Discussion on problems that may be encountered in designing LED lighting driver power supplies

First, the general requirements for LED drivers

Driving LEDs faces many challenges. For example, the forward voltage will change with temperature and current. The LED forward voltage of different individuals, different batches, and different suppliers will also vary. In addition, the color of the LED The point will also drift as the current and temperature change.

In addition, multiple LEDs are often used in applications, which involves the arrangement of multiple LEDs. Among the various arrangements, it is preferred to drive a single string of LEDs in series because this method provides excellent current matching performance regardless of how the forward voltage changes and how the output voltage (Vout) "drifts".

Discussion on problems that may be encountered in designing LED lighting driver power supplies

Of course, users can also use parallel, series-parallel combinations and cross-connects for other applications that require "mutually matched" LED forward voltage and other advantages. For example, in a cross-connect, if one of the LEDs is open due to a fault, only one LED in the circuit will double the drive current, thereby minimizing the impact on the entire circuit.

Common LED arrangement

The arrangement of the LEDs and the specification of the LED source determine the basic driver requirements. The main function of the LED driver is to limit the current flowing through the LED under certain operating conditions, regardless of the input and output voltage changes. The basic working circuit diagram of the LED driver is shown in Figure 2. The so-called "isolation" means that there is no physical electrical connection between the AC line voltage and the LED (ie, input and output). The most common is to use a transformer to electrically isolate. "Non-isolated" does not use high-frequency transformers for electrical isolation.

It is worth mentioning that in the LED lighting design, the two parts of the AC-DC power conversion and constant current drive can be configured differently:

1) The integral configuration, that is, the fusion of the two, is located in the lighting fixture, the advantages of this configuration include optimizing energy efficiency and simplifying installation;

2) Distributed configuration, ie both exist separately, this configuration simplifies security considerations and increases flexibility. LED driver can work with constant voltage (CV) output according to different application requirements, that is, the output voltage is clamped under a certain current range; it can also work with constant current (CC) output, and the output design can strictly limit the current; A constant current constant voltage (CCCV) output operation may be used, that is, a constant output power is provided, so the current is determined as the forward voltage of the LED of the load.

In general, LED lighting design needs to consider the following factors:

Output power: related to LED forward voltage range, current and LED arrangement, etc.

Power supply: AC-DC power supply, DC-DC power supply, direct AC drive

Functional requirements: dimming requirements, dimming methods (analog, digital or multi-level), lighting control

Other requirements: energy efficiency, power factor, size, cost, fault handling (protection characteristics), standards to be followed, reliability, etc.

More considerations: mechanical connection, installation, repair/replacement, life cycle, logistics, etc.

Second, the topology of the LED driver power supply

In LED lighting applications with AC-DC power supplies, the power conversion building blocks include discrete components such as diodes, switches (FETs), inductors, and capacitors and resistors to perform their functions, while pulse width modulation (PWM) regulators are used to control Power conversion.

The isolated AC-DC power conversion with a transformer usually included in the circuit includes topologies such as flyback, forward and half bridge. The flyback topology is the standard choice for medium and low power applications with power less than 30W, while the half bridge structure is Most suitable for providing higher energy efficiency / power density. For transformers in isolated structures, the size of the transformer is related to the switching frequency, and most isolated LED drivers basically use "electronic" transformers.

Common isolated topology

In the LED lighting application using DC-DC power supply, the LED driving methods that can be used are resistance type, linear regulator and switching regulator. The basic application diagram is shown in the resistance type driving mode, and the current detection in series with the LED is adjusted. The resistor controls the forward current of the LED. This drive is easy to design, low cost, and has no electromagnetic compatibility (EMC) problems. The disadvantage is that it relies on voltage, binning LEDs, and low energy efficiency.

Common DC-DCLED driving method

Linear regulators are also easy to design and have no EMC problems. They also support current regulation and over-current protection (foldback), and provide an external current set point. The power dissipation problem is insufficient, and the input voltage must always be higher than the forward voltage. And energy efficiency is not high. The switching regulator continuously controls the opening and closing of the switch (FET) through the PWM control module to control the flow of current.

Switching regulators have higher energy efficiency, are independent of voltage, and can control brightness. Insufficient is relatively high cost, high complexity, and electromagnetic interference (EMI) problems. Common topologies for LEDDC-DC switching regulators include Buck, Boost, Buck-Boost, or Single-Ended Primary Inductor Converter (SEPIC).

