The document provides an overview of LED lighting, highlighting major markets and applications including entertainment and architectural lighting. It addresses challenges in LED design, particularly binning, and offers solutions for board-level manufacturing and thermal management. Additionally, it discusses PCB design considerations and showcases SMT assembly solutions for LED production.

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LED Lighting Overview: Major Players

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LED Lighting Overview: Market Considerations
 Major Markets
 Entertainment / Theatrical
 Architectural Lighting
 Retail / Office Lighting
 Signage
 Street Lighting
 Applications
 RGB
– Early growth in entertainment space
– Quick adoption into architectural lighting
 White
– Vast adoption following the growth in LED technology
– Energy efficiency initiatives speeding up market penetration

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LED Design Challenges: Binning
 LED Manufacturing companies sort their product by “Bins”
based on lumen output, chromaticity, and wavelength
 Leads to complications in the board-level manufacturing
process
 Many ways to compensate:
 SMT Line part placement
 Calibration in software
 Closed loop feedback

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LED Design Challenges: Binning
 LED Manufacturing companies sort their product by “Bins”
based on lumen output, chromaticity, and wavelength
 Leads to complications in the board-level manufacturing
process
 Many ways to compensate:
 SMT Line part placement
 Calibration in software
 Closed loop feedback

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LED Binning (Cont’d)

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LED Binning (Cont’d)

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Binning Compensation
 SMT line placement:
 Treat different bins of LEDs as different components and place
accordingly
 Calibration Techniques:
 Current Control
– Use 1 bin per board
– Constant current control
 Power Control
– Forward voltage implications over time and temperature
– Adjust current real time to compensate for variation in
forward voltage

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Binning Compensation (Cont’d)
 Feedback techniques:
 Light sensor:
– Sense light output and adjust power accordingly
– Lifetime adjustment:
– Use light sensor to detect reduced light output due to
degradation of efficiency over long periods of time
– Adjust power to achieve previous light output, extending
the lifetime of the product
 Lifetime considerations:
 Thermal Management
 Current and temperature relationship used to estimate lifetime
 Measured by “L70” for white and “L50” for RGB

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PCB Design Considerations
 LED lighting fixtures are usually serial in nature
 Power is usually passed along the “daisy chain” along w/ data
 Leads to increased difficulty in board-level designs to minimize
losses
 When designing for manufacturability, must provide for worst-
case scenario
– e.g. A 4 fixture chain powered by 24V @ 1A
– Power only comes into first board so it must carry current for
all other boards to the output connector
– Size traces accordingly
– Minimize distances between input and output
 EMI Critical for offline applications
 LED fixtures held to same EMI standards as traditional lighting
sources
 Difficult to design for EMI with PWM implications

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PCB Design Considerations (Cont’d)
 Thermal issues:
 Transistors switching LEDs will generate heat
 LEDs themselves generate heat (~25% efficient)
 Thermal solutions:
 Metal Core PCBs popular for heat dissipation
 Mechanical integration key for heat sinking / thermal flow
 Temperature monitoring via onboard thermistors
– Thermal shutdown or compensation
– Active over LED lifetime

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PCB SMT assembly Solutions
6 Months ROI
One line equipments Investment: $120k
40K T8 LED tubes/ Day
SMT Assembly earning $0.05 /Tube
Profit: $50K per month

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Fast then Fast
—Actual Speed: 120K CPH
(one pick & place cycle: 1 sec)
—36 nozzles: Gang pick/Gang Place
—2 Placement head: Linear motor
—Smart Feeder: 100% compatible NXT
—Cross platform: PCB size 1.2x0.3m

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Lower then Lower cost
Creative Nozzle: Life cycle > 1 year
(Unit price for nozzle: $6.00)
Less and less PM
Saving power consumption: 3KW
One line space: 5 lines throughput

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Totally Support
7x24 supporting respond
Worldwide Installation and on site support
Factory (machine and lighting assembly) training
2 years warranty for whole machine

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Welcome inquiry
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