Basics of LEDs by KwalityPhotonics_VijayKumarGupta

KWALITY PHOTONICSKWALITY 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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Kwality LEDs SEMI NCPREKwality LEDs SEMI NCPRE
Jul2014Jul2014

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 LEDs
TOP LED BRAND 2012 & 2013TOP LED BRAND 2012 & 2013
 Established in 1966Established in 1966
 Employs over 150 workersEmploys over 150 workers
 Started off with manufacture ofStarted off with manufacture of
Lamps, Filaments & WiresLamps, Filaments & Wires
 Manufacturing LED & LEDManufacturing LED & LED
Segment Displays since1987Segment 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 DiodesIndia'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 firstKwality is not only the pioneer, being the first
Indian Company to have successfullyIndian Company to have successfully
established LEDs production in India but alsoestablished LEDs production in India but also
commands the highest market share in domesticcommands 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 LUMINAIRESRETROFIT LED LUMINAIRES
 INFLUENCE OF STANDARDS ON THEINFLUENCE OF STANDARDS ON THE
LEDS ( ZHAGA, ENERGY STAR, LM84)LEDS ( ZHAGA, ENERGY STAR, LM84)
 LED DRIVERS TECHNOLOGYLED 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 Wavelength
Peak WavelengthPeak Wavelength

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Radiometric and PhotometricRadiometric and Photometric
UnitsUnits

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Intensity I and Solid AngleIntensity I and Solid Angle ΩΩ
Radiometric Intensity: Iv [W/sr]
Photometric Intensity: I [lm/sr] or [cd], Candela
Solid Angle Units: Ω [sr], Steradian

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Conversion from Intensity to fluxConversion from Intensity to flux

DIEBONDING STAGE
LEAD FRAME
LED CHIPs
Silver Epoxy
WIRE BONDING
STAGE
Bonding Wire
ENCAPSULATION
STAGE
Epoxy
MATERIALS USED in PLCC LEDs Manufacture
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Kwality PLCC LED -Manufacturing Process
Die Bonding Section
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1. Automatic Die Bonding Machine
Kwality PLCC LED -Manufacturing Process
Die 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 Process
Encapsulation Section
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PLCC LED Testing (fig.2)
Kwality PLCC LED
-Manufacturing Process
Finished 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 LAMPSMERITS RETROFIT LED LAMPS
There are several reasons why a consumerThere are several reasons why a consumer
wants a replacement lamp.wants a replacement lamp.
It saves costs of outer luminaire as well costIt saves costs of outer luminaire as well cost
of labour and time to pull the old fixturesof labour and time to pull the old fixtures
out of the ceiling and replace them without of the ceiling and replace them with
new ones.new ones.
Benefits of LED Lighting can be brought inBenefits of LED Lighting can be brought in
even before end of standard maintenanceeven before end of standard maintenance
cycle of the Fittings. Retrofitting suits anycycle of the Fittings. Retrofitting suits any
fixture that has a large enough mechanicalfixture that has a large enough mechanical
envelope.envelope.11/07/201411/07/2014 4343
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MERITS OF RETROFIT LEDMERITS OF RETROFIT LED
LAMPSLAMPS
Huge opportunityHuge opportunity - billions of existing- billions of existing
"sockets" out there."sockets" out there.
InertiaInertia - it will take time for decisions that- it will take time for decisions that
call for migration to completely integratedcall for migration to completely integrated
LED systems. giving longer opportunityLED systems. giving longer opportunity
window for retrofit business.window for retrofit business.
Design aspects:Design aspects: we'll need a new series ofwe'll need a new series of
bases or platforms that are more suitablebases or platforms that are more suitable
for issues involving thermal dissipation.for issues involving thermal dissipation.
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LED Retrofit LampsLED Retrofit Lamps
Maintainability aspectsMaintainability aspects: In a lot of applications: In a lot of applications
(task lighting, track lighting, chandeliers,(task lighting, track lighting, chandeliers,
pendants) replacing the entire fixture takespendants) replacing the entire fixture takes
little more labor or expertise, but it wouldlittle 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 Lamps
The retrofit LED has reduced performance dueThe retrofit LED has reduced performance due
limitations imposed by Form factorlimitations imposed by Form factor due todue to
requires tradeoffs.requires tradeoffs.
Either it will cost more,Either it will cost more,
or not perform as well, or perhaps both.or not perform as well, or perhaps both.
The best integrated fixtures have an efficacyThe best integrated fixtures have an efficacy
edge of 30-50% over replacement lamps.edge of 30-50% over replacement lamps.
The implementations that you can do in aThe implementations that you can do in a
fixture are really quite difficult with afixture are really quite difficult with a
lamp.lamp.
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Retrofit LED ConstructionRetrofit LED Construction
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Retrofit LEDRetrofit 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 toIt is important never to
connect LEDs directlyconnect LEDs directly
to a voltage source.to a voltage source.
 Must use a currentMust use a current
limiter Like a resistor inlimiter Like a resistor in
series ( see theseries ( see the
formula here)formula here)
 Three different ways ofThree different ways of
operating LEDs,operating LEDs,
depending of area ofdepending 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 maintaininglamps with LED lamp, while maintaining
compatibility with existing dimmers.compatibility with existing dimmers.
 Existing wall dimmers are designed to driveExisting wall dimmers are designed to drive
purely resistance A-lamp loads. When it drivespurely resistance A-lamp loads. When it drives
a capacitive load or current source, the dimmera capacitive load or current source, the dimmer
may not work properly.may not work properly.
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 LED lamp should operate with different dimmerLED 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 preventthe 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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 WALL Dimmer types:WALL Dimmer types:
– Leading-edgeLeading-edge
– Trailing-edgeTrailing-edge
– Smart dimmers, adaptive adjust the turn-on angle toSmart 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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 WALL Dimmer with TriacWALL Dimmer with Triac
– The gate current must remain present until the loadThe gate current must remain present until the load
current has reached the latch current (IL) and thencurrent has reached the latch current (IL) and then
the triac will remain on until the load current fallsthe 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-modeThis requirement creates the issue for switch-mode
power supply where the impedance is not purelypower supply where the impedance is not purely
resistive (reactive load = current not in phase withresistive (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 IntegralENERGY 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 theUnique Method to Configure the
Dimmer TypeDimmer Type
– Provide the Pure resistiveProvide the Pure resistive
impedance to Wall Dimmerimpedance to Wall Dimmer
– Line current shape to improveLine 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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Heatsinks & heatpipesHeatsinks & heatpipes
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ELEMENTS of LEDELEMENTS of LED
Luminaires HeatsinksLuminaires Heatsinks
Typically made of aluminum or copperTypically made of aluminum or copper
Heat sinks conduct heat from a heatHeat sinks conduct heat from a heat
source and then convey the heat to thesource and then convey the heat to the
ambient.ambient.
The required size of the heat sink dependsThe required size of the heat sink depends
on application specific maximum,on application specific maximum,
ambient and case temperature limitations.ambient and case temperature limitations.
The material composition of the heat sink.The material composition of the heat 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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Heatsinks & 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 noIn retrofit T8 you have a poorer thermal dissipation no
matter how much aluminum you place to absorbmatter how much aluminum you place to absorb
the heat, especially if you are talking about enclosedthe heat, especially if you are talking about enclosed
devices.devices.
The “FTL housings” was designed for tubes that didThe “FTL housings” was designed for tubes that did
not needed to be ventilated as SSL-LED's.not needed to be ventilated as SSL-LED's.
One mitigation has been toOne mitigation has been to use hundreds of lowuse 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 eachThe availability of larger surface area around each
such LEDs greatly influences the temperaturessuch LEDs greatly influences the temperatures
levels from accumulating.levels from accumulating.

