Final report EN13540036 De Silva G H C N

Project No: ECNR / 16 / 04
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Analysis of performance
improvement of Solid State
Lighting Systems
A Project Progress Report
Submitted by: De Silva G.H.C.N
Student Number: EN13540036
Supervisor: Dr. Nimal Rathnayake
SRI LANKA INSTITUTE OF INFORMATION TECHNOLOGY
DEPARTMENT OF ELECTRICAL AND COMPUTER ENGINEERING
December 2016

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Table of Contents
Chapter 1........................................................................................................................ 8
1.1 Motivation...................................................................................................... 9
1.2 Objectives and Scope................................................................................... 10
1.3 Introduction of project problems ................................................................. 10
1.4 Outcome of the work in each semester........................................................ 12
Chapter 2...................................................................................................................... 13
2.1 Background.................................................................................................. 13
2.2 Environment Impact..................................................................................... 14
Chapter 3...................................................................................................................... 15
3.1 Project methodology Overview ................................................................... 15
3.2 Details .......................................................................................................... 16
3.2.1 Design the LED Array ........................................................................................16
3.2.2 Search and learn about solid state device modeling and methods. ................19
3.2.3 Select linear model for modeling the LED and LED array.................................20
3.2.4 Study about temperature effect for the LED....................................................22
3.2.5 Select a better thermal management method.................................................24
3.2.6 Design circuit diagram of final product and peltier connection.......................29
3.2.7 Design the final product’s physical shape and structure. ................................31
3.2.8 List down the all necessary items for the full product.....................................33
3.2.9 Purchase and order the necessary items. ........................................................36
Chapter 4...................................................................................................................... 38
4.1 Construct the product overview................................................................... 38
4.2 Procedure ..................................................................................................... 38
4.2.1 Construct the LED Array ...................................................................................38
Step 01..............................................................................................................................38
Step 02..............................................................................................................................38

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Step 03..............................................................................................................................38
Step 04..............................................................................................................................39
Step 05..............................................................................................................................40
4.2.2 Make the thermal management system..................................................................42
4.2.3 Make the LED casing. ...............................................................................................44
4.2.4 Fit the all items to the casing. ..................................................................................45
Step 01..............................................................................................................................45
Step 02..............................................................................................................................46
Step 03..............................................................................................................................46
Step 05..............................................................................................................................47
Chapter 5...................................................................................................................... 48
Chapter 6...................................................................................................................... 49
Chapter 7...................................................................................................................... 51
7.1 Future work.................................................................................................. 51
7.1.1 Product development.......................................................................................51
7.1.2 Found my Own LED production Company. ......................................................58
7.2 Conclusion ................................................................................................... 61

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Abstract
According to Electrical and Electronic Degree programme at SLIIT we have to complete
the project for final year. Our topic is “Analysis of performance improvement of Solid State
Lighting System”. Today, our nation is facing the urgent challenges of revitalizing our
economy, strengthening our energy security, and reducing greenhouse gas emissions. Solid-
state lighting is an emerging technology with the potential to address all three of these
challenges. LED behavior greatly differs from conventional electric light resources, such
as incandescent bulbs or discharge lamps, which are widely use in general lighting. SSL
will become a key to affordable high-performance buildings— buildings that consume less
energy and produce fewer greenhouse gas emissions than their counterparts.
We are designing the LED drivers to achieve the best operation conditions without
degrading the longer lifetime. Our overarching objectives are Overcoming technical
and design barriers to issues that limit performance. The goal now is to maximize high-
quality solid-state lighting; and Establishing the foundations for successful what can be.
Today’s LED research focuses on improving market introduction.
To achieve our main goals we conduct the project by dividing it in to three parts. For the
selected brands of the LEDs we are going to tabulate LED array and select the best array
design for the highest efficiency power. To obtain the power to the circuit we are planning
to use two methods. First is using AC power supply and second is using DC power supply.
The Global warming is a huge problem in the today’s world. There for, when we make a
new product and introduce it to the world, our main purpose should be, release the minimum
possible heat to the environment. We have designed heat re-using method that generates a
small current which is used to work cooling Fan. We call that as “Seebeck effect” and it
has been used for the very first time to the solid state lighting system (as an experiment).
As a result we can optimize light energy, increase efficiency and decrease power loss.
My Part is that Design and improve the performances of the LED array system.

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Acknowledgments
First and foremost, we would like to express our sincere gratitude to Dr. Nimal
Ratnayake, the supervisor of our project; Analysis of performance improvement of
Solid State Lighting Systems, who helped us in every step of this project so far and who
guides us through this project. As the Examiners, Dr: Sunil Aberathnaye and Mrs:
Thilini Maheshika trotted out to us, the points, which we should improve to make a
better product and their opinions were very importance to us to think beyond the
boundary and add some new concepts to our product. Also we would like to extend our
gratitude towards our parents who has been with us together in our whole lifetime.

