EP3365957A1 - Method of supplying an emergency supply module and emergency supply module with reduced power consumption - Google Patents

Method of supplying an emergency supply module and emergency supply module with reduced power consumption

Info

Publication number
EP3365957A1
EP3365957A1 EP16798280.0A EP16798280A EP3365957A1 EP 3365957 A1 EP3365957 A1 EP 3365957A1 EP 16798280 A EP16798280 A EP 16798280A EP 3365957 A1 EP3365957 A1 EP 3365957A1
Authority
EP
European Patent Office
Prior art keywords
supply
module
battery
power supply
emergency
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP16798280.0A
Other languages
German (de)
French (fr)
Inventor
Tomasz KACZOR
Maciej ZOLCINSKI
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Tm Technologie Spolka Z Ograniczona Odpowiedzialnoscia
Original Assignee
Tm Technologie Spolka Z Ograniczona Odpowiedzialnoscia
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Tm Technologie Spolka Z Ograniczona Odpowiedzialnoscia filed Critical Tm Technologie Spolka Z Ograniczona Odpowiedzialnoscia
Publication of EP3365957A1 publication Critical patent/EP3365957A1/en
Withdrawn legal-status Critical Current

Links

Classifications

    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02J—CIRCUIT ARRANGEMENTS OR SYSTEMS FOR SUPPLYING OR DISTRIBUTING ELECTRIC POWER; SYSTEMS FOR STORING ELECTRIC ENERGY
    • H02J9/00—Circuit arrangements for emergency or stand-by power supply, e.g. for emergency lighting
    • H02J9/04—Circuit arrangements for emergency or stand-by power supply, e.g. for emergency lighting in which the distribution system is disconnected from the normal source and connected to a standby source
    • H02J9/06—Circuit arrangements for emergency or stand-by power supply, e.g. for emergency lighting in which the distribution system is disconnected from the normal source and connected to a standby source with automatic change-over, e.g. UPS systems
    • H02J9/062—Circuit arrangements for emergency or stand-by power supply, e.g. for emergency lighting in which the distribution system is disconnected from the normal source and connected to a standby source with automatic change-over, e.g. UPS systems for AC powered loads
    • H02J9/065—Circuit arrangements for emergency or stand-by power supply, e.g. for emergency lighting in which the distribution system is disconnected from the normal source and connected to a standby source with automatic change-over, e.g. UPS systems for AC powered loads for lighting purposes
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02J—CIRCUIT ARRANGEMENTS OR SYSTEMS FOR SUPPLYING OR DISTRIBUTING ELECTRIC POWER; SYSTEMS FOR STORING ELECTRIC ENERGY
    • H02J9/00—Circuit arrangements for emergency or stand-by power supply, e.g. for emergency lighting
    • H02J9/005—Circuit arrangements for emergency or stand-by power supply, e.g. for emergency lighting using a power saving mode
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02B—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO BUILDINGS, e.g. HOUSING, HOUSE APPLIANCES OR RELATED END-USER APPLICATIONS
    • Y02B70/00—Technologies for an efficient end-user side electric power management and consumption
    • Y02B70/30—Systems integrating technologies related to power network operation and communication or information technologies for improving the carbon footprint of the management of residential or tertiary loads, i.e. smart grids as climate change mitigation technology in the buildings sector, including also the last stages of power distribution and the control, monitoring or operating management systems at local level
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y04—INFORMATION OR COMMUNICATION TECHNOLOGIES HAVING AN IMPACT ON OTHER TECHNOLOGY AREAS
    • Y04S—SYSTEMS INTEGRATING TECHNOLOGIES RELATED TO POWER NETWORK OPERATION, COMMUNICATION OR INFORMATION TECHNOLOGIES FOR IMPROVING THE ELECTRICAL POWER GENERATION, TRANSMISSION, DISTRIBUTION, MANAGEMENT OR USAGE, i.e. SMART GRIDS
    • Y04S20/00—Management or operation of end-user stationary applications or the last stages of power distribution; Controlling, monitoring or operating thereof
    • Y04S20/20—End-user application control systems

