Design and performance improvement of the LED Array

De Silva G H C N

EN13540036

1

Key points should be achieved.

1) Total number of LEDs,

500 LUX Level

15 ft. X 15 ft. area.

3m ( 9ft 10.11024in) above from the surface.

2) Equal circuit of modeled LED.

3) Thermal management strategy.

4) Demonstrate the Product.

2

Calculate the Lumen Value of a LED.

Reference:[1] Specification for White LED – NSPW 500DS, NICHIA Corparation.

[1]

[1]

3

Cont.…

[1]

Reference:[1] Specification for White LED – NSPW 500DS, NICHIA Corparation.

4

Cont.…

Surface Area = 15 ft. X 15 ft. = 20.9032 Square meter

-90° to +90° Wide angle

Single LED

3m(9ft 10.11024in)

5

Cont.…

• we use equation 6 to find relevant Lux Value,

IV = EV. D2

27 = EV * 32

EV = 27/9 = 3Lux

• Then we use equation 4 to find the Lumen value,

ɸv = Ev * A

ɸv = 3 * 20.9032 = 62.7026 Lumen

[1]

References:[1] 2016.[Online],Available:http://www.compuphase.com/electronics/candela_lumen.htm .[Accessed: 10, May, 2016]

6

Calculate the Total Number of LEDs Then we use below equation and its derivations to calculate total number of bulbs,

• I = Ll C

u L

LF / A

l

Where

• I = illumination (lux, lumen/m2

) (Consider the illumination of a 15ft * 15 ft

room in a house)

• Ll = luminance of lamp (lumen) ( Ll = luminance per bulb x Number of bulbs )

• Cu = coefficient of utilization

• LLF

= light loss factor

• Al = area per lamp (m

2

)

• = Ll = luminance per bulb x Number of bulbs

References:[1] 2016. [Online], Available: http://personal.cityu.edu.hk/~bsapplec/lumen.htm [Accessed: 20, April, 2016][2] 2016. [Online], Available: http://studentnotes.co.uk/2360/lumen_method.php [Accessed: 20 April, 2016]

[1] , [2]

7

Calculate the Total Number of LEDs continue…

• Cu = 0.64, LLF = 0.8, I = 500Lux, A = 20.9032, l per bulb = 62.7026Lumen

Vf

8

Model the LED.

• There are 03 main methods of LED modeling.

1)An equal resistance model

2)A linear Model

3)Linear electro thermal model

References:

[1] Bender V. C, Marchsan B.T, Solid-State Lighting, IEEE Electronics Magazine, 9th Volume, June, 2015.

[1]

[1]

[1]

9

Model the LED by Using Linear Model Method

≈

10

Modeled LED Array Each resistor should be0.56 Ω * 13 = 7.28 Ω

11

Power Calculations of the Array.

Each resistor should be0.56 Ω * 13 = 7.28 Ω

• each 7.28 ohm resistor dissipates 2.912 mW ( p= I*I *R)

• together, all resistors dissipate 72.8 mW ( = p *25)

• together, the diodes dissipate 19955 mW ( =325 * V* I)

• total power dissipated by the array is 20027.8 mW

• the array draws current of 500 mA from the source

12

Thermal Management (Seebeck Methode) [1/3]

What is seebeck method?

• The Seebeck effect is a phenomenon in which a temperature difference between two dissimilar electrical conductors or semiconductors produces a voltage difference between the two substances.

• When one of the two conductors or semiconductors is become heated, heated electrons flow toward the cooler one. If the pair is connected through an electrical circuit, direct current (DC) flows through that circuit.

• Seebeck Element can be used to convert heat into electric power.

References:

[1] Neva Agarwala, Thermoelectric Measurements of Silicon Nanowire Arrays for the Seebeck Effect, 2nd International Conference on Advances in Electrical Engineering (ICAEE 2013), Dhaka, Bangladesh, 19-21 December, 2013

13

Thermal Management Cont.… [2/3]

• http://www.mhtl.uwaterloo.ca/Professional_Animation_Seebeck_File_HTML.html

14

References:[1] 2016.[Online],Available :http://www.mpoweruk.com/thermoelectricity.htm.[Accessed: 21,september,2016]

[1]

Thermal Management Cont.… [3/3]

15

Design the Physical structure of the LED Product.

16

Front lookBack side look side look

Top look

Circuit Diagram

17

18

Seebeck Element Connection

Necessary items (1/3)

Item name Quantity

NSPW500DS LEDs 325

Dot board 01

Heat sink 02

5.1Ω resistors (1W) 13

2.2Ω resistors (1W) 13

Peltier 15

Indicator lamp (Red, Orange, Green) 03

Selector switch 01

ON/OFF switch 0119

Necessary items Cont. (2/3)

20

Cooling fan Large (12V) 02

Cooling fan small (12V) 01

Reflector sticker (ORACAL 352) 1ft x 4ft

230 AC/ 40V DC power supply 01

DC base 01

Aluminum bar 4ft x 0.5ft

Cladding boards (white) 1.75ft x 0.5ft

Black sticker 1m x 0.5m

Glass (5mm) 1.25ft x 0.5ft

3 core wire cord with 0.75A fuse protector 01

Glue sticks 03

Super glue 01

Heat Sleeves (Heat Shrinkage) 15

Necessary items Cont.(3/3)

21

Flexible wire (TT wire) 2 x 0.50 mm2 1.5m (Approximately)

Heat Transferable Gum (Heat sick Compounder) 01

SKC ROCK, Super solder wire 0.5mm, 60/40, 500g Roll 01

Steel Epoxy glue 01

Purchase and order the items.