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List of Figures.
Figure 1 : LED Positioning..........................................................................................16
Figure 2: Simulation of LED Array.............................................................................18
Figure 3: LED Modeling Methods...............................................................................20
Figure 4: Forward Voltage Vs Forward Current Graph...............................................21
Figure 5: LED Model simulation.................................................................................21
Figure 6: Modeled LED substitution to The Array......................................................22
Figure 7: Ambient temperature Vs Relative luminosity Graph...................................23
Figure 8: Dynamic Cooling Effect in Luminous Flux Curves.....................................24
Figure 9: Semiconductor Thermocouple Seebeck Effect. ...........................................26
Figure 10: Seebeck element schematic. Thermoelectric legs are thermally in
parallel and electrically in series................................................................27
Figure 11: Simple Structure of Thermal management Method....................................28
Figure 12: Peltier Connection Bock diagram...............................................................30
Figure 13:Full circuit Block diagram...........................................................................30
Figure 14: Front Look..................................................................................................31
Figure 15: Top Look ....................................................................................................31
Figure 16: Side Look ...................................................................................................32
Figure 17: Backside Look............................................................................................32
Figure 18: Purchased item bill 01................................................................................36
Figure 19: Purchased item bill 02................................................................................37
Figure 20: Purchased item bill 03...............................................................................37
Figure 21: Some LED Bulbs........................................................................................39
Figure 22: Dot board....................................................................................................39
Figure 23: LEDs are soldered to the dot board............................................................40
Figure 24: Soldered Back side of the...........................................................................40
Figure 25: Resistors after cleaning there edges ...........................................................41
Figure 26: soldered resistors to the dot board..............................................................41
Figure 27: pasted two heat sinks..................................................................................42
Figure 28: Peltiers........................................................................................................43
Figure 29: connected Peltiers as series ........................................................................43
Figure 30: LED product casing front side view...........................................................44
Figure 31: LED product casing Back side view. .........................................................44
Figure 32: Drilling the holes on cladding board. .........................................................45
Figure 33: connected cooling fans to the cladding board. ...........................................45
Figure 34: connected the indicator lights and switch to the front side cladding
board. .........................................................................................................46
Figure 35: set the LED array to the casing ..................................................................46
Figure 36: set the Power supply to the casing.............................................................47
Figure 37: Me, Testing the LUX value while focusing the Light to the LUX meter.
Distance between light and LUX meter is 5ft............................................50
Figure 38: Skimming Price chart. ................................................................................53
Figure 39: LOGO of my Company..............................................................................58

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List of Tables
Table 1: Initial Electrical Characteristics Design the LED Array ...............................16
Table 2: Equations .......................................................................................................17
Table 3: List of necessary items...................................................................................33
Table 4: Project cost.....................................................................................................48

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Chapter 1
Solid State lighting technology is the currently growing technology in the worldwide
lighting market. Compared to other lighting solutions, LED technologies present
competitive advantages in terms of their electrical efficiency, economical value, and
environmental impact.
Our research group presents an analysis of LED technologies by
a) Investigate electrical characteristics of the solid state light devices and
derivation of suitable circuit models.
b) Study of device connections; series connection of individual lighting devices
with sub string and paralleling issues of sub modules- (series sub string
modules).
c) Matching issues of light module & driver circuits, Design a thermal
management method optimization of light output, life span issues
Firstly we select the LED light which will be used throughout this project. Then its
electrical characteristics is observed.
Then we improve LED and design the LED String Array and the converter circuits
and simulate that in PSim software.
Lastly we design this using actual components and match issues of light module &
driver circuits, Design a thermal management method, optimization of light output
and life span issues.

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1.1 Motivation
Solid-state lighting has the potential to reduce lighting energy use in Sri Lanka by
nearly one half. Designing a LED light suitable for the need of a lower power
consumable, low maintenance, to use as a lighting source operated by battery.
Rural areas like Vilachchiya, Nochchiyagama, Kabathigollawa, Meemure are still lack
of electricity. People living in those areas still use the old technology to light up their
houses. This design will help lighting up the houses for the people in rural areas who
has no electricity and considerably poor because we provide a battery system to the
design.
LED light uses low power. Therefore using LEDs to develop lighting sources is cost
effective as well as power efficiency. Even other people with electricity supply will be able
to use this product to optimize their electricity usage and the electricity bill by using this as
a light source, because this product is also included with 230V AC supply.

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1.2 Objectives and Scope
Today, LED lamps are expensive. These lamps save money in the long run, because we
need to replace them every decade or two, and the electric bill is reduced. However,
their upfront cost is high. It is highly probable that in the future many household lighting
fixtures will be equipped with LED lamps. There for our objective is to produce a low
cost, Environment friendly, higher efficiency LED lighting system.
1.3 Introduction of project problems
At the very first of this project, my main problem was how to find the total number of
LED bulbs for this product. Then the main guild line was given by the supervisor and
provided some reference notes. By reading those references and search through the
Internet I could find a best theoretical way to find/ calculate the total number of LED
bulbs.
The next problem was, how to model the LED. Then I referred the supervisor provided
reference article which is mentioned at 3rd
under the references of this report and I
could find a proper way to model the LED.
Then I had to find a solution to the thermal management problem of this product. I was
vehemently on the stage that my product should be released the minimum possible heat
amount the environment. There for I had to find the best way to manage the thermal
effect. First I could find a method that; Microjet Array Cooling System for Thermal
Management of Active Radars and High-Brightness LEDs. Even this method is very
reliable and high efficiency, the cost is very high for making this kind of a thermal
management method. The other side is that our aim is, to make a product which can use
in the home and the high cost can’t be bear to the people in Sri Lanka. This thermal
management method may be suitable for an operation theater. But not for a house.
Then I turned to the seebeck cooling method. It is simple and cheap but efficiency
finally I used this method as my thermal management method and it is clearly described
in the futures step in this report.

