单相离线式高亮度LED照明驱动的研究与设计
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摘要
随着能源危机和气候变暖问题日趋严重,节能已经成为全球普遍关注的话题。照明是人类电能消耗的重要方面,约占世界总能耗的20%,成为节能的关键。相较于传统照明光源,高亮度发光二极管(High-Brightness Light-Emitting-Diodes, HB-LEDs)以其高光效、长寿命、环保、体积紧促等诸多优点,已经成为替代白炽灯和荧光灯的最佳照明技术。
     LED的光通量与通过其的平均电流成正比,因此必须采用恒流驱动。由于封装技术和散热的限制,单个LED的光通量或功率较弱,仅仅几瓦。为了获取足够的光通量,必须并联多串LED。 PET (General Photo-electro-thermal Theory)理论研究表明:对于相同的功率等级,多个低功率LED组成的分布式系统优于高功率LED组成的集中式系统。另一方面,LED是低压直流器件,无法直接与交流电网相连,必须通过电力电子驱动装置进行电能转换。这就要求LED照明驱动必须具有较高的功率因数和低的输入电流谐波以兼容诸如IEC61000-3-2和Energy Star等相关国际标准。此外还必须最大化提高效率、延长寿命和降低成本,以匹配LED光源高光效、长寿命的优点。另外,为了获取进一步的功率节省和适用不同的应用环境,PWM调光也成为LED照明系统必需的基本功能之一
     当前大量的LED照明驱动研究主要集中在提高功率因数和控制LED电流的方面。因此,如何同时实现LED驱动的高效率、高功率因数、长寿命、低成本、PWM调光便成为保证LED灯具照明品质及整机性能的关键。为此,本学位论文以研究实现高效率、长寿命、高功率因数、低成本和PWM调光的LED照明驱动为目标,从系统架构、电路拓扑、控制策略等角度对LED照明驱动进行了深入研究和探讨。
     首先,系统架构方面,传统LED照明驱动采用多级级联结构,不但电路复杂、成本较高,而且效率较低,为此论文提出了一种非级联的Twin-Bus驱动结构。该结构通过前级AC/DC变换器产生两个Twin-Bus电压源,并配以具有Twin-Bus输入的后级电流调节器,降低了功率的处理次数,因此可以在不增加系统成本的前提下,大大提高整个驱动的效率。基于此架构,本文研究提出了一种与之匹配的后级开关型电流调节器拓扑:Twin-Bus Buck变换器。在介绍Twin-Bus驱动架构的同时,详细讨论了基于Twin-Bus Buck变换器的调光策略。实验结果证明,在1MHz的开关频率下,从10W到满载100W的负载范围内,Twin-Bus Buck型电流调节器的效率均在98%以上,峰值效率高达98.8%。
     然后,针对传统AC/DC LED照明驱动中大容值电解电容寿命短的问题,以SEPICAC/DC变换器为突破口,提出了无电解电容的SEPIC-derived AC/DC变换器。该电路形式上与SEPIC变换器相同,但通过特殊的DCM工作模式使得SEPIC电路的中间电容电压不再跟随输入电压,而具有功率解耦的作用。同时通过增大电容纹波的方法,降低了电容的容值,从而消除了短寿命的电解电容,延长了LED驱动的寿命。进一步,引入填谷电路,提出了Valley Filled SEPIC-derived AC/DC变换器。与传统填谷电路改进功率因数和降低输出电压纹波不同的是,该变换器中填谷电路不但可以减小解耦电容的尺寸,而且可以降低输出二极管的电压应力和输出电压纹波。基于CV2为电容尺寸衡量指标,在相同的功率因数和输出电压纹波下,可将电容的尺寸减小为原来的1/4。
     针对传统的AC/DC LED照明驱动中二极管整流桥影响变换器效率的缺陷,在对无桥AC/DC变换器进行述评的基础上,将图腾(Totem-pole)式无桥结构引入上述两种SEPIC-derived AC/DC变换器,提出了两种新型无桥式SEPIC-derived AC/DC变换器。相较于传统AC/DC变换器,无桥电路的电流通路拥有较少的开关数,因此能够大大降低损耗,实现变换效率的最大化和成本的最低化。
     上述所研究的四种无电解电容的AC/DC变换器具有很强的普适性,不仅适用于传统级联结构,也适用于Twin-Bus架构,不但可以独立的驱动单串LED,也可以配合电流调节器,驱动多串LED。
     最后,对大于75W的高功率LED照明驱动进行研究。基于75W以上的应用场合,业内普遍采用Boost PFC级联LLC谐振变换器外加多个电流调节器的三级级联方案。虽然该方案可以实现各级电路的最优设计,实现高的电路性能;但是由于较多的级数,导致电路和控制过于复杂、成本较高。为此,本文通过共用开关管的方法,将Boost PFC和LLC谐振变换器集成在在一起,提出了一种新型的单级软开关无桥AC/DC变换电路,该电路具有如下优点:(1)对于级联结构,可将驱动级数降为2级,降低了成本。如果配以Twin-Bus架构,整个驱动将不足1.5级。(2)基于增大电压纹波法,同样可消除电解电容。论文第七章详细讨论的该电路的工作原理和设计考虑。实验室完成的100W原理样机的测试效率高达94%,证明电路的高效性。
With increasingly serious global energy crisis and the climate issue, energy conservation has become a common topic. Worldwide, about20%of the electric power is consumed by residential, commercial or industrial lighting. Due to the potential of high efficacy, long lifetime, environmental friendliness, and compact size over the conventional lighting devices, high-brightness light-emitting-diodes (HB-LEDs) have emerged as a promising lighting technology to replace the energy inefficiency incandescent lamps and mercury-based fluorescent lamps.
