Basics of LEDs by KwalityPhotonics_VijayKumarGupta

KWALITY PHOTONICS KWALITY PHOTONICS POLYWA POWER LEDSPOLYWA POWER LEDS

India’s First Manufacturer of LEDs, LED DisplaysIndia’s First Manufacturer of LEDs, LED Displays( since1987 ) ( since1987 )

11/07/201411/07/2014 11Kwality LEDs SEMI NCPRE Kwality LEDs SEMI NCPRE

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Kwality Group of IndustriesKwality Group of Industries

Kwality Electronic IndustriesKwality Electronic Industries Kwality Photonics Pvt. LtdKwality Photonics Pvt. Ltd.. Kwality Electricals Pvt. Ltd.Kwality Electricals Pvt. Ltd. Ocean Park Ltd.Ocean Park Ltd.


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The Kwality polyWa LEDsThe Kwality polyWa LEDsTOP LED BRAND 2012 & 2013TOP LED BRAND 2012 & 2013

Established in 1966 Established in 1966 Employs over 150 workers Employs over 150 workers Started off with manufacture of Started off with manufacture of

Lamps, Filaments & Wires Lamps, Filaments & Wires Manufacturing LED & LED Manufacturing LED & LED

Segment Displays since1987 Segment Displays since1987 after successful indigenous R&Dafter successful indigenous R&D


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Kwality Photonics P LtdKwality Photonics P Ltd

India's largest producer of Light Emitting Diodes India's largest producer of Light Emitting Diodes (LEDs), LED Displays & Opto Electronic (LEDs), LED Displays & Opto Electronic Products. Products.

Kwality is not only the pioneer, being the first Kwality is not only the pioneer, being the first Indian Company to have successfully Indian Company to have successfully established LEDs production in India but also established LEDs production in India but also commands the highest market share in domestic commands the highest market share in domestic sales. sales.


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AGENDAAGENDA LEDs –STRUCTURE &THERMAL DESIGNLEDs –STRUCTURE &THERMAL DESIGN DEMYSTIFY – LEDs COLOR & LIGHTDEMYSTIFY – LEDs COLOR & LIGHT LEDs -MANUFACTURING PROCESSESLEDs -MANUFACTURING PROCESSES RETROFIT LED LUMINAIRES RETROFIT LED LUMINAIRES INFLUENCE OF STANDARDS ON THE INFLUENCE OF STANDARDS ON THE

LEDS ( ZHAGA, ENERGY STAR, LM84)LEDS ( ZHAGA, ENERGY STAR, LM84) LED DRIVERS TECHNOLOGY LED DRIVERS TECHNOLOGY


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Thermal Designof LED LampThermal Designof LED Lamp

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Structure of LED LampStructure of LED Lamp


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Structure of LED LampStructure of LED Lamp


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LED LIFE INFLUENCED BY STRUCTURE OF PACKAGE

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InGaN White LED structureInGaN White LED structure


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LED Spectrum & OpticsLED Spectrum & Optics


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Correlated Color TemperatureCorrelated Color Temperature


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Typical LED SpectraTypical LED Spectra


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Dominant WavelengthDominant WavelengthPeak WavelengthPeak Wavelength


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Radiometric and Photometric Radiometric and Photometric UnitsUnits


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Intensity I and Solid Angle Intensity I and Solid Angle ΩΩ

Radiometric Intensity: Iv [W/sr]Photometric Intensity: I [lm/sr] or [cd], CandelaSolid Angle Units: Ω [sr], Steradian


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Conversion from Intensity to fluxConversion from Intensity to flux

DIEBONDING STAGELEAD FRAMELED CHIPsSilver Epoxy

WIRE BONDING STAGEBonding Wire

ENCAPSULATION STAGEEpoxy

MATERIALS USED in PLCC LEDs Manufacture


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Kwality PLCC LED -Manufacturing ProcessDie Bonding Section

1. Die-Bonding Section 11/07/201411/07/2014 3535Kwality LEDs SEMI NCPRE Kwality LEDs SEMI NCPRE

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1. Automatic Die Bonding Machine

