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Three Dimensional Passive Integrated Electronic Ballast for Low Wattage HID lamps

Yan Jiang. Three Dimensional Passive Integrated Electronic Ballast for Low Wattage HID lamps. Committee Members: Dr. Fred C. Lee (Chair) Dr. J. D. van Wyk Dr. Dushan Boroyevich Dr. Shuo Wang Dr. William T. Baumann Dr. Carlos T. A. Suchicital. January 27 th , 2009.

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Three Dimensional Passive Integrated Electronic Ballast for Low Wattage HID lamps

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  1. Yan Jiang Three Dimensional Passive Integrated Electronic Ballast for Low Wattage HID lamps Committee Members: Dr. Fred C. Lee (Chair) Dr. J. D. van Wyk Dr. DushanBoroyevich Dr. Shuo Wang Dr. William T. Baumann Dr. Carlos T. A. Suchicital January 27th, 2009

  2. Lighting 19% of global power consumption and 3% of global oil demand is attributable to lighting Gas discharge Solid State Incandescent Low pressure discharge High (pressure) intensity discharge (HID) Standard Incand. halogen Fluorescent (FL) CFL CCFL Low pressure sodium Metal halide (MH) Ceramic MH Mercury vapor High pressure sodium LED Organic LED Efficacy: 15~20 lm/W Life time: 1k~3k hours 60~200 lm/W 8k~18k hours 40~160 lm/W 50k~60k hours 60~150 lm/W 8k~40k hours

  3. HID Applications Automotive headlights (35W~70W) Track lighting for offices and retail environment (20W~39W) • LCD projectors (100W~150W) • Stadium, parking area and roadway/tunnel lighting (400W~2000W) Supermarket lighting (175W~400W)

  4. Track Lighting Halogen HID • Lower efficacy • Shorter lamp life (≈4kHr) • ≈70% of market share • Lower cost, smaller size • (Basically incandescent lamp, doesn’t need ballast) • Higher efficacy • Longer lamp life (up to 20kHr) • <20% of market share • Higher cost, larger size • (Needs sophisticated ballast) 70W halogen≈20W HID HID lamp system has higher initial cost, but is more energy efficient in long run. Need around 4 yr to break even Market requirements for HID ballast: • Compact size • Low cost

  5. Ballast for Gas Discharge Lamp VS VAB VR Voltage (V) + VAB- Lamp R + VR- + VLamp- VLamp ISS Current (A) • Ballast is needed to stabilize the current for gas discharge lamps fs>20kHz L Lamp C High Q parallel-load series-resonant tank generate high voltage peak Transformer boost voltage pulse • Ignitor is needed to initiate the gas discharge

  6. From Magnetic to Electronic Ballast HF Electronic Ballast Magnetic Ballast fs>20kHz L Ignitor Lamp L 110V/60Hz Lamp • Higher cost • Small and light • Integrated ignitor • No reignition, no flickering and audible noise • With lamp power regulation (more intelligent) • Improved lamp efficacy • Simple, low cost, high reliability • large and heavy • External ignitor • Reignition causes line frequency flickering • No lamp power regulation HF electronic ballast greatly reduce the size and weight of ballast, and greatly improve the lamp performance

  7. . Most Significant Lighting Advance: CFL FL with magnetic ballast Typical CFL ballast circuit: Self-oscillating HB series resonant circuit * from Delta In CFL below 25 W, PFC and constant power control are not often used to achieve low cost CFL w/ built-in ballast Why this topology is not suitable for HID ballast?

