U.S. patent application number 15/714337 was filed with the patent office on 2018-03-29 for method and apparatus for horticultural lighting and associated optic systems.
This patent application is currently assigned to Illum Technology, LLC. The applicant listed for this patent is Illum Technology, LLC. Invention is credited to Stephen P Adams, Darin M. Carpenter, Johnathan J. Heiner, Megan M. Tidd.
Application Number | 20180084733 15/714337 |
Document ID | / |
Family ID | 61687124 |
Filed Date | 2018-03-29 |
United States Patent
Application |
20180084733 |
Kind Code |
A1 |
Adams; Stephen P ; et
al. |
March 29, 2018 |
METHOD AND APPARATUS FOR HORTICULTURAL LIGHTING AND ASSOCIATED
OPTIC SYSTEMS
Abstract
A method and apparatus for a horticultural light for use in a
horticultural facility that projects a substantially uniform target
illuminance onto a flat surface or that projects increasing target
illuminance onto a flat surface that increases as the beam angle
increases with respect to the optical axis. A lens array of the
horticultural light mechanically maintains an optimal separation
distance between each LED of the horticultural light and the
corresponding lens of the lens array. Each lens of the lens array
receives the raw light distribution from the LED and then
distributes an optically varied distribution having a nominal
centerbeam intensity with an increasing beam intensity as the beam
width increases. As the distance to target increases, so does the
intensity of the light distribution, which projects a substantially
uniform target illuminance, or an increasing target illuminance
with increasing angle of incidence, onto a flat surface.
Inventors: |
Adams; Stephen P; (Mesa,
AZ) ; Tidd; Megan M.; (Arvada, CO) ; Heiner;
Johnathan J.; (Mesa, AZ) ; Carpenter; Darin M.;
(Las Vegas, NV) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Illum Technology, LLC |
Mesa |
AZ |
US |
|
|
Assignee: |
Illum Technology, LLC
Mesa
AZ
|
Family ID: |
61687124 |
Appl. No.: |
15/714337 |
Filed: |
September 25, 2017 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62399447 |
Sep 25, 2016 |
|
|
|
62422243 |
Nov 15, 2016 |
|
|
|
62489965 |
Apr 25, 2017 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
A01G 9/20 20130101; H05B
47/11 20200101; Y02B 20/40 20130101; A01G 7/045 20130101; Y02P
60/149 20151101; H05B 45/00 20200101; H05B 45/46 20200101; Y02P
60/14 20151101; Y02B 20/46 20130101; H05B 47/00 20200101 |
International
Class: |
A01G 7/04 20060101
A01G007/04; A01G 9/20 20060101 A01G009/20; H05B 33/08 20060101
H05B033/08 |
Claims
1. A horticultural light, comprising: an array of LEDs coupled to a
printed circuit board, wherein each LED of the array of LEDs is
configured to produce a first light distribution; an array of
lenses, wherein the array of lenses includes, a mechanical portion
configured to maintain an optimal separation distance between each
LED of the array of LEDs and a corresponding lens of the array of
lenses; and an optical portion configured to receive the first
light distribution and configured to produce a second light
distribution that projects a substantially uniform target
illuminance onto a flat surface regardless of the angle of
incidence of the second light distribution onto the flat surface; a
transparent media in communication with the array of lenses; and a
bezel coupled to the transparent media and the horticultural light,
wherein the bezel is configured to maintain a substantially
constant pressure around a perimeter of the horticultural light and
is further configured to maintain the transparent media in
communication with the array of lenses, wherein the transparent
media is configured to press the array of lenses against the
printed circuit board.
2. The horticultural light of claim 1, wherein the mechanical
portion includes raised portions configured to maintain the optimal
separation distance.
3. The horticultural light of claim 2, wherein the raised portions
are in communication with the printed circuit board.
4. The horticultural light of claim 3, wherein each raised portion
is configured to impose a substantially uniform pressure onto a
portion of the printed circuit board that surrounds a corresponding
LED of the LED array.
5-7. (canceled)
8. The horticultural light of claim 1, wherein the mechanical
portion includes indented portions configured to receive at least a
portion of each LED of the LED array.
9. A horticultural light, comprising: an array of LEDs coupled to a
printed circuit board, wherein each LED of the array of LEDs is
configured to produce a first light distribution; an array of
lenses, wherein the array of lenses includes, a mechanical portion
configured to maintain an optimal separation distance between each
LED of the array of LEDs and a corresponding lens of the array of
lenses; and an optical portion configured to receive the first
light distribution and configured to produce a second light
distribution having an illuminance that increases as the beam angle
of the second light distribution increases up to a maximum beam
angle; a transparent media in communication with the array of
lenses; and a bezel coupled to the transparent media and the
horticultural light, wherein the bezel is configured to maintain a
substantially constant pressure around a perimeter of the
horticultural light and is further configured to maintain the
transparent media in communication with the array of lenses,
wherein the transparent media is configured to press the array of
lenses against the printed circuit board.
10. The horticultural light of claim 9, wherein the mechanical
portion includes raised portions configured to maintain the optimal
separation distance.
11. The horticultural light of claim 10, wherein the raised
portions are in communication with the printed circuit board.
12. The horticultural light of claim 11, wherein each raised
portion is configured to impose a substantially uniform pressure
onto a portion of the printed circuit board that surrounds a
corresponding LED of the LED array.
13-15. (canceled)
16. The horticultural light of claim 9, wherein the mechanical
portion includes indented portions configured to receive at least a
portion of each LED of the LED array.
17. The horticultural light of claim 9, wherein the second light
distribution projects an illumination onto a flat surface that
increases as the angle of incidence of the second light
distribution onto the flat surface increases up to a maximum angle
of incidence.
18. A horticultural light, comprising: an array of LEDs coupled to
a PCB, wherein each LED of the array of LEDs is configured to
produce a first light distribution; an array of lenses in
mechanical communication with the PCB, wherein each lens of the
array of lenses includes, a mechanical portion configured to impose
a substantially uniform pressure on the PCB around a perimeter of
each LED of the array of LEDs; and an optical portion configured to
receive the first light distribution and configured to produce a
second light distribution having an illuminance that increases as
the beam angle of the second light distribution increases up to a
maximum beam angle; a transparent media in communication with the
array of lenses, wherein the transparent media is configured to
press each lens of the array of lenses against the PCB to prohibit
the first light distribution from being redirected back into the
horticultural light; and a bezel coupled to the transparent media,
the bezel configured to maintain horticultural light in a water
resistant state.
19-20. (canceled)
21. The horticultural light of claim 18, wherein the water
resistant state includes a water proof state.
Description
FIELD OF THE INVENTION
[0001] The present invention generally relates to horticultural
lighting, and more particularly to optical systems used in
horticultural lighting.
BACKGROUND
[0002] Light emitting diodes (LEDs) have been utilized since about
the 1960s. However, for the first few decades of use, the
relatively low light output and narrow range of colored
illumination limited the LED utilization role to specialized
applications (e.g., indicator lamps). As light output improved, LED
utilization within other lighting systems, such as within LED
"EXIT" signs and LED traffic signals, began to increase. Over the
last several years, the white light output capacity of LEDs has
more than tripled, thereby allowing the LED to become the lighting
solution of choice for a wide range of lighting solutions.
[0003] LEDs exhibit significantly optimized characteristics, such
as source efficacy, optical control and extremely long operating
life, which make them excellent choices for general lighting
applications. LED efficiencies, for example, may provide light
output magnitudes up to 200 lumens per watt of power. Energy
savings may, therefore, be realized when utilizing LED-based
lighting systems as compared to the energy usage of, for example,
incandescent, halogen, compact fluorescent and high-intensity
discharge (HID) lighting systems. As per an example, an LED-based
lighting fixture may utilize a small percentage (e.g., 15-20%) of
the power utilized by a halogen-based lighting system, but may
still produce an equivalent magnitude of light.
[0004] While HID lighting systems have been the predominant choice
for conventional horticultural lighting applications, LED
technologies are gaining attraction due to their high luminous
efficacy and their ability to produce narrow-band spectral
distributions. Current LED-based horticultural lighting systems,
however, fail to produce adequate light uniformity for indoor
horticulture facility applications where natural light is not
present nor do they produce adaptable spectral tuning. In addition,
conventional LED-based horticultural lighting systems produce light
rays exhibiting decreased intensity with increasing emission angle
relative to the optical axis. Accordingly, none of the control
systems used to effect adequate light distribution characteristics,
spectral tuning and power efficiency are in existence either.
[0005] Efforts continue, therefore, to develop an LED lighting
system and associated controls that exceed the performance
parameters of conventional horticultural lighting systems.
SUMMARY
[0006] To overcome limitations in the prior art, and to overcome
other limitations that will become apparent upon reading and
understanding the present specification, various embodiments of the
present invention disclose methods and apparatus for the control
and production of LED-based lighting for indoor horticultural
systems that may exhibit specific light distribution having
increased intensity as the beam angle increases with respect to the
optical axis.
[0007] In accordance with one embodiment of the invention, a
horticultural light comprises an array of LEDs, where each LED of
the array of LEDs is configured to produce a first light
distribution and an array of lenses. The array of lenses includes a
mechanical portion configured to maintain an optimal separation
distance between each LED of the array of LEDs and a corresponding
lens of the array of lenses and an optical portion configured to
receive the first light distribution and configured to produce a
second light distribution that projects a substantially uniform
target illuminance onto a flat surface regardless of the angle of
incidence of the second light distribution onto the flat
surface.
[0008] In accordance with an alternate embodiment of the invention,
a horticultural light comprises an array of LEDs, where each LED of
the array of LEDs is configured to produce a first light
distribution and an array of lenses. The array of lenses includes a
mechanical portion configured to maintain an optimal separation
distance between each LED of the array of LEDs and a corresponding
lens of the array of lenses and an optical portion configured to
receive the first light distribution and configured to produce a
second light distribution having an illuminance that increases as
the beam angle of the second light distribution increases.
[0009] In accordance with an alternate embodiment of the invention,
a horticultural light comprises an array of LEDs coupled to a PCB,
where each LED of the array of LEDs is configured to produce a
first light distribution and an array of lenses in mechanical
communication with the PCB. Each lens of the array of lenses
includes a mechanical portion configured to impose a substantially
uniform pressure on the PCB around a perimeter of each LED of the
array of LEDs and an optical portion configured to receive the
first light distribution and configured to produce a second light
distribution having an illuminance that increases as the beam angle
of the second light distribution increases.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] Various aspects and advantages of the invention will become
apparent upon review of the following detailed description and upon
reference to the drawings in which:
[0011] FIG. 1 illustrates an LED-based horticultural light in
accordance with one embodiment of the present invention;
[0012] FIGS. 2A and 2B illustrate a lens array in accordance with
one embodiment of the present invention;
[0013] FIG. 3 illustrates a cross-section of an LED/lens pair in
accordance with one embodiment of the present invention;
[0014] FIGS. 4A and 4B illustrate an intensity distribution and
shaded illuminance plot in accordance with one embodiment of the
present invention;
[0015] FIGS. 5A and 5B illustrate a conventional intensity
distribution and shaded illuminance plot resulting from a bare LED
without a lens or an LED with a standard Lambertian optic;
[0016] FIG. 6 illustrates a cross-section of an LED/lens pair in
accordance with an alternate embodiment of the present
invention;
[0017] FIGS. 7A and 7B illustrate an intensity distribution and
shaded illuminance plot in accordance with an alternate embodiment
of the present invention;
[0018] FIG. 8 illustrates a horticulture system in accordance with
one embodiment of the present invention;
[0019] FIG. 9 illustrates an LED-based horticultural light in
accordance with an alternate embodiment of the present
invention;
[0020] FIG. 10 illustrates a block diagram of a power supply that
may be used with the LED-based horticultural light of FIG. 9;
[0021] FIG. 11 illustrates a lighting system in accordance with one
embodiment of the present invention;
[0022] FIG. 12 illustrates flow diagrams in accordance with several
embodiments of the present invention;
[0023] FIG. 13 illustrates a lighting system in accordance with an
alternate embodiment of the present invention;
[0024] FIG. 14 illustrates flow diagrams in accordance with several
alternate embodiments of the present invention;
[0025] FIGS. 15A, 15B and 15C illustrate timing diagrams in
accordance with several embodiments of the present invention;
and
[0026] FIG. 16 illustrates an indoor horticultural system in
accordance with one embodiment of the present invention.
DETAILED DESCRIPTION
[0027] Generally, the various embodiments of the present invention
are applied to a light emitting diode (LED) based lighting system
that may contain an array of LEDs and an array of associated
lenses. The LED array may be mechanically and electrically mounted
to a PCB having control and bias circuitry that allows specific
sets of LEDs to be illuminated on command (e.g., specific rows
and/or columns of LEDs in the LED array). An associated lens array
may be mounted in proximity to the LED array in such a way that the
lens array may perform more than one function. For example, the
lens array may mechanically impose a uniform pressure onto the PCB
against the associated heat sink to optimize heat transfer from the
PCB to the heat sink. Further, the lens array may contain
individual lenses with mechanical standoffs so as to maintain an
optimal separation distance between the LED and associated lens so
that light rays generated by each individual LED may be optically
varied before projection onto a target.
[0028] The mechanical standoffs may, for example, exhibit a shape
(e.g., circular) having a dimension (e.g., circumference) that is
slightly larger than a dimension (e.g., a circumference) of the
LED's footprint as mounted on its associated PCB. Accordingly, as
the lens array is pressed against the PCB, each mechanical standoff
of each lens of the lens array may impose a substantially uniform
pressure along a circular perimeter surrounding the LED to further
enhance heat transfer from the LED to the heat sink.
