Emergency Lighting Converter Control Without Dedicated Driver ICs
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Solution Overview
Problem
Emergency lighting converters require high-cost and space-intensive dedicated ICs for controlling switched mode power supplies, which are costly and complex, limiting cost-effective solutions for controlling converters in emergency lighting applications.
Innovation Solution
A microcontroller-based system that controls both the charger and driver circuits in emergency lighting converters, using a coupled inductor boost topology and zero-crossing information to eliminate the need for dedicated LED driver ICs, thereby reducing component count and cost while maintaining high efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If dedicated LED driver ICs are used to control the driver circuit, then the converter can operate reliably at high switching frequencies, but the device complexity and cost increase
Solution Approach 1:
The patent merges the control functions of the charger circuit and driver circuit into a single microcontroller unit. The microcontroller generates PWM signals to control both the charger switch and driver circuit switch, eliminating the need for separate dedicated LED driver ICs. This integration reduces device complexity while maintaining reliable operation through centralized control logic that can coordinate both circuits effectively.
Solution Approach 2:
The microcontroller is designed to perform multiple functions: it controls both the charger circuit and driver circuit, processes feedback signals from both circuits, and manages the overall converter operation. This multi-functional approach replaces multiple specialized ICs with a single universal control unit, reducing component count and device complexity while maintaining the reliability needed for high switching frequency operation.
2Loss of time
If dedicated LED driver ICs are used, then the converter can be controlled with precise timing, but the space requirements and manufacturing costs increase
Solution Approach 1:
By combining the control functions into a single microcontroller, the patent reduces the total space required for control electronics. The microcontroller integrates timing generation, PWM output, and feedback processing in one component, eliminating the need for separate dedicated ICs and reducing PCB real estate requirements while maintaining precise timing control through the microcontroller's internal timing mechanisms.
3Ease of manufacture
If multiple separate control circuits are used, then each circuit can be optimized for its specific function, but the manufacturing effort and costs increase
Solution Approach 1:
The patent merges multiple control circuits into a single microcontroller unit that handles both charger and driver circuit control. This consolidation reduces the number of discrete components that need to be sourced, assembled, and tested separately, thereby reducing manufacturing effort and costs. The integrated design simplifies the bill of materials and assembly process while maintaining the specialized control functions needed for each circuit through software configuration rather than hardware separation.
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AI summary
Emergency converter (1) for lighting applications for operation from an energy storage device (2) in case of mains failure. In particular, it is proposed a fast closed loop system in a converter using a microcontroller (9) and a corresponding method for controlling the converter. The converter device (1) comprises a battery charger (7) circuit configured to charge the energy storage device (2), a driver circuit (12) including a switch and a microcontroller circuit (9) configured to control the battery charger circuit (7). The microcontroller circuit (9) controls the switch in a mode in which the driver circuit (12) is operated from the energy storage device. The driver circuit (12) is implemented in a coupled inductor boost circuit topology.