, "more than" means two or more, "greater than," "less than," "exceeding," etc. are understood to exclude the stated number, while "above," "below," "within," etc. are understood to include the stated number. If "first" or "second" is mentioned, it is only for the purpose of distinguishing technical features and should not be construed as indicating or implying relative importance, or implicitly indicating the number of indicated technical features, or implicitly indicating the order of the indicated technical features.

[0027] In the description of this invention, unless otherwise explicitly defined, terms such as "setting," "installing," and "connecting" should be interpreted broadly, and those skilled in the art can reasonably determine the specific meaning of the above terms in this invention in conjunction with the specific content of the technical solution.

[0028] The above embodiments are merely preferred embodiments of the present invention and should not be construed as limiting the scope of protection of the present invention. Any non-substantial changes and substitutions made by those skilled in the art based on the present invention shall fall within the scope of protection claimed by the present invention.

Claims

1. A high power density dimming power supply, characterized in that, The system includes a housing (100) and a control circuit board (200). The housing (100) includes a control panel (110) and a rear housing (120). The control circuit board (200) is disposed within the space enclosed by the control panel (110) and the rear housing (120). The control panel (110) is equipped with control devices, and the control circuit board (200) is equipped with a control circuit. The rear housing (120) is equipped with input terminals and output terminals. The control circuit includes a rectifier filter circuit, a power factor correction circuit, a DC-to-DC power conversion circuit, an output control circuit, and a main control circuit. The input terminal of the rectifier filter circuit is electrically connected to the mains power through the input terminal. The output terminal of the rectifier filter circuit is electrically connected to the input terminal of the power factor correction circuit. The output terminal of the power factor correction circuit is electrically connected to the input terminal of the DC-to-DC power conversion circuit. The output terminal of the DC-to-DC power conversion circuit is electrically connected to the input terminal of the output control circuit. The DC-to-DC power conversion circuit supplies power to the main control circuit. The output terminal of the output control circuit is electrically connected to the lamp load through the output terminal. The output control circuit is controlled by the main control circuit. The control device is electrically connected to the main control circuit. The DC-to-DC power conversion circuit adopts a soft-switching circuit architecture. The operating frequency of the DC-to-DC power conversion circuit is set above 110KHz. The control circuit board (200) includes a main board (210) and multiple sub-boards (220) erected on the main board (210). The electronic components in the control circuit are distributed on the main board (210) and the sub-boards (220). The operating frequency of the power factor correction circuit in continuous conduction mode is above 75KHz; or, in critical conduction mode, the operating frequency of the power factor correction circuit is not limited near the zero crossing point, and when the voltage is above 1 / 2 of the peak of the AC current, the operating frequency of the power factor correction circuit is set above 75KHz.

2. The high power density dimming power supply according to claim 1, characterized in that, The motherboard (210) is provided with multiple slots or soldering vias. One end of the subboard (220) is provided with a conductive contact that matches the slot or a soldering pad that matches the soldering via. The subboard (220) is electrically connected to the motherboard (210) by inserting the conductive contact into the slot or by soldering.

3. The high power density dimming power supply according to claim 1, characterized in that, The MOS transistor in the power factor correction circuit is a third-generation semiconductor gallium nitride MOS transistor.

4. The high power density dimming power supply according to claim 1, characterized in that, The MOSFETs in the DC-to-DC power conversion circuit are third-generation gallium nitride MOSFETs.

5. The high power density dimming power supply according to claim 1, characterized in that, The coils of the boost inductor in the power factor correction circuit and the transformer in the DC-DC power conversion circuit are both made of multi-strand wire with a diameter of less than 0.1 mm.

6. The high power density dimming power supply according to claim 1, characterized in that, The rectifier and filter circuit is an active bridge rectifier circuit.

7. The high power density dimming power supply according to claim 1, characterized in that, The control device includes a switch (111) and a dimming control device.

8. A control method for a high power density dimming power supply according to any one of claims 1 to 7, characterized in that, The operating frequency of the DC-to-DC power conversion circuit is controlled to be above 110kHz, and when the power factor correction circuit is operating in continuous conduction mode, the operating frequency of the power factor correction circuit is controlled to be above 75kHz; when the power factor correction circuit is operating in critical conduction mode, the minimum operating frequency near the zero crossing point is not limited, and when the voltage is above 1 / 2 of the peak voltage of the AC current, the operating frequency of the power factor correction circuit is controlled to be above 75kHz.

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