Definitions

  • the invention is related to a new method of supplying emergency supply module and emergency supply module with reduced power consumption from the network.
  • Solution according to the invention is related to emergency supply systems, especially emergency lighting systems.
  • Emergency lighting system requires that central and autonomous (self-contained) emergency supply units are supplied continuously from the network.
  • Emergency supply modules become receivers which continuously consumption energy from the supply network.
  • such modules show increased power demand only during battery charging phase, i.e. up to 24 hours since starting.
  • this power is not reduced but dissipated and changed to heat by charging and supplying circuits. This leads to increased electrical energy consumption.
  • US20050088100 Al discloses emergency lighting system with automatic charging / discharging and network supply monitoring system. Moreover, emergency lighting system is equipped with automatic selfcontrol system, monitoring internal battery status, which signals battery status. In other aspect, the application discloses charging / discharging method that allows for automatic charging or discharging the battery within the area of emergency lighting.
  • US20150015076 Al discloses battery charging systems together with emergency supply device equipped with LEDs, including emergency supply detection system and external supply unit as well as converter (AC - DC or DC - DC), charger, low voltage control unit, transformer, control unit and constant charging current control unit.
  • emergency supply detection system and external supply unit as well as converter (AC - DC or DC - DC), charger, low voltage control unit, transformer, control unit and constant charging current control unit.
  • US6502044 B 1 discloses electronic system for automatic diagnostics which is especially useful in emergency light fittings, including e.g. exits identification.
  • System function testing is performed by means of programmable microprocessor, diagnostic circuit, supply circuit and controlled charger system, which may implement various strategies of reducing power consumption.
  • Microprocessor power is controlled using the same microprocessor thus it can stop designated functions at power faults, which fact effectively reduces energy consumption to zero.
  • Purpose of the invention is to develop alternative emergency supply module with power consumption from the network reduced to minimum when in the non-maintained mode through the system controlling battery pack charging.
  • the present invention refers to the supply method of emergency supply module where the power supply connected to the network charges battery using a charger and supplies the following functional blocks of the module: switching module, measurement block, microprocessor, detection system, driver LED DC/DC, built-in EEPROM memory and signalling diodes characterized in that after charging the battery pack, the control system disconnects the power supply from the remaining functional module blocks which fact causes that the power supply switches automatically to less power consumption mode from the network to the level not exceeding 50 mW, and then after disconnecting the power supply, the remaining functional units of the emergency supply module are supplied from the battery and after reducing voltage in the batteries, the control system connects the power supply automatically switching to full power mode from the network and supplies all module functional units and charges the batteries using the charger.
  • control system connects the power supply that automatically switches to full power mode from the supply network and supplies all module functional blocks and the charging activates with a drop of battery voltage by no more than 7% in relation to fully charge battery.
  • the supply module switches to less consumption mode in case of version designed for maintained operation only in the event of no external control signal LI.
  • total current consumption by module functional blocks: switching system, measurement block, microprocessor, detection system, driver LED DC/DC, built-in memory EEROM and signalling diodes does not exceed 2.5 mA.
  • power consumption by microprocessor in sleeping mode does not exceed 20 nA/MHz and in operation mode - 30 uA/MHz.
  • power consumption by threshold detection system is not more than 10 mW.
  • the present invention refers also to emergency supply module with less power consumption from the network including power supply, charger, battery as well as switching and detection system, LED module and signalling diodes characterized in that the emergency supply module is equipped with electrical energy consumption control system, fitted with programmable microprocessor and the power supply is equipped with integrated AC/DC controller with function of automatic switching to less power consumption mode from the network and the signalling diodes are supplied from microprocessor which in turn is supplied from battery via the switching system.
  • module according to invention is additionally equipped with system detecting threshold of switching into emergency mode with limited power consumption. Also preferably, module according to the invention is further equipped with testing system.
  • Essential advantage of the emergency supply module according to the invention is reduction of energy consumption from the network to minimum by application of standby mode to the level below 50 mW.
  • Implementation of standby mode is possible with the use of AC/DC drivers and microprocessors optimized in terms of minimum power consumption the way it is described above.
  • Fig. la presents block diagram of module designed for maintained mode
  • Fig. la presents block diagram of module designed for non-maintained mode
  • Fig. 2 and 3 present algorithm of emergency power supply module operation according to the invention.
  • emergency supply module with less power consumption from the network according to the invention is equipped with the power supply 1 of power 10W with standby function and built-in threshold detection system 6 which is connected to a charger 2 and switching system 4.
  • the power supply 1 AC/DC operates in isolated flyback configuration.