  8. CFL v.s. HID CFL start up profile HID lamp start-up profile • Requires much higher ignition voltage: 1kV~5kV (cold strike), ~20KV (hot strike), Voltage need to be further boosted by transformer or else • Requires lower ignition voltage: 400V~600V, Series resonant parallel loaded circuit is enough • LF SQ AC current driving is needed to avoid Acoustic Resonance, additional LF inverter is needed. • No Acoustic Resonance, can use HF AC current driving

  9. Acoustic Resonance Vlamp(V) 100 90 80 70 200 10 20 100 fs(kHz) Acoustic Resonance in HID lamps: standing pressure waves occur on the discharge tube at high frequency (f>4kHz) Normal arc Arc with AR Detrimental effect of AR: • Light lumens fluctuation • Lamp color temperature variation • Arc tube overheat • Extinguish Lamp voltage increase (due to AR) vs. freq. Methods (for Ballast) to eliminate AR: Acoustic Resonance is due to: • Lamp frequency is within AR frequency band • High frequency energy is larger than the AR threshold Operate in non-AR frequency Reduce HF energy to below the threshold * E. Rasch, Osram, 1988

  10. Existing Methods to Eliminate AR_1 1. Operate in non-AR frequency DC Ultra HF 10kHz 20kHz 100kHz 200kHz AR AR-free 1) DC-type ballast (*S. Wada, 1987) • Etching and asymmetrical eroding of electrodes due to cataphoretic effect 2) Operate at AR-free Zone (*E. Rasch, 1988) • Difficult to select these windows due to dependency on lamp geometry and physical characteristics. 3) Operates at frequency higher than 300kHz (*R. Redl, 1999) High EMI caused by high frequency lamp arc.

  11. Existing Methods to Eliminate AR_2 2. Reduce HF energy to below the threshold 1) Lamp Power spectrum spreading frequency modulation, phase-angle modulation… feedback modulation or random modulation Original Lamp voltage: Modulated Lamp voltage: 40dBV 20dBV 0dBV 0dBV • Threshold varies due to lamp parameter inconsistency • Possible to introduce AR on other frequency point * L. Laskai, 1998

  12. Existing Methods to Eliminate AR-3 vlamp ilamp ≈x00Hz The only one used in commercial product 3. Square-wave current driving 1) Low Frequency Square Wave (LFSW) lamp current. (*Janos Melis, 1995) Completely eliminate Acoustic Resonance, but has relatively complicated system structure. 2) High Frequency Square Wave (HFSW) lamp current. (*M. Ponce, APEC 2001) Flat instantaneous power ideally, due to parasitics, there is still HF energy provided to lamp

  13. Requirements for HID Ballast Functions: • Stabilize lamp current • Provide high voltage (several kV) pulse for initial starting • Acoustic resonance free (LF SW AC current driving) • Constant lamp power regulation (maximize lamp life time) Regulations: • High power factor (PF>0.9) • Small input current harmonics (IEC 61000-3-2 Class C and ITHD <10% ) • EMI standard (FCC 18)

  14. Typical Electronic HID Ballast LF DC/AC Inv & Ignitor DC/DC Buck AC/DC PFC Unregulated Regulated • Provide high ignition voltage • Avoid Acoustic resonance(10K~500kHz) • Achieve high PF, low ITHD • Provide constant lamp power regulation Vin • High PF, low ITHD • Constant power • Acoustic resonance free • Low Crest Factor To compete with halogen and CFL in low wattage application, HID ballast need: • Compact size • Low cost • Complicated circuit • Low power density • High cost

  15. Research Objective HID ballast CHID Built-in HID ballast A high power density, high performance, low cost solution for HID lamp ballast • Compact system architecture • Novel circuit topology • Novel integration technology • 3D packaging scheme

  16. Integrated Ignitor Output filter Integrated EMI filter Integrated ballast Discrete ballast Benchmark

  17. Dissertation Outline Chapter 1: Introduction Chapter 2: High Density HID Ballast Topology Study, Design and Implementation Chapter 3: High Density 3D Passive Integrated Ballast Chapter 4: Thermal Modeling, Management and Experimental Verification for Integrated Ballast Chapter 5: Conclusions and Future Work

  18. Chapter 2: High Density HID BallastTopology Study, Design and Implementation • Investigation on system architecture for CHID ballast • SSPFC AC/DC frond-end design • Experimental verification

  19. Three-stage HID Ballast Structure vlamp LF SW Inv. & Ignitor Unregulated ilamp ≈400Hz L1 L2 S3 S5 S2 Cb Ignitor B1 Co vin S1 Lamp S4 S6 For soft-start DC/DC Buck AC/DC PFC Vin Regulated • Complicated circuit • Low power density • High cost • High PF, low ITHD • Constant power • Acoustic resonance free • Low Crest Factor *Janos Melis, 1995