[0029] Each lens of the lens array may, for example, be placed in
such proximity to its corresponding LED so as to collect
substantially all of the light generated by its associated LED and
virtually none of the light generated by neighboring LEDs. Each
lens may optically vary (e.g., refract) the light distributed by
its associated LED into an optically varied light distribution,
such that the light distributed by the lens may exhibit a modified
intensity distribution as compared to the intensity distribution of
light generated by a bare LED. In alternate embodiments, multiple
LEDs may be associated with a single lens such that the intensity
of light generated by each of the multiple LEDs may be modified by
the single lens.
[0030] The Full Width Half Maximum (FWHM) beam angle may be defined
as the beam angle where the light distribution exhibits an
intensity equal to half the peak intensity. A conventional LED may
exhibit an FWHM beam angle of about 120 degrees, where the peak
intensity of light distribution may exist at a zero-degree offset
from the optical axis of the LED (e.g., centerbeam). Each lens of
the lens array may, however, modify the intensity distribution,
such that the FWHM beam angle may either be less than, or
substantially the same as, the FWHM beam angle produced by a bare
LED, but the intensity distribution may be modified by the lens
such that the peak intensity may not exist at centerbeam, but
rather may be offset from centerbeam.
[0031] In one example, the intensity distribution of a bare LED may
exhibit a relatively wide FWHM beam angle (e.g., a 120-degree FWHM
beam angle) having a peak intensity at centerbeam. A lens of the
lens array may, for example, be used to substantially refract the
FWHM beam angle of the bare LED between about 100 degrees and 140
degrees (e.g., between approximately 115 degrees and 128 degrees),
but may alter the intensity distribution such that the peak
intensity may not exist at centerbeam, but instead may exist at an
offset between about 40 and 60 degrees (e.g., between approximately
50 and 55 degrees) half angle from centerbeam.
[0032] As per another example, a lens of the lens array may be used
to substantially reduce the FWHM beam angle of the bare LED from
about 120 degrees to between about 50 degrees and 90 degrees (e.g.,
between approximately 65 degrees and 75 degrees) and may further
alter the intensity distribution such that the peak intensity may
not exist at centerbeam, but instead may exist at an offset between
about 15 and 35 degrees (e.g., between approximately 20 and 28
degrees) half angle from centerbeam.
[0033] Generally, each lens of the lens array may distribute light
into a ray set that exhibits varying intensity depending upon the
angle that each light ray of the projected ray set exhibits
relative to a reference axis. For example, a reference axis of the
LED may be defined as the axis that is orthogonal to the surface of
the PCB to which the LED is mounted and each light ray emitted by
the LED may be refracted by the lens to exhibit an intensity that
is proportional to the angle that the refracted light ray forms
with respect to the reference axis. In one embodiment, refracted
light rays at lower angles relative to the reference axis may
exhibit lower intensities while refracted light rays at higher
angles relative to the reference axis may exhibit relatively larger
intensities.
[0034] Refracted light rays incident upon a target surface may
similarly be defined with respect to the reference axis. For
example, light rays refracted by the lens that exhibit a
zero-degree offset from the reference axis may be described as
exhibiting a zero-degree incidence angle. Similarly, light rays
refracted by the lens that exhibit non-zero-degree offsets from the
reference axis may be described as exhibiting incidence angles
greater than zero as measured relative to the reference axis.
[0035] A lens may be configured to refract light rays emitted by
the LED to exhibit intensities that are proportional to their
respective incidence angles. For example, refracted light rays with
lower incidence angles may exhibit lower intensities as compared to
refracted light rays with higher incidence angles. The lens may be
further configured to substantially prohibit refraction of light
rays exhibiting incidence angles greater than a reference
angle.
[0036] The lens, therefore, may produce lower intensity light rays
having lower incidence angles as compared to the intensity of light
rays having relatively higher incidence angles. Such a lens may be
particularly useful when the beam is to be projected onto a flat
surface target with a substantially uniform illuminance across the
entire illuminated surface regardless of the angle of incidence, or
when the beam is to be projected onto a flat surface target with an
increasing illuminance across the entire illuminated surface as the
angle of incidence increases. Such a lens may be further useful
when the beam is to be projected not only onto a flat surface below
the light, but also onto objects that are adjacent to the flat
surface at higher incidence angles with respect to the light.
[0037] Stated differently, since target illuminance is proportional
to the intensity of the projected light ray and inversely
proportional to the square of the distance between the target and
the lens that is producing the projected light ray, a lens that
produces light rays having intensities that are proportional to the
angle of incidence up to a threshold angle may be used to produce
substantially even or uniform illuminance on a flat plane across
the full beam width. That is to say in other words, that as the
angle of incidence of light rays projected by the lens increase, so
does their intensity. Furthermore, by increasing the intensity of
the light rays in proportion to the square of the distance between
the lens and the target, a substantially even target illuminance
may be projected across the entire illuminated flat surface
regardless of the angle of incidence of light rays onto the target,
or an illuminance may be projected onto a flat surface that
increases with the angle of incidence. Adjacent targets may also be
illuminated by light rays that do not illuminate the flat surface
due to their higher angles of incidence, but due to the higher
intensity of such light rays, may illuminate such adjacent targets
with substantially equal illuminance, or with substantially
increasing illuminance, as compared to those light rays that are
incident on the flat surface.
[0038] It should be noted that the advantages obtained by using the
horticultural lights in accordance with the present invention do
not exist with conventional horticultural lights, which may include
LED-based horticultural lights as well. For example, conventional
horticultural lights typically use a very small, yet high power
light source with a secondary reflector in order to obtain a
particular distribution of light onto a typical grow bed. Such a
light source, however, produces non-reflected light rays directly
from the light source having increased intensity at centerbeam,
which in turn requires increased vertical distance between the
horticultural light and the canopy of plants below the
horticultural light.
[0039] Alternately, smaller LED-based horticultural lights may be
used, but are used in very large numbers so as to obtain a
projection area substantially equal to that of the larger
conventional horticultural lights. While reduced vertical distance
between the smaller LED-based horticultural lights and the plant
canopy may be achieved, cross-lighting becomes virtually
non-existent and the amount of light projecting throughout the
depth of the plant canopy is significantly reduced.
[0040] Accordingly, even when a particular coverage area is
achieved, the illuminance projected onto the grow bed lacks
uniformity and, therefore, includes "hot spots" and "dim spots" and
generally provides uneven projected illuminance due to the inverse
square law as discussed in more detail below. As discussed above,
for example, conventional horticultural lights generally project
maximum intensity at zero to low angles of incidence, which
requires relatively large vertical distances to be established
between the conventional horticultural light and the underlying
plant. As a result, vertical distances between the conventional
horticultural light and the corresponding plant must be maximized
to, for example, prevent plant burn.
[0041] Horticultural lights in accordance with the present
invention, on the other hand, utilize a dense array of lenses that
optically vary the intensity of the light distributed by an
associated array of LEDs to project a uniform illuminance across a
large surface area of a flat plane, or to project an increasing
illuminance as the angle of incidence increases from centerbeam,
despite the effects of the inverse square law (e.g., regardless of
the increased distances that the light travels to the target due to
the increased angles of incidence). Accordingly, not only may the
light projection area from each horticultural light fixture in
accordance with the present invention be increased as compared to
conventional horticultural lights, but the illuminance within the
illuminated area may be made substantially uniform, or
substantially increasing as incidence angles increase from
centerbeam outward, as well. In addition, the illuminance projected
onto secondary targets that are adjacent to the primary target may
also be made to be substantially uniform, or substantially
increasing as incidence angles increase from centerbeam outward,
due to the increased intensity of light rays projected by the
horticultural light fixture at angles that are incident upon the
secondary targets.
[0042] In other embodiments, horticultural lights in accordance
with the present invention may utilize other techniques, with or
without optics, to vary light intensity. Variability of the light
output (e.g., spectral variability) may be controlled, for example,
using any number of wired protocols including 0-10V, I2C, digital
multiplex (DMX), ethernet or digital addressable lighting interface
(DALI) to name only a few. In addition, spectral variability may be
achieved via wireless protocols, such as via ZigBee, Wi-Fi,
Bluetooth or a thread-based mesh network, along with other wireless
protocols. Furthermore, by combining broad-spectrum white LEDs with
a combination of other LEDs may increase the efficiency of the
horticultural light in producing photosynthetically active
radiation (PAR).
[0043] For example, two or more sets of broad-spectrum LEDs may be
utilized along with one or more sets of fixed-color LEDs (e.g., one
set of blue LEDs and one set of red LEDs) in order to implement
broad-spectrum illumination that may better simulate sun light. In
addition, the two or more sets of broad-spectrum LEDs may exhibit
different correlated color temperatures (CCT), such that once
varying intensities of the light generated by both sets of
broad-spectrum LEDs is mixed, a tunable CCT composite spectrum may
result that may better simulate the various phases of the sun, may
better simulate sunlight at the various latitudes that the sun may
assume and may better simulate sun light across each of the four
seasons.
[0044] In addition, the intensities of multiple horticultural
lighting fixtures may be controlled within an indoor grow facility
to better simulate the position of the sun throughout the daylight
hours. For example, by increasing the intensity of
easterly-positioned horticultural lighting fixtures in the morning
hours may better simulate the rising sun, by increasing the
intensity of centrally-positioned horticultural lighting fixtures
during the mid-day hours may better simulate the
mid-morning/mid-afternoon sun and by increasing the intensity of
westerly-positioned horticultural lighting fixtures in the late
afternoon/evening hours may better simulate the setting sun.
[0045] In one embodiment, each set of the multiple sets of LEDs may
be arranged as independent channels of LEDs, where each channel of
LEDs may be independently operated at a selected intensity based
upon a magnitude of current that may be conducted by each channel
of LEDs. The control circuitry that may be used to select the
magnitude of current that may be conducted by each channel of LEDs
may be integrated within the power supply that may also contain the
bulk power conversion (e.g., alternating current (AC) to direct
current (DC) and/or DC to DC power conversion electronics) and
regulation (e.g., constant current regulation or constant voltage
regulation) electronics.
[0046] Turning to FIG. 1, horticultural light 100 is exemplified,
which may include one or more lens arrays (e.g., lens array 118 and
126). Each lens array may include one or more rows of lenses (e.g.,
four rows of lenses) and one or more columns of lenses (e.g., 12
columns of lenses). One or more LEDs (not shown) may be included
behind each lens (e.g., lens 102) so that in one example, the
number of LEDs included within horticultural light 100 may be equal
to the number of lenses included in each lens array (e.g., 48 LEDs
per lens array for a total of 96 LEDs per horticultural light 100).
As per another example, multiple LEDs (e.g., one red, one green,
one blue and one white LED from each RGBW channel of LEDs) may be
included behind each lens and may further be rotated with respect
to one another so as to smooth the light distribution projected by
each multiple LED/single lens combination. In one embodiment, for
example, each of 4 LEDs combined under a single lens may be
attached to the underlying PCB at 0 degree, 45 degree, 90 degree
and 135 degree offsets, respectively, whereby the magnitude of
angle offset may be inversely proportional to the number of LEDs
combined under a single lens (e.g., 180 degrees/4 equals a rotation
offset of 45 degrees from one LED to the next).
[0047] Bezel 134 may, for example, provide a substantially constant
pressure around a perimeter of horticultural light 100 to, for
example, seal a substantially transparent media to horticultural
light 100 thereby maintaining horticultural light 100 in a water
proof/water resistant state. The transparent media may also press
the lens array against the PCB behind the lens array, such that
substantially 100% of the light generated by each LED may be
directed through its respective lens and through the transparent
media to prohibit virtually any of the light from being redirected
back into horticultural light 100. While the dimensions (e.g., 4.5
inches wide.times.22 inches long) of horticultural light 100 may be
significantly smaller than conventional LED horticultural lights
(e.g., 4 feet wide.times.4 feet long), horticultural light 100 via
its dense array of LEDs and associated lenses may nevertheless
project a substantially equivalent amount of light onto a
conventional grow bed, but may do so with substantially uniform
illuminance, or substantially increasing illuminance from
centerbeam outward, across the entire grow bed and adjacent grow
beds unlike the substantially non-uniform illuminance, or
substantially decreasing illuminance from centerbeam outward, as
projected by conventional horticultural lights.
[0048] Horticultural light 100 may further include control
circuitry (e.g., controllers 110, 112, 114 and 116) and associated
circuitry (e.g., bias circuitry 124) such that any one or more LEDs
(not shown) may be independently transitioned into conductive and
non-conductive states on command. Alternately, LED control and bias
circuitry (e.g., controllers 110, 112, 114, 116 and associated bias
control circuitry 124) may not be co-located on the same PCB to
which the associated LEDs are mounted, but may instead be located
remotely to the PCB (e.g., on a modular control and bias circuit
that may be interchangeably introduced into horticultural light 100
or into a bias and control bus that connects two or more
horticultural lights 100 together).
[0049] In one embodiment, the conductive state of any multiple of
LEDs (e.g., the LEDs, not shown, behind each row of lenses 126,
128, 130 and 132) may be independently controlled. In other
embodiments, the conductive state of any multiple of LEDs (e.g.,
the LEDs, not shown, behind each column of each array of lenses 118
and 126) may be independently controlled. Once an LED (not shown)
is transitioned to its conductive state, the associated lens (e.g.,
lens 102) may produce a light distribution that may exhibit a
particular intensity profile, which may produce a substantially
uniform target illuminance, or a substantially increasing target
illuminance from centerbeam to the edge of the beam pattern, across
a flat surface as discussed in more detail below.
