Two-stage AC-DC power converter with selectable dual output current
View Patent ↗A two-stage AC-DC power converter for powering a load at a substantially constant current, and related methods and systems. The first stage of the AC-DC power converter includes a conventional power factor correction (PFC) circuit that outputs a direct current (DC) voltage and a DC current. The second stage of the AC-DC power converter includes a low voltage flyback circuit that receives the DC voltage and the DC current. The low voltage flyback circuit includes a flyback transformer and a switch circuit that selectably toggles the substantially constant output current provided by the low voltage flyback circuit to the load between a first and a second, preset constant current. The secondary windings of the flyback transformer are split into two sections, and the switch circuit toggles the two sections of the secondary windings between a series and a parallel configuration to provide the first and second, preset constant currents.
1. An AC-DC power converter for powering a load at a substantially constant current, comprising:
a power factor correction (PFC) circuit, the PFC circuit connected to an alternating current (AC) power supply and configured to output a direct current (DC) voltage and a DC current; and
a low voltage flyback circuit, the low voltage flyback circuit receiving the DC voltage and the DC current output by the PFC circuit,
wherein the low voltage flyback circuit includes a flyback transformer and a switch circuit that selectably toggles the substantially constant output current provided by the low voltage flyback circuit to the load between a first, preset constant current and a second, preset constant current.
2. The AC-DC power converter of claim 1 , wherein the flyback transformer comprises a primary winding and a secondary winding, the secondary winding being split into two sections.
3. The AC-DC power converter of claim 2 , wherein the two sections of the secondary winding are split into equal halves.
4. The AC-DC power converter of claim 2 , wherein the two sections of the secondary winding are bifilar windings.
5. The AC-DC power converter of claim 2 , wherein the switch circuit toggles between a first configuration in which the two sections of the secondary winding are in series and a second configuration in which the two sections of the secondary winding are in parallel.
6. The AC-DC power converter of claim 5 , wherein, when the two sections of the secondary winding are in series, the low voltage flyback circuit provides the first, preset constant current to the load.
7. The AC-DC power converter of claim 5 , wherein, when the two sections of the secondary winding are in parallel, the low voltage flyback circuit provides the second, preset constant current to the load.
8. The AC-DC power converter of claim 1 , wherein the first, preset constant current is half the amperage of the second, preset constant current.
9. The AC-DC power converter of claim 1 , wherein the switch circuit includes a switch and three, fast Schottky diodes.
10. The AC-DC power converter of claim 9 , wherein, when the switch is in a closed position, the two sections of the secondary winding are in series with each other.
11. The AC-DC power converter of claim 9 , wherein, when the switch is in an open position, the two sections of the secondary winding are in parallel with each other.
12. The AC-DC power converter of claim 1 , wherein the low voltage flyback circuit further comprises a controller and wherein the controller sets the second, preset constant current.
13. The AC-DC power converter of claim 1 , wherein the AC-DC power converter includes two stages, and wherein the PFC circuit is the first stage of the AC-DC power converter and the low voltage flyback circuit is the second stage of the AC-DC power converter.
14. A method for powering a load at a substantially constant current using a two stage AC-DC power converter, comprising:
receiving an alternating current (AC) voltage from an AC power supply;
converting the AC voltage into a direct current (DC) voltage and a DC current;
providing the DC voltage and the DC current to a low voltage flyback circuit, the low voltage flyback circuit including a flyback transformer and a switch circuit; and
using the switch circuit, setting the output current provided to the load at either a first, preset constant current or a second, preset constant current.
15. The method of claim 14 , wherein the flyback transformer comprises a primary winding and a secondary winding, further comprising splitting the secondary winding into two equal halves, wherein the step of setting the output current provided to the load at either the first, preset constant current or the second, preset constant current further comprises toggling the switch circuit between a first configuration in which the two sections of the secondary winding are in series and a second configuration in which the two sections of the secondary winding are in parallel, wherein the step of configuring the two sections of the secondary winding in series further comprises providing the first, preset constant current to the load, and wherein the step of configuring the two sections of the secondary winding in parallel further comprises providing the second, preset constant current to the load.
16. The method of claim 15 , wherein the switch circuit includes a switch and three, fast Schottky diodes, wherein closing the switch causes the low voltage flyback circuit to be in the first configuration in which the two sections of the secondary winding are in series and wherein opening the switch causes the low voltage flyback circuit to be in the second configuration in which the two sections of the secondary winding are in parallel.
17. A system for powering a load at a substantially constant current, comprising:
an alternating current (AC) power supply that provides an AC input voltage and an AC input current;
a first stage of a two stage LED driver, the first stage including a power factor correction (PFC) circuit connected to the AC power supply and configured to output a direct current (DC) voltage and a DC current; and
a second stage of the two stage LED driver, the second stage including a low voltage flyback circuit;
wherein the low voltage flyback circuit receives the DC voltage and the DC current output by the PFC circuit, and
wherein the low voltage flyback circuit includes a flyback transformer and a switch circuit that selectably toggles the substantially constant output current provided by the low voltage flyback circuit to the load between a first, preset constant current and a second, preset constant current.
18. The system of claim 17 , wherein the flyback transformer comprises a primary winding and a secondary winding, the secondary winding being split into two equal halves, wherein the switch circuit toggles between a first configuration in which the two sections of the secondary winding are in series and a second configuration in which the two sections of the secondary winding are in parallel, and wherein, when the two sections of the secondary winding are in series, the low voltage flyback circuit provides the first, preset constant current to the load and, when the two sections of the secondary winding are in parallel, the low voltage flyback circuit provides the second, preset constant current to the load.
19. The system of claim 17 , wherein the first, preset constant current is half the amperage of the second, preset constant current, wherein the low voltage flyback circuit further comprises a controller, and wherein the controller sets the second, preset constant current.
20. The system of claim 17 , wherein the switch circuit includes a switch and three, fast Schottky diodes and wherein, when the switch is in a closed position, the two sections of the secondary winding are in series with each other and, when the switch is in an open position, the two sections of the secondary winding are in parallel with each other.