Wherein, the lowest input voltage under all working conditions is greater than the maximum voltage of the LED string, and the step-down structure is adopted, for example, 6 series LEDs are driven by 24Vdc; in contrast, the maximum input voltage is less than the minimum output voltage under all working conditions. The voltage structure, such as driving 6 series LEDs with 12Vdc; and the input voltage and output voltage range overlap, you can use buck-boost or SEPIC structure, such as driving 12 series LEDs with 12Vdc or 12Vac, but this kind of The cost and energy efficiency of the structure is the least desirable.

The way of directly driving LEDs with AC power has also achieved certain development in recent years. See the application diagram for details. In this configuration, the LED strings are arranged in opposite directions, operating in a half cycle, and the LEDs are turned on when the line voltage is greater than the forward voltage. This structure has its advantages, such as avoiding power loss caused by AC-DC conversion. However, in this configuration, the LED is switched at a low frequency, so the human eye may be aware of flicker. In addition, LED protection must be added to this design to protect it from line surges or transients.

Third, power factor correction

Power Factor Correction (PFC) is mandatory for any power class specified by the US Department of Energy (DOE) ENERGY STAR Solid State Lighting (SSL) specification. This standard applies to a range of specific products, such as recessed lights, cabinet lights and table lamps, where the LED driver power factor for residential applications must be greater than 0.7, and for commercial applications greater than 0.9; however, this standard is a voluntary standard. The EU's IEC61000-3-2 harmonic content standard specifies the total harmonic distortion performance of lighting applications with power greater than 25W. The maximum limit is equivalent to total harmonic distortion (THD) "35%, and power factor (PF). 》0.94.

While not all countries absolutely mandate improved power factor in lighting applications, some applications may have this requirement, such as utilities that promote commercial applications of products with high power factor in utilities, and utilities. When an organization purchases/maintains a street light, it can also decide whether it is required to have a high power factor (usually 0.95+) according to their wishes.

PFC technology includes passive PFC and active PFC. Passive PFC solutions are bulky and require additional components to better change the current waveform to achieve a power factor of about 0.8 or higher. Among them, in lower power applications of less than 5W to 40W, almost the standard choice of flyback topology requires only passive components and minor circuit modifications to achieve a power factor greater than 0.7. Active PFC is usually added to the circuit as a dedicated power conversion section to change the input current waveform. Active PFCs typically provide boost, with a wide input range of 100 to 277Vac and a PFC output voltage range of 450 to 480Vdc. If properly designed for PFC sections, 91% to 95% energy efficiency can be achieved. However, with the addition of active PFC, a dedicated DC-DC conversion is still required to provide current regulation.

Fourth, energy efficiency issues

The energy efficiency of LED lighting applications needs to be considered in conjunction with power output. The US Energy Star solid-state lighting specification specifies the energy efficiency of the lighting fixture level, but does not address the energy efficiency requirements of individual LED drivers. As mentioned earlier, LED applications using AC-DC power supplies can use a two-stage distributed topology, so they may be powered by an external AC-DC adapter.

The "Energy Star" does include specifications for single-output external power supplies. The 2.0 version of the external power supply specification came into effect in November 2008, requiring a minimum energy efficiency of 87% in the standard operating mode and a minimum energy efficiency of 86 in the low-voltage operating mode. %; In this specification, PFC is required when the power is greater than 100W. The US Department of Energy's LED lighting fixture energy efficiency research and development target proposed in the fall of 2008, in the LED application using AC-DC power supply, to provide higher AC-DC conversion Energy efficiency involves trade-offs between cost, size, performance specifications, and energy efficiency. For example, using higher quality components and lower on-resistance (RDSon) can reduce losses and improve energy efficiency; lowering the switching frequency generally improves energy efficiency, but increases system size. New topologies such as resonance provide greater energy efficiency, but also increase the complexity of the design and components. If we limit the design to a narrower power and voltage range, it can help optimize energy efficiency.

Five, the drive standard

The LED driver itself is also evolving, with a focus on further energy efficiency, increased functionality and power density. The US "Energy Star" solid-state lighting specification proposes energy efficiency limits at the lighting fixture level, involving specific product requirements including power factor. The European Union's IEC61347-2-13 (5/2006) standard for LED modules with DC or AC power supply includes: Maximum safety extra low voltage (SELV) working output voltage ≤ 25Vrms (35.3Vdc) under appropriate fault conditions "/Safe work does not smoke or flammable when it fails. In addition, the ANSI C82.xxx LED driver specification is still under development. In terms of safety, it is required to comply with UL, CSA and other standards, such as UL1310 (Class 2), UL60950, UL1012. In addition, LED lighting design also involves product life cycle and reliability issues.