     The luminous flux of LEDs is in proportion to its forward average current. In order to ensure the constant luminous flux, LEDs have to be derived as constant current source. Presently, the power ratings of individual LED devices are a few watts, limited by the packaging technology and heat dissipation. To obtain sufficient luminance for lighting application, many LEDs have to be connected and arranged in parallel LED strings. The general photo-electro-thermal (PET) theory also indicates that a distributed LED system based on a plurality of relatively low-power LEDs has advantages over a concentrated system consisting of a small number of high-power LEDs for the same power level. Hence, paralleling LED strings has been a common practice. On the other aspect, LEDs typically require power electronic drivers to regulate the LED current and provide a high efficiency interface between LEDs and AC grid. Generally speaking, high power factor and low-input-current harmonics are becoming the mandatory criteria for this power electronics driver. In lighting equipment, the input current of ballasted lamps exceeding25-W are required to comply with stricter requirements as stated in IEC61000-3-2-Class C. Energy Star also requires the input power factor higher than0.9for commercial luminaries. Furthermore, to match the features of LED lighting source, low cost, high efficiency, and long lifespan will become the significant design requirements of LED drivers. In addition, PWM dimming control is often needed to regulate lighting levels for human needs as well as to achieve energy saving.
     Much research has been directed toward improving the power factor and controlling the LED current. Thus, how to implement LED divers with the feathers such as high efficiency, high power factor, long lifetime, PWM dimming and low cost is considered to be the key challenge lying ahead. This thesis is dedicated to the study and design of effective LED lighting drivers to overcome the inherent deficiencies and provide solutions for modern lighting applications.
     First of all, the traditional solution for driving multiple LED strings is the cascade configuration. This structure is a very good candidate with unity power factor (PF) and fast dynamic response. However, the complicated circuit, low efficiency and high cost are the main drawbacks. To increase the efficiency of LED lighting drivers, a non-cascade Twin-Bus structure is proposed in the third chapter. It is composed of a front-end isolated AC/DC converter with Twin-Bus output stage and post-stage current regulators with Twin-Bus input stage. Post-stage current regulators only handle the parts of the entire energy, thus, the total system efficiency can be increased significantly while maintaining the same cost. Meanwhile, a novel Twin-Bus buck converter is presented and employed as the post-stage current regulator with PWM dimming function. The Twin-Bus configuration and dimming control strategies is introduced in detail. To verify the validity of the studied Twin-Bus configuration and Twin-Bus Buck type current regulator, a100-W laboratory prototype is built and tested. The experimental results shows:(1) the independent string current can be regulated from zero to the desired350-mA for PWM dimming control;(2) for the individual stage efficiency, the current regulator employing the twin-bus buck converter has a peak efficiency of98.5%and maintains above98%for the output power range from10-W power to100-W under1MHz operation frequency.