  • pulse transformer keying frequency is fixed - within 60- 120kHz
  • the power supply 1 according to the invention its frequency changes together with change of load. This allows for minimizing power losses with less loads. Together with the increase of operation frequency, it is possible to reduce dimensions of electronic elements such as capacities or inductances.
  • the power supply is fitted with a transformer which is able to supply maximum 10W of continuous power. If load at a given moment is less, transformer would be temporarily oversized and this means losses. The power supply thus reduces operation frequency so that not to generate such significant losses. In case of more load, converter increases frequency of transformer control pulses. Increase of this parameter means more losses within the keying element itself.
  • the basic power supply unit is integrated controller equipped with a driver that has integrated switching element. Application of integrated controller allows for limiting the number of external elements to minimum and activating the standby function.
  • the power supply 1 is additionally optimized in terms of power consumption thus the power consumption in the normal operation mode is reduced even by 100 mW.
  • the power supply is equipped with pulse transformer, snubber circuit, I/O capacitors, filters, feedback system, output diode on the DC side and suitably selected controller system.
  • the power supply is connected to analogue charging system 2 to which a battery pack equipped with controller 3 is connected, which is to protect the cells against overcharging, too high load, short-circuit and too deep discharging. Because of combination of the analogue charging system with digital control using a microprocessor 7, it is possible to switch the supply system into reduced power consumption mode, despite continuous supply of signalling diodes 12 and to detect power loss on AC side and properly fast response of the module according to the invention, so called fast switching of emergency supply module into battery supply operation. Battery with the controller 3 is connected with the switching system 4.
  • the switching system 4 is also connected with the measurement block 5 and integrated driver LED DC/DC 9 equipped with a driver as well as with microprocessor 7 using a feedback which in turn is connected with non-volatile memory EEPROM 10 also using a feedback.
  • Microprocessor 7 is also connected to signalling diodes 12 (green / red) and to integrated driver LED DC/DC 9 which in turn is connected with LED module 13 using a feedback.
  • Detection system LI 8 us connected to microprocessor system 7.
  • microprocessor 7 is optimized in terms of low power consumption with XLP (eXtreme Low Power). Microprocessor 7 made using this technology allows for reducing power consumption to extremely low values, even down to 20 nA in sleeping mode and 30uA/MHz in normal operation mode.
  • XLP eXtreme Low Power
  • Program algorithm the microprocessor is programmed with is also of significant meaning.
  • the program uses the sleeping mode as much as possible to minimize average power consumption.
  • Integrated driver AC/DC 14 allows for automatic switching of the system into lower power consumption mode, when the load drops to the level below 0.6% of the full load which is 10W, detecting load connection and automatic restart as well as it has a frequency jittering function reducing EMI filters costs. Based on the tests, power consumption reduction was achieved at the level not exceeding 50mW with no load.
  • Integrated driver AC/DC 14 further enables protecting the system against overheating, it has universal range of input voltages, automatic restart function reducing the supplied power during output short-circuit, simple on / off control without compensation loop.
  • module according to the invention continuously turned on signalling diode 12 consumes current from the microprocessor 7 which is supplied from two lines - from the power supply 1 and battery 3 though the switching system 4.
  • the module switches to emergency mode at the specified input threshold detected by threshold detection system 6 of AC voltage.
  • Module according to the invention continuously monitors supply voltage using the switching system 4 and microprocessor 7 and provides charging / trickle charging using the charging system consisting of charger 2 and battery with controller 3 from which energy is consumption during emergency operation.
  • the module is equipped with additional functionality in the form of a testing system 11 or terminals to connect remote testing device and switching system 4, protecting the battery against too deep discharging.
  • the testing system 11 allows for simulating emergency mode operation (disconnection of supply).
  • Emergency module should operate in the battery 3 supply mode and control the connected load to 100%.
  • Test result is positive when light sources operate and parameters measured by the device are in conformity with specifications.
  • the module has terminals to connect remote testing device in the form of external button. Connecting and short-circuiting the button starts the test. Test result is signalled with additional signalling diode, which is usually red.
  • emergency supply module monitors the following parameters: battery voltage, charging and discharging current and light source status.
  • Measurement block 5 connected to microprocessor 7 and EEPROM memory 10 is used for monitoring purposes.
  • EEPROM memory 10 is used for monitoring purposes.
  • detection system LI 8 is necessary to continuously monitor the terminal LI status.
  • Detection system of voltage threshold 6 is an additional load on the supply side.
  • Module according to the invention is equipped with a system so that it enables correct functionality of the module with minimum power consumption. Development of the detection system is possible by means of an additional ON/OFF terminal on the integrated controller AC/DC. Because of it, this is possible using only a few external elements. Power reduction is obtained by application of high resistance resistors and mosfet transistors, gate current of which is very low.