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When I was going to demonstrate the product, the main problem was, the price of
selected LED (NSPW500DS) is very high. One LED light price is US $ 0.8. We use
325 LEDs and total cost were US $ 260 !! . It was very high and I had to find a
substitution which has same characteristic as NSPW500DS and as well as a cheap one.
Then I could find 5mm cool white LED bulb which is having approximately same
characteristic as NSPW500DS and the main this is, it price is LKR 4.50 and for 325
LEDs cost is LKR 1462.50. Then I finally bought that LED bulb to demonstrate.
Other problem was find a good reflection material to reflect the LED light beam. 5mm
LED reflectors are costly bust reflective efficiency is high. Then I had to find a cheap
and as well as efficiency way to reflect the Light beam. Finally I’ve choose reflective
sheet (ORACAL 352) as my light reflective material and had to cut the sheet and make
a proper structure to reflect the light beam.

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1.4 Outcome of the work in each semester
Semester 01-Simulation of LED string array.
 Select a LED bulb (a Brand) for the product.
 Find a suitable method to calculate the total number of LEDs.
 Calculate and decide the total number of bulbs.
 Model the LED.
 Study about the temperature effect of the product.
Semester 02-Implimentation of simulated results.
 Select a better thermal management method.
 Design the final product’s physical shape and structure.
 List down the all necessary items for the full product.
 Purchase and order the necessary items.
 Construct the LED array and thermal management system.
 Make the casing for the product.
 Amassing the LED array, thermal management system and the casing
 Add some additional switches and selectors and make the final full product.

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Chapter 2
Literature Review
2.1 Background
Solid-state lighting (SSL) is the direct conversion of electricity to visible white light
using semiconductor materials and has the potential to be just such an energy-efficient
lighting technology. By avoiding the indirect processes (producing heat or plasmas)
characteristic of traditional incandescent and fluorescent lighting, it can work at a far
higher efficiency, “taking the heat out of lighting,” it might be said. Recently, for
example, semiconductor devices emitting infrared light have demonstrated an
efficiency of 76%. There is no known fundamental physical barrier to achieving similar
(or even higher) efficiencies for visible white light, perhaps
approaching100%efficiency.
Light emitted by LEDs have different properties compared to the light emitted by
incandescent bulbs. Characteristics such as high luminous efficacy, robustness, long
lifetime, high color rendering index and high reliability make LEDs good candidates
for replacing traditional light sources
To generate light near the theoretical efficiency limit, essentially every electron injected
into the material must result in a photon emitted from the device. Furthermore, the voltage
required to inject and transport the electrons to the light-emitting region of the device must
be no more than that corresponding to the energy of the resulting photon. It is insufficient
to generate “simple” white light; the distribution of photon wavelengths must match the
spectrum perceived by the human eye to render colors accurately, with no emitted photons
outside the visible range. Finally, all of these constraints must be achieved in a single device
with an operating lifetime of at least a thousand hours (and preferably ten to fifty times
longer), at an ownership cost-of-light comparable to, or lower than, that of existing lighting
technology.

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Today, we cannot produce white SSL that is simultaneously high in efficiency, low in
cost, and high in color-rendering quality. In fact, we cannot get within a factor of ten in
either efficiency or cost. Doing so in the foreseeable future will require breakthroughs
in technology, stimulated by a fundamental understanding of the science of light-
emitting materials
2.2 Environment Impact
Uncommon earth mining creates plenty of environmental pollutants. But, the quantity
of rare earth substances used in fluorescent lighting bulbs and tubes these days is lots
more extensive in comparison to the quantity present in LED bulbs. Fluorescent tubes
are fully covered internally with phosphorescent cloth, at the same time as LED bulbs
can clearly remove darkness from a nearby patch of phosphor material. Fluorescent
tubes and bulbs also contain mercury vapor, at the same time as LED bulbs are mercury
free. Whilst evaluating the relative environmental footprint of each fluorescent lighting
fixtures and LED lights technology, LEDs are extra environmentally friendly in terms
of uncooked resource intake and waste generation. moreover, LEDs are a good deal
greater electricity efficient- a regular incandescent lamp produces 10 lumens of
brightness per watt of electricity, a fluorescent lamp 60 lumens per watt, however an
LED extra than a hundred and fifty lumens in line with watt.

