Patent Application
20090243558
The present disclosure relates to control ballasts, and particularly, to electronic control ballasts for powering alternating current discharge loads, such as gas discharge lamps.
Many applications call for the operation of alternating current (AC) discharge loads such as discharge lamps, including ultraviolet (UV) discharge lamps. For example, UV lamps are used for curing inks in printing systems. Many other uses for UV lamps are popular, representative examples of which include curing furniture varnish or heat-sensitive substrates, decontaminating food substances, sterilizing medical equipment or contact surfaces, optically pumping solid state lasers, electrically neutralizing surfaces, inducing skin tanning, and passing through fluorescent coatings to provide visible illumination. Additional uses for discharge lamps in other wavelengths are also popular, such as visible wavelength discharge lamps for providing illumination.
Gas discharge lamps are operated by power supplies commonly called ballasts. A ballast is necessary to operate a gas discharge lamp because the lamp appears as a constant voltage load. A constant voltage load cannot be controlled if it is connected to a constant voltage source such as the electric utility. An incandescent lamp appears as a simple resistive load and can be connected directly to the utility voltage.
Therefore, a lamp ballast allows a constant voltage load to be operated from a constant voltage source and provides control over current or power delivered to the lamp. High power discharge lamps typically must operate as an ac-device. These lamps will be damaged or destroyed if operated with in a dc-mode. This is true even if there is a small dc-component to the otherwise ac-voltage applied to a gas discharge lamp. The root mean square (rms) voltage at which a lamp operates is proportional on a first-order to the temperature of the gas inside the lamp. When a lamp starts to ignite, it will be cold and will operate at a very low voltage. As the gas heats up, the voltage will rise until steady-state operating conditions are obtained. Lamps are typically warmed-up with a constant ac-current.
Typically, lamps are used in industry with power ratings for several kilowatts to tens of kilowatts. Lamps often operate with a maximum current of 10 amps to 30 amps and operate at voltages in the range of 200 volts to 2000 volts.
A gas discharge lamp applies the operating voltage to the gas or vapor within the lamp. Several varieties of gas or vapor are used in gas discharge lamps. Mercury vapor is a popular choice; other gas discharge lamps are based on gallium, halogen, metal halide, xenon, sodium, or other varieties. The electricity ionizes the gas within the lamp, so that when electrons recombine with ions, light is emitted. This discharge light is alternately described as an arc, a glow, or a corona.
For a gas molecule to ionize, a minimum threshold electric field must be applied to it. A lesser field will only polarize gas molecules without causing ionization. So, an ignition voltage is typically required for a discharge lamp to achieve ionization of the gas molecules.
Once ionization begins, it initially drives a positive feedback chain reaction as the initially freed electrons collide with other polarized molecules close to the ionization energy and provide the extra energy needed to ionize. As the populations of ionized molecules and free electrons rise, the rate of recombination also rises, until an equilibrium is reached where the rate of new ionizations is equal to the rate of recombinations. A discharge load goes from the initial equilibrium with no current, through the unstable ignition transition with negative resistance, to the new operating equilibrium.
It is typically desirable to compensate for the negative resistance of the discharge load during the ignition transition, and to provide a lower voltage than the ignition voltage when the ionization equilibrium has been achieved. An enhanced level of current is often used for warm-up, while a lower run level of current is required to maintain normal operation.
Discharge lamps come in a wide range of sizes, and a correspondingly wide range of current, voltage, and power ratings. The voltage and power ratings on many lamps are considerably high.
The current, voltage, and power characteristics over time of the electrical supply must therefore be controlled within acceptable tolerances. The voltage provided to such lamps must also typically be in alternating current (AC) form. Allowing any net direct current through a discharge lamp often causes undesirable effects, such as gas migration and accumulation on the lamp electrodes, and saturation of the ballast.