  • Fitting of the emergency modules may be deigned as maintained or non-maintained mode supplied fittings and differences between these two fittings are presented in fig. la and fig. lb.
  • Lighting fitting, light source of which is supplied continuously when it is necessary to provide both basic and emergency light is a maintained mode fitting (fig. la).
  • fittings, light source of which is supplied only in case of basic light supply fault are non-maintained mode fittings (fig. lb).
  • Maintained mode is frequently defined as “light mode” and non-maintained mode is referred to as "dark mode”.
  • Diagrams on fig. 2 and fig. 3 present the method of operation of emergency supply module according to the invention. Diagram is divided to separate threads that interpenetrate. However, a division has been made in order to provide detailed information. Sections determine range of energy consumed by a device at a given moment.
  • Fig. 2 and fig. 3 present ( ) standby mode (ii) mode of the highest energy consumption, present during charging or turned on LED output, (Hi) idle mode, without additional loads, but not yet in standby mode.
  • Fault notification means detection of error and notification of user about such fact by means of proper signalling.
  • Device is in the idle mode as briefly as possible in order to switch to battery 3 charging. Module consumes maximum power (up to 10 W). When the battery 3 was charged, module switches to power saving mode. In this mode, it stays as long as possible to reduce losses almost to zero. In all three modes the device awaits AC power decay.
  • LiFePC batteries are used internal controllers of which protect them against short-circuiting the cells. Such short-circuit may lead to significant heating of the whole package and to its damage as the best case scenario.
  • Controller is designed so that when the battery is connected to the charger and short-circuit occurs on its terminals which short-circuit both the battery and charger, battery protection activates and cuts off power supplied from it thus protecting it at the same time. When the short-circuit is removed, the controller must detect that it is safe to turn off the protection. Unfortunately, the charger itself is a load also. Even though it is perceived through a very large resistance (order of hundreds of kiloohms), the controller will not activate the battery. The solution turned out to be forcing current flow towards the battery, i.e. initiation of charging with very short pulses which fact effectively resets the package and restarts charging.
  • the control system 15 When in the network supply mode, after charging the battery 3, the control system 15 disconnects the power supply 1 from the remaining module functional blocks: charger 2, switching system 4, measurement block 5, microprocessor 7, detection system 8, driver LED DC/DC 9, built-in EEPROM memory 10, test system 11, signalling diodes 12 and switches these blocks to battery 3 supply. After disconnecting a load, the power supply 1 automatically switches to reduced power consumption mode. The control system 15 monitors battery 3 voltage and if its level drops by more than 7% all module functional block are reconnected to the supply, which fact automatically switches the power supply from the reduced power consumption mode to normal operation mode and the battery 3 is recharged. After recharging the package, the control system 15 disconnects the power supply 1 and the aforementioned cycle is repeated.
  • the detection system 8 informs about this fact the control system 15 which causes that the system controls the driver LED DC/DC 9 so that it starts supplying external LED module 13. If the power supply 1 was in the mode of reduced power consumption at the moment LI signal appeared, the control system 15 connects all module functional blocks to the power supply 1 making it to return to normal operation mode. It it this not possible for the power supply 1 to operate in the mode of reduced power consumption during LI signal presence when the module LED 13 is supplied.
  • Testing status can be called only at presence of external AC voltage supply. It can be activated by short-circuiting proper input terminals of the module or automatically by a microprocessor 7. If this mode is called, the control system 15 disconnects the power supply 1 from the remaining functional blocks which fact causes that the switching system 4 starts supplying driver LED DC/DC 9 and current flows to load LED 13.
  • the microprocessor 7 monitors and analyses data sent by measurement block 5. If any of the parameters is out of the limits set by the program, the test is stopped to protect the module and / or battery against possible defect. After the test, its result is saved in EEPROM memory 10 and signalled using red signalling diode 12. Moreover, during the test, green signalling diode 12, informing about battery charging, should turn off. Test can be called regardless of the presence or not of LI controlling signal.
  • the third operation mode of the module i.e. emergency mode is called always when supply input voltage drops to the level specified as 0.6 - 0.9 of the rated supply voltage.
  • threshold detection system 6 Satisfaction of this condition is ensured by threshold detection system 6. Switching the module to emergency operation mode is possible always after power losses, regardless of the mode the module was before and regardless of LI input condition. In case of power loss, the power supply 1 stops working.
  • the control system 15 in cooperation with the switching system 4 supplies voltage from the battery 3 to driver LED DC/DC 9 and in turn it supplies LED module 13. When in this mode, signalling diodes 12 are off, and the control system reduces energy consumption by the remaining functional blocks, by controlling or shutting them off, LED module 13 is supplied for a set time (lh - 3h), depending on configuration and capacity of the battery. Except the control system 15, the switching system 4 watches over so that the battery is not discharged too deeply - when the set threshold is achieved (dangerous for the battery 3) it is disconnected from the load and the consumed power is limited to quiescent current at level of nA.
  • the system automatically switches from the emergency mode to operation from the network mode.