  20. Full-bridge Buck Converter with ignitor From Three-stage to Two-stage Structure BCM L1 L2 S3 S5 S2 Cb Ignitor B1 Co vin S1 Lamp S4 Co S2 S4 S6 Lr Lo Lamp Cr For soft-start S3 S5 20W MH ballast (2.4W/in3) * U.S. patent 5,932,976, MEW Vin AC/DC PFC DC/AC Inv. DC/DC & Ignitor Regulated Unregulated • Save 1 switch and controller • BCM Boost-type PFC: unity PF, ITHD<10%, High VB(>Vin,pk), need additional soft-start switch • 3 HF switches • Need complicated sensing circuit for constant power control

  21. Two-stage HID Ballast_type A Boost *M. Sen, et al, IEEE transaction on IA, 2003 *J. Zhao, et al, IAS 2003 Buck Boost • Save 1 switch and controller • BCM Boost-type PFC: unity PF, low ITHD,High bus voltage(>Vin,pk),need soft-start switch • 3 HF switches • Only constant current control is achieved (also need complicated sensing circuit for constant power control) • Save 3 switches • BCM Boost-type PFC: unity PF, low ITHD High bus voltage(>Vin,pk), Need soft-start switch • 3 HF switches • Only constant current control is achieved • Large Cs, Lamp voltage or duty cycle is limited by the Vdc and Vcs

  22. Two-stage HID Ballast_Type B DC/AC Inv. DC/AC Inv. Single Stage PFC AC/DC AC/DC DC/DC & Ignitor & Ignitor PFC Vin Vin (Unregulated) (Unregulated) (Regulated) (Regulated) *Y. Yang, APEC 2005 *Y. Jiang, IAS 2000 LF FB inv. SSPFC:DCM Boost + Flyback • DCM Boost type PFC: ITHD>10%, High bus voltage(>Vin,pk), need additional soft start switch, • only 1 HF switch, but with higher current stress • Save 2 LF switch, but adding passive component: one L winding, one C, and one diode. • DCM Boost type PFC: ITHD>10% , High bus voltage(>Vin,pk), need additional soft start switch • only 1 HF switch, but with higher current stress

  23. Two-stage Structure Comparison DC/AC Inv & Ignitor LF DC/AC Inv & Ignitor regulated Unregulated AC/DC PFC SSPFC AC/DC Vin Vin • BCM Boost type PFC: unity PF, ITHD <10% , High bus voltage(>Vin,pk), Need additional-soft start switch • 3 High Freq. switches • Complex sensing and control • DCM Boost type SSPFC: ITHD >10% High bus voltage(>Vin,pk) Need additional soft-start switch • Only 1 High Freq. switch • Simple control Specific requirements of SSPFC for Low-wattage HID Ballast: Stringent input current harmonic requirement (ITHD<10%) Low bulk cap voltage under large load range (open-circuit to short-circuit) Load characteristic: constant powerregulation , large output voltage range. No isolation requirement

  24. DCM Single Stage Single Switch PFC DCM S2PFC is suitable for Low power application due to inherent PFC with simple control DCM PFC + DCM DC/DC: DCM PFC + CCM DC/DC: • DC bus voltage is independent of load • Higher current stress • Small current stress • Higher efficiency • High voltage stress at light load * M. Madigan, etc, PESC’92

  25. DCM S4PFC with DC Bus Voltage Feedback • Reduce the bulk cap voltage stress • Reduce the switch current stress • THD increase due to the dead time in input current(much larger than 10%) * F. Tsai etc. INTELEC’96

  26. DCM PFC +DCM DC/DC • Low bus voltage stress • lTHD <10% • Unity PF, Low ITHD (<10%) • Low and adjustable bus voltage • Easy soft start Flyback PFC: DCM PFC + DCM DC/DC • large lamp load range (from open-circuit to short-circuit) Flyback DC/DC: DCM Flyback + DCM Flyback • Good PFC • Low DC bus voltage • High current stress on the switch (only suitable for low power application) *Jingrong Qian, Ph.D dissertation,