Traditional ballasts are magnetic, which include end stage transformers placed in connection with the lamps, and banks of high-voltage capacitors. However, these traditional solutions have substantial drawbacks. For example, a traditional ballast may have only one set amount of power it can provide to its lamp, or at best only two or three options for power settings. For another example, a traditional ballast may have only a single voltage setting that is tailor-made for a specific lamp. This means a multi-lamp system will impose separate maintenance and replacement requirements for each of several different ballasts. As another example, traditional ballasts often provide a substantially inaccurate or variable current, with typical inaccuracy of up to 20% or more. As another example, traditional ballasts are often electrically inefficient and convert a significant fraction of current into waste heat, causing the ballasts to operate at high temperature, often leading to additional problems. As another example, traditional ballasts are often bulky, heavy, inconvenient, and expensive. To illustrate, a typical ultraviolet discharge lamp used for curing inks in a printing operation may be twelve feet long, and be supplied by a transformer ballast weighing 700 pounds. And a typical printing operation might have nine discharge lamps, each with a ballast rated for 15 kilowatts.
The inflexibility and inefficiency of power consumption in traditional ballasts therefore creates a demand for a substantial amount of input power. This problem is acute in multiple lamp systems, where the inflexible and inefficient demands of multiple lamps creates a substantial demand for the overall power. The greater the system demand for electrical power, the greater the initial capital costs and the ongoing maintenance and power costs.
Newer solutions are therefore desired for the problem of delivering electrical power to discharge lamp ballasts.
An aspect of the present disclosure relates to an electronic ballast, which includes an energy hold-up circuit that maintains operation of an AC discharge load, such as a gas discharge lamp, during at least a portion of a utility source outage.
An aspect of the present disclosure relates to an electronic ballast, which includes first and second input nodes for receiving input power, an AC discharge load output, an input capacitor coupled in parallel with the first and second input nodes, a DC-to-DC converter coupled to the input capacitor and having a DC output, and an inverter, operatively coupled to the DC output and configured to provide an AC voltage to the AC discharge load output. The ballast further includes a hold-up energy circuit coupled to the input capacitor.
In one embodiment, the hold-up energy circuit includes a resistor and a diode coupled in parallel with one another and a hold-up capacitor coupled in series with the resistor and diode.
Another aspect of the present disclosure relates to an electronic ballast energy hold-up circuit. The circuit includes a housing having first and second interface connection terminals adapted to be connected to an electronic ballast contained in a separate housing. A resistor and a diode are contained in the housing and are coupled in parallel with one another. A hold-up capacitor is contained in the housing and is coupled in series with the resistor and diode, wherein the resistor, diode and hold-up capacitor are together coupled in series between the first and second interface connection terminals.
An aspect of the present disclosure relates to a method of maintaining operation of an AC discharge load, such as a gas discharge lamp, through an electronic ballast during at least a portion of a utility source outage.
For example, the method includes receiving electrical charge from a utility source that is susceptible to a utility outage; maintaining operation of an AC discharge load through an electronic ballast having an input capacitor, using the charge received from the utility source; charging a hold-up capacitor bank, separate form the input capacitor, using the charge received from the utility source; and discharging at least a portion of the charge stored in the hold-up capacitor bank into the electronic ballast in response to the utility outage.
For high power applications a three phase utility connection is used and applied to the utility input 102. In one example, the electronic ballast control system 100 shown in
The utility voltage is converted to a dc-voltage by the rectifier diodes in rectifier 104 across dc-bus filter capacitor C1. An inductor can also be used between the output of the rectifier diodes and dc-bus filter capacitor C1 to improve the power factor. The voltage VC1 across capacitor C1 is the input to DC-to-DC converter 106.
Converter 106 includes transistors Q 1 and Q2, diodes D1 and D2, inductor L1, converter-current sense resistor RCS, and output capacitor C2.
During normal operation, both switches Q1 and Q2 of the converter 106 are operated synchronously by control circuit 114. When they are turned on, the input voltage VC1 is applied to the inductor L1 and the current IL1 in the inductor L1 will increase linearly. When the switches are off, a path for the current IL1 in the inductor L1 must be maintained. This current will flow through diodes D1 and D2. The voltage across L1 will be equal to the negative of the voltage VC2 across the output capacitor C2. This will cause the current IL1 in the inductor L1 to decrease linearly during the “off time” of switches Q1 and Q2.