Abstract

The invention is related to the method of supplying the emergency supply module, wherein the power supply (1) connected to the supply network charges the battery (3) using the charger (2) and supplies the following module functional blocks: switching section (4), measurement block (5), microprocessor (7), detection system (8), driver LED DC/DC (9), built-in EEPROM memory (10) and signalling diodes (12), characterized in that after charging the battery packs, the control system (15) disconnects the power supply (1) from the remaining module functional blocks causing the power supply (1) to automatically switch to reduced power consumption mode from the supply network to the level not exceeding 50mW; after disconnecting the power supply (1), the remaining functional blocks of the emergency supply module are supplied from the battery (3), and after reduction of voltage on the batteries (3), the control system (15) connects the power supply (1) which automatically switches to full power mode supplied from the network and supplies all module functional blocks, including the battery (3) using the charger (2). The invention is also related to emergency supply module manufactured according to the aforementioned method.

Description

Method of supplying an emergency supply module and emergency supply module with reduced power consumption
The invention is related to a new method of supplying emergency supply module and emergency supply module with reduced power consumption from the network. Solution according to the invention is related to emergency supply systems, especially emergency lighting systems.
In the state of the art, various emergency supply systems are known, including emergency lighting. Both simple devices including only battery charging during network supply and operating communication protocols, autonomous (self-contained) with own battery or using "central battery" topology are known, which enable their supervision by means of operator interfaces used to supply LEDs or fluorescent lamps. According to state of the art, solutions consume a lot of energy and are not of power-saving type.
Emergency lighting system requires that central and autonomous (self-contained) emergency supply units are supplied continuously from the network. Emergency supply modules become receivers which continuously consumption energy from the supply network. In fact, such modules show increased power demand only during battery charging phase, i.e. up to 24 hours since starting. However, due to applied system solution, in the solutions according to the art, this power is not reduced but dissipated and changed to heat by charging and supplying circuits. This leads to increased electrical energy consumption.
Solutions according to the art, operate based on continuous charging of the battery pack. Due to applied battery capacities of 1.0 Ah to 5.0 Ah and introduced requirement of charging the battery pack within 24 hours, charging power supplied from the network is 2 to 6 W.
Usually, power consumption increases within the first 24 hours and reduces after charging the battery pack, however this power is reduced only by 30 - 50%.
Such condition leads to a situation where a lot of energy is lost due to trickle charging the battery pack at the level 1 - 3W and in extreme case up to 6W (in case of fixed current). In case of installing 1000 emergency supply modules in a building, losses may reach 6 kW, one must remember that modules are supplied 24 hours per day.
In particular, there are also known supply modules for emergency lighting systems. This type of supply modules, in contrast to standard power supplies, should have a series of additional functionalities. One of the functionalities is signalling LED, which is continuously on.
US20050088100 Al discloses emergency lighting system with automatic charging / discharging and network supply monitoring system. Moreover, emergency lighting system is equipped with automatic selfcontrol system, monitoring internal battery status, which signals battery status. In other aspect, the application discloses charging / discharging method that allows for automatic charging or discharging the battery within the area of emergency lighting.
In turn, US20150015076 Al discloses battery charging systems together with emergency supply device equipped with LEDs, including emergency supply detection system and external supply unit as well as converter (AC - DC or DC - DC), charger, low voltage control unit, transformer, control unit and constant charging current control unit. As a result of application of the system and device according to the mentioned invention, it is possible to increase charging efficiency. The device allows for detecting LED system supply faults without the need to install separate earthing.
US6502044 B 1 discloses electronic system for automatic diagnostics which is especially useful in emergency light fittings, including e.g. exits identification. System function testing is performed by means of programmable microprocessor, diagnostic circuit, supply circuit and controlled charger system, which may implement various strategies of reducing power consumption. Microprocessor power is controlled using the same microprocessor thus it can stop designated functions at power faults, which fact effectively reduces energy consumption to zero.
Purpose of the invention is to develop alternative emergency supply module with power consumption from the network reduced to minimum when in the non-maintained mode through the system controlling battery pack charging.
The present invention refers to the supply method of emergency supply module where the power supply connected to the network charges battery using a charger and supplies the following functional blocks of the module: switching module, measurement block, microprocessor, detection system, driver LED DC/DC, built-in EEPROM memory and signalling diodes characterized in that after charging the battery pack, the control system disconnects the power supply from the remaining functional module blocks which fact causes that the power supply switches automatically to less power consumption mode from the network to the level not exceeding 50 mW, and then after disconnecting the power supply, the remaining functional units of the emergency supply module are supplied from the battery and after reducing voltage in the batteries, the control system connects the power supply automatically switching to full power mode from the network and supplies all module functional units and charges the batteries using the charger.
Preferably, when the control system connects the power supply that automatically switches to full power mode from the supply network and supplies all module functional blocks and the charging activates with a drop of battery voltage by no more than 7% in relation to fully charge battery.
Also preferably, the supply module switches to less consumption mode in case of version designed for maintained operation only in the event of no external control signal LI.
Preferably, after disconnecting the power supply, total current consumption by module functional blocks: switching system, measurement block, microprocessor, detection system, driver LED DC/DC, built-in memory EEROM and signalling diodes, does not exceed 2.5 mA. Also preferably, after disconnecting the power supply, power consumption by microprocessor in sleeping mode does not exceed 20 nA/MHz and in operation mode - 30 uA/MHz. Also preferably, after disconnecting the power supply, power consumption by threshold detection system is not more than 10 mW.
The present invention refers also to emergency supply module with less power consumption from the network including power supply, charger, battery as well as switching and detection system, LED module and signalling diodes characterized in that the emergency supply module is equipped with electrical energy consumption control system, fitted with programmable microprocessor and the power supply is equipped with integrated AC/DC controller with function of automatic switching to less power consumption mode from the network and the signalling diodes are supplied from microprocessor which in turn is supplied from battery via the switching system.
Preferably, module according to invention is additionally equipped with system detecting threshold of switching into emergency mode with limited power consumption. Also preferably, module according to the invention is further equipped with testing system.