[0050] Multiple horticultural lights 100 may be employed for use as
horticultural lighting in a greenhouse, small indoor grow room, or
in a commercial production facility as part of an integrated
horticultural system. Horticultural light 100 may, for example,
replicate natural light that may be absent in an indoor grow
facility and may be controlled (e.g., via bias controller 124 and
controllers 110, 112, 114 and 116) to deliver virtually any
wavelength of light that may be produced by an LED, at virtually
any intensity, at virtually any duty cycle that may be useful in a
horticultural facility. Furthermore, virtually any mixture of LEDs
may be utilized within horticultural light 100 to produce a wide
range of color temperature, spectrum and color rendering index
(CRI).
[0051] As an example, each row of LEDs (e.g., rows of LEDs, not
shown, behind rows of lenses 126, 128, 130 and 132, respectively)
may each include a selection of LEDs that may produce a range of
color temperature and CRI attributes. For example, the rows of LEDs
(not shown) behind lens rows 126 and 128 may include LEDs
exhibiting a color temperature of approximately 3000.degree. K and
a CRI greater than 90. As another example, the row of LEDs (not
shown) behind lens row 130 may include LEDs exhibiting a color
temperature of approximately between 5700.degree. K and
6500.degree. K and may exhibit a CRI less than 80. As per another
example, the row of LEDs (not shown) behind lens row 132 may
include LEDs exhibiting a narrow-bandwidth red color spectrum
(e.g., at or below 1800.degree. K or between 580 nm and 750 nm). It
should be noted that virtually any combination of wavelength, color
temperature, spectrum and CRI may be used to match the particular
photosynthetic and photomorphogenic requirements of the crop of
interest.
[0052] It should be further noted that the LEDs (not shown) may
include a percentage (e.g., 75%) of phosphor converted white LEDs
and a percentage (e.g., 25%) of narrow band red or blue spectrum
LEDs, such as aluminum gallium indium phosphide (AlGaInP) LEDs.
Alternately, for example, phosphor converted red LEDs may also be
used, which may facilitate the use of indium gallium nitride
(InGaN) LEDs exclusively, both for the phosphor converted white
LEDs and the phosphor converted red LEDs. Such an arrangement of
matched InGaN LEDs may, for example, provide a very broad spectrum
white light with an emphasis on the blue and red spectra while also
providing uniform thermal performance and degradation as well as
the advantage of facilitating the implementation of strings of
multiple LEDs (e.g., the string of LEDs, not shown, behind lens
rows 126, 128, 130 and 132) that may be arranged serially with a
substantially constant forward voltage.
[0053] As discussed in more detail below, bias controller 124 may
include wired and/or wireless access control systems, such as
Bluetooth, Wi-Fi, thread-based mesh, digital multiplex (DMX), I2C,
ethernet or telecommunications-based control systems that may allow
horticultural light 100 to be controlled remotely, either within
the same facility, or via a regional or national control room.
Accordingly, the lighting of one or more unmanned horticultural
facilities may be centrally controlled by a single control station.
Such a control station, for example, may also control other aspects
of the horticultural facility. Air filtration and circulation
systems, for example, may require remote access control for heat
and exhaust mitigation. Various irrigation systems, such as drip
irrigation, hydroponic flood benches and trough benches along with
a nutrient management system may also be controlled by the control
station. In general, the control station may not only control the
one or more horticultural lights 100 of the horticultural facility,
but also the nutrients, air circulation, irrigation,
dehumidification, carbon dioxide (CO.sub.2) injection and other
facilities that may be required to maintain the exact environment
needed by the various growing rooms, cloning rooms and flowering
rooms of the horticultural facility.
[0054] Turning to FIGS. 2A and 2B, a front view and a rear view,
respectively, of a lens array (e.g., lens array 118 of FIG. 1) are
exemplified. Mechanical portions 202 and 204, for example, of the
lens array may not include any optical attributes, but may instead
provide a framework within which optical portions (e.g., lenses
206) may be configured into an array (e.g., multiple rows and
columns of lenses 206). Mechanical portions 202 and 204 may, for
example, include mounting features (e.g., apertures 208) that may
facilitate the insertion of mounting hardware (e.g., screws) that
may be used to mount the lens array to the underlying PCB and
lighting fixture housing/heat sink (not shown). By utilizing such
mounting hardware, mechanical portion 204 may be pressed against
the underlying PCB and LEDs (not shown), which may in turn press
the underlying PCB against the housing/heat sink (not shown) of the
horticultural light (e.g., horticultural light 100) so as to
promote effective conduction of heat away from the LEDs.
[0055] Mechanical portion 204 may further include raised portions
210 that may be used to create an optimal separation distance
between the lens array and the underlying LED array (not shown).
Indented portions 212 may, for example, accommodate the insertion
of at least a portion of an LED package (e.g., the dome portion of
an LED package). The height of raised portions 210 may be selected
to create an optimal separation distance between the optical input
portion of the lens (e.g., lens 206) and the associated LED (not
shown) that is inserted into the corresponding indented portion 212
of lens 206 as discussed in more detail below. Raised portions 210
may exhibit a particular geometric shape (e.g., circular) so as to
match a particular foot print of each LED (not shown) of the LED
array. As such, raised portions 210 may impose a substantially
uniform pressure surrounding, and in close proximity to, each
associated LED (not shown) so as to create a uniform conduction
path so that heat may be conducted away from the LED through the
associated PCB and heat sink, thereby improving the performance of
the LED.
[0056] In one embodiment, the array of lenses 206 may be arranged
as an array of rows and columns of lenses, where each lens may
exhibit a circular shape having a diameter (e.g., 13 mm diameter)
and a separation distance from each neighboring lens (e.g., a
separation distance of 16 mm center to center). The composition of
the array of lenses 206 may be that of an optical grade polymer
(e.g., acrylic) that may exhibit an index of refraction of between
about 1.48 and 1.5 (e.g., approximately 1.491) or that of an
optical grade polycarbonate that may exhibit an index of refraction
of between about 1.5 and 1.7 (e.g., approximately 1.58).
[0057] Turning to FIG. 3, a cross-sectional view is exemplified in
which LED package 306, having hemispherical dome portion 312, may
protrude into indented portion 304 of lens 314. It should be noted
that indented portion 304 may exemplify a cross-section of a lens
array (e.g., a cross-section of indented portion 212 of the lens
array of FIG. 2) where indented portion 304 may include optical
input 308 to lens 314 that may accept the light distribution from
LED package 306 into lens 314. Protrusion 302 may exemplify a
cross-section of a lens array (e.g., a cross-section of mechanical
portion 210 of the lens array of FIG. 2) where protrusion 302
includes surface area 316 that may be in communication with a PCB
(not shown) to select an optimal separation distance (e.g.,
separation distance 318) between the LED deck (e.g., PCB 326 of LED
package 306) and optical input 308 to lens 314. In one embodiment,
separation distance 318 may be between about 0.3 mm and about 0.4
mm (e.g., approximately 0.35 mm).
[0058] Portion 310 may exemplify a cross-section of a lens array
(e.g., a cross-section of lens 206 of FIG. 2) where portion 310 may
be the optical output of lens 314 that produces the optically
varied (e.g., refracted) light distribution. Light distribution
from lens 314 may exhibit an optical axis (e.g., axis 320) that may
be orthogonal to the mounting surface of the PCB (not shown) to
which LED package 306 is mounted. In addition, the projected light
distribution from lens 314 may be described in terms of the
intensity of each ray and its geometric orientation with respect to
axis 320 as well as the projected illuminance onto a flat plane and
projected illuminance onto targets adjacent to the flat plane.
[0059] It should be noted that the lens array is configured such
that a projected light distribution from an individual lens (e.g.,
lens 314) of the lens array may not be incident upon adjacent
lenses (e.g., lenses 326 and 328) of the lens array. In one
embodiment, for example, lens 314 may refract the light
distribution of LED 306 into a half-beam angle between about 50
degrees and 90 degrees (e.g., between approximately 65 degrees and
75 degrees) having full-beam width 322 that is not incident on any
adjacent lenses (e.g., lenses 326 and 328).
[0060] Turning to FIG. 4A, a light distribution is exemplified that
may be produced by an LED/lens combination in accordance with one
embodiment that may include an LED (e.g., LED package 306 of FIG.
3) and a lens (e.g., lens 314 of FIG. 3) to produce a light
distribution as exemplified in FIG. 4A. As illustrated, for
example, the light distribution from lens 314 may exhibit a center
beam intensity (e.g., about 77 candela) at a zero-degree offset
from the optical axis (e.g., axis 320 of FIG. 3). The light
distribution from lens 314 may exhibit a peak intensity (e.g., 84
candela) offset from the center beam by an angle of about 22.5
degrees to about 27.5 degrees.
[0061] It can be seen, therefore, that if the light distribution of
FIG. 4A is projected onto a target having a flat surface by a lens
(e.g., lens 314 of FIG. 3), the distance between the lens and the
target changes depending upon the angle of incidence of the light
distribution onto the target. As an example, if the angle subtended
by a light ray is offset from the optical axis (e.g., axis 320 of
FIG. 3) by zero degrees, then the distance traveled by the light
ray to the target is at its minimal value. As the angle subtended
by a light ray referenced to the optical axis increases, so does
the distance that the light ray must travel before being incident
onto the target's surface.
[0062] According to the inverse square law, therefore, the target
illuminance decreases in proportion to the inverse square of the
distance between the lens and the target, thereby causing the
target illuminance to decrease with increasing beam width. However,
since the intensity of the light distribution of FIG. 4A increases
with increasing beam angle up to a reference beam angle (e.g.,
between about 22.5 degrees to about 27.5 degrees), the target
illuminance may nevertheless remain substantially uniform, or may
substantially increase with increasing beam angle, despite the
effects of the inverse square law as exemplified, for example, in
the associated shaded illuminance plot of FIG. 4B. In addition, for
example, since the intensity of light distribution is maximum at
maximum beam angle, the effective distance of the illuminance onto
targets adjacent to the main target may be extended, such as may be
the case when projecting light through side portions of the
canopies of adjacent plants.
[0063] As a comparison, FIG. 5A exemplifies an intensity
distribution from a bare LED (e.g., an LED without an optically
varied distribution found on conventional horticultural lights) and
FIG. 5B exemplifies the associated shaded illuminance plot. As can
be seen from FIG. 5A, the intensity peaks at centerbeam (e.g.,
zero-degree offset from the LED's optical axis) and then decreases
with increasing beam angle, which causes the illuminance, as
exemplified by the shaded illuminance plot of FIG. 5B, to be
non-uniform and decreasing in proportion to the inverse of the
square of the increasing distance between the LED and its
illumination target. It can be seen, therefore, that without the
optical distribution of a lens in accordance with the various
embodiments of the present invention, uniform illuminance onto a
flat target is not possible. Rather, decreasing illuminance with
increasing angles of incidence is produced.
[0064] Turning to FIG. 6, a cross-sectional view of an alternate
LED/lens embodiment exhibiting a wider beam angle is exemplified in
which LED package 606, having hemispherical dome portion 612, may
protrude into indented portion 604 of lens 614. It should be noted
that indented portion 604 may exemplify a cross-section of a lens
array (e.g., a cross-section of indented portion 212 of the lens
array of FIG. 2) where indented portion 604 includes optical input
608 to lens 614 that accepts the light distribution from LED 606
into lens 614. Protrusion 602 may exemplify a cross-section of a
lens array (e.g., a cross-section of mechanical portion 210 of the
lens array of FIG. 2) where protrusion 602 includes surface area
616 that may be in communication with a PCB (not shown) to select
an optimal separation distance (e.g., separation distance 618)
between the LED deck (e.g., PCB 626 of LED package 606) and optical
input 608 to lens 614. In one embodiment, separation distance 618
may be between about 0.3 mm and about 0.4 mm (e.g., approximately
0.35 mm).
[0065] Portion 610 may exemplify a cross-section of a lens array
(e.g., a cross-section of lens 206 of FIG. 2) where portion 610 may
be the optical output of lens 614 that produces the optically
varied (e.g., refracted) light distribution. Light distribution
from lens 614 may exhibit an optical axis (e.g., axis 620) that may
be orthogonal to the mounting surface of the PCB (not shown) to
which LED package 606 is mounted. In addition, the projected light
distribution from lens 614 may be described in terms of the
intensity of each ray and its geometric orientation with respect to
axis 620 as well as the projected illuminance onto a flat plane and
the projected illuminance onto targets adjacent to the flat
plane.
[0066] It should be noted that the lens array is configured such
that a projected light distribution from an individual lens (e.g.,
lens 614) of the lens array may not be incident upon adjacent
lenses (e.g., lenses 626 and 628) of the lens array. In one
embodiment, for example, lens 614 may refract the light
distribution of LED 606 into a beam angle between about 100 degrees
and 140 degrees (e.g., between approximately 115 degrees and 128
degrees) having beam width 624 that is not incident on adjacent
lenses 626 and 628.
[0067] Turning to FIG. 7A, a light distribution is exemplified that
may be produced by an LED/lens combination in accordance with an
alternate embodiment that may include an LED (e.g., LED package 606
of FIG. 6) and a lens (e.g., lens 614 of FIG. 6) to produce a light
distribution as exemplified in FIG. 7A. As illustrated, for
example, the light distribution from lens 614 may exhibit a center
beam intensity (e.g., about 20 candela) at a zero-degree offset
from the optical axis (e.g., axis 620 of FIG. 6). The light
distribution from lens 614 may exhibit a peak intensity (e.g., 59
candela) offset from the center beam by an angle of about 50
degrees to about 55 degrees (e.g., approximately 54 degrees).
[0068] It can be seen, therefore, that if the light distribution of
FIG. 7A is projected onto a target having a flat surface by a lens
(e.g., lens 614 of FIG. 6), the distance between the lens and the
target changes depending upon the angle of incidence of the light
distribution onto the target. As an example, if the angle subtended
by a light ray is offset from the optical axis (e.g., axis 620 of
FIG. 6) by zero degrees, then the distance traveled by the light
ray to the target is at its minimal value. As the angle subtended
by a light ray referenced to the optical axis increases, so does
the distance that the light ray must travel before being incident
onto the target's surface.