Through this “charge and dump” of inductor L1 the voltage at the output capacitor C2 can be regulated. If the duty cycle D is defined as the portion of the switching cycle that the switches Q1 and Q2 are conducting, then the output voltage is determined by the equation:
Thus, the converter section operates as a step-up/step-down DC-to-DC converter, for example, as controlled by the duty cycle D. The above equation is true if the circuit is operating in steady state conditions, in continuous conduction mode and if the input and output capacitors are large enough so the ripple voltages across these components can be ignored. To be considered to be in continuous conduction, the inductor current may not be zero for any significant portion of the switching cycle
When insulated gate bipolar transistors (IBGTs) are used for switches Q1 and Q2, for example, which are capable of operating at power levels of tens of kilowatts, a typical switching frequency is in the range of about 5 to 15 kHz.
In one example, ballast control system 100 is configured to be used to drive a gas discharge lamp that requires an ac-voltage to operate. The lamp is connected across lamp outputs 112. The average voltage across the lamp over many cycles should be zero to avoid long-term damage to the lamp. The converter 106 can control the dc-power at its output. The inverter 108 is used to deliver this power to the lamp by applying a square wave voltage (and more correctly a square wave current) to the lamp. This is typically done at a lower frequency in the range from 50 to 500 Hz.
The inverter 108 includes transistors (or switches) Q3, Q4, Q5 and Q6 and inverter-current sense resistor RIS. The inverter transistors Q3-Q6 are controlled by control circuit 114, as discussed in more detail below. The square wave alternating current and voltage at lamp outputs 112 are produced by simultaneously turning on switches Q3 and Q6 (with Q4 and Q5 being off) for a time interval followed by an equal time interval (for example) during which switches Q4 and Q5 are turned on (with Q3 and Q6 being off). The arrangement of switches Q3 through Q6 is commonly called an “H-Bridge” and is used in power electronics for many applications such as this where an alternating or bipolar output voltage is needed across a load that is operated from a dc-source.
During normal, steady-state operation, the lamp (which is electrically connected across the lamp output terminals 112 in
The electronic ballast is controlled by control circuit 114, which in the example shown in
In one example, the customer or plant operator inputs a requested power to be delivered to the lamp, such as through the digital communications interface 134. Other control inputs can be provided such as an analog input signal 136 and/or other voltage states from DIP switches, etc. The control system 120 receives the requested power command and calculates the actual power by multiplying the instantaneous voltage and current being delivered to the lamp to determine the instantaneous power being delivered to the lamp. This value is low-pass filtered to determine an average power level, which is compared to the requested power from the customer input to determine a power-error value. In response, the control system 120 alters either continuously or intermittently the instantaneous current value at which the switches of the converter Q1 and Q2 are turned off to maintain a minimum power error under closed loop feedback control.
Various elements of the control system 114 shown in
Typically the machine in which the ballast or multiple ballasts are installed has a computer that functions as a master controller (not shown in
In industrial automation, several communication protocols can be used for sending commands and data from one part of the machine to another. Some commonly used communication protocols include EtherNet/IP, DeviceNet, ControlNet, and ProfiBus. There are standards and specifications that control the detailed operation of devices communicating on these networks.
The electronic ballast control system shown in
The Host controller may give commands to the ballast over the host machine digital network 140 to control the ballast output power, output current and output voltage. The ballast controller 120 will continuously monitor the commands and cause the lamp output 112 to reach whichever parameter (output power, output current, or output voltage) is encountered as an operating limit. Typically, the lamp is controlled with a power request and the lamp voltage and lamp current parameters are used to limit the operation under special situations such as starting or stopping the lamp.
To maintain backward compatibility with other product lines or plant control systems, the electronic ballast control system 100 shown in
In one example, the Host control system operates with circuit potentials that are within a few volts of earth ground. The electronic ballast 100 is connected to 480 Vac, which when rectified produces nodes at +325 Vdc and −325 Vdc compared to the earth ground. Most of the ballast control circuits operate connected to the negative side of the input rectifier, which is typically at a potential of −325 Vdc compared to earth ground. Signals passing to and from the ballast controller 120 must have sufficient electrical isolation for this environment. In one example, optical isolation can be used inside the ballast controller 120 for passing these signals through the digital communications interface 134. Other types of electrical isolation can also be used.