Essential advantage of the emergency supply module according to the invention is reduction of energy consumption from the network to minimum by application of standby mode to the level below 50 mW. Implementation of standby mode is possible with the use of AC/DC drivers and microprocessors optimized in terms of minimum power consumption the way it is described above.
The invention is presented in the following embodiments which are not to limit the scope of the invention and on the enclosed figures, in which:
Fig. la presents block diagram of module designed for maintained mode,
Fig. la presents block diagram of module designed for non-maintained mode,
Fig. 2 and 3 present algorithm of emergency power supply module operation according to the invention.
Example 1 Emergency supply module design
As presented in fig. la (version for maintained mode) and lb (version for non-maintained mode), emergency supply module with less power consumption from the network according to the invention is equipped with the power supply 1 of power 10W with standby function and built-in threshold detection system 6 which is connected to a charger 2 and switching system 4.
The power supply 1 AC/DC operates in isolated flyback configuration. Opposite to solutions according to state of the art, when pulse transformer keying frequency is fixed - within 60- 120kHz, in case of the power supply 1 according to the invention, its frequency changes together with change of load. This allows for minimizing power losses with less loads. Together with the increase of operation frequency, it is possible to reduce dimensions of electronic elements such as capacities or inductances. The power supply is fitted with a transformer which is able to supply maximum 10W of continuous power. If load at a given moment is less, transformer would be temporarily oversized and this means losses. The power supply thus reduces operation frequency so that not to generate such significant losses. In case of more load, converter increases frequency of transformer control pulses. Increase of this parameter means more losses within the keying element itself. Power is reduced on a transistor only when it is not fully closed. During transient modes, power losses are product of voltage on a transistor and current flowing through it. Because activation and deactivation times of a given specimen are approximately fixed, this means that with the increase of frequency, ratio of time in which the transistor is in transient modes instead of the mode of full activation or deactivation increases. The amount of heat released by the element increases.
Full separation between AC side (dangerous voltage) and DC side is provided by application of insulated pulse transformer with tap and opto-coupler. PCB design considers minimum safe creepage distance and clearances. The basic power supply unit is integrated controller equipped with a driver that has integrated switching element. Application of integrated controller allows for limiting the number of external elements to minimum and activating the standby function.
The power supply 1 is additionally optimized in terms of power consumption thus the power consumption in the normal operation mode is reduced even by 100 mW. The power supply is equipped with pulse transformer, snubber circuit, I/O capacitors, filters, feedback system, output diode on the DC side and suitably selected controller system.
The power supply is connected to analogue charging system 2 to which a battery pack equipped with controller 3 is connected, which is to protect the cells against overcharging, too high load, short-circuit and too deep discharging. Because of combination of the analogue charging system with digital control using a microprocessor 7, it is possible to switch the supply system into reduced power consumption mode, despite continuous supply of signalling diodes 12 and to detect power loss on AC side and properly fast response of the module according to the invention, so called fast switching of emergency supply module into battery supply operation. Battery with the controller 3 is connected with the switching system 4.
The switching system 4 is also connected with the measurement block 5 and integrated driver LED DC/DC 9 equipped with a driver as well as with microprocessor 7 using a feedback which in turn is connected with non-volatile memory EEPROM 10 also using a feedback. Microprocessor 7 is also connected to signalling diodes 12 (green / red) and to integrated driver LED DC/DC 9 which in turn is connected with LED module 13 using a feedback. Detection system LI 8 us connected to microprocessor system 7.
In the embodiment, microprocessor 7 is optimized in terms of low power consumption with XLP (eXtreme Low Power). Microprocessor 7 made using this technology allows for reducing power consumption to extremely low values, even down to 20 nA in sleeping mode and 30uA/MHz in normal operation mode.
Program algorithm the microprocessor is programmed with is also of significant meaning.
The program uses the sleeping mode as much as possible to minimize average power consumption.
Integrated driver AC/DC 14 allows for automatic switching of the system into lower power consumption mode, when the load drops to the level below 0.6% of the full load which is 10W, detecting load connection and automatic restart as well as it has a frequency jittering function reducing EMI filters costs. Based on the tests, power consumption reduction was achieved at the level not exceeding 50mW with no load. Integrated driver AC/DC 14 further enables protecting the system against overheating, it has universal range of input voltages, automatic restart function reducing the supplied power during output short-circuit, simple on / off control without compensation loop.
Achieving low power consumption was also possible despite of application of threshold detection systems 6 (switching threshold into emergency mode operation), which additionally load the supply side.
In the module according to the invention, continuously turned on signalling diode 12 consumes current from the microprocessor 7 which is supplied from two lines - from the power supply 1 and battery 3 though the switching system 4. The module switches to emergency mode at the specified input threshold detected by threshold detection system 6 of AC voltage. Module according to the invention continuously monitors supply voltage using the switching system 4 and microprocessor 7 and provides charging / trickle charging using the charging system consisting of charger 2 and battery with controller 3 from which energy is consumption during emergency operation.
In one embodiment of the module according to the invention, the module is equipped with additional functionality in the form of a testing system 11 or terminals to connect remote testing device and switching system 4, protecting the battery against too deep discharging.
The testing system 11 allows for simulating emergency mode operation (disconnection of supply). Emergency module should operate in the battery 3 supply mode and control the connected load to 100%. Test result is positive when light sources operate and parameters measured by the device are in conformity with specifications. Usually, the module has terminals to connect remote testing device in the form of external button. Connecting and short-circuiting the button starts the test. Test result is signalled with additional signalling diode, which is usually red.
During normal operation, especially during the tests, emergency supply module according to the invention monitors the following parameters: battery voltage, charging and discharging current and light source status. Measurement block 5 connected to microprocessor 7 and EEPROM memory 10 is used for monitoring purposes. In case of a maintained module for continuous operation, it is possible to control the function of "light" operation mode using additional input terminal LI. To continuously monitor the terminal LI status, detection system LI 8 is necessary.
Detection system of voltage threshold 6 is an additional load on the supply side. Module according to the invention is equipped with a system so that it enables correct functionality of the module with minimum power consumption. Development of the detection system is possible by means of an additional ON/OFF terminal on the integrated controller AC/DC. Because of it, this is possible using only a few external elements. Power reduction is obtained by application of high resistance resistors and mosfet transistors, gate current of which is very low.