Kwality PLCC LED -Manufacturing ProcessDie Bonding Section


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Wire Bonding Section



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2. Auto Wire Bonding Machine



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3. Auto Encapsulation Dispensing Machine

Kwality PLCC LED -Manufacturing ProcessEncapsulation Section


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PLCC LED Testing (fig.2)

Kwality PLCC LED -Manufacturing ProcessFinished LEDs Testing Section


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LED Tape and REEL Packing Machine

LED Tape and REEL Packing Process


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Retrofit LED ConstructionRetrofit LED Construction


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MERITS RETROFIT LED MERITS RETROFIT LED LAMPSLAMPSThere are several reasons why a There are several reasons why a

consumer wants a replacement lamp.consumer wants a replacement lamp.

It saves costs of outer luminaire as well It saves costs of outer luminaire as well cost of labour and time to pull the old cost of labour and time to pull the old fixtures out of the ceiling and replace fixtures out of the ceiling and replace them with new ones.them with new ones.

Benefits of LED Lighting can be Benefits of LED Lighting can be brought in even before end of brought in even before end of standard maintenance cycle of the standard maintenance cycle of the Fittings. Retrofitting suits any fixture Fittings. Retrofitting suits any fixture that has a large enough mechanical that has a large enough mechanical envelope.envelope.11/07/201411/07/2014 4343

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MERITS OF RETROFIT LED MERITS OF RETROFIT LED LAMPSLAMPSHuge opportunity Huge opportunity - billions of existing - billions of existing

"sockets" out there."sockets" out there.

Inertia Inertia - it will take time for decisions - it will take time for decisions that call for migration to completely that call for migration to completely integrated LED systems. giving longer integrated LED systems. giving longer opportunity window for retrofit opportunity window for retrofit business. business.

Design aspects: Design aspects: we'll need a new series we'll need a new series of bases or platforms that are more of bases or platforms that are more suitable for issues involving thermal suitable for issues involving thermal dissipation. dissipation.


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LED Retrofit LampsLED Retrofit Lamps

Maintainability aspectsMaintainability aspects: In a lot of : In a lot of applications (task lighting, track applications (task lighting, track lighting, chandeliers, pendants) lighting, chandeliers, pendants) replacing the entire fixture takes little replacing the entire fixture takes little more labor or expertise, but it would more labor or expertise, but it would be easier to slip in a LED retrofit.be easier to slip in a LED retrofit.


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LED Retrofit LampsLED Retrofit LampsThe retrofit LED has reduced The retrofit LED has reduced performance due limitations imposed performance due limitations imposed by Form factorby Form factor due to requires due to requires tradeoffs. tradeoffs.

Either it will cost more,Either it will cost more,

or not perform as well, or perhaps or not perform as well, or perhaps both. both.

The best integrated fixtures have an The best integrated fixtures have an efficacy edge of 30-50% over efficacy edge of 30-50% over replacement lamps.replacement lamps.

The implementations that you can do The implementations that you can do in a fixture are really quite difficult in a fixture are really quite difficult with a lamp. with a lamp.


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Retrofit LED ConstructionRetrofit LED Construction


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Retrofit LED Retrofit LED Tubelight StructureTubelight Structure


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SSL Standards – ZHAGASSL Standards – ZHAGA


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LEDs DRIVER DESIGNLEDs DRIVER DESIGN It is important never to It is important never to

connect LEDs directly connect LEDs directly to a voltage source. to a voltage source.