[0069] According to the inverse square law, therefore, the target
illuminance decreases in proportion to the inverse square of the
distance between the lens and the target, thereby causing the
target illuminance to decrease with increasing beam width. However,
since the intensity of the light distribution of FIG. 7A increases
with increasing beam angle up to a reference beam angle (e.g.,
about 54 degrees), the target illuminance may nevertheless remain
substantially uniform, or may substantially increase with
increasing beam angle, despite the effects of the inverse square
law as exemplified, for example, in the associated shaded
illuminance plot of FIG. 7B. In addition, for example, since the
intensity of light distribution is maximum at maximum beam angle,
the effective distance of the illuminance onto targets adjacent to
the main target may be extended, such as may be the case when
projecting light through side portions of the canopies of adjacent
plants.
[0070] In comparing the intensity distribution plots of FIGS. 4A
and 7A, it can be seen that lens 314 of FIG. 3 produces a greater
peak intensity than the peak intensity produced by lens 614 of FIG.
6. Furthermore, since the beam angle produced by lens 614 of FIG. 6
is wider than that produced by lens 314 of FIG. 3, the area
illuminated by lens 614 may be greater than the area illuminated by
lens 314, but the illuminance produced by lens 614 may be less than
that produced by lens 314 given the same distance to target.
Accordingly, while the number of horticultural lights (e.g.,
horticultural lights 100 of FIG. 1) utilizing lens 614 needed to
illuminate a given target area may be less than the number of
horticultural lights utilizing lens 314 needed to illuminate the
same target area, horticultural lights utilizing lens 614 may be
mounted closer to the target area to achieve the same illuminance
generated by horticultural lights utilizing lens 314 that are
mounted further away from the target area. Accordingly, less
vertical distance between the horticultural light and the
associated grow bed may be needed when utilizing lens 614, thereby
allowing multiple levels of grow beds to be established floor to
ceiling within the indoor horticultural facility.
[0071] Turning to FIG. 8, horticultural system 800 is exemplified
including horticulture light 804, which may include a lens array
(e.g., lens array 118 and 126 as exemplified by horticulture light
100 of FIG. 1). In alternate embodiments, horticulture light 804
may not include a lens array, or may use a different lens array
layout. In addition, horticultural system 800 may include grow beds
808, 808A and 808B that may be used to cultivate virtually any crop
that may be grown within a horticulture facility. Horticultural
lighting system 800 may further include, for example, quantum
sensor 806, which may include a photosynthetically active radiation
(PAR) sensor having a uniform sensitivity to PAR light, a light
meter to measure instantaneous light intensity and/or a data logger
to measure cumulative light intensity. Quantum sensor 806 may, for
example, provide spectrographic data, which may include correlated
color temperature (CCT), CRI, chromaticity and photosynthetic
photon flux (PPF) associated with horticulture light 804, among
other spectrographic data.
[0072] In one embodiment, controller 802 may access a database
(e.g., light prescription database 814), which may include
predetermined light prescriptions for controlling the light output
from horticulture light 804 and may then utilize interface 810 to
tune horticulture light 804 in accordance with the predetermined
light prescriptions (e.g., prescribed light intensity, CCT and
color spectrum). Controller 802 and interface 810 may, for example,
be used by an operator to either manually tune horticulture light
804 to manual settings or tune horticulture light 804 to
predetermined light prescriptions 814. Alternately, controller 802
may automatically update horticulture light 804 based upon
comparisons between quantum sensor measurements 812 and light
prescriptions 814 using closed-loop feedback control so as to
maintain horticulture light 804 within operational constraints as
defined by light prescriptions 814.
[0073] Controller 802 may provide command and control signals to
horticulture light 804 via interface 810 (e.g., via a wired
protocol such as 0-10V, I2C, DALI or DMX, or via a wireless
protocol, such as ZigBee, Wi-Fi, thread-based mesh network or
Bluetooth). Controller 802 may receive all measurement data from
quantum sensor 806 and may provide such results via human-machine
interface (HMI) 816 to an operator of horticultural system 800 so
that the operator may ascertain the performance characteristics of
horticulture light 804. It should be noted that HMI 816 may either
be located within the same facility as controller 802, or may be
located remotely within a regional or national control room, so
that multiple controllers 802 in multiple grow facilities may be
centrally managed remotely.
[0074] As discussed above in relation to FIG. 1, horticulture light
804 may implement multiple arrays of LEDs, whereby each LED array
may be arranged along rows and/or columns and each row and/or
column of LEDs may be controlled separately using unique and
independent control channels. In one embodiment, horticulture light
804 (e.g., as discussed above in relation to horticulture light 100
of FIG. 1) may implement multiple channels (e.g., 4 channels)
whereby each row of LEDs (e.g., rows 126, 128, 130 and 132 of FIG.
1) may represent a separately and independently controllable LED
channel.
[0075] Horticulture light 804 may be utilized to produce
broad-spectrum white light (e.g., between about 420 nm and about
750 nm) with variable CCT so that the light spectrum may be tuned
to better simulate various aspects of sun light. For example,
multiple phases of the sun, simulation of sun light in all four
seasons (e.g., fall, winter, spring, summer) and latitude of the
sun may be better simulated using CCT control. Furthermore, no
matter what CCT value may be selected, the intensity of light
produced may be selectable as well, such that in one example,
multiple CCT values may be obtained while maintaining a constant
intensity.
[0076] As discussed above, horticultural light 804 may include
appropriate lens/LED combinations to provide illuminance 818, where
illuminance 818 may be substantially uniform or may substantially
increase as the angle of incidence increases with respect to
optical axis 824. In addition, through increased intensity at
increased beam angles as compared to optical axis 824, light rays
820 and 822 may illuminate adjacent grow beds 808A and 808B,
respectively, with increased illuminance from the sides of the
respective grow beds to better simulate light received from the
sun. Stated differently, by increasing the intensity at increasing
angles of incidence as compared to optical axis 824, light
generated by horticulture light 804 may not only be effective as to
grow bed 808, but also to grow beds 808A and 808B even though grow
beds 808A and 808B are further away from horticulture light 804 as
compared to grow bed 808.
[0077] In one embodiment, horticulture light 804 may include
multiple rows (e.g., two rows) of broad-spectrum white LEDs,
whereby the intensity of each row of LEDs may be controlled by a
separate channel (e.g., 1 of N channels 810) of controller 802. The
first set of broad-spectrum white LEDs may, for example, exhibit a
first CCT (e.g., a CCT equal to about 2700K) and the second set of
broad-spectrum white LEDs may exhibit a second CCT (e.g., a CCT
equal to about 5700K). Through operation of controller 802, the
intensity of each set of broad-spectrum white LEDs may be
controlled to create an averaged mix of light exhibiting a CCT
between about 2700K and 5700K as may be required (e.g., as required
by light prescription 814).
[0078] In alternate embodiments, the number of channels of
broad-spectrum white LEDs may, for example, be increased (e.g.,
increased to 3 channels) each channel exhibiting a different CCT
value (e.g., 2700K, 4000K and 6000K). In such an instance, the
averaged CCT value of the 3-channel combination may be variable
between about 2700K and 6000K, but with an emphasis of mid-range
energy due to the addition of the 3.sup.rd channel (e.g., the 4000K
channel) of broad-spectrum white LEDs.
[0079] In yet other embodiments, horticulture light 804 may include
one or more channels of fixed color LEDs (e.g., one channel of red
LEDs and/or one channel of blue LEDs) in addition to one or more
channels of broad-spectrum white LEDs. In such an instance, even
wider ranging mixed CCT values may be obtained, since the averaged
CCT values produced by the broad-spectrum white LEDs may be pushed
to lower values (e.g., through the use of the variable intensity
red channel) and/or pushed to higher values (e.g., through the use
of the variable intensity blue channel).
[0080] Even broader spectrums may be achieved, for example, when
the one or more channels of fixed color LEDs may themselves be
implemented using multiple wavelengths. For example, a channel of
red LEDs may be implemented through use of a first proportion of
red LEDs (e.g., 50% of the red LEDs producing light with a 660 nm
wavelength) and a second proportion of red LEDs (e.g., 50% of the
red LEDs producing light with a 625 nm wavelength). Additionally, a
channel of blue LEDs may be implemented through use of a first
proportion of blue LEDs (e.g., 50% of the blue LEDs producing light
with a 440 nm wavelength) and a second proportion of blue LEDs
(e.g., 50% of the blue LEDs producing light with a 460 nm
wavelength). Accordingly, even broader spectrum red and blue
channels may be combined with broad-spectrum white channels to
create the broadest spectrum light possible all while also
providing variable CCT.
[0081] Turning to FIG. 9, an alternate embodiment of horticulture
light 900 is exemplified, in which substantially none of the bias
and control circuitry that may be associated with each channel of
LEDs is co-located on the same PCB as each LED. Instead, the bias
and control circuitry for each channel of LEDs (e.g., 4 channels
810 of FIG. 8) may be integrated within the bulk power conversion
(e.g., power supply 904) that may be mounted to horticulture light
900. In addition, power supply 904 may convert the AC voltage
(e.g., 110 VAC at 60 Hz applied via power cord 902) to a wide
ranging DC potential between approximately 10 VDC and 300 VDC
(e.g., approximately between about 12 VDC and 48 VDC). Buck, boost
and/or buck/boost converters (not shown) also contained within
power supply 904 may form at least a portion of the bias and
control circuitry that may be required to illuminate each channel
of LEDs contained within horticulture light 900 at specified
intensities as may be selected via a wired or wireless control
interface (e.g., a wired DMX interface).
[0082] Horticulture light 900 may exhibit a longer length profile
as compared, for example, to horticulture light 100 of FIG. 1. For
example, a longer profile may be obtained by concatenating two
horticulture lights 910 and 912 (e.g., two horticulture lights 100
of FIG. 1 end to end for twice the length). It should be noted that
the circuitry of controller areas (e.g., areas 908) that may
otherwise exist within other horticulture lights (e.g.,
horticulture light 100 of FIG. 1) may instead be contained within
power supply 904.
[0083] Turning to FIG. 10, a block diagram of power supply 904 of
FIG. 9 is illustrated, which may include AC/DC bulk conversion
block 1002, power management block 1004 and one or more DC-DC
converters (e.g., buck, boost and/or buck/boost converters
1006-1008) to, for example, provide sufficient power to vary the
intensity of the one or more arrays of LEDs contained within the
horticulture light (e.g., horticulture light 900 of FIG. 9).
[0084] In one embodiment, for example, converters 1006-1008 may
generate a voltage substantially equal to the forward voltage of
their respective LED arrays and may vary the drive current
according to a constant current topology to achieve a desired
intensity of each LED array (e.g., as may be determined by light
prescription 814 or HMI 816 of FIG. 8). The desired intensity of
each LED array may, for example, be controlled via DMX 1010 and/or
I2C 1020, where each LED array may exist within the same DMX
universe and may be responsive to an 8-bit intensity control word
received within its designated DMX slot. DMX 1010 may facilitate
remote device management (RDM) data handling, whereby full duplex
communications may be accommodated to, for example, define DMX slot
numbers and to correlate those DMX slot numbers to each of the
respective LED arrays.
[0085] Firmware executed by CPU 1018 may reside, for example,
within memory (e.g., flash memory), which may be local to CPU 1018
or remotely located with respect to CPU 1018. Firmware may, for
example, be changed or updated (e.g., boot loaded) via universal
serial bus (USB) 1012 (e.g., USB port 906 of FIG. 9). Such firmware
may control, for example, power management to the LED arrays as
provided by converters 1006-1008. In one embodiment, for example,
firmware executed by CPU 1018 may operate DC-DC converters
1006-1008 according to a fixed-frequency, constant current topology
that may select a minimum and a maximum current to be conducted by
each LED array through analog control. Furthermore, firmware
executed by CPU 1018 may operate DC-DC converters 1006-1008 (e.g.,
via pulse width modulated (PWM) control signals) to select any
number (e.g., 255) of intensity levels that may be generated by
each LED array at any current setting. In one example, current
magnitudes between 1% and 25% of the maximum current magnitude may
be PWM modulated so as to provide precision dimming at the lowest
levels of dimming (e.g., 255 levels of dimming may be implemented
via PWM modulation to achieve approximately 0.1% dimming
granularity between 1% and 25% of maximum current).
[0086] Firmware executed by CPU 1018 may, for example, receive
telemetry data (e.g., thermal data via temperature sensors 1016)
relative to, for example, the operating temperature of the
horticulture light (e.g., horticulture light 900 of FIG. 9). In
response, CPU 1018 may issue fan control signals (e.g., fan RPM
control signals) to fan 1014 so as to maintain horticulture light
900 within a specified temperature range. In addition, CPU 1018 may
limit the maximum current conducted by each LED array as discussed
above to maintain the operating temperature of horticulture light
900 below a maximum temperature range. For example, if the maximum
temperature range is exceeded by horticulture light 900, CPU 1018
may first increase the speed at which one or more fans 1014 may be
operating, thereby providing increased air flow to horticulture
light 900 in an effort to lower the operating temperature of
horticulture light 900 below its maximum operating temperature. If
the operating temperature is not reduced below the maximum
temperature range, then CPU 1018 may decrease the magnitude of
current conducted by each LED array in a linear rollback fashion
until the operating temperature is reduced below the maximum
temperature range.