Fitting of the emergency modules may be deigned as maintained or non-maintained mode supplied fittings and differences between these two fittings are presented in fig. la and fig. lb. Lighting fitting, light source of which is supplied continuously when it is necessary to provide both basic and emergency light is a maintained mode fitting (fig. la). However, fittings, light source of which is supplied only in case of basic light supply fault, are non-maintained mode fittings (fig. lb). Maintained mode is frequently defined as "light mode" and non-maintained mode is referred to as "dark mode".
Example. 2. Operation of emergency supply module
Diagrams on fig. 2 and fig. 3 present the method of operation of emergency supply module according to the invention. Diagram is divided to separate threads that interpenetrate. However, a division has been made in order to provide detailed information. Sections determine range of energy consumed by a device at a given moment. Fig. 2 and fig. 3 present ( ) standby mode (ii) mode of the highest energy consumption, present during charging or turned on LED output, (Hi) idle mode, without additional loads, but not yet in standby mode. Fault notification means detection of error and notification of user about such fact by means of proper signalling.
Switching between supply modes is presented in fig. 2. Device is in the idle mode as briefly as possible in order to switch to battery 3 charging. Module consumes maximum power (up to 10 W). When the battery 3 was charged, module switches to power saving mode. In this mode, it stays as long as possible to reduce losses almost to zero. In all three modes the device awaits AC power decay.
Satisfaction of the requirement concerning switching to emergency mode by the module during power losses is presented in fig. 3. It consists in continuous monitoring the supply voltage using a control system 15 by means of the measurement block 5 and making decision based on this concerning activation of emergency mode. Parameters of the battery and LED load are monitored continuously. When pressing the TEST button, the module acts accordingly - cuts off DC supply and switches to simulated emergency operation. Operation algorithm is the same with the difference that the TEST button is the trigger not the power decay.
Battery charging
Correct charging of the battery 3 is the most important operation affecting its condition and durability. Pay special attention to this section of the device that is responsible for battery charging. To maintain this basic functionality, one must provide continuous monitoring of alternative supply source quality.
In the embodiment, LiFePC batteries are used internal controllers of which protect them against short-circuiting the cells. Such short-circuit may lead to significant heating of the whole package and to its damage as the best case scenario. Controller is designed so that when the battery is connected to the charger and short-circuit occurs on its terminals which short-circuit both the battery and charger, battery protection activates and cuts off power supplied from it thus protecting it at the same time. When the short-circuit is removed, the controller must detect that it is safe to turn off the protection. Unfortunately, the charger itself is a load also. Even though it is perceived through a very large resistance (order of hundreds of kiloohms), the controller will not activate the battery. The solution turned out to be forcing current flow towards the battery, i.e. initiation of charging with very short pulses which fact effectively resets the package and restarts charging.
During module operation, one can distinguish three basic conditions. Operation mode from the network, test and emergency operation mode. During operation from the network (AC voltage supply is present), the module continuously monitors LI input status, controls AC voltage level and its presence. When in this mode, the battery 3 is charged by means of the charger 2, however the necessary energy is supplied by the power supply 1 consisting of the integrated driver AC/DC 14, threshold detection system 6 and flyback transformer, rectifier and filters 16. The whole process is controlled by the control system 15 based on processor 7 with built-in EEPROM memory 10. Microprocessor additionally controls signalling diodes 12 and monitors the test system 11. All necessary signals are sent to the control system 15 via the measurement block 5.
When in the network supply mode, after charging the battery 3, the control system 15 disconnects the power supply 1 from the remaining module functional blocks: charger 2, switching system 4, measurement block 5, microprocessor 7, detection system 8, driver LED DC/DC 9, built-in EEPROM memory 10, test system 11, signalling diodes 12 and switches these blocks to battery 3 supply. After disconnecting a load, the power supply 1 automatically switches to reduced power consumption mode. The control system 15 monitors battery 3 voltage and if its level drops by more than 7% all module functional block are reconnected to the supply, which fact automatically switches the power supply from the reduced power consumption mode to normal operation mode and the battery 3 is recharged. After recharging the package, the control system 15 disconnects the power supply 1 and the aforementioned cycle is repeated. If during network operation mode an external control signal LI occurs, the detection system 8 informs about this fact the control system 15 which causes that the system controls the driver LED DC/DC 9 so that it starts supplying external LED module 13. If the power supply 1 was in the mode of reduced power consumption at the moment LI signal appeared, the control system 15 connects all module functional blocks to the power supply 1 making it to return to normal operation mode. It it this not possible for the power supply 1 to operate in the mode of reduced power consumption during LI signal presence when the module LED 13 is supplied.
Testing status can be called only at presence of external AC voltage supply. It can be activated by short-circuiting proper input terminals of the module or automatically by a microprocessor 7. If this mode is called, the control system 15 disconnects the power supply 1 from the remaining functional blocks which fact causes that the switching system 4 starts supplying driver LED DC/DC 9 and current flows to load LED 13.
During test, the microprocessor 7 monitors and analyses data sent by measurement block 5. If any of the parameters is out of the limits set by the program, the test is stopped to protect the module and / or battery against possible defect. After the test, its result is saved in EEPROM memory 10 and signalled using red signalling diode 12. Moreover, during the test, green signalling diode 12, informing about battery charging, should turn off. Test can be called regardless of the presence or not of LI controlling signal.
The third operation mode of the module, i.e. emergency mode is called always when supply input voltage drops to the level specified as 0.6 - 0.9 of the rated supply voltage.
Satisfaction of this condition is ensured by threshold detection system 6. Switching the module to emergency operation mode is possible always after power losses, regardless of the mode the module was before and regardless of LI input condition. In case of power loss, the power supply 1 stops working. The control system 15 in cooperation with the switching system 4 supplies voltage from the battery 3 to driver LED DC/DC 9 and in turn it supplies LED module 13. When in this mode, signalling diodes 12 are off, and the control system reduces energy consumption by the remaining functional blocks, by controlling or shutting them off, LED module 13 is supplied for a set time (lh - 3h), depending on configuration and capacity of the battery. Except the control system 15, the switching system 4 watches over so that the battery is not discharged too deeply - when the set threshold is achieved (dangerous for the battery 3) it is disconnected from the load and the consumed power is limited to quiescent current at level of nA.
When the voltage is restored, the system automatically switches from the emergency mode to operation from the network mode.