Must use a current Must use a current limiter Like a resistor in limiter Like a resistor in series ( see the series ( see the formula here)formula here)

Three different ways of Three different ways of operating LEDs, operating LEDs, depending of area of depending of area of applicationapplication


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LEDs DRIVER DESIGNLEDs DRIVER DESIGN


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LED LUMINAIRE EFFICENCYLED LUMINAIRE EFFICENCY


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LED DRVR –MAINS ISOLATIONLED DRVR –MAINS ISOLATION


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LED DRIVER CONFIGURATIONLED DRIVER CONFIGURATION Basic Flyback: Single-stageBasic Flyback: Single-stage

– AdvantageAdvantage SimpleSimple No bulk e-capNo bulk e-cap

– DisadvantageDisadvantage Line frequency ripple currentLine frequency ripple current

Boost + Flyback: Two-stageBoost + Flyback: Two-stage– AdvantageAdvantage

No flickersNo flickers High PFHigh PF

– DisadvantageDisadvantage CostCost


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LEDs DIMMABLE DRIVERLEDs DIMMABLE DRIVER DIMMABLE LEDS are liked by ArchitectsDIMMABLE LEDS are liked by Architects

The first challenge is to replace the socket of A-The first challenge is to replace the socket of A-lamps with LED lamp, while maintaining lamps with LED lamp, while maintaining compatibility with existing dimmers.compatibility with existing dimmers.

Existing wall dimmers are designed to drive Existing wall dimmers are designed to drive purely resistance A-lamp loads. When it drives purely resistance A-lamp loads. When it drives a capacitive load or current source, the dimmer a capacitive load or current source, the dimmer may not work properly.may not work properly.


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Kwality LEDs SEMI NCPRE Kwality LEDs SEMI NCPRE

LEDs DIMMABLE DRIVERLEDs DIMMABLE DRIVER LED lamp should operate with different dimmer LED lamp should operate with different dimmer

types:types:– Leading-edge dimmers, Trailing-edge dimmers, Smart DimmersLeading-edge dimmers, Trailing-edge dimmers, Smart Dimmers

– In case the LED lamp can not work properly with certain dimmers, In case the LED lamp can not work properly with certain dimmers, the LED lamps should provide certain safety protections to prevent the LED lamps should provide certain safety protections to prevent

fire, high leakage current etcfire, high leakage current etc.. Dimming PerformanceDimming Performance

– Wide dimming range 1% to 100%Wide dimming range 1% to 100%– No visible FlickerNo visible Flicker

AC-cycle inrush currentAC-cycle inrush current– High Power Factor at maximum dimming levelHigh Power Factor at maximum dimming level– Residential > 0.7Residential > 0.7– Commercial > 0.9Commercial > 0.9

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LEDs DIMMABLE DRIVERLEDs DIMMABLE DRIVER WALL Dimmer types:WALL Dimmer types:

– Leading-edgeLeading-edge– Trailing-edgeTrailing-edge– Smart dimmers, adaptive adjust the turn-on angle to Smart dimmers, adaptive adjust the turn-on angle to

minimum the line distortion; could be leading-edge, minimum the line distortion; could be leading-edge, could be trailing-edgecould be trailing-edge

– More..More..

Dimmer impedance and power level also variesDimmer impedance and power level also varies– RR– R-LR-L– R-CR-C– 50W, 200W etc50W, 200W etc

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LEDs DIMMABLE DRIVERLEDs DIMMABLE DRIVER

WALL Dimmer with TriacWALL Dimmer with Triac– The gate current must remain present until the load The gate current must remain present until the load

current has reached the latch current (IL) and then current has reached the latch current (IL) and then the triac will remain on until the load current falls the triac will remain on until the load current falls below the hold current (IH).below the hold current (IH).

– This requirement creates the issue for switch-mode This requirement creates the issue for switch-mode power supply where the impedance is not purely power supply where the impedance is not purely resistive (reactive load = current not in phase with resistive (reactive load = current not in phase with voltage).voltage).

