LED Array Luminaires with Dynamic Power and Beam Control
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Solution Overview
Problem
Existing LED array systems in luminaires face challenges in maximizing light output while maintaining LEDs within their optimal operating temperature and achieving consistent luminosity across the array, while also dealing with spill light and beam angle control, which are often inefficient and require complex adjustments.
Innovation Solution
A system utilizing a temperature sensor and predictive algorithm to optimize LED power usage, combined with a beam control array featuring adjustable optical elements to manage beam angles and reduce spill light, allowing for simultaneous control of multiple LEDs and uniform light output.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If maximum power is applied to LEDs to maximize light output, then illumination intensity is improved, but LED temperature rises above optimal operating parameters reducing reliability
Solution Approach 1:
The system dynamically adjusts LED power levels based on real-time temperature feedback from the semiconductor die. The control system continuously monitors temperature and modulates the power supplied to LEDs, transitioning from static maximum power operation to dynamic adaptive power management that maintains optimal temperature while maximizing light output within thermal constraints.
Solution Approach 2:
A temperature sensor is placed in direct thermal contact with the LED semiconductor die to provide real-time temperature feedback. This feedback loop enables the control system to adjust power levels based on actual die temperature, eliminating the need for conservative safety bands and allowing operation at maximum safe power levels while preventing overheating.
2Ease of manufacture
If temperature probes are placed to measure LED package or heat sink temperature, then measurement is simplified, but the critical LED die temperature is not accurately measured requiring safety bands that reduce light output
Solution Approach 1:
The invention extracts the temperature measurement function from indirect locations (heat sink or package) and places it directly at the critical point - the LED semiconductor die. This eliminates the thermal lag and inaccuracy of indirect measurement, allowing the control system to directly monitor and control the actual die temperature without requiring conservative safety margins.
Solution Approach 2:
The system replaces indirect thermal measurement mechanisms with direct die temperature sensing. By substituting the mechanical/thermal coupling method of measuring heat sink temperature with direct electrical/thermal sensing at the die level, the system achieves accurate temperature control that maximizes light output while preventing thermal damage.
3Device complexity
If total power of LED bank is controlled rather than individual LED power, then device complexity is reduced, but consistent luminosity across different LED configurations cannot be achieved
Solution Approach 1:
The system segments the LED bank into individually controllable units with dedicated temperature monitoring for each LED or LED group. This segmentation allows independent power control and temperature management for each LED, enabling consistent luminosity output regardless of which specific LEDs are active, while the modular approach keeps the control architecture manageable.
4Object-affected harmful factors
If optical devices are permanently attached to control beam angle and spill light, then beam control is achieved, but adaptability and ease of adjustment are reduced
Solution Approach 1:
The optical devices are designed with dynamic adjustability, allowing beam angle and spill light control to be modified without permanent fixation. The system enables runtime reconfiguration of optical parameters, transitioning from static optical control to dynamic adaptive control that responds to different application requirements.
Solution Approach 2:
The optical control system is designed to perform multiple functions - beam angle control, spill light reduction, and adaptive adjustment for different LED configurations. By creating a universal optical control mechanism that can handle various scenarios, the system eliminates the need for separate fixed optical devices for each function.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system effectively maximizes LED output while maintaining optimal temperatures, reduces spill light and color fringing, and enables quick adjustments to beam angles, ensuring consistent and efficient light delivery across the array.
Implementation Method 1
a temperature sensor in an LED system to measure the temperature of the LEDs and use that information to control the operating current and voltage
Implementation Method 2
High power LEDs are commonly used in luminaires
Implementation Method 3
LEDs are highly temperature sensitive and running them at too high a temperature will both reduce their output and shorten their life
Implementation Method 4
the critical temperature is that of the LED semiconductor die itself and such temperature probes are often situated to measure the LED package or the heat sink
Data Source
AI summary
The present invention provides LED array systems with improved methods of powering LED in the array by monitoring the relationship between temperature and driving power to predict how much power can be safely applied to the LEDs. The present invention also provides for a control system for LED arrays that allows for display of images or light patterns across and array of luminairs over a low bandwidth control protocol. The present invention also provides for a LED array luminair with reduced color fringing, light spill reduction and beam angle control.