     A review of literature shows many existing LED lighting drivers and solutions have to employ the electrolytic capacitor with large capacitance to obtain the smaller output ripple and to balance the difference between instantaneous input power and output power. Unfortunately, the lifetime of the high-quality electrolytic capacitor is typically10,000hours at105℃, which is much shorter than the lifetime of LEDs that is generally higher than50,000hours. Moreover, it is temperature-dependent due to the use liquid electrolyte and is reduced by half for every10℃rise in operating temperature. Thus electrolytic capacitors are the obstacle for prolonging the lifetime of the LED lighting driver. In order to prolong the overall lifetime of LED lighting products, a SEPIC-derived AC/DC converter topology is proposed as the front-end AC/DC stage. By allowing a relatively large voltage ripple in the AC/DC converters and operating in special discontinuous conduction mode (DCM), the proposed circuit is able to eliminate the electrolytic capacitor while maintaining high power factor and high efficiency. Furthermore, another novel AC/DC converter is also presented by inserting the valley fill circuit in the above SEPIC-derived circuit. Unlike the previous usage of the valley-fill circuit for improving the power factor and reducing the output voltage ripple, the major function of the valley fill circuit is to reduce the size of decoupling capacitors and decrease the voltage stress of output diodes. Under the electrolytic capacitor-less condition, considering the energy amount (CV2) as the capacitor sizing criterion, the proposed circuit requires only one quarter of the capacitor energy as compared to the origin circuit. Meanwhile, the voltage stress of storage capacitor and output diode under the same power factor condition can be reduced by half. The presented two SEPIC-derived AC/DC circuits are suitable for the traditional cascade and Twin-Bus structure, simultaneously. Two50-W laboratory prototypes are built and tested. The experimental results shows that the features of the proposed circuits.
     It is well known that the diode bridge hampers the further improvement of AC/DC converter efficiency. In an effort to maximize the AC/DC converter efficiency, considerable research efforts have been directed toward the development of bridgeless AC/DC circuit topologies. A bridgeless AC/DC converter allows the current to flow through a minimum number of switching devices compared to the conventional AC/DC circuit. Accordingly, the converter conduction losses can significantly be reduced, and high efficiency can be obtained, as well as cost savings. The sixth chapter reviewed and compared several bridgeless AC/DC converter topologies; based on which, the two bridgeless SEPIC-derived AC/DC converters are derived by inserting totem-pole bridgeless configuration in the SEPIC-derived and valley-filled SEPIC-derived converters to further improve the efficiency. Experimental results of two50-W laboratory prototypes are given to verify the validity of the studied two bridgeless AC/DC converters.
     Boost PFC plus LLC resonant converter in series post-stage current regulators has become the preferred solution for LED lighting application with power level above75-W. Although such a driver can help LEDs in achieving good operating performance, too many components, large size, low efficiency and relatively high cost are its main drawbacks. A single-stage bridgeless AC/DC converter with soft-switching feather is put forward and investigated. The totem-pole bridgeless boost PFC and half-bridge LLC resonant converter are integrated in together by sharing the switches. The bridgeless boost PFC cell works in discontinuous current mode (DCM) for achieving high power factor and low input current harmonics. Thus the resulted topology only needs one controller to regulate the output voltage, and that high efficiency can be obtained easily. The conventional resonant control chip, such as L6599and UCC25600can be employed to implement the controller. This circuit can be coupled with the Twin-Bus buck type current regulator for driving multiple LED strings, but also can drive the single LED string independently. The seventh chapter introduced the operation principle and design consideration in detail. The experimental efficiency is high as94%for100-W laboratory prototype, which shows that the features of the proposed circuits. It is noted that this circuit is suitable for the street lighting application especially.
     Finally, the contribution is summarized. Accordingly, the limits and future work are also pointed out.
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