[0087] As discussed above, firmware received via USB 1012 may be
used to control certain parameters of operation of horticulture
light 900 via a computer (not shown) that may be communicating with
USB 1012. For example, any number of DC-DC converters 1006-1008 may
be activated depending upon the number of LED arrays or channels
that may exist within horticulture light 900. For example, if eight
DC-DC converters exist within power supply 904, but only four LED
arrays or channels exist within a particular horticulture light,
then half of the DC-DC converters may be activated for operation
via firmware loaded via USB 1012 while the other half remain in a
deactivated state. In operation, each activated DC-DC converter may
receive a unique DMX address, such that DMX control words may be
correctly addressed to the corresponding DC-DC converter to
correctly control the intensity of the associated LED array.
[0088] In addition, firmware loaded via USB 1012 may be used to
select the temperature trigger value, such that either fan RPM may
be increased or LED array current drive may be decreased (as
discussed above) once the temperature trigger value (e.g., as
detected by temperature sensors 1016) is exceeded. Dim control may
also be selected via firmware loaded via USB 1012 to, for example,
select the rate at which the LED array(s) may be dimmed. For
example, each DMX control word (e.g., 256 control words per DMX
slot total) may correspond to a particular LED array intensity as
may be controlled by a corresponding PWM signal as generated by CPU
1018. User controllable dimming as defined by firmware loaded via
USB 1012 may, for example, be used to select the rate at which such
intensity variation occurs.
[0089] Turning to FIG. 11, a schematic diagram of lighting system
1100 is illustrated, which may include AC/DC converter 1102 (e.g.,
power supply 904 of FIG. 9), which may include one or more constant
current and/or constant voltage DC output stages (e.g., DC stages
1110, 1112 and/or 1140) and an auxiliary low voltage output (e.g.,
5 VDC not shown) with which components (e.g., processor 1104,
wireless node 1106 and wired node 1108 of lighting system 1100) may
derive their operational power. Any one or more of DC output stages
1110, 1112 and 1140 may provide power via any one or more
switched-mode conversion techniques (e.g., buck, boost, buck/boost
or flyback).
[0090] AC/DC converter 1102 may be configured to provide sufficient
power to, for example, vary the intensity of the one or more arrays
of LEDs contained within one or more horticulture lights (e.g., one
or more horticulture lights as exemplified in FIG. 9). It should be
noted that while only two LED arrays 1122 and 1124 are exemplified,
any number of LED arrays 1138 and associated bias control circuitry
may be accommodated by any number of DC stages within AC/DC
converter 1102. Furthermore, each LED array 1122 and 1124 may
include virtually any number (e.g., one or more) of LEDs 1144 and
1146, respectively.
[0091] As discussed in more detail below, the magnitude of DC
voltage available from any one DC stage 1110, 1112 or 1140 may be
adjusted as needed (e.g., via control 1148 from processor 1104) to
be substantially equal to the combined forward voltage of any one
associated LED string 1122, 1124 or 1138. In one embodiment, for
example, processor 1104 may empirically deduce the magnitude of
forward voltage required to forward bias each LED in each string
LED string 1122, 1124 and/or 1138. Once the magnitude of forward
voltage needed to forward bias each LED in each LED string 1122,
1124 and/or 1138 is known, processor 1104 may then command one or
more associated DC stages 1110, 1112 and/or 1140 (e.g., via control
1148) to the determined magnitude of forward voltage so that each
LED string may be operated as efficiently as possible. In alternate
embodiments, DC stages 1110, 1112 and/or 1140 may automatically
determine the magnitude of forward voltage needed to forward bias
each LED in each LED string 1122, 1124 and/or 1138 and may
communicate that voltage to processor 1104 (e.g., via control
1148).
[0092] In one embodiment, each LED array may be configured to
operate in accordance with one or more bias topologies. As per one
example, LED array 1122 and 1124 may be configured in parallel to
operate using a single voltage rail (e.g., a single voltage rail
generated by one of DC stages 1110, 1112 or 1140) such that
switches 1118 and/or 1120 may be configured as shown (e.g., via
control 1148 from processor 1104) to produce a forward voltage
across each LED array and a forward current through each LED array
as may be modulated by a power switch (e.g., field effect
transistors (FETs) 1150 and/or 1152) via control signals 1154
and/or 1156, respectively, as may be appropriately level shifted by
level shifters 1180 and 1182, respectively, whereby the current
conducted by each LED array may be stabilized via ballast elements
(e.g., resistors 1126 and 1128). Other power switching elements,
such as insulated gate bipolar transistors (IGBTs) or vertical
MOSFETs, may be used instead of FETs 1150 and 1152 as well.
[0093] As per another example, each LED array may be configured in
parallel to operate using a single voltage rail (e.g., a single
voltage rail generated by DC stage 1110 or DC stage 1112) whereby
switches 1118 and 1120 may be configured in the opposite
configuration as shown to produce a forward voltage across each LED
array and a forward current through each LED array as may be
modulated by a power switch (e.g., FETs 1150 and 1152) via control
signals 1154 and/or 1156, respectively, as may be appropriately
level shifted by level shifters 1180 and 1182, respectively,
whereby the average current conducted by each LED array may be
stabilized via a current stabilization network (e.g., inductor
1130/diode 1132 and inductor 1134/diode 1136, respectively).
[0094] Still other examples include configurations whereby each LED
array (e.g., LED array 1122 and 1124) may be operated independently
using a dedicated DC stage (e.g., DC stage 1112 and DC stage 1110,
respectively) in either of a constant voltage or constant current
configuration using either ballast or inductor-based current
stabilization techniques as may be selected by switches 1118 and
1120.
[0095] As discussed in more detail below, wired node 1108 may
include any wired interface (e.g., DMX, I2C, Ethernet, USB, DALI,
etc.) that may be used to configure lighting system 1100 (e.g., via
processor 1104) for operation and/or allow processor 1104 to
communicate the status and operational capability of lighting
system 1100 to wired network 1158 (e.g., BACnet-enabled wired
network 1158). Similarly, wireless node 1106 may include any
wireless interface (e.g., Wi-Fi, thread-based mesh, Bluetooth,
ZigBee, etc.) that may similarly be used to configure lighting
system 1100 (e.g., via processor 1104) for operation and/or allow
processor 1104 to communicate the status and operational capability
of lighting system 1100 to wireless network 1160 (e.g.,
BACnet-enabled wireless network 1160).
[0096] As discussed above, processor 1104 may be configured to
deduce the number of LED strings that may be under its control as
well as the number of LEDs in each LED string. Such deduction, for
example, may occur each time lighting system 1100 is provisioned
with LEDs, either at initial deployment or after reconfiguration.
Processor 1104 may then configure the operation of AC/DC converter
1102 for optimal performance in response to the number of LED
strings found and/or the number of LEDs in each LED string
subsequent to such deduction. Accordingly, the number of LED
strings and the number of LEDs in each LED string contained within
lighting system 1100 may not necessarily be fixed at initial
deployment or after each reconfiguration, but rather may be dynamic
such that processor 1104 may intelligently determine the lighting
capability of lighting system 1100 (e.g., the number of LED strings
and the number of LEDs in each LED string after initial deployment
and/or after each reconfiguration) and may, therefore,
intelligently select the most efficient mode of operation of each
DC stage (e.g., constant current, constant voltage or a mixture of
both), the most efficient magnitude of voltage and/or current to be
generated by each DC stage and may also intelligently select the
most efficient current stabilization mode for each LED string
(e.g., ballast or inductor-based current stabilization).
[0097] It should be noted that the mode of operation of DC stages
1110, 1112 and 1140 may be programmable (e.g., via control 1148 of
processor 1104) to either a constant-voltage or a constant-current
mode of operation. Conversely, the mode of operation of DC stages
1110, 1112 and 1140 may be fixed such that a mixture of both
constant-voltage and constant-current DC stages may exist within
AC/DC converter 1102 and may be individually selected for operation
(e.g., via control 1148 of processor 1104) and individually
connected to respective LED strings 1122, 1124 and/or 1138 via a
multiplexer (not shown) within AC/DC converter 1102.
[0098] In alternate embodiments, each DC stage of AC/DC converter
1102 may be paired with either a ballast-based current
stabilization network or an inductor-based current stabilization
network, such that switches 1118 and 1120 may no longer be
necessary. In addition, the operational mode of each DC stage
(e.g., constant-current or constant-voltage) may be predetermined,
such that upon configuration of lighting system 1100, LED strings
1122, 1124 and/or 1138 may be statically paired with a
ballast-based current stabilization network, an inductor-based
current stabilization network, or both, and each pairing may
include constant-voltage and/or constant-current topologies.
[0099] Turning to FIG. 12, flow diagrams are exemplified whereby
processor 1104 may first discover the number of LED strings
initially provisioned and/or reconfigured within lighting system
1100. Next, processor 1104 may then configure the bias and
stabilization networks of lighting system 1100 that may be
necessary for the most efficient mode of operation of each detected
LED string.
[0100] In step 1202, for example, processor 1104 may first select a
continuity mode, whereby AC/DC converter 1102 may be selected to
perform a continuity test to determine the number of LED strings
that may exist within lighting system 1100. Initially, a first DC
stage of AC/DC converter 1102 (e.g., DC stage 1112) may be
configured by processor 1104 via control 1148 to provide a maximum
output voltage (e.g., 250 VDC) as in step 1204, which may then be
applied to a first LED string (e.g., LED string 1122 in a
current-limited fashion). In one embodiment, for example, processor
1104 may select switch 1118 to the position shown via control 1148
and FET 1150 may be momentarily rendered conductive by processor
1104 via control 1154 (e.g., as in step 1206). In response, a
current may or may not be conducted by resistor 1126, as may be
sensed by current sensor 1162 of processor 1104, to determine
whether or not LED string 1122 exists within lighting system 1100.
A voltage developed across resistor 1126, for example, may lead to
the determination that a particular magnitude of current is being
conducted by LED string 1122, which may then lead processor 1104 to
deduce that LED string 1122 exists within lighting system 1100.
Steps 1202-1206 may then be repeated as above (e.g., with the same
DC stage or a different DC stage within AC/DC converter 1102) to
determine the number of LED strings that may or may not exist
within lighting system 1100, the result may then be logged as in
step 1208.
[0101] For the one or more LED strings that may be detected through
execution of steps 1202-1208 by processor 1104, a substantially
minimum magnitude of forward voltage may then be empirically
determined such that each LED string may be operated at maximum
efficiency using the determined minimum magnitude of forward
voltage. For example, processor 1104 may first select a continuity
mode (as in step 1210), whereby AC/DC converter 1102 may be
selected to perform a continuity test to determine the forward
voltage required to illuminate all of the LEDs that may exist
within a previously detected LED string. A first DC stage of AC/DC
converter 1102 (e.g., DC stage 1112) that may correspond to the
first detected LED string may first be configured by processor 1104
via control 1148 to provide a maximum output voltage (e.g., 250
VDC) as in step 1212, which may then be applied to the first
detected LED string (e.g., LED string 1122 in a current-limited
fashion) as discussed above, for example, in relation to step
1206.
[0102] In step 1214, the applied voltage may be modulated (e.g.,
decreased from 250 VDC) by processor 1104 via control 1148 in
coarse voltage steps (e.g., 10V steps) until current stops flowing
(e.g., as detected by current sense 1162 as the applied voltage is
decreased from 250 VDC). The coarse voltage obtained in step 1214
may then be logged by processor 1104 as the minimum coarse voltage
magnitude required to illuminate the LED string.
[0103] In step 1216, the DC stage may be programmed to the minimum
coarse voltage from step 1214 increased by one coarse voltage step
and then modulated (e.g., decreased) by processor 1104 via control
1148 in medium voltage steps (e.g., 1V steps) until current stops
flowing (e.g., as detected by current sense 1162). The medium
voltage obtained in step 1216 may then be logged by processor 1104
as the minimum medium voltage magnitude required to illuminate the
LED string.
[0104] In step 1218, the DC stage may be programmed to the sum of
the minimum coarse voltage from step 1214 and the minimum medium
voltage from step 1216 increased by one medium voltage step and
then modulated (e.g., decreased) by processor 1104 via control 1148
in fine voltage steps (e.g., 0.1V steps) until current stops
flowing (e.g., as detected by current sense 1162). The voltage may
then be increased in fine voltage steps (e.g., 0.1 VDC steps) until
the current begins to flow again. The fine voltage obtained in step
1218 may then be logged by processor 1104 as the minimum fine
voltage magnitude required to illuminate the LED string.
[0105] Once steps 1214-1218 have been completed, the minimum
forward voltage required to most efficiently illuminate the LED
string may have been determined within a minimum voltage resolution
(e.g., 0.1 VDC). For example, if the LED string under test contains
72 LEDs where each LED exhibits a forward voltage of 3.1 volts and
assuming that the on-resistance of FET 1150 and the resistance of
resistor 1126 adds an additional overhead voltage (e.g., 0.5 VDC)
to the magnitude of forward voltage required to illuminate LED
string 1122, then a minimum forward voltage of approximately
72*3.1+0.5=223.7 VDC (e.g., constituting a coarse voltage magnitude
of 220 VDC, a medium voltage magnitude of 3 VDC and a fine voltage
magnitude of 0.7 VDC) would be required to illuminate the LED
string under test. In such an instance, the first DC stage of AC/DC
converter 1102 (e.g., DC stage 1112) corresponding to the first
detected LED string of lighting system 1100 may be programmed by
processor 1104 via control 1148 to provide approximately 223.7 VDC
(perhaps rounding up to 225-230 volts for increased headroom),
instead of the maximum output voltage (e.g., 250 VDC), such that
the first detected LED string of lighting system 1100 may be
operated at the most efficient voltage rail possible (e.g.,
substantially equal to the sum of forward voltages (V.sub.f) of all
LEDs in the LED string plus the FET, current sense and
miscellaneous voltage overhead) and the current magnitude
corresponding to such voltage may be measured (e.g., via current
sense 1162) and logged by processor 1104 (e.g., as in step 1220).