Project No: ECNR / 16/ 04
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Chapter 3
Methodology
3.1 Project methodology Overview
1) Design the LED array.
2) Search and learn about solid state device modeling and methods.
3) Select linear method for modeling the LED and model the LED array.
4) Study about Temperature effect for the LED.
5) Select a better thermal management method.
6) Design circuit diagram of final product and peltier connection.
7) Design the final product’s physical shape and structure.
8) List down the all necessary items for the full product.
9) Purchase and order the necessary items.

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3.2 Details
Table 1 : Initial Electrical Characteristics Design the LED Array
Above table is captured from the NSPW500Ds data sheet. It shows that for If = 20mA,
Luminous Intensity is 24 cd. The apex angle of the LED is 180°.
Figure 1 : LED Positioning
If we think LEDs set 3m above the floor level and surface area is 20.9032m2
which is
relevant to 15ft * 15ft area room. So we cover that surface area.

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Table 2: Equations
Then 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
So this is the one LED light Lumen Value.
Then we use below equation and its derivations to calculate total number of bulbs,
• I = L
l
C
u
L
LF
/ A
l
Where
• I = illumination (lux, lumen/m
2
) (Consider the illumination of a 15ft * 15 ft
room in a house)
• L
l
= luminance of lamp (lumen) ( Ll = luminance per bulb x Number of bulbs )
• C
u
= coefficient of utilization
• L
LF
= light loss factor
• A
l
= area per lamp (m
2
)
01
02
03
04
05
06

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• = L
l
= luminance per bulb x Number of bulbs
Cu = 0.64, LLF = 0.8, I = 500Lux, A = 20.9032
Luminance per bulb = 62.7026Lumen
ID = 30mA
VD = 3.2 V
Total number of bulbs = = 325.55
Vo = n x VD n = n =
m = 326 / 13 = 25.04
Figure 2: Simulation of LED Array

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3.2.1 Search and learn about solid state device modeling and methods.
There are 03 main methods of LED modeling.
1) An equal resistance model
2) A linear Model
3) Linear electro thermal model
(1) An equal resistance model.
 Simple
 Only valid for steady- state operations
 Considerable errors
 The small signal model should account for the perturbation in current and
this model is not able to do so because it only considers a constant
resistance.
(2) A linear model
 Combination of series resistor, which represent the dynamic resistance, and
an independent voltage source which represent the threshold voltage
 An extremely good approximation when operating point occurs high level
of current.
 Very commonly employed in Led driver design.
(3) Linear electro thermal model
 A dependent voltage source may be used, formatting on electro thermal
model
 A model to predict color changes.
 The model estimate LED colorimetric properties passed on driving current
and voltages.
 LED operating temperature depends on the thermal management strategy
adopted.

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Figure 3: LED Modeling Methods
3.2.2 Select linear model for modeling the LED and LED array
Combination of series resistor, which represent the dynamic resistance, and an independent
voltage source which represent the threshold voltage. An extremely good approximation
when operating point occurs high level of current. Very commonly employed in Led driver
design.
We use DC to Dc converter and AC to AC converter, for the LED driver designs, this
method is the best method to use.
Figure 01: LED Positioning

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Figure 4: Forward Voltage Vs Forward Current Graph
(According to the data sheet)
Figure 5: LED Model simulation
ΔIf = 0.9A
ΔVf = 0.5V

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Figure 6: Modeled LED substitution to The Array
3.2.3 Study about temperature effect for the LED.
 Relative luminosity is reduced when ambient temperature is increasing
 So this may be an impact for reducing the brightness of the LED array.
 Temperature strongly affects the LED photometric characteristics. When
Led current is controlled and kept constant, an increase in temperature will
cause a decrease in the LED light output due to higher level of
nonradioactive recombination inside the crystal lattice.
 As may be perceived, the photometrical, electrical, and thermal
characteristics are dependent on each other.

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 The temperature influence in the LED system, the thermal design is
considered one of the most important aspect when designing an LED- based
lighting System.
Figure 7: Ambient temperature Vs Relative luminosity Graph
 This above figure is captured from the LED datasheet. It clearly shows the
relative luminosity is being reduced with the increasing ambient
temperature.

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Figure 8: Dynamic Cooling Effect in Luminous Flux Curves
 This above figure shows that if we can cool the system, we can increase the
luminous flux which which increase the relative luminosity.
 Increase cooling effect may be caused to higher luminous flux. There for
we have to make temperature decreasing method which increasing cooling
effect to get constant (approximately) light/brightness.
3.2.4 Select a better thermal management method.
The best thermal management method is micro jet cooling system. But it costly
and not applicable for a product which use in a home. There for the most
appropriate method is seebeck effect thermal management system and we use it.
3.2.4.1 Microjet thermal management Method.
Three cooling methods for LED array such as natural convection, heat sink
and heat pipe, are also experimentally good. The comparison results

