Cypress Semiconductor Perform CY8CLEDxx Spécifications télécharger pdf (Page 10)

POWER

•

THERMAL

•

INTEGRATION

•

OPTICAL

In 2004 MAL Effekt-Technik undertook

the challenge of creating a high-power

LED swimming-bath floodlight to replace

existing halogen lighting. The aim was to

create a module fitting the standard

mounting of a 150W halogen-based

underwater floodlight with comparable

or improved quality illumination.

They began by sizing up the competition, and analysing relevant

data for the halogen model. For instance, the halogen floodlight

was measured with an optical measuring bench to register the

whole lighting allocation which would need to be reproduced.

Additionally, the halogen reflector was optically measured and

included in the data used to develop the secondary optic for the

high-power LED module.

The first major challenge was to specify the electronic

requirements. Since there was only a two-core wire leading to the

floodlight, electronic control had to be placed within the high-power

LED module itself. The maximum voltage was limited to 24V, so

MAL Effekt-Technik decided to use an external switching power

supply with Power Factor Correction, featuring an input voltage

range from 100V to 300V and an output voltage of 24V.

Based on the analysed optical data MAL Effekt-Technik calculated

that the required amount of lumen output equated to 24 LUXEON

III LEDs. Ideally, MAL Effekt-Technik would have preferred to use

more LEDs but, as this was a retro-fit assignment, space was

limited. Using LUXEON III Stars various prototypes were built and

tested, which MAL Effekt-Technik used to develop the secondary

optic and to test the electronic control equipment.

After final mechanical configuration of the LEDs, the PCB was

developed. MAL Effekt-Technik opted for Metal Core Printed Circuit

Board (MCPCB) material by Bergquist as this offered the heat

conductance required to efficiently drive the high-power LEDs.

As MAL Effekt-Technik strongly believe in the importance of efficient

and intelligent thermal management, an 8-bit microcontroller was

integrated into the high-power LED module to control temperature,

supply constant current via a switching regulator step and to

implement soft-start. Both the microcontroller and the switching

regulator were to be included on the PCB, which added to the

demand on the limited amount of available board space.

The biggest issue, however, was how to remove heat from high-

power LEDs housed in a stainless steel floodlight case. Stainless

steel has a bad heat conductance value, so MAL Effekt-Technik

designed an aluminium heat-sink which stored enough heat to

allow dissipation through the stainless steel case and into the

surrounding water. To achieve this, various calculations, simulations

and prototypes were required. MAL Effekt-Technik eventually

achieved a slug temperature of 45°C at a water temperature of

30°C.

Since the completion of the project MAL Effekt-Technik have built

and sold hundreds of the underwater floodlights – single colours as

well as RGB. Also, their adoption of high-power LED technology

has not stopped and today MAL Effekt-Technik produce underwater

floodlights with 27 LUXEON K2 LEDs and an input voltage of 12V.

For the second half of 2007 MAL Effekt-Technik plans to release a

module with 36 of the latest LUXEON Rebel LEDs. These continuing

developments are reducing maintenance cost, lowering power

consumption and improving colour capabilities for swimming-

bath lighting.

Markus Vockenroth

Managing Director – MAL Effekt-Technik

Development of

a high-power LED

swimming-bath floodlight

to reduce maintenance cost,

lower power consumption and

improve colour rendering

LED

underwater lighting

replaces

halogen

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