The VC1 Sense input to the control system 120 is an analog input voltage, for example, which is proportional to the input voltage across capacitor C1 after being rectified. Analog-to-digital conversion is used to further process this signal inside the control system 120.
The VC2 Sense input to the control system 120 is an analog input voltage, for example, which is proportional to the DC output voltage produced across output capacitor C2 that feeds the inverter 108. Analog-to-digital conversion is used to further process this signal inside the control system 120.
2.6 Inverter Current Sense The Inv Cur Sense input to the control system 120 is an analog input, for example, which is proportional to the current in the inverter 108 across sense resistor RIS, while the inverter drives the lamp. In one example, this current is represented by the voltage VRIS developed across sense resistor RIS. Analog-to-digital conversion is used to further process this signal. The control system 120 can also include a circuit that multiplies the inverter current (output current) and the output dc-bus voltage (equal to the magnitude of the lamp square wave) to produce a signal for use in the controller that is proportional to the lamp output power.
2.7 Microcontroller Based Control System 120 In one example, the control system 120 includes two Programmable Intelligent Controllers (PIC microcontrollers) by Microchip Inc, which are used along with other supporting circuitry to implement the controller function for the ballast 100. Other types and brands of controllers could also be used. One microcontroller interfaces with the external inputs and is referenced to earth ground. Digital data is passed back and forth using opto-isolators. The second microcontroller is referenced to the power system ground (about 325 V negative compared to the earth ground). In addition to the microcontrollers, the control system includes various digital and analog components.
The control system 120 can include a computer-readable medium, such as a RAM and/or ROM memory, which stores software and/or firmware instructions, for example, that when executed perform the control and other functions described herein in response to commands received over the Host-Machine digital network 140 and various operating states of the ballast.
On one example, the control system 120 generates an analog output signal, IRef, which is produced using digital-to-analog conversion. The current in the converter 106 is sensed by measuring the voltage across the converter current sense resistor RCS. When the converter power switches Q1 and Q2 are on, the current IL1 in the converter inductor L1 will increase. IRef defines the upper limit for the converter inductor current on a cycle-by-cycle basis. Comparator 122 compares the upper limit defined by IRef with the the actual converter current IL1, as sensed by sense resistor RCS. When the converter current IL1 reaches a value equal to IRef, comparator 122 resets flip-flop 124 to terminate the “on time” of converter transistors Q1 and Q2. The operation of set-reset flip-flop 124 and buffers 126 is described in more detail below.
The control system 120 generates an output signal, Con Drv Enbl, which enables the converter transistors Q1 and Q2 to operate if it is high. If it is low, the converter transistors are off. For simplicity, the gating of Con Drv Enbl with the transistors' gate control signals “Gate Q1” and “Gate Q2” is not shown in
The control system 120 generates an output signal, Inv Drv Enbl, which enables the inverter transistors Q3-Q6 to operate if it is high. If it is low, the inverter transistors Q3-Q6 are off. Again, for simplicity, the gating of Inv Drv Enbl with the transistors' gate control signals “Gate Q3”, “Gate Q4”, “Gate Q5” and “Gate Q6” is not shown in
The control system 120 generates a clock signal, Clock fSW, which defines the switching frequency of the converter 106. For example a 6 kHz clock may be used in a 15 kW converter. Each rising edge of the clock is used to turn on the converter transistors Q1 and Q2.
In one example, control circuit 114 includes a variable frequency divider, such as a divide by 64 circuit 128, which includes a synchronous counter that produces a clock frequency that is 64 times slower than the converter switching clock. A divide by 64 circuit is a convenient circuit to implement with digital logic. The clock output from the divider is guaranteed to have a 50% duty ratio as long as the converter clock is running at a constant frequency. This clock is used to drive the inverter transistors Q3-Q6. It is easy to divide by a power of two with digital circuits, although dividing by any integer is possible with relatively simple circuits.
A switch setting, for example, can be provided on the control board to change the frequency divider to divide by 16 or 32 instead of 64, or example. There could be some reasons for wanting a particular frequency square wave at the lamp. One might be using a “400 Hz” transformer (which is an industry standard frequency) between the ballast and the lamp. This could be the case if a lamp is to be used that operates with a current or voltage that is not in the range of what the electronic ballast can produce.
