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A replacement LED lamp design

With the LED product innovation, LED lighting has gradually been widely used in the field of lighting, such as home, office, public facilities construction. Straight tube lamp as a traditional lighting area of ​​a major specialty products, with a high market share, LED lighting products in the large-scale development trend, straight tube LED lamp research and development promotion is also in full swing carried out. This article describes a design that can replace the traditional lamp LED lamp, through the mass production verification, the process is simple, high reliability, can be promoted and applied, which can replace the traditional straight tube Fluorescent lamps, the market prospects are very broad.
1, straight tube LED product classification and characteristics
1.1, Product Structure Classification
From the perspective of the characteristics of the tube structure, the current market are more common straight-tube LED products mainly include the following categories: ① semi-aluminum semi-plastic; ② plastic bag aluminum; ③ all-plastic; ④ all-glass tube and so on.
1.2, all-glass LED tube light features
All-glass straight tube LED with its own characteristics: the shape and the traditional T8 (T5) light source, soft light color, high luminous efficiency, easy replacement, etc., in the market more and more accepted, the market share Also steadily rising. Although the glass straight tube LED has a certain market share, but can really directly replace the traditional fluorescent lamps, direct point of the original fluorescent lamps in the product is small, we replace the convenience based on the consideration of design and manufacture of a look and tradition of straight The same LED tube.
2, LED lamp design
Combined with the traditional shape of fluorescent lamps, replacement LED lamp components are divided into: drive design, selection of shell glass, plug head, light-emitting devices.
2.1, drive circuit design
Driver circuit is the key to replace LED tube design, circuit access to simulate the traditional fluorescent filament. The drive power supply consists of a main circuit for buck current limit, rectification and filtering, and an analog filament resistance circuit with a normally lit LED tube and an LED lamp to protect against high voltage surges. The design includes an overvoltage and overcurrent protection circuit to prevent the lamp from being damaged due to over-current and / or over-voltage, and a frequency detection circuit to generate an induced voltage only at the time of high-frequency current input for connecting the low frequency AC or high frequency The alternating current is converted to a non-cluttered direct current rectifying and filtering circuit, the direct current output from the rectifying and smoothing circuit is stepped down to obtain the working voltage of the LED lamp bead group in the LED fluorescent tube, and the buck buck circuit is used for shielding the BUCK buck circuit in the PWM switching circuit to directly control the BUCK step-down circuit high frequency circuit; the overvoltage and overcurrent protection circuit input terminal connected to the city of low-frequency AC or electronic ballast output High-frequency alternating current, an output terminal of the over-voltage / over-current protection circuit is connected to an input terminal of the frequency detection circuit, an output terminal of the frequency detection circuit is connected to an input terminal of the rectification filter circuit, The other output terminal of the frequency detection circuit is connected to the input terminal of the high-frequency direct circuit, the output terminal of the rectifier filter circuit is connected to the output terminal of the high- BUCK step-down circuit connected to the input terminal, the output of the high-frequency circuit directly connected to the BUCK buck control circuit is connected to the output terminal of the BUCK buck circuit and LED tube LED Light bead group connection. Drive line as shown in Figure 1
2.2, LED straight tube lamp with glass performance requirements
Straight tube LED lamp shell glass tube performance include appearance, light transmittance, atomization degree, temperature and humidity resistance, moisture resistance, hardness, conductivity, expansion rate, curvature, and the whole light color parameters influences.
The key indicators are as follows:
① Appearance: the color is generally milky white, smooth surface, no bubbles, no scratches, no noise and other points;
② transmittance: test calculation method, with the same light source at the specified voltage power were applied the same specifications of the transparent glass tube and milky white glass tube, with the test of its photoelectric ball photoelectric parameter test, milky white and transparent light effect Ratio is the light transmittance, usually under the light transmittance of 92% or more;
③ atomization degree: the matching light source (lamp beads) device on the glass tube, the rated voltage, power will light the lamp, do not see the light-emitting point (lamp beads), requiring the entire glass tube atomization degree of uniformity, light Consistent performance, no significant difference between light and dark;
④ temperature performance: the glass tube on the 150 ℃ high temperature box, 200 hours later, no color change, no burst, no deformation and other anomalies;
⑤ water resistance: the glass on the 60 ℃ constant temperature water bath, 24 hours later, no color change, no burst, no deformation and other anomalies;
⑥ expansion coefficient fluctuations: the same batch of glass tube expansion coefficient fluctuation control requirements ± 1 × 10-7 / ℃;
⑦ conductivity: glass tube inside and outside the wall are required non-conductive;
⑧ light color effects: milky white glass tube and transparent glass tube with the same light source test light color parameters, spectral, color temperature, color rendering index can not have significant differences;
⑨ hardness: T8 glass, for example, the use of universal glass pressure gauge to test the vertical pressure of the general requirements of more than 300N, specific to the factory customers prevail.
⑩ bending: T8-1.2 m long glass tube, for example, the general requirements of the curvature of not more than 3 °.
The above performance, light transmittance, degree of atomization, temperature and humidity, light color effect is more emphasis on the majority of manufacturers.
2.3, lamp design
Replacement LED lamp mainly consists of: plug 1, the end of the circuit board 2, power-driven, light-emitting module 3, 4 shell glass tube. Light-emitting module has a substrate material and SMD LED lamp beads, the LED lamp beads evenly distributed in the middle of the substrate. As shown in Figure 2 below
(Click on the image for a larger view)
3, LED glass lamp production program
3.1, LED lamp production process, there are difficulties
Under normal circumstances, the glass tube light-emitting devices and glass with glue for bonding, first of all, there is difficulty in curing glue. Glue in LED glass tube production process is generally silica gel, which takes a long time in the curing process, thus increasing the number of product turnover in the entire production process, the fluency in the connection of each production link is affected, and the production efficiency is low. Second, dispensing equipment, LED glass tube in the production process, the installation of PCB and plug require dispensing equipment to complete the current dispensing equipment technology matures, the process is relatively small difficulty; the third , In the entire installation process of LED lamp, power supply and plug installation is the most complex, to achieve the greatest resistance to the operation of the pipeline.
3.2, lamp production process automation program to consider
In order to solve the related problems existing in LED production technology and realize its systematic production of fluidized production, we must concentrate on solving the above problems in the production process. And, LED glass lamp production process automation program also have to focus on the work to start, automated process in the production of LED glass tube play a role in reducing costs and improve production efficiency, all enterprises in the relevant production process, the right The introduction of automation technology to make the appropriate provisions, of which the introduction of automation must simplify the production process, the fixed product structure, to protect the substantial increase in product output. Therefore, the introduction of automation technology to improve product output in the process must be in accordance with the fixed product structure, to simplify the process of production process.
4 Conclusion:
In this paper, the design scheme of an all-replacement LED glass tube is briefly described and the technical difficulties are analyzed. It is proposed to solve the technical difficulties by using simulated filament resistance design circuit and lamp bead arrangement to solve the technical difficulties. At the same time, Plastic, automated assembly process program, in order to optimize LED glass lamp design, process plan, LED glass lamp production promotion have some guiding significance.
[1] Cheng Bin.LED glass lamp production process and automation solutions [J]. Journal of Foshan University (Natural Science Edition), 2016,34 (2): 65-71.

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