It should be noted that reduced resolution may be obtained when
determining the minimum forward voltage required to most
efficiently illuminate the LED string by simply eliminating step
1218 or steps 1218 and 1216.
[0106] In an alternate embodiment (e.g., as in step 1224), the
applied voltage may be modulated (e.g., increased from 0 VDC) by
processor 1104 via control 1148 in coarse voltage steps (e.g., 10V
steps) until current begins to flow (e.g., as detected by current
sense 1162 as the applied voltage is increased from 0 VDC). The
coarse voltage obtained in step 1224 may then be decreased by one
coarse voltage step and then logged by processor 1104 as the
minimum coarse voltage magnitude required to illuminate the LED
string.
[0107] In step 1226, the DC stage may be programmed to the minimum
coarse voltage from step 1224 and then modulated (e.g., increased)
by processor 1104 via control 1148 in medium voltage steps (e.g.,
1V steps) until current begins to flow (e.g., as detected by
current sense 1162). The medium voltage obtained in step 1226 may
be decreased by one medium voltage step and then logged by
processor 1104 as the minimum medium voltage magnitude required to
illuminate the LED string.
[0108] In step 1228, the DC stage may be programmed to the sum of
the minimum coarse voltage from step 1224 and the minimum medium
voltage from step 1226 and then modulated (e.g., increased) by
processor 1104 via control 1148 in fine voltage steps (e.g., 0.1V
steps) until current begins to flow (e.g., as detected by current
sense 1162). The fine voltage obtained in step 1228 may then be
logged by processor 1104 as the minimum fine voltage magnitude
required to illuminate the LED string. Once steps 1224-1228 have
been completed, the minimum forward voltage required to most
efficiently illuminate the LED string may have been determined
within a minimum voltage resolution (e.g., 0.1 VDC) similarly as
discussed above in relation to steps 1214 to 1218 and the current
magnitude corresponding to such voltage may be measured (e.g., via
current sense 1162) and logged by processor 1104 (e.g., as in step
1220). It should be noted that reduced resolution may be obtained
when determining the minimum forward voltage required to most
efficiently illuminate the LED string by simply eliminating step
1228 or steps 1228 and 1226.
[0109] In one embodiment, processor 1104 may determine which
current stabilization mode to utilize depending upon the results of
steps 1210-1220 or steps 1210-1212, steps 1224-1228 and step 1220.
For example in step 1230, processor 1104 may compare the optimal
forward voltage for each detected LED string. In step 1234,
comparison of the optimal forward voltage deduced for each detected
LED string may lead to a determination that each optimal forward
voltage may be approximately equal and in such an instance, a
ballast-based stabilization technique may be selected as in step
1236, whereby each LED string may be operated from the same DC
stage of AC/DC converter 1102 and the current in each LED string
may be appropriately stabilized by its associated ballast resistor
and modulated (e.g., increased or decreased on average over time)
by analog control and/or appropriate control of the duty cycle of
each power switch associated with each LED string (e.g., FET
1150/duty cycle control 1154 for LED string 1122 and FET 1152/duty
cycle control 1156 for LED string 1124).
[0110] If, on the other hand, the deduced optimal forward voltages
for each detected LED string are not substantially equal,
inductor-based current stabilization may instead be selected (e.g.,
as in step 1238), whereby each LED string may be operated from
independent DC stages of AC/DC converter 1102 (e.g., constant
current DC stages each set at the optimal forward voltage
associated with each LED string) and the current in each LED string
may be appropriately stabilized by its associated inductor/diode
pair and modulated (e.g., increased or decreased on average over
time) by analog control and/or appropriate control of the duty
cycle of each power switch associated with each LED string (e.g.,
FET 1150/duty cycle control 1154 for LED string 1122 and FET
1152/duty cycle control 1156 for LED string 1124).
[0111] It should be noted that the inductor (e.g., inductor 1130 or
inductor 1134) of an inductor-based current stabilization network
may add an additional forward voltage component to the minimum
voltage required to operate an LED string. However, since the
voltage magnitude of each DC stage of AC/DC converter 1102 may be
optimally controlled (e.g., minimized), the magnitude of inductance
required by each inductor may be minimized as well (thereby
minimizing the physical size of the inductor), since the required
inductance magnitude is directly proportional to the voltage
developed across the inductor.
[0112] In one embodiment, a capacitor (e.g., capacitor 1168 and
1170) may be optionally placed across LED strings 1122 and 1124,
respectively, to a reference potential (e.g., ground) in either of
a ballast-based or inductor-based current stabilization mode of
operation. In a ballast-based mode of operation, for example, the
capacitor may be selected for a specific output voltage ripple to
maintain a substantially constant output voltage under load
transient conditions.
[0113] In an inductor-based current stabilization mode of
operation, on the other hand, capacitors (e.g., capacitors 1168 and
1170) may interact with inductors (e.g., inductors 1130 and 1134,
respectively) to provide AC current filtering, thereby allowing the
capacitor to control the ripple current to acceptable levels as
required by each LED string while at the same time decreasing the
required inductance magnitude, thereby further minimizing the
physical size and cost of the inductor. For example, by allowing
smaller inductance magnitudes to be selected, the resulting
increase in peak-to-peak current ripple may be conducted by each
capacitor (e.g., capacitor 1168 and 1170), thereby maintaining the
magnitude of current ripple experienced by each LED string (e.g.,
LED string 1122 and 1124, respectively) to within acceptable limits
(e.g., 10% of the DC forward current conducted by each LED
string).
[0114] It should also be noted that other algorithms may be used to
determine the current stabilization technique other than those
algorithms depicted in steps 1230-1238. For example, inductor-based
current stabilization may be selected by processor 1104 even though
the optimal forward voltage for each detected LED string may be
approximately equal and operated from the same or different DC
stages of AC/DC converter 1102. Conversely, ballast-based current
stabilization may be selected by processor 1104 even though the
optimal forward voltage for each detected LED string may be
substantially unequal and operated from the same or different DC
stages of AC/DC converter 1102.
[0115] Algorithms defining the operation of lighting system 1100
(e.g., algorithms described by the execution steps of FIG. 12) may,
for example, fully reside within processor 1104 (e.g., flash memory
that is local to processor 1104). Alternately, such algorithms may
fully reside within a network (e.g., wired network 1158 and/or
wireless network 1160) whereby execution instructions associated
with such algorithms may be received by processor 1104 via wired
node 1108 and/or wireless node 1106. Conversely, algorithms
defining the operation of lighting system 1100 (e.g., algorithms
described by the execution steps of FIG. 12) may be distributed to
partially reside within processor 1104 and partially reside within
a network (e.g., wired network 1158 and/or wireless network 1160)
whereby a portion of execution instructions may be received by
processor 1104 via wired node 1108 and/or wireless node 1106.
[0116] In operation, the status of lighting system 1100 may be
continuously monitored and such status may be relayed to wired
network 1158 and/or wireless network 1160 via wired node 1108
and/or wireless node 1106, respectively. As per one example,
processor 1104 may continuously monitor the current conducted by
each LED string (e.g., LED strings 1122, 1124 and/or 1138 as may be
measured by current sense 1162, 1164 and/or 1166, respectively) to
determine whether each LED string is operating in accordance with
the logged current magnitudes for each LED string (e.g., as logged
by step 1220 of FIG. 12). A detected fault (e.g., zero conducted
current) in one LED string, for example, may result in the
deactivation of at least the faulted LED string and perhaps the
remaining LED strings by causing the associated voltage and current
regulation devices (e.g., FETs 1150 and/or 1152) to remain
non-conductive (e.g., via control signals 1154 and 1156,
respectively). Such detected faults and subsequent actions taken by
processor 1104 may then be reported (e.g., via wired network 1158
and/or wireless network 1160) to allow maintenance personnel to
react to the reported fault (e.g., decommissioning of the faulted
lighting system and the subsequent commissioning of a replacement
lighting system).
[0117] In alternate embodiments, trends of each LED string may be
tracked to predict, for example, efficiency, maximum light output,
peak wavelength and spectral wavelength variations due to increased
junction temperature. Increased junction temperatures, for example,
may be related to a forward voltage decrease of a particular LED
string due to a reduction in the bandgap energy of the active
region of each LED in the LED string as well as a decrease in the
series resistance of each LED occurring at high temperatures.
Accordingly, for example, by tracking a reduced forward voltage of
a particular LED string over time, predictions may be made and
reported by processor 1104 (e.g., via wired network 1158 and/or
wireless network 1160) as to certain performance parameters of each
LED string so that maintenance personnel may respond
accordingly.
[0118] Turning to FIG. 13, an alternate embodiment of lighting
system 1300 is exemplified, such that the current stabilization
topologies may not be selectable and may instead be provided as
ballast-based current stabilization networks for each LED string
utilized within lighting system 1300. In addition, a single DC
stage 1340 may be utilized within AC/DC converter 1302, which may
provide a single-rail voltage magnitude in a constant-current mode
of operation to multiple LED strings connected in a parallel
configuration (e.g., LED strings 1322, 1324 and 1380).
[0119] Similarly as discussed above in relation to FIG. 11, wired
node 1308 may include any wired interface (e.g., DMX, I2C,
Ethernet, USB, DALI, etc.) that may be used to configure lighting
system 1300 (e.g., via processor 1304) for operation and/or allow
processor 1304 to communicate the status and operational capability
of lighting system 1300 to wired network 1358 (e.g., BACnet-enabled
wired network 1358). Similarly, wireless node 1306 may include any
wireless interface (e.g., Wi-Fi, thread-based mesh, Bluetooth,
ZigBee, etc.) that may similarly be used to configure lighting
system 1300 (e.g., via processor 1304) for operation and/or allow
processor 1304 to communicate the status and operational capability
of lighting system 1300 to wireless network 1360 (e.g.,
BACnet-enabled wireless network 1360).
[0120] The number of series-connected LEDs (e.g., one or more) in
each LED string (e.g., 1322, 1324 and 1380) may be selected based
upon the sum of forward voltage (V.sub.f) of each series-connected
LED, where the forward voltage of each LED string may be selected
to be substantially equal. In one embodiment, for example, an LED
string may be selected to contain about 45 to 50 (e.g., 46) LEDs
each having a V.sub.f between about 2.5V and 3.5V (e.g., 3V) for a
cumulative forward voltage of 46*3=138V for the LED string. In an
alternate embodiment, for example, an LED string may be selected to
contain about 60 to 75 (e.g., 69) LEDs each having a V.sub.f
between about 1.5V and 2.5V (e.g., 2V) for a cumulative forward
voltage of 69*2=138V for the LED string.
[0121] In alternate embodiments, each LED string may have the same
or a different number of LEDs, but due to differences in V.sub.f
for each LED type in each LED string, each LED string may exhibit a
forward voltage that is substantially equal to the forward voltage
of each of the other LED strings. Furthermore, while only three LED
strings are depicted, any number of LED strings (e.g., 4) may be
utilized. Still further, each of LED strings 1322, 1324 and 1380
may reside within a single lighting fixture or may reside within
multiple lighting fixtures.
[0122] Due to slight deviations in the V.sub.f for each LED of each
LED string (e.g., due to forward current deviations in each LED
string), the cumulative forward voltage for each LED string may not
necessarily conform to the calculations above, which may
necessitate the existence of ballast elements (e.g., resistor 1326,
1328 and 1382) such that the voltage magnitude at node 1386 may be
allowed to remain substantially equal under all load conditions for
each LED string. Furthermore, each ballast element may facilitate
current stabilization as well as current sense measurements by
processor 1304 as discussed in more detail below.
[0123] Processor 1304 may be configured to deduce the number of LED
strings that may be under its control as well as the forward
current requirements (e.g., minimum and maximum forward current) in
each LED string. Such deduction, for example, may occur each time
lighting system 1300 is provisioned with LEDs, either at initial
deployment or after reconfiguration.
[0124] Turning to FIG. 14, flow diagrams are exemplified whereby
processor 1304 may first discover the number of LED strings
initially provisioned and/or reconfigured within lighting system
1300. Next, processor 1304 may then configure the current
provisioning for each LED string of lighting system 1300.
[0125] In a first embodiment, processor 1304 may have control of
both the voltage and current magnitude output of DC stage 1340 via
control 1348. In such an instance, processor 1340 may configure DC
stage 1340 to its minimum voltage output (e.g., as in step 1402)
and its maximum current output (e.g., as in step 1404). Processor
1340 may then configure lighting system 1300 for a continuity check
(e.g., as in step 1406) whereby, for example, processor 1304 may
render one of LED strings 1322, 1380 and 1324 conductive by
transitioning one of power switches (e.g., FETs 1350, 1352 or 1386,
respectively), into a conductive state. In step 1408, the output
voltage magnitude of DC stage 1340 may be increased (e.g., as in
steps 1224 through 1228 of FIG. 12) until current is conducted
through the LED string under test (e.g., as may be detected by
current sense 1362, 1366 or 1364, respectively). Processor 1304 may
then decrease the current conducted by the LED string under test
via control 1348 by programming the current output of DC stage 1340
to decreasingly lower magnitudes (e.g., in 1 mA steps decreasing
from the maximum current set in step 1404) until current ceases to
flow (e.g., as in step 1410). In step 1412, for example, processor
1304 may then log the minimum voltage and current magnitudes as
measured by steps 1408 and 1410 into a memory location (e.g., as
located on-board processor 1304 and/or as may be located in memory
locations of wired network 1358 and/or wireless network 1360).
[0126] In an alternate embodiment, processor 1304 may program the
current magnitude output of DC stage 1340 via control 1348, but DC
stage 1340 may internally adjust the output voltage as required to
produce the programmed current magnitude output of DC stage 1348.