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demonstrate that present microjet cooling system has the best cooling
performance. To fully understand present cooling system for real world
applications, the cost, reliability and volume comparison and analyses
among different cooling means are also importance.
the angle of cost, heat sink with fan is the cheapest solution in three cooling
means. As for the present cooling system, since it adopts micro pump to
drive, its cost is slightly higher than other two methods. However, it is
known that LED life strongly depends on LED temperature, there is
exponential relation between them as demonstrated in reference, longer life
means cost increase. For present cooling system, it will cool the LEDs to a
lower temperature than that by other means, therefore, present cooling
system can make the LEDs work longer, from this viewpoint, present
cooling system will increase the LEDs cost, although the initial cost of its
system devices is a little higher than other means.
3.2.4.2 Seebeck thermal management 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 heat is applied to one
of the two conductors or semiconductors, heated electrons flow toward the
cooler one. If the pair is connected through an electrical circuit, direct
current (DC) flows through that circuit.

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Figure 9: Semiconductor Thermocouple Seebeck Effect.
If the temperature difference is large enough, some Seebeck-effect devices
can produce a Voltage. Numerous such devices can be connected in series
to increase the output voltage or in parallel to increase the maximum
deliverable current. Large arrays of Seebeck-effect devices can provide
useful, small-scale electrical power if a large temperature difference is
maintained across the junctions.
Two unique semiconductors, one n-type and one p-type, are used because
they need to have different electron densities. The semiconductors are
placed thermally in parallel to each other and electrically in series and then
joined with a thermally conducting plate on each side. When a voltage is
applied to the free ends of the two semiconductors there is a flow of Direct
current (DC) across the junction of the semiconductors causing a
temperature difference. The side with the cooling plate absorbs heat which
is then moved to the other side of the device where the heat sink is. TECs
are typically connected side by side and sandwiched between two ceramic

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plates. The cooling ability of the total unit is then proportional to the
number of TECs in it.
Figure 10: Seebeck element schematic. Thermoelectric legs are thermally in parallel and electrically in series.
The Seebeck effect is a thermoelectric phenomenon where an applied
temperature gradient is directly converted to an electrical voltage. The
relationship between the temperature difference (ΔT) and voltage is
ΔV = -S ΔT
Where S is the Seebeck coefficient. By convention, a positive Seebeck
coefficient indicates that a semiconductor is p-type while a negative
coefficient indicates n-type. The Seebeck coefficients generally vary as
function of temperature, and depend strongly on the composition of the
conductor. For ordinary materials at room temperature, the Seebeck
coefficient may range in value from −100 μV/K to +1,000 μV/K.
For Our LED Product, the thermal management method is operated by
the Seebeck effect. The device has two sides, the "hot" side/plate is
attached to a heat sink so that it absorbs at LEDs and its circuit emitted
temperature, while the cool side remains at ambient or room
temperature. There are three cooling fans under the cool side/surface

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and it enhances the efficiency of the system. The voltage difference
between the hot and cool surfaces creates a Direct current (DC).
Figure 11: Simple Structure of Thermal management Method
Heat absorbed
Heat rejected
Cooling Fan
Heat sink
Ceramic Substrate
Ceramic Substrate
Voltage
Amplifier
HOT Surface
COOL Surface
LED array and its Circuit.

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Some benefits of using a Seebeck element are:
 No moving parts so maintenance is required less frequently
 No chlorofluorocarbons (CFC)
 Temperature control to within fractions of a degree can be
maintained
 Flexible shape (form factor); in particular, they can have a very
small size
 Can be used in environments that are smaller or more severe
than conventional refrigeration
 Long life, with mean time between failures (MTBF) exceeding
100,000 hours
 Controllable via changing the input voltage/current
Some disadvantages of using a Seebeck element are:
 Only a limited amount of heat flux is able to be dissipated
 Relegated to applications with low heat flux
 Not as efficient, in terms of coefficient of performance, as
vapor-compression systems
3.2.5 Design circuit diagram of final product and peltier
connection.
First we need to design the full circuit diagram of all connection and peltire
connection. Below two figures shows the connections.

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Figure 13: Full circuit Block diagram
Figure 12: Peltier Connection Bock diagram

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3.2.6 Design the final product’s physical shape and structure.
Before purchasing the all necessary item for the product, it must be designed a
physical structure of our product. Especially the physical shape with all need item.
There for we need to look the top look, side look, front look and backside look.
Figure 14: Front Look
Figure 15: Top Look

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Figure 16: Side Look
Figure 17: Backside Look

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3.2.7 List down the all necessary items for the full product.
Before purchasing all the item, it should be listed down all the necessary items for
the product with needed quantity.
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 01
Table 3: List of necessary items.

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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
1 kΩ Resistors 04

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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

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3.2.8 Purchase and order the necessary items.
5.1Ω resistors, 2.2Ω resistors are 1W resistors and have been ordered through
the ‘ebay”. All other items are purchased in local shops. The total cost for the
all items will be analysis in a future step in this report. Some purchased item’s
bills (Not all) are shown in this step.
Figure 18: Purchased item bill 01

37

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Chapter 4
Construct the product
4.1 Construct the product overview.
1. Construct the LED Array
2. Make the thermal management system.
3. Make the LED casing.
4. Fit the all items to the casing.
4.2 Procedure
4.2.1 Construct the LED Array
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.