IESNA /DOE
LM79-08 ( 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-3
Europe and World- IEC ,CIE
IEC-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 CULTURE
Plant growth Lights emit just the spectrum ofPlant growth Lights emit just the spectrum of
light plants use, with no wasted heat or nonlight plants use, with no wasted heat or non
usable light.usable light.
The lights allow a 24 hour growth cycle whichThe 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 throughoutgoal is to grow high quality crops throughout
the year and avoid damage caused bythe year and avoid damage caused by
natural conditions and the excessive use ofnatural conditions and the excessive use of
pesticidespesticides
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PURPLE –RED+BLUE LIGHTPURPLE –RED+BLUE LIGHT..
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LED lighting is adjustable and requires lessLED lighting is adjustable and requires less
electricity;electricity;
Different wavelengths of LED lighting could beDifferent wavelengths of LED lighting could be
matched with various types of plants. Differentmatched with various types of plants. Different
plants may receive sufficient lighting (thoughplants may receive sufficient lighting (though
still weaker than sunlight).still weaker than sunlight).
Appropriate amount of lighting could beAppropriate amount of lighting could be
supplemented to the sunshine duration.supplemented to the sunshine duration.
Sunlight is unavailable during night time, thus theSunlight is unavailable during night time, thus the
supplement of LED lighting may assist insupplement of LED lighting may assist in
shortening the growing period of plants.shortening the growing period of plants.
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 ‘‘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,, aIn an environment with good climate and soil,, a
basic greenhouse would be enough to enhancebasic greenhouse would be enough to enhance
the capacity of plant factories.the capacity of plant factories.
 FULL ENVIRONMENTAL CONTROL coversFULL ENVIRONMENTAL CONTROL covers
light, temperature, humidity, nutrients, water,light, temperature, humidity, nutrients, water,
carbon dioxide, and other environmental factorscarbon 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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 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 LEDB. Mix of Red, Blue and UV LED
 PHOTOSYNTHESIS -The plants only needPHOTOSYNTHESIS -The plants only need
650-655nm Red & 450-470nm Blue light in650-655nm Red & 450-470nm Blue light in
order to perform photosynthesisorder to perform photosynthesis
 Therefore, the mixed LED light source is moreTherefore, the mixed LED light source is more
suitable for growing plants than the white lightsuitable for growing plants than the white light
source.source.
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Manufacturers fromManufacturers from
Europe, the US,Europe, the US,
China, and TaiwanChina, and Taiwan
aggressively investaggressively invest
in the plant lightingin the plant lighting
marketmarket
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KWALITY PHOTONICSKWALITY 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 8585
Jul2014Jul2014

Basics of LEDs by KwalityPhotonics_VijayKumarGupta

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