In such an instance, processor 1340 may configure DC stage 1340 to
its maximum current output (e.g., as in step 1414). Processor 1340
may then configure lighting system 1300 for a continuity check
(e.g., as in step 1416) whereby, for example, processor 1304 may
render one of LED strings 1322, 1380 and 1324 conductive by
transitioning one of power switches (e.g., FETs 1350, 1352 or 1386,
respectively), into a conductive state. The output voltage
magnitude of DC stage 1340 may then be internally increased (e.g.,
increased by circuitry located internal to DC stage 1340) until
current is conducted through the LED string under test (e.g., as
may be detected by current sense 1362, 1366 or 1364, respectively).
Processor 1304 may then decrease the current conducted by the LED
string under test via control 1348 by programming the current
output of DC stage 1340 to decreasingly lower magnitudes (e.g., in
1 mA steps decreasing from the maximum current set in step 1414)
until current ceases to flow (e.g., as in step 1418). In step 1420,
for example, processor 1304 may then log the minimum voltage (e.g.,
as may be reported by DC stage 1340 to processor 1304 via control
1348) and current magnitudes (e.g., minimum and maximum current
magnitudes) as measured by step 1418 into a memory location (e.g.,
local to processor 1304 and/or as may be located in memory
locations of wired network 1358 and/or wireless network 1360).
[0127] Once the initial configuration of each LED string is
complete and lighting system 1300 is operational, each subsystem of
lighting system 1300 may be monitored (e.g., as in step 1422) to,
for example, continuously determine the operational status of
lighting system 1300. For example, each LED string of lighting
system confirmed to be operational (e.g., as in steps 1402-1412 or
steps 1414-1420) may be continuously monitored (e.g., the forward
current of each LED string may be continuously monitored) for
normal operation. If the measured forward current substantially
equals the current magnitudes as logged in steps 1412 or 1420
taking into account any digital current modulation performed by
power switches (e.g., FETs 1350, 1352 and/or 1386), such as reduced
forward current through less than 100% duty cycle modulation of the
power switches, then normal status of lighting system 1300 may be
reported (e.g., as in step 1426). If, on the other hand, the
modulated forward current does not meet previously verified current
magnitudes, then abnormal status of lighting system 1300 may be
reported (e.g., as in step 1428) and reported to, for example,
wired network 1358 and/or wireless network 1360 to alert
maintenance personnel of the abnormal status.
[0128] Other operational aspects of lighting system 1300 may be
monitored as well. For example, temperature sensors and fans (e.g.,
temperature sensors 1016 and fans 1014 as exemplified in FIG. 10)
may be utilized by lighting system 1300 to ensure that, for
example, the temperature of each LED string is operating within
specification. If not, the abnormal temperature and/or fan
malfunction may be reported as in step 1428; otherwise, normal fan
and temperature status may be reported as in step 1426.
[0129] Processor 1304 may implement a hybrid dimming scheme,
whereby both digital modulation of LED string current (e.g., via
PWM control of the power switches) and analog modulation of LED
string bias current may be used to provide deep dimming control of
the LED string intensity while minimizing audible and radiated
noise. In step 1430, for example, the minimum and maximum current
magnitudes (e.g., as determined in steps 1414 and 1418) may be
accessed by processor 1304 to determine the full range of DC bias
current magnitudes (e.g., as produced by DC stage 1340) that may be
utilized to illuminate a particular LED string (e.g., LED string
1322) across a range of intensity. As per one example, the maximum
current for an LED string (e.g., LED string 1322) may be determined
to be equal to an upper current limit (e.g., 1.25 A as determined
in step 1414 so that LED string 1322 may produce full intensity),
whereas the minimum current for the LED string may be determined to
be equal to a percentage of the upper current limit (e.g., 30% of
1.25 A or 0.375 A).
[0130] In step 1432, processor 1304 may determine the range over
which analog control of the current magnitude may be used to select
a particular intensity of light emission from a particular LED
string. In one embodiment, for example, processor 1304 may
determine that for all current magnitudes conducted by an LED
string (e.g., LED string 1322) between a maximum current magnitude
and a minimum threshold current magnitude (e.g., 30% of the maximum
current magnitude), analog control (e.g., the bias current
magnitude provided by DC stage 1340 as commanded by control 1348)
may be used. That is to say for example, that for light intensities
produced by LED string 1322 between a maximum intensity and a lower
threshold intensity (e.g., 30% of maximum intensity), processor
1304 may command DC stage 1340 to the desired bias current
magnitude via control 1348 as required to produce the desired
intensity range (e.g., 1.25 A of bias current for maximum intensity
and 0.375 A of bias current for 30% intensity). Variation between
maximum intensity and the lower threshold intensity may be
accomplished through variation of the bias current generated by DC
stage 1340 via control 1348 from processor 1304 in programmable
steps (e.g., 1 mA steps).
[0131] In step 1434, processor 1304 may determine the range over
which digital control of the current magnitude may be used to
select a particular intensity (e.g., below the lower threshold
intensity) of light emission from a particular LED string. In one
embodiment, for example, processor 1304 may determine that for all
current magnitudes conducted by an LED string (e.g., LED string
1322) between the lower threshold intensity (e.g., 30% of maximum
intensity) and a minimum intensity (e.g., 1% of maximum intensity),
digital control (e.g., PWM modulation of FET 1350) may be used to
select any number (e.g., 256) of PWM duty cycle variations to
modulate the minimum bias current generated by DC 1340 between an
average bias current required to produce the lower threshold
intensity and an average bias current required to produce the
minimum intensity.
[0132] In step 1436, dimming may be adjusted through a combination
of both analog and digital controls. As per one example, analog
control of light intensities produced by an LED string (e.g., LED
string 1322) between a maximum intensity and a lower threshold
intensity (e.g., 30% of maximum intensity) may be accomplished via
appropriate control of DC stage 1340 via control 1348 to generate
bias current magnitudes required to produce intensities between the
maximum intensity (e.g., 1.25 A bias current magnitude) and the
lower threshold intensity (e.g., 0.375 A bias current magnitude) in
programmable current steps (e.g., 1 mA steps) for an intensity
control granularity substantially equal to, for example,
(0.001/(1.25-0.375))*100=0.1%. As per the same example, digital
control of light intensities produced by an LED string (e.g., LED
string 1322) between the lower threshold intensity (e.g., 30% of
maximum intensity) and a minimum intensity (e.g., 1% of maximum
intensity) may be accomplished via appropriate modulation of the
lower threshold bias current generated by DC stage 1340 via PWM
control 1354 to produce programmable light intensities below the
lower threshold intensity. In one embodiment, for example, 256 DMX
control values via wired node 1308 may be used to vary the
intensity between the lower threshold intensity (e.g., 30% of
maximum intensity) and the minimum intensity (e.g., 1% of maximum
intensity) with a control granularity substantially equal to
(30%-1%)/256=0.1%.
[0133] Through implementation of PWM control only over the lower
portion of the current control range (e.g., the lower 30% of the
current control range), fidelity may be improved within that range
by, for example, reducing conducted emissions, reducing radiated
emissions and reducing audible noise pollution. Furthermore, color
mixing control across all LED strings (e.g., LED strings 1322, 1380
and 1324) may be enhanced through the application of digital
dimming control beyond the limitations conventionally imposed by
analog dimming, which for example, may deteriorate when analog
dimming is attempted below a threshold dimming percentage (e.g.,
10% of maximum intensity). Furthermore, by limiting the digital
dimming control to lower levels of intensity (e.g., 1% to 30% of
maximum intensity), the frequency of the PWM control waveform may
be increased to frequencies (e.g., between about 150 kHz and 1 MHz)
that may be less prone to generate detectable flicker and shimmer
thereby further enhancing dimming fidelity.
[0134] In one embodiment, processor 1304 may determine that DC
stage 1340 may not provide a magnitude of current that may be
required by each of LED strings 1322, 1324 and 1380 operating at
100% intensity or lower. In such an instance, processor 1304 may
implement a current sharing algorithm whereby each of the LED
strings 1322, 1380 and 1324 may be operated at a percentage
intensity that may be accommodated by DC stage 1340. For example,
DC stage 1340 may only be capable of providing an upper limit of
current magnitude (e.g., 1.2 A) and in such and instance, processor
1304 may apportion a percentage of the upper limit current
magnitude to each of LED strings 1322, 1380 and 1324 as may be
necessary using analog control, digital control or a combination of
analog and digital control as discussed above.
[0135] It should be noted that any one LED string may be
apportioned 100% of the available current from DC stage 1340 using
the current sharing algorithm. Conversely, any number of LED
strings may share any portion of the available current from DC
stage 1340. As per one example, each LED string may equally share
in the available current, whereby the magnitude of current
apportioned to any one LED string may be calculated as the maximum
current available divided by the number of activated LED strings
(e.g., three activated LED strings may each receive 0.4 A of the
available 1.2 A from DC stage 1340) by any of an analog, digital or
combination of analog/digital current control algorithm as
discussed above.
[0136] In an alternate embodiment, for example, processor 1304 may
determine that DC stage 1340 may provide a magnitude of current
that may meet or exceed the requirement of any one or more LED
strings 1322, 1324 and 1380 operating at 100% intensity or lower.
In such an instance, processor 1304 may implement a current
provisioning algorithm whereby any one or more of the LED strings
1322, 1380 and 1324 may be operated at a commanded percentage
intensity using a combination of analog and/or digital current
control as discussed above.
[0137] As per one example, DC stage 1340 may be commanded to a
current magnitude of 1.2 A, but each of LED strings 1322, 1380 and
1324 may only require 0.4 A on average via appropriate PWM control
of their associated power switches (e.g., FETs 1350, 1352 and 1386,
respectively) to operate at their respective commanded intensity.
In such an instance, 1.2 A may be conducted instantaneously by any
one LED string 1322, 1380 and 1324 at a time (e.g., only one of LED
strings 1322, 1380 and 1324 may be conductive at any given time),
but through time division multiple access (TDMA) control, each LED
string may be operating at 33% duty cycle to receive only the
required 0.4 A on average to operate at its commanded intensity. It
should be noted that through analog and/or digital current control
and proper time division multiple access to such controlled
current, any one LED string may operate at any intensity (e.g.,
0-100%) at any given time (e.g., any one LED string may be
conductive to the mutual exclusion of all of the other LED string
conductivity states) to operate on average at the commanded
intensity.
[0138] Examples of such TDMA control are illustrated in FIGS. 15A,
15B and 15C. In FIG. 15A, for example, in any given TDMA period
1502, any LED string (e.g., any of LED strings 1322, 1380 and/or
1324 of FIG. 13) may be allocated a time slot (e.g., time slots
1504, 1506 and 1508, respectively) within which any one LED string
may receive any magnitude percentage (e.g., 0-100%) of any of an
analog and/or a digitally controlled current signal.
[0139] In time slot 1504, for example, processor 1304 may command
LED string 1322 to conduct a percentage (e.g., 100%) of the maximum
available current by causing a maximum magnitude of bias current
from a corresponding DC stage (e.g., DC stage 1340) to be conducted
by LED string 1322. In time slots 1506 and 1508, LED strings 1380
and 1324, respectively, may similarly be programmed to receive
analog and/or digitally controlled current signals so that a
percentage (e.g., 100%) of the maximum available current from DC
stage 1340 may be received by each of LED strings 1380 and 1324 in
their respective time slots.
[0140] It should be noted that since each of LED strings 1322, 1380
and 1324 receive a maximum bias current magnitude in each of
respective time slots 1504, 1506 and 1508 and since each of time
slots 1504, 1506 and 1508 are of equal time duration, the average
amount of current conducted by each of LED strings 1322, 1380 and
1324 over multiple time periods 1502 is substantially equal to
about 1/3 the maximum current available from DC stage 1340.
[0141] It should be further noted that current conducted by LED
strings 1322, 1380 and 1324 in each of time slots 1504, 1506 and
1508, respectively, may be modulated (e.g., pulse width modulated)
to further reduce the average amount of current conducted over
time. As discussed above, for example, any one of 256 duty cycle
selections may be made by processor 1304 such that the amount of
current conducted by each LED string 1322, 1380 and 1324 in each
time slot 1504, 1506 and 1508, respectively, may be further reduced
on average by the duty cycle selection of control signals 1354,
1342 and 1356, respectively.
[0142] Turning to FIG. 15B, in any given TDMA period 1510, any one
or more LED strings (e.g., any of LED strings 1322, 1380 and/or
1324 of FIG. 13) may be denied a time slot (e.g., time slot 1514
does not provide for an active current conduction state within
which LED string 1380 may receive current). As per an example, only
two time slots (e.g., time slots 1512 and 1516) may be allocated
within which any two LED strings (e.g., LED strings 1322 and 1324,
respectively) may receive any of an analog and/or a digitally
controlled current signal.
[0143] In time slot 1512, for example, processor 1304 may command
LED string 1322 to conduct a percentage (e.g., 100%) of the maximum
available current by causing a maximum magnitude of bias current
from a corresponding DC stage (e.g., DC stage 1340) to be conducted
by LED string 1322. In time slot 1516, LED string 1324 may
similarly be programmed to receive an analog and/or digitally
controlled current signal so that a percentage (e.g., 100%) of the
maximum available current from DC stage 1340 may be received by LED
string 1324.
[0144] It should be noted that since each of LED strings 1322 and
1324 receive a maximum bias current magnitude in each of respective
time slots 1512 and 1516 and since time slot 1512 is twice the
duration of time slot 1516, the average amount of current conducted
by LED string 1322 over multiple time periods 1510 is substantially
equal to about 2/3 the maximum current available from DC stage 1340
and the average amount of current conducted by LED string 1324 over
multiple time periods 1516 is substantially equal to about 1/3 the
maximum current available from DC stage 1340.