39
Step 04
Clean the dot board. We can very softly sandpapering by sing a soft
carborundum. (150 – 220).
Figure 21: Some LED Bulbs.
Figure 22: Dot board

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Step 05
Reflector sticker (ORACAL 352) is pasted on the dot board and Each LEDs are
soldered on the Dot Board bore.
Figure 23: LEDs are soldered to the dot board
Figure 24: Soldered Back side of the

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Step 06
Clean the Resistor’s Edges and solder to the dot board.
Figure 25: Resistors after cleaning there edges
Figure 26: soldered resistors to the dot board.

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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.
4.2.2 Make the thermal management system.
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.
Figure 27: pasted two heat sinks.

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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.
Figure 28: Peltiers
Figure 29: connected Peltiers as series

44
4.2.3 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.
Figure 30: LED product casing front side view.
Figure 31: LED product casing Back side view.

45
Step 03
Drill the holes to fit the indicator lights to the casing.
4.2.4 Fit the all items to the casing.
Step 01
Cooling fans and DC base are connected on the backside cladding board of the
LED casing.
Figure 32: Drilling the holes on cladding board.
Figure 33: connected cooling fans to the cladding board.

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Step 02
Connect the wires to the ON/OFF switch & Indicator lights and connect them to
front side cladding board of the casing.
Step 03
Fixation the LED array to the casing.
Figure 34: connected the indicator lights and switch to the front side cladding board.
Figure 35: set the LED array to the casing

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Step 04
Set the peltires and the heat sink (Thermal management system) to the LED
array in the casing.
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.
Figure 36: set the Power supply to the casing

48
Chapter 5
Project cost
Item 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
Table 4: Project cost

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Chapter 6
Discussion
When sale or market this product, the main problem is Price. Because the initial cost is Rs:
15 762.50. It is very difficult to market this kind of a product in a country like Sri Lanka.
Specially, people don’t buy this much cost product for the home usage. It is the main
problem of this LED product.
The weight of this product is 2.65 kg. The weight is high. As the very first product, this
product is some kind of an experiment. Especially the thermal management method is a
very new method for the LED industry. There for the initial cost for this kind of a thermal
management method is high and also some extra weight include for that part as well. More
than 50% of weight includes in the aluminum casing. We can replace some insulated,
alleviatory but sturdy material instead of Aluminum. We can experiment some new material
for the future development such as Graphene, Self-healing plastic... Etc.
The unit cost for the NSPW500DS LED bulb is US $ 0.80 – US $ 1.20. If we purchase this
LED bulbs the total price for the LEDs is US $ 260- US $ 390. It is too much! There for we
had to find a replacement for that while keeping the basic characteristic of NSPW500DS. I
searched that kind of a better replacement in the local market, then I could find 3.0 V – 3.4
V forward voltage, intensity 12000 mcd, 20 mA forward current, color temp 3000k – 3500k,
viewing angle 25 degree and life rating 100 000 hrs. White LED bulb which unit price is
LKR 4.50 that can be usable for our product. But the main disadvantage is viewing angle.
The viewing angle is -25° to +25°. But NSPW500DS viewing angle is -90° to +90°. There
for our replacement light is little bit focus. Left and right horizontal directions may be bit
darker than the direction which perpendicular to the bulb. But it is not a big problem and
would be developed in future developments.
When we focus the light to a LUX meter it shows 10 000 LUX value which 20 times
brighter than the Day light (Day light 500LUX). We tested that focus LUX value with the
5ft above the LUX meter and hence showed that 10 000 LUX value.

50
A single peltire generates 50mV- 100mV while it is being heated between 35 Celsius and
55 Celsius. There for I connected 15 peltiers series to add the voltages because we give the
power which is generated by the peltiers to work the 12V, 3 cooling fans. The series
connected 15 cooling fans generate near 1V and we need to step up that voltage to 12v to
work the cooling fans. We can set the voltage which correspond to 35 °C as cooling fan
operate voltage (need to step up) and when the voltage rises than 35 °C, cooling fans are
automatically ON and when voltage goes below 35 °C, cooling fans are automatically OFF.
Because the voltage and the temperature of the peltires show a linear relationship according
to ΔV = -SΔT equation.
As my first experimental construct of analysis and performance improvement of solid state
lighting system product, this product has several sides to improve. My only ambition is that
do the testing and developing of the product to achieve the current LED product market
with the competitive quality.
Figure 37: Me, Testing the LUX value while focusing the Light to the LUX meter. Distance
between light and LUX meter is 5ft.