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WALL DIMMER TYPESWALL DIMMER TYPES

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SSL DRIVER STANDARDSSSL DRIVER STANDARDS ENERGY STAR® Program Requirements for Integral ENERGY STAR® Program Requirements for Integral

LED LampsLED Lamps • • FCC requirementsFCC requirements

– 47 CFR part 15 & • Class A and Class B47 CFR part 15 & • Class A and Class B

• • Harmonic Emission limits and related power qualityHarmonic Emission limits and related power quality– ANSI C82.77-2002 & • IEC 61000-3-2ANSI C82.77-2002 & • IEC 61000-3-2

• • SafetySafety– UL8750 & • IEC 60950 Part 1UL8750 & • IEC 60950 Part 1

• • Line Transient protections ( Lighting Surge)Line Transient protections ( Lighting Surge)IEEE C62.41-1991; Class A, 100kHz ringwave, 2.5kV combineIEEE C62.41-1991; Class A, 100kHz ringwave, 2.5kV combine

• • Audible NoiseAudible Noise– – – Class AClass A

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LEDs DRIVERLEDs DRIVER

Dimmer Flyback: Single-stageDimmer Flyback: Single-stage

– Unique Method to Configure the Unique Method to Configure the Dimmer TypeDimmer Type

– Provide the Pure resistive Provide the Pure resistive impedance to Wall Dimmerimpedance to Wall Dimmer

– Line current shape to improve Line current shape to improve power factorpower factor

– Reduce AC-cycle Inrush currentReduce AC-cycle Inrush current


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THERMAL DRIFT & PROTECTIONTHERMAL DRIFT & PROTECTION

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EMI - CONDUCTEDEMI - CONDUCTED


LED DRIVERS SHAPESLED DRIVERS SHAPES


TUBE LIGHT>TUBE LIGHT>

iWatt Designs


IT’S A GREEN TECHNOLOGY


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ELEMENTS of LED LuminairesELEMENTS of LED Luminaires


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ELEMENTS of LED LuminairesELEMENTS of LED LuminairesHeatsinks & heatpipesHeatsinks & heatpipes


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ELEMENTS of LED ELEMENTS of LED Luminaires Luminaires HeatsinksHeatsinksTypically made of aluminum or copperTypically made of aluminum or copper

Heat sinks conduct heat from a heat Heat sinks conduct heat from a heat source and then convey the heat to the source and then convey the heat to the ambient. ambient.

The required size of the heat sink The required size of the heat sink depends on application specific depends on application specific maximum, ambient and case maximum, ambient and case temperature limitations.temperature limitations.

The material composition of the heat The material composition of the heat sink.sink.

Surface characteristics of the heat sink,.Surface characteristics of the heat sink,.

Physical constraints for the application.Physical constraints for the application.


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ELEMENTS of LED LuminairesELEMENTS of LED LuminairesHeatsinks & heatpipesHeatsinks & heatpipes


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Retrofit T8 LED TubelightRetrofit T8 LED Tubelight


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Retrofit T8 Tube lightRetrofit T8 Tube light


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In retrofit T8 you have a poorer thermal dissipation In retrofit T8 you have a poorer thermal dissipation no matter how much aluminum you place to no matter how much aluminum you place to absorb the heat, especially if you are talking absorb the heat, especially if you are talking about enclosed devices.about enclosed devices.

The “FTL housings” was designed for tubes that The “FTL housings” was designed for tubes that did not needed to be ventilated as SSL-LED's. did not needed to be ventilated as SSL-LED's.

One mitigation has been to One mitigation has been to use hundreds of low use hundreds of low current LEDscurrent LEDs in place of high power LEDs. in place of high power LEDs.

The availability of larger surface area around each The availability of larger surface area around each such LEDs greatly influences the temperatures such LEDs greatly influences the temperatures levels from accumulating.levels from accumulating.

IESNA /DOELM79-08 ( Luminaires)LM80-08 (Sources)IESNA TM-16-05, RP-16-05, TM-21†, LM-XX1†, LM-XX2† ,IES G-2†ANSI/NEMA C78.377- 2008 ,NEMA.SSL-1† NEMA SSL-3Europe and World- IEC ,CIEIEC-60598 , (62031 M_SS) , 62560 (LL SS†) , 62612 (LL_P†), 61341 , 61231 , Pr. 62504(def) , 60061 , 60838-2-2 , 61347-1 , 61347-2-13 , 62384 (CG) , 62386-207 , 60825-1 , 61000-3-2: , 61000-3-3: , 61547: , EN 55015: EN 62471: 2008 ( 62471:2006 modified) S 009:2002 TR 62471-2


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LEDs in AGRI/AQUA CULTURELEDs in AGRI/AQUA CULTUREPlant growth Lights emit just the spectrum of Plant growth Lights emit just the spectrum of

light plants use, with no wasted heat or non light plants use, with no wasted heat or non usable light. usable light.