[0145] It should be further noted that current conducted by LED
strings 1322 and 1324 in each of time slots 1512 and 1516,
respectively, may be modulated (e.g., pulse width modulated) to
further reduce the average amount of current conducted over time.
As discussed above, for example, any one of 256 duty cycle
selections may be made by processor 1304 such that the amount of
current conducted by each LED string 1322 and 1324 in each time
slot 1512 and 1516, respectively, may be further reduced on average
by the duty cycle selection of control signals 1354 and 1356,
respectively.
[0146] Turning to FIG. 15C, in any given TDMA period 1520, any one
or more LED strings (e.g., any of LED strings 1322, 1380 and/or
1324 of FIG. 13) may be denied a time slot (e.g., time slots 1524
and 1526 do not provide for an active current conduction state
within which LED string 1380 and 1324 may receive current). As per
an example, only one time slot (e.g., time slot 1522) may be
allocated within which an LED string (e.g., LED string 1322) may
receive any of an analog and/or a digitally controlled current
signal.
[0147] In time slot 1522, for example, processor 1304 may command
LED string 1322 to conduct a percentage (e.g., 100%) of the maximum
available current by causing a maximum magnitude of bias current
from a corresponding DC stage (e.g., DC stage 1340) to be conducted
by LED string 1322. It should be noted that since LED string 1322
receives a maximum bias current magnitude in time slot 1522 and
since time slot 1522 is the same duration as time period 1520, the
average amount of current conducted by LED string 1322 over
multiple time periods 1520 is substantially equal to all of the
maximum current available from DC stage 1340.
[0148] It should be further noted that current conducted by LED
string 1322 in time slot 1522 may be modulated (e.g., pulse width
modulated) to further reduce the average amount of current
conducted over time. As discussed above, for example, any one of
256 duty cycle selections may be made by processor 1304 such that
the amount of current conducted by LED string 1322 in time slot
1522 may be further reduced on average by the duty cycle selection
of control signal 1354.
[0149] Turning to FIG. 16, indoor horticultural system 1600 is
exemplified, which may include a horticultural lighting system
(e.g., horticultural lighting fixtures 1604-1612 as exemplified by
the lighting fixtures of FIGS. 1, 9, 10, 11 and/or 13) each
implementing any number of wired control topologies (e.g., DMX,
I2C, Ethernet, USB, DALI, etc.) and/or any number of wireless
control topologies (e.g., Wi-Fi, thread-based mesh, Bluetooth,
ZigBee, etc.) that may be utilized to control, for example,
intensity, color temperature and/or color spectrum as well as any
other attribute of light that may be emitted by the horticultural
lighting fixtures.
[0150] Indoor horticultural system 1600 may also contain any number
of area sensors (e.g., sensors 1674-1677), which may be used to
detect, for example, occupancy, room temperature, humidity, etc.
and may provide an associated status signal (e.g., thread-based
mesh network status signal) that may be indicative of the sensors'
status (e.g., temperature reading, humidity level, motion
detection, etc.). Plant-based sensors may also be paired with each
plant of the grow bed (e.g., plant/sensor pairs 1630/1631 through
1646/1647) so that parameters (e.g., temperature, humidity, light
intensity, moisture, pH, canopy height, etc.) may be sensed for
each plant, or group of plants, and reported at regular time
intervals via an associated status signal (e.g., thread-based mesh
network status signal). It should be noted that each sensor of FIG.
16 may include a computing module (not shown), which may be used to
administer communications, conduct sensor measurements and sensor
measurement/status reporting and whose operational power may be
derived from a solar cell (not shown) and/or internal battery (not
shown).
[0151] Indoor horticultural system 1600 may also include nutrient
distribution 1654 that may provide the nutrients and water that may
be required by each plant of each grow bed(s). Nutrient
distribution may be implemented as a closed-loop system, whereby
nutrients and water may be extracted from their respective storage
containers (not shown) and mixed to proper proportions. Once
properly mixed, the nutrient solution may be pumped (e.g., at a
monitored flow rate) into hydroponic flood benches and/or trough
benches (not shown) to be delivered for consumption by each plant
of each grow bed that may be contained within indoor horticultural
system 1600. Any unused nutrient solution retrieved from nutrient
distribution 1654 may be collected, filtered and prepared to be
recirculated to the hydroponic flood benches and/or trough benches.
Nutrient distribution 1654 may also include sensors (not shown),
which may be used to test the collected nutrient flow for any
deficiencies and subsequently reported as additional status
information which may then be used to adjust (e.g., automatically
via master controller 1688) the nutrient/water content for
optimized growth of the associated plants in the associated grow
beds.
[0152] As shown, indoor horticultural system 1600 may include
lighting systems that may be included within any facility that may
exhibit structural components such as walls (not shown) and
ceilings (e.g., ceiling 1696). Each of the lighting fixtures,
sensors and associated control elements of indoor horticultural
system 1600, therefore, may be deployed within such structural
components of the facility as a fixed or permanent asset.
[0153] For example, light controller 1692 may be deployed within
ceiling 1696 as a fixed asset within indoor horticultural system
1600. Light controller 1692 may, for example, include a DMX master
controller (not shown) that may receive wireless commands (e.g.,
from master controller 1688) and in response, may control the
desired intensity of each horticultural light fixture 1604-1612
(e.g., each LED array of each horticultural light fixture
1604-1612) accordingly. In one embodiment, for example, each LED
array of each horticultural light fixture 1604-1612 may exist
within the same DMX universe and may be responsive to an 8-bit
intensity control word received within its uniquely designated DMX
slot from light controller 1692.
[0154] Other fixed assets within indoor horticultural system 1600
may include, for example, horticultural lighting fixtures 1604-1612
and their associated height control mechanisms (e.g., winch
mechanisms that may control the length of cable assemblies 1602).
Cable assemblies 1602, for example, may be controlled by a height
controller (e.g., height controller 1652) that may be used to raise
and lower horticultural lighting fixtures 1604-1612 in accordance
with the canopy height of the associated plants (e.g., as may be
reported by plant/sensor pairs 1630/1631 to 1646/1647 to master
controller 1688). For example, as the plants grow taller, it may be
necessary to raise the associated horticultural lighting fixtures
1604-1612 in relation to the extended height of the associated
plant canopies.
[0155] In one embodiment, each of the horticultural lighting
fixtures and associated sensors/controllers of indoor horticultural
system 1600 may be interconnected wirelessly (e.g., via a
thread-based mesh network). Accordingly, for example, indoor
horticultural system 1600 may be implemented as a wireless personal
area network (WPAN) utilizing a physical radio layer (e.g., as
defined by the IEEE 802.15.4 communication standard). As such, the
thread-based mesh network may utilize an encapsulation and header
compression mechanism (e.g., 6LoWPAN) so as to allow data packets
(e.g., IPv6 data packets) to be sent and received over the physical
radio layer. Messaging between each device within indoor
horticultural system 1600 may be implemented using a messaging
protocol (e.g., user datagram protocol (UDP)), which may be
preferred over an alternative protocol such as the transmission
control protocol (TCP).
[0156] In addition, each device may use an application layer
protocol for delivery of the UDP data packets to each device. Such
application layer protocols may include the Constrained Application
Protocol (CoAP), Message Queue Telemetry Transport (MQTT) or the
Extensible Messaging and Presence Protocol (XMPP) within the
thread-based mesh network as contrasted with the Hypertext
Transport Protocol (HTTP) as may be used, for example, within
Internet 1684. CoAP, for example, may be more conducive for use by
the thread-based mesh network, rather than HTTP, due to the smaller
packet header size required by CoAP, which may then yield smaller
overall packet sizes required by the components of indoor
horticultural system 1600 interconnected by the thread-based mesh
network.
[0157] In operation, some components (e.g., horticultural lighting
fixtures 1604-1612) interconnected by the thread-based mesh network
of FIG. 16 may be connected to an alternating current (AC) source
that may be used throughout the facility for use with other
components requiring AC power for operation, such as heating,
ventilation and air conditioning (HVAC) systems, air circulators,
humidifiers/dehumidifiers and CO.sub.2 dispensing systems 1694.
Furthermore, operational power derived from the AC source may be
further controlled (e.g., via relays) so as to be compliant with,
for example, the Energy Star.RTM. standard for energy efficiency as
promulgated jointly by the Environmental Protection Agency (EPA)
and the Department of Energy (DOE).
[0158] In one embodiment, device 1686 may be used to manually
operate indoor horticultural system 1600 wirelessly (e.g., through
the use of a thread-based mesh network). For example, device 1686
may send a control signal to light controller 1692 via the
thread-based mesh network to cause one or more horticultural
lighting fixtures 1604-1612 to illuminate in accordance with a
particular light prescription (e.g., intensity, color temperature
and/or color spectrum) as may be contained within database 1690.
Alternately, device 1686 may send a control signal to height
controller 1652 via the thread-based mesh network so as to cause
the height between one or more horticultural lighting fixtures
1604-1612 to change with respect to a height of the one or more
plant canopies contained within indoor horticultural system 1600.
In alternate embodiments, master controller 1688 may completely
automate the operation of indoor horticultural system 1600 by
accessing grow recipes from database 1690, which may then be used
to control the lighting in a specific manner to produce a specific
effect (e.g., modify the intensity, color temperature and/or color
spectrum of each of horticultural lights 1604-1612 to simulate a
rising sun, a midday sun and a setting sun in direction 1698 from
east to west).
[0159] Indoor horticultural system 1600 may, for example, be
sensitive to control signals as may be provided by controlling
entities (e.g., external BACnet network 1682) that may exist
external to the thread-based mesh network of FIG. 16. As per an
example, one or more entities within indoor horticultural system
1600 may be BACnet enabled, which may allow communication with a
BACnet enabled border router (e.g., master controller 1688). In
such an instance, control signals bound for indoor horticultural
system 1600 may be transmitted by external BACnet network 1682 via
Internet 1684 and propagated throughout indoor horticultural system
1600 via master controller 1688. Conversely, status information
related to indoor horticultural system 1600 may be gathered by
master controller 1688 and may then be disseminated to external
BACnet network 1682 via Internet 1684. Accordingly, many grow
facilities as exemplified by FIG. 16 may exist and may be
geographically dispersed and remotely controlled via external
BACnet network 1682.
[0160] Each of horticultural light fixtures 1606-1612 may, for
example, generate relatively wide beam patterns (e.g., beam
patterns 1615-1621, respectively) that may be produced by a
particular LED/lens combination (e.g., the LED/lens combination as
discussed above in relation to FIG. 6), which may produce maximum
intensity at the edges of the beam pattern. Accordingly, for
example, the resulting light distribution (e.g., the light
distribution of FIG. 7A) may produce a uniform illuminance onto a
plant canopy directly below each of horticultural light fixtures
1606-1612 (e.g., uniform illuminance distributions 1622-1628) while
producing relatively equal intensities on adjacent plants. In
alternate embodiments, illuminance distributions 1622-1628 may
increase as the angle of incidence increases with respect to the
optical axis of illuminance distributions 1622-1628.
[0161] As an example, horticultural light 1606 may produce a
uniform illuminance, or an increasing illuminance from centerbeam
outward (e.g., illuminance 1622) onto a plane that may be defined
by the canopy of plant 1632 due to the increasing intensity of
light at increasing angles with respect to the optical axis of
horticultural light 1606. Since the intensity of light generated by
horticultural light 1606 is greatest at the edges of light
distribution 1615, plants 1630 and 1634 may receive a substantially
equal intensity of light as received by plant 1632 from
horticultural light 1606 owing to the effects of the inverse square
law as discussed above. In such an instance, each plant may not
only receive a uniform illuminance, or an increasing illuminance
from centerbeam outward, onto its canopy by an associated
horticultural light fixture, but may also receive substantially
equal intensities of light on the sides of the plant by adjacent
horticultural light fixtures, thereby more correctly simulating
sunlight, since light is being received by each plant from multiple
angles. It should be noted that horticultural light fixtures
1604-1612 may be arranged not only as a linear-array, but as a
two-dimensional array (e.g., arranged along rows and columns) such
that each plant may receive light from its associated horticultural
light fixture and adjacent horticultural light fixtures at all
angles formed from a 360-degree light distribution (e.g., each
plant may receive a substantially uniform cone of light from its
associated and adjacent horticultural light fixtures).
[0162] Plants on the edge of each grow bed (e.g., plants 1630 and
1646) may receive light from their associated horticultural
lighting fixtures configured at angles that are different than the
angles of horticultural lighting fixtures 1606-1612. For example,
horticultural lighting fixtures 1604 and 1605 may be angled (e.g.,
via height controller 1652 and associated cable assemblies 1602) as
shown to direct light onto their associated plants (e.g., plants
1630 and 1646, respectively) as well as the adjacent plants (e.g.,
plants 1632 and 1644, respectively). In addition, each of
horticultural light fixtures 1604-1605 may, for example, generate
relatively narrow beam patterns (e.g., beam patterns 1613-1614,
respectively) that may be produced by a particular LED/lens
combination (e.g., the LED/lens combination as discussed above in
relation to FIG. 3), which may similarly produce maximum intensity
at the edges of the beam pattern as discussed above in relation to
FIGS. 4A and 4B so as to illuminate adjacent plants (e.g., 1632 and
1644, respectively) with substantially the same intensity as
associated plants 1630 and 1632, respectively.
[0163] Other aspects and embodiments of the present invention will
be apparent to those skilled in the art from consideration of the
specification and practice of the invention disclosed herein. It is
intended, therefore, that the specification and illustrated
embodiments be considered as examples only, with a true scope and
spirit of the invention being indicated by the following
claims.
* * * * *