51
Chapter 7
Future work and conclusion
7.1 Future work
7.1.1 Product development
7.1.1.1 Setting an attractive price
The main aim of the future work is diminution the initial cost. The initial cost is LKR 15
762.50. It should be a bearable price to a country like Sri Lanka. There for we need to make
a total overview of the product and should point out each and every possible points which
have an ability to diminution of the initial cost. My personal opinion is that we should not
exceed the price limit more than LKR 3500.00 for a LED product which aim is the home
day today usage. As the first experiment product this initial cost may be ok. But for the
future development, the price should be a bearable in Sri Lanka.
Importance of price,
 The only element in the marketing mix which generates profit/revenue
 Major Determination of buyer choice, and most flexible marketing mix element.
 Customer react immediately to the “price”.
 Interactive effect with other elements, it is not effective to set price independently
from those of other elements

52
Price
 Broadly: Price is the sum of all the values that customers give up in order to gain
the benefits of having or using a product.
Setting price,
 Selecting the pricing objectives
 Determining demands
 Estimating cost
 Analyzing competitors’ costs prices and offers
 Selecting a pricing method
 Selecting the final price
Before we set the price for a product, we should concern the following pricing strategy,
Market skimming strategy.
 Situation: discover new technology, invent new product.
 Set high initial prices to “skim” the market layer by layer
Goals,
 Product quality leadership
 Use price to signal high quality in an attempt to position the product as the quality
leader.

53
Penetration strategy
 Set the lowest price in the market to increase sales and achieve maximum market
share.
Goal:
 to capture the largest market share
 to overcome competition
 to impose switching barriers
For a developing country like Sri Lanka, the best price setting method is Penetration
strategy. The main reason for selecting this method is per capita income in the Sri Lanka.
There for before further developing of this product, we should think about that. Furthermore
we can make the product under two category which one is costly, has more features, aim
developed country and other one is a fundamental cheaply product, aim local market.
Figure 38: Skimming Price chart.

54
7.1.1.2 Weight reduction.
The weight of the product is 2.67 Kg which is bit higher. The new trend is small and smart
concept. There for we have to lighten the product. Especially we have to select light and
strength material for casing. This may be a huge reason to reduce the weight in a
considerable factor.
7.1.1.3 Improve the wiring order
This experimental product wiring method is not much neat. When this develop as a better
product, it is very importance to make very clean and neat wiring system. Especially for
the thermal management method. It is very importance for getting a better understand of
system for other person and as well as for the operating if there is a problem.
7.1.1.4 Design a voltage step up module for thermal management system
Series connected peltiers generate approximately 1V. But the cooling fan’s operating
voltage is 12V. There for we need to step up the system to 12V. For that, we can buy or
design a voltage step up device. In this made product I didn’t have enough time to design
or order a 1V to 12V, Voltage step up device. In the future development, it must be placed
a voltage step up device.
7.1.1.5 Improve the viewing angle of the bulb.
The viewing angle of used LEDs is -25° to +25°. But NSPW500DS viewing angle is -90°
to +90°. There for when we switch on the LED product, the light beam bit focus and lack
of extensive. We designed our product for 15ft x 15ft size room. There for the light should
be equally divided in all directions. This is a one of main problem in this product. to
overcome that product we have to either re-arrange the bulbs positions or replace the bulbs
with a wide angle bulb which having the same characteristic.

55
7.1.1.6 Achieving the industrial standard. (Bench- mark)
International Standards are the backbone of our society, ensuring the safety and quality of
products and services, facilitating international trade and improving the environment in
which we live in.
Conformity to International Standards helps reassure consumers that products, systems and
organizations are safe, reliable and good for the environment.
When we introduce a LED product to the local or global market, we should achieve the
industrial stand. It has many benefits,
 For business
International Standards are strategic tools and guidelines to help companies tackle some of
the most demanding challenges of modern business. They ensure that business operations
are as efficient as possible, increase productivity and help companies’ access new markets.
ISO standards help businesses to:
 Cut costs, through improved systems and processes
 Increase customer satisfaction, through improved safety, quality and processes
 Access new markets, through ensuring the compatibility of products and services
 Reduce their impact on the environment.
ISO 9001, for example, has been shown to improve sales, customer satisfaction, corporate
image and market share (Manders 2014) and ISO 14001 has been shown to have a positive
impact on environmental performance.
 For Consumers
ISO has over 21000 standards touching almost all aspects of daily life.
When products and services conform to International Standards consumers can have
confidence that they are safe, reliable and of good quality. For example, ISO's standards on
road safety, toy safety and secure medical packaging are just a selection of those that help
make the world a safer place.

56
To make sure that the benefits of ISO International Standards are as broad as possible, ISO
supports the involvement of consumers in standard development work with its Committee
on consumer policy (COPOLCO).
International Standards on air, water and soil quality, on emissions of gases and radiation
and environmental aspects of products contribute to efforts to preserve the environment and
the health of citizens.
 For government
ISO standards draw on international expertise and experience and are therefore a vital
resource for governments when developing public policy.
National governments can use ISO standards to support public policy, which has a number
of benefits, including:
 Getting expert opinion - By integrating an ISO standard into national regulation,
governments can benefit from the opinion of experts without having to call on their
services directly.
 Opening up world trade - ISO international standards are adopted by many
governments, so integrating them into national regulation ensures that requirements
for imports and exports are the same the world over, therefore facilitating the
movement of goods, services and technologies from country to country.
Learn more about ISO standards and public policy.
ISO standards can also remove barriers to world trade by providing the technical basis on
which political trade agreements can be put into practice, whether they are at the regional
or international level.
There for, when we improve this product, it must be achieved the Industrial standard. If
think beyond the boundary that this is NOT only a 4th
year project, we should think about
these things as well. When we go to the industry and develop this kind of product to win
the market, these thing are key points.