The lights allow a 24 hour growth cycle which The lights allow a 24 hour growth cycle which maximizes the benefits of aquaponics.maximizes the benefits of aquaponics.

goal is to grow high quality crops throughout goal is to grow high quality crops throughout the year and avoid damage caused by the year and avoid damage caused by natural conditions and the excessive use of natural conditions and the excessive use of pesticidespesticides


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LEDs in AGRI/AQUA CULTURELEDs in AGRI/AQUA CULTUREPURPLE –RED+BLUE LIGHTPURPLE –RED+BLUE LIGHT..


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LEDs in AGRI/AQUA CULTURELEDs in AGRI/AQUA CULTURE LED lighting is adjustable and requires less LED lighting is adjustable and requires less

electricity; electricity; Different wavelengths of LED lighting could be Different wavelengths of LED lighting could be

matched with various types of plants. Different matched with various types of plants. Different plants may receive sufficient lighting (though plants may receive sufficient lighting (though still weaker than sunlight). still weaker than sunlight).

Appropriate amount of lighting could be Appropriate amount of lighting could be supplemented to the sunshine duration.supplemented to the sunshine duration.

Sunlight is unavailable during night time, thus the Sunlight is unavailable during night time, thus the supplement of LED lighting may assist in supplement of LED lighting may assist in shortening the growing period of plants.shortening the growing period of plants.


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LEDs in AGRI/AQUA CULTURELEDs in AGRI/AQUA CULTURE ‘‘PLANT FACTORIES’ -two types: PLANT FACTORIES’ -two types: BASIC GREENHOUSE – Low initial cost .BASIC GREENHOUSE – Low initial cost . In an environment with good climate and soil,, a In an environment with good climate and soil,, a

basic greenhouse would be enough to enhance basic greenhouse would be enough to enhance the capacity of plant factories.the capacity of plant factories.

FULL ENVIRONMENTAL CONTROL covers FULL ENVIRONMENTAL CONTROL covers light, temperature, humidity, nutrients, water, light, temperature, humidity, nutrients, water, carbon dioxide, and other environmental factors carbon dioxide, and other environmental factors - suitable for growing high value crops or high-- suitable for growing high value crops or high-priced ornamental plants- EXPENSIVEpriced ornamental plants- EXPENSIVE


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LEDs in AGRI/AQUA CULTURELEDs in AGRI/AQUA CULTURE White light LED vs. red/blue light LEDWhite light LED vs. red/blue light LED There are two types of light sourcesThere are two types of light sources

– A. Phosphor base white LED lightA. Phosphor base white LED light– B. Mix of Red, Blue and UV LED B. Mix of Red, Blue and UV LED

PHOTOSYNTHESIS -The plants only need PHOTOSYNTHESIS -The plants only need 650-655nm Red & 450-470nm Blue light in 650-655nm Red & 450-470nm Blue light in order to perform photosynthesis order to perform photosynthesis

Therefore, the mixed LED light source is more Therefore, the mixed LED light source is more suitable for growing plants than the white light suitable for growing plants than the white light source.source.


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LEDs in AGRI/AQUA CULTURELEDs in AGRI/AQUA CULTURE

Manufacturers from Manufacturers from Europe, the US, Europe, the US, China, and Taiwan China, and Taiwan aggressively invest aggressively invest in the plant lighting in the plant lighting marketmarket


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KWALITY PHOTONICS KWALITY PHOTONICS POLYWA POWER LEDSPOLYWA POWER LEDS

India’s First Manufacturer of LEDs, LED DisplaysIndia’s First Manufacturer of LEDs, LED Displays( since1987 ) ( since1987 )


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Technology

Basics of LEDs by KwalityPhotonics_VijayKumarGupta