22

Construct the Product.

1. Construct the LED Array

2. Make the thermal management system.

3. Make the LED casing.

4. Fit the all items to the casing.

23

Construct the LED Array (1/3)

Step 01

Collect the all necessary items. Ex: LEDs 325, Dot Board, Resistors ….etc.

Step 02

Check the each LED bulb one by one.

Step 03

Clean the edges of each LED by using a paper cutter. Because Oxide can be attached on the edge.

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Construct the LED Array contd. (2/3)Step 04

Clean the dot board. We can very softly sandpapering by sing a soft carborundum. (150 – 220).

Step 05

Reflector sticker (ORACAL 352) is pasted on the dot board and Each LEDs are soldered on the Dot Board bore.

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Step 06

Clean the Resistor’s Edges and solder to the dot board.

Step 07

Check the accuracy of the soldering. For that we can use 40V power supply and check the soldered bulbs. Need to confirm that there are NOT any mistakes and all the bulbs are lighting well.

26

Construct the LED Array Contd. (3/3)

Make the thermal management system. (1/2)

Step 01

Clean the surfaces of the two heat sinks (For removing the Oxide film) by using a sandpaper (100) and Affix the two heat sinks by using Steel Epoxy glue.

Step 02

Find the hot surfaces of the 15 peltiers. For that, we can use 12V DC power supply and connect + and –edges with peltier’s one. By touching the two surfaces, we can sense the hot surface of the peltiers. Do this checking to all 15 pelties and find the hot surface

Make the thermal management system Contd. (2/2)

Step 03

Paste the 15 peltiers on the two heat sinks surfaces by using heat transferable glue. Connect the peltiers as series and connect wires edges by using heat shrinkage joints.

Make the LED casing.Step 01

Make the LED product’s casing by using Aluminum, cladding board and 5mm glass.

Step 02

Paste the Reflector sticker in to the inside the Casing.

Step 03

Drill the holes to fit the indicator lights to the casing.

Fit the all items to the casing. (1/3)Step 01

Cooling fans and DC base are connected on the backside cladding board of the LED casing.

Step 02

Connect the wires to the ON/OFF switch & Indicator lights and connect them to front side cladding board of the casing.

Fit the all items to the casing Contd. (2/3)Step 03

Fixation the LED array to the casing.

Step 04

Set the peltires and the heat sink (Thermal management system) to the LED array in the casing.

Fit the all items to the casing Contd. (3/3)Step 05

Paste the 230V AC / 40V DC power supply to the LED casing by using glue stick and connect the wires.

Step 06

Connect the all wires inside the casing and check the accuracy of the system. Finally plug socket to the 230V AC plug Point and switch ON. Test the system.

Project costItem Quantity Unit price (Rs) Price (Rs)

TEC1-12706 Peltier 15 425 6375

5mm white LED cool White 4.5 325 1462.5

Heat sink mediam 2 600 1200

12V cooling fan small 1 100 100

dot board large 1 175 175

indicator bulb 3 30 90

ON/OFF switch 1 35 35

selector switch 1 80 80

nob 1 10 10

12V cooling fan large 2 140 280

LED product full casing 1 1350 1350

40V power AC/DC power supply 1 1200 1200

heat transferable glue 1 600 600

steel epoxy 1 190 190

Heat sleeves 15 10 150

Flexible wire 1 125 125

3 core cable with fuse 1 450 450

glue stick 3 30 90

super glue 1 40 40

ORACAL 352 1 435 435

Resistors (1W) 50 13 650

DC base 1 25 25

Black sticker 1 450 450

Super solder wire 0.5mm 1 200 200

TOTAL (Rs) 15762.5

Future work

Product development

i. Weight reduction.

ii. Improve the wiring order

iii. Design a voltage step up module for thermal management system

iv. Improve the viewing angle of the bulb.

v. Setting an attractive price

vi. Achieving the industrial standard. (Bench- mark)

vii. Improving the attractively of the product.

viii. Introducing the new varieties for the product.

Future work

• Found Our Own LED production Company.we planned a conceptual company for LED production. This conceptual company invents and makes all kind of LED products to the global and local market with the competitive price and quality.

Vision of Our companyThe global leading partner for sustainable and environmental friendly lighting solutions.

Mission of Our companyDesigns and supplies sustainable lighting solutions for all customers, enabling them to reduce costs, energy consumption and environmental impact.

Aim of Our companyColor the whole world.

LOGO of Our Company.

Future work

Future work

Thank you !