57
7.1.1.7 Improving the attractively of the product.
The attraction is a one of major reason to buy a product. There for we need to think about
product appearance as well. For the further improvement we should plan to make a
competitive and attractive product. Especially the design of the casing is very importance.
Need to experiment about light weight insulator material and attractive design.
7.1.1.8 Introducing the new varieties for the product.
This product is mainly designed to hang on a ceiling. But we can introduce some other
verities for this product. We can design a product which can put on a table, cabinet and as
well as light weight portable product with contraction handle. Also we can experiment
varies colors, varies shapes, designs. Some water proof product can be introduced for the
kitchen, washroom, and bathroom usage. We can arrange the LED array lights
arrangements and can make varies shapes like round, string, rectangular, triangle…etc.

58
7.1.2 Found my Own LED production Company.
“Imagination is everything. It is the preview of life’s coming attractions.”
-Albert Einstein -
I 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.
LOGO of My Company.
My name is Chanaka De Silva. The CDS represents my name. My company’s theme is “We
color the whole World”. This image shows that we can color the whole world. The first and
last W s are capital. That means we are in worldwide from start to End.
Figure 39: LOGO of my Company.

59
Introduction about my company
This company mainly based LED associated product. The above logo image represent
the world and a halo. That means we cover the whole world under our LED halo. The
World image has blue and Red Square. Red Square means the brighter side of the world.
That means the developed countries. Blue square means still dark sides of the world.
That means developing countries and un-developed countries. But our halo doesn’t have
any separation either red square or blue square. We service same to both. That means
our company has varies of product under different price ranges for whole world. We
also design product for the lower and middle class people while designing product for
the first class people. Because light is common for all.
Vision of my company
The global leading partner for sustainable and environmental friendly lighting solutions.
Mission of my company
Designs and supplies sustainable lighting solutions for all customers, enabling them to
reduce costs, energy consumption and environmental impact.
Aim of my company
Color the whole world.

60
Organization structure of my company
Company Organization Chart of CDS Product (PVT) Ltd.
Research & Development Department Organization Chart of LED Lighting Solution Division
Mr.: Chanaka de silva

61
7.2Conclusion
The evolution of standards has, at large, followed the development of lighting
technologies, cost of lighting and the increased scientific understanding of vision. The
recommended values of illuminances have followed the development of light sources. For
instance, in the second half of the 20th
century the evolution of fluorescent lamps led to
increases in the recommended illuminance levels. The difference between the lighting
standards and recommendations in different countries has been attributed to the economical
context and the geographical zone of the country. The current indoor lighting design is
based largely on providing more or less uniform levels of illuminances in the room, while
the perception of the luminous environment is related mainly to light reflected from surfaces
i.e. luminances. Thus innovative lighting design methods could be introduced which give a
high priority to the quality of the luminous environment as our eyes perceive it. Both the
electrical lighting design and the use of daylight have a major impact on lighting quality
and energy efficiency. The present lighting recommendations do not specify recommended
values of daylight factors or other daylight parameters.
The aim of an optimum lighting design is to achieve certain appearances and, at the same
time, to fulfill the fundamental physiological and psychological visual requirements and to
ultimately put the whole thing into effect in an energy efficient manner. LEDs allow for
completely new designs and architectures for lighting solutions, thus opening a new and
wide field of creativity for all lighting professionals. At the same time, some old rules and
standards for a good lighting design are no more applicable to LEDs (e.g. glare assessment,
color rendering, light distribution, etc.).
The introduction of more energy efficient lighting products and procedures can, at the
same time provide better living and working environments, and also contribute in a cost-
effective manner to the global reduction of energy consumption, heating and greenhouse
gas emissions.

62
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: 10, May, 2016]
[3] Bender V. C, Marchsan B.T, Solid-State Lighting, IEEE Electronics Magazine, 9th
Volume, June, 2015.
[4] Specification for White LED – NSPW 500DS, NICHIA Corporation.
[5][Online]Available:http://www.compuphase.com/electronics/candela_lumen.htm .[Acces
sed: 10, May, 2016]
[6] [Online] Available: http://searchnetworking.techtarget.com/definition/Seebeck-effect.
[Accessed 1, 10, 2016]
[7] [Online] Available: https://en.wikipedia.org/wiki/Thermoelectric_cooling. [Accessed,
15, 10, 2016]
[8] [Online] Available: http://www.iso.org/iso/home/standards/benefitsofstandards.htm
[Accessed, 01, 12, 2016]
[9] 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

Final report EN13540036 De Silva G H C N

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