In a further example, the switching frequency of the converter is set to just under 5 kHz and the frequency divider 128 is set to divide by 16 for a frequency at the lamp of 300 Hz. Alternatively, the frequency divider 128 can be set to divide by 64 for a frequency at the lamp of 75 Hz. Other examples also exist.
The Toggle flip-flop 130 receives the divided clock signal produced by the divide by 64 frequency divider 128 and creates low frequency square wave control signals for an inverter gate drive circuit, represented by buffers 132, which drives the gates of transistors Q3-Q6.
In the example shown in
To avoid instabilities in the process when the duty ratio for switches Q1 and Q2 is greater than 50%, a technique know as “slope compensation” can be used. This type of instability and the slope compensation is well reported in literature. A time varying signal (in our exemplary implementation) that is synchronous with the switching action is subtracted from the reference signal. So, as the switch is on longer, the threshold at which it turns off is reduced.
To avoid a false termination of the pulse, a technique known as leading edge blanking can be used. Noise is picked up on the current sense signal when switching occurs. The leading edge blanking is used to momentarily disable the comparator at the turn-on instant so any noise present will be ignored.
Lamp ballasts that operate with line frequency transformers do not have significant internal energy storage to maintain lamp operation during outages of the utility source.
The AC utility voltage 301 drops out in the middle of the plot. The lamp current 303 stays at zero after the utility voltage drops out, indicating that the lamp has extinguished. In 60 Hz designs, the lamp current is zero for a portion 25 of each cycle, which is about 3 mS out of every 8.3 mS. A large voltage must be applied to re-strike the lamp after being off for 3 mS as shown in the voltage spikes of Channel 3 (reference number 302). If the lamp is off for something more like 10 mS or 20 mS, the ballast cannot produce enough voltage to re-strike the lamp.
The machine in which the lamp is installed must then stop and wait for the lamp to cool down before it is restarted. This is costly as product is scrapped and operator intervention is needed to restart the machine.
Other components such as electric motors on the machine can operate over 10s to 100s of mS of utility outage. The ballast shown in
Hold-up circuit 402 includes a capacitor bank CH, a current-limiting resistor RH and a diode DH, for example. Capacitor bank CH, which might be at least 10 times larger than capacitor C1, is added to the converter side of the ballast, generally in parallel with C1. This capacitor bank is charged slowly through current limiting resistor RH in the hold-up circuit 402. Resistor RH prevents inrush surge currents when the utility is switched on or returns after an outage.
Capacitor bank CH can include a single capacitor or multiple capacitors connected in parallel with one another, for example. Other connection configurations can also be used.
If the utility voltage fails, the energy in the hold-up capacitor bank CH is automatically connected to the converter through diode DH, which become forward biased. This energy maintains the lamp operation for a longer period of time following the utility voltage failure than the time period during which input capacitor C1 can maintain the lamp operation.
In this example, the hold-up energy circuit 402 is adapted to store hold-up energy, wherein the hold-up energy circuit is coupled to the DC-to-DC converter 106 such that the hold-up energy remains charged when nodes N3 and N4 are supplied with at least a threshold level of charge to the input capacitor C1 and discharges into the DC-to-DC converter 106 when nodes N3 and N4 are supplied with less than the threshold level of charge to the input capacitor C1.
The hold-up circuit 402 can be contained in the same housing as ballast 400 or can be contained in a separate housing. A separate housing allows the user to purchase and/or utilize the hold-up circuit separately for applications where more energy storage is needed due to frequent utility outages and/or where the process is more sensitive to outages, for example. The larger capacitor bank CH can add significant size and weight to a ballast system. Therefore, the optional separate housing can be eliminated in applications where longer energy storage is not needed.
Although the present disclosure has been described with reference to one or more examples, workers skilled in the art will recognize that changes may be made in form and detail without departing from the scope of the disclosure and/or the appended claims.
This application claims priority from and the benefit of U.S. Provisional Application No. 61/041,122, filed Mar. 31, 2008 and entitled ELECTRONIC BALLAST WITH HOLD-UP ENERGY STORAGE, the contents of which is hereby incorporated by reference in its entirety.
| Number | Date | Country | |
|---|---|---|---|
| 61041122 | Mar 2008 | US |