Claims

Claims
Supply method of emergency supply module, wherein the power supply (1) connected to the supply network charges the battery (3) using the charger (2) and supplies the following module functional blocks: switching system (4), measurement block (5), microprocessor (7), detection system (8), driver LED DC/DC (9), built-in EEPROM memory (10) and signalling diodes (12) characterized in, that:
after charging battery packs, the control system (15) disconnects the power supply (1) from the remaining module functional blocks, which causes that the power supply (1) automatically switches to reduced power consumption mode from the network to the level not exceeding 50 mW,
after disconnecting the power supply (1), the remaining functional block of the emergency supply module are supplied from the battery (3),
after reduction of voltage from the battery (3), the control system (15) connects the power supply (1) that automatically switches to full power mode from the network and supplies all module functional blocks and trickle charges the battery (3) using the charger (2).
Method according to claim 1 characterized in, that the control system (15) connects the power supply (1) automatically switching into full power mode from the supply network and supplies all module functional blocks and the charging activates with the reduction of battery (3) voltage by no more than 7% in relation to full charging of the battery
Method according to claim 1 characterized in, that the supply module switches to the mode of reduced power in the version designed for maintained operation only in case of no external control signal LI.
Method according to claim 1 characterized in, that after disconnecting the power supply (1), total current consumption by module functional blocks: switching system (4), measurement block (5), microprocessor (7), detection system (8), driver LED DC/DC (9), built-in EEPROM memory (10), and signalling diodes (12) does not exceed 2.
5 mA. Method according to claim 1 characterized in, that after disconnecting the power supply (1), power consumption by the threshold detection system (6) is not more than 10 mW.
6. Emergency supply module with reduced power consumption from the network comprising power supply (1), charger (2), battery (3), switching system (4) and detection system (8), LED module (13) and signalling diodes (12) characterized in, that the emergency supply module is equipped with the control system (15) controlling electrical energy consumption, comprising programmable processor (7) and the power supply (1) is equipped with integrated driver AC/DC (14) with the function of automatic switching into reduced power consumption mode from the supply network, and the signalling diodes (12) are supplied from the microprocessor (7), which in turn is supplied from the battery (3) via the switching system (4).
7. Emergency supply module according to claim 6 characterized in, that it is additionally equipped with threshold detection system (6), switching into emergency mode with limited power consumption.
8. Emergency supply module according to claim 6 characterized in, that it is additonally equipped with testing system (6).
EP16798280.0A 2015-10-22 2016-10-19 Method of supplying an emergency supply module and emergency supply module with reduced power consumption Withdrawn EP3365957A1 (en)

Applications Claiming Priority (2)

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PL414455A PL231411B1 (en) 2015-10-22 2015-10-22 Method for powering the emergency power supply module and the emergency power supply module with reduced power consumption
PCT/IB2016/056297 WO2017068519A1 (en) 2015-10-22 2016-10-19 Method of supplying an emergency supply module and emergency supply module with reduced power consumption

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