  27. Derivation of proposed SSPFC Converter No isolation requirement DCM Flyback (PFC) DCM Buck-Boost (DC/DC) Constant Pout means constant D and fs iav Vin, Unity PF and Low THD can be achieved at constant D and fs

  28. SSPFC AC/DC Front-end D1 + Vb _ D2 * Cb L1b L1a * B1 D3 L2 Co RL S DCM Buck-Boost DCM Flyback • Benefits • Automatic unity PF and very low THD (<10%) • Constant and low bulk cap voltage at all load conditions • Simple duty cycle control, constant power regulation • Easy soft start, no additional sw needed

  29. Implementation Issues-1 D4 L1a L1b D2 D3 * * * * Cb B1 S1 RL Co L2 Vgs IL2 Vb=120V VL2 Vo Vo=90V - + Vo,igi=300V VD3 - + Vo+Vb Vo,igi+Vb High voltage stress on D3 due to voltage ringing when IL2 =0 @ ignition mode (Vo=300V) VD3= -(Vo+VL2) ≈2Vo,igi

  30. Implementation issue-2 L L 1b 1b 1a 1a 1b 1a C o o o L 2 2 2 D1 D2 D3 * * * * irr of D1 + Vo - C C C @ peak (vin > Vo) b b b B1 Vin D4 S1 Large output voltage ripple due to the reverse recovery of D1 iD1 Irr of D1 Vo Irr of D1 iD3 • Eliminate D1 • Split S1 to two separate MOSFETs Solution:

  31. Two-Switch Version of SSPFC Stage D4 S2 L1a L1b D2 D3 * * * * Cb B1 S1 RL Co L2 • Benefits: • Reduce the output voltage ripple (by eliminating the reverse recovery current of D1) • Remove the clamping diode D4 by using the body diode of S2 • Change 1 Mosfet to 2 smaller Mosfet (share the same gate signal), save 2 diodes • Separate the power loss into two switches. S1.S2 can use smaller package (IPAK) and no heat sink is needed

  32. Proposed HID Ballast L L 1b 1b 1b 1a 1a 1a D5 D6 * * * * S3 S5 Lr Lamp Cb Vin Co L2 S1 S2 Cr S4 S6 Io Vo KI KV VVL VCL Iswi driver driver PRef G5 G2 G4 G3 d Function generator PI Comp. Multiplier MCU PWM IC Single stage PFC stage Inverter/Ignitor stage fs=400Hz fs=200kHz U.S. Patent 7,391,165 B2

  33. Constant Power Control Scheme Pref VVL KIIo multiplier Vcon PI KVVo VCL PO VO 50V 300V Control scheme Ideal ballast curve Current limiting mode: VCL* KIIO = Pref IO=Const. Constant power mode:KIIO* KVVO = Pref VOIO=Const. Voltage limiting mode: VVL* KVVO = Pref VO=Const.

  34. Inverter/Ignitor Steady state: fs=400Hz, D=0.5 Ignition mode: fs=100~200kHz(sweeping), D=0.5 • 3rd harmonic resonance is used to reduce the size of Lr (fr=450kHz) • Auto-transformer structure is used to reduce the voltage across the cap 90V fs=400Hz Ignition Mode Steady state

  35. Experimental Results – I PF>99.5%, ITHD<10% @ Vin=120Vac +/-10%

  36. Experimental Results-II Vlamp Ilamp • Low bulk cap voltage at all load conditions • Bulk cap voltage is lower than vin,pk Vo=89V, Po=19.9W Efficiency = 84.7%(w/o control power) Efficiency  81.3%(with control power)

  37. Experimental Results – III Constant power regulation during steady state Current limiting during start-up Voltage limiting before ignition

  38. Power Density New commercial product Benchmark: Commercial 20W HID ballast CPES Prototype Use same circuit topology 6.0W/in3 (2.5x) 4.5W/in3 (1.8x) 2.4W/in3

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