Complete Report Jatin

Under the Guidance of Mr. Aditya Tyagi & Mr. Manish Mohan Sr.
R&D Engineers
Compiled By: Name :Jatin Sharma Roll No :277264 Branch :ECE (Eve)
CERTIFICATE
TO WHOM IT MAY CONCERN
This is to certify that Master Jatin Sharma Pursuing Diploma in Electronics and communication from Guru Nanak Dev Co-ed Polytechnic under Delhi technical university, Delhi has been under Industrial training from 10th July to 22nd August 2009 under my guidance. During this tenure he has worked on testing and working of various product from our range and successfully completed them to the best of his abilities. His conduct has been good during this tenure. We wish him good luck for his future Assignments.
Jatin Sharma Roll No :277264 CE (Eve)
For Instapower
(Authorized signatory) Mr. Arun Bhatia V.P. Business Development
Table Of Contents
Preface. i Acknowledgement... ii Company profile..iii Chapter 1: Introduction .1 Chapter 2: New Technology...3 Chapter 3: Lighting facts..11 Chapter 4: How to produce LEDs16 Chapter 5: Market potential.19 Chapter 6: Case studies22 Chapter 7: Assignment Undertaken.25 Appendix: Photo gallery...35
TRAINING REPORT ON LED LIGHTING
PREFACE
The industrial training gives students an opportunity to learn the practical experience. This provides him a wisdom of applying his theoretical knowledge into practical fields. I got this opportunity to enhance my practical experience at Instapower Ltd, Gurgaon.
Energy conservation has become the hottest topic these days. So, Government is working on it and formed many organizations like Bureau of Energy Efficiency (BEE) are working very dedicatedly. This report explains the basics of the LED technology and its application in Energy efficient lighting. Comparative studies between conventional or contemporaries like Incandescent bulbs, CFL with LEDs light has been done and hence the forthcoming potential market is observed.
In total the motto of the report is Power Saved is Power Earned.
GND POLYTECHNIC, ROHINI, NEW DELHI
ACKNOWLEDGEMENT
This industrial training has been carried out due to the kind support from Mr. Himanshu Rai Vaish, Managing Director, Instapower Ltd., Gurgaon, Haryana. I am grateful to him for giving me an opportunity to do my six weeks summer training in his Organization. I take this privilege to express my gratitude and sincere appreciation to Mr. Arun Bhatia, Sr. V. P., Business Development, my guides Mr. Aditya Tyagi, Sr. Engineer R&D and Mr. Manish Mohan, Sr. Engineer R&D for their extremely intruding valuable guidance, constant encouragement and personal involvement and gracious relationship that has been of illimitable significance in shaping the quality of work. I would like to thank, Mr. Rajdeep Pant, Project Engineer, Mr. Zia-UlHassan, Technical Support Engineer and other R&D Engineers of the organization, for their knowledgeable support and constant guidance during the training. Also, I convey my gratitude to complete Instapower team who helped me in gaining this valuable experience during the past six weeks.
Last but not the least; I would like to thank my parents and lecturers for their valuable support during the training at this prestigious organization.
Jatin Sharma
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COMPANY PROFILE
Instapower is a known name in the field of power electronics and has expertise in the field of designing and manufacturing world class products. It has been promoted by an alumnus of Indias premier institute, Indian Institute of Technology, Delhi. It is an ISO 9001 TUV (Germany) certified organization, and has been in the field of power electronics for nearly two decades. In the past 5 years it has diversified into the area of Energy Efficient Lighting Solutions using T5 Tube lights and LEDs. The company has, over years, developed new and innovative products and there has been constant endeavor to improve the quality of the products. The company achieved an average growth rate of 100% per year in the last 5 years and is now poised for a steep growth. Instapower is the only organization in India which has such a diverse range of Led Lighting and Fluorescent Tube light (Insta T5) products under one roof. It has developed the technology for LED-based system after investing many man-years in R&D, mastering the technology, electronics and optics. Instapower and its founder have filed more than 10 patents in India and abroad in the area of LED lighting and energy efficiency. Instapower has been recognized as R&D House by DSIR (Department for Industrial Research, Govt. of India ) and also listed as an ESCO organization by the Bureau of Energy Efficiency (BEE). Instapower is amongst the select few pioneers in India who have propagated the LED technology.
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Chapter 1: INTRODUCTION
We all know Power is a concurrent subject. It is not just in India but the entire world that has failed to make up for the shortage of power. With energy prices on the rise and natural resources receding, it has become more important to conserve power for the brighter life of our future generation. Small steps at the individual level can really change the way we utilize electricity at homes or even outside. A good supply of light does not necessarily mean the consumption of a great deal of electricity. If the right lamp is selected for the right type of function, it is possible to save electricity Unlike the CFLs, LEDs can illuminate your houses as well as streets and even the outdoors replacing the HIDs, at a fraction of cost. Until recently, LEDs were limited to single-bulb use in applications such as instrument panels, electronics, and pen lights and, more recently, strings of indoor and outdoor Christmas lights, but now these small bulbs are ready to take the place of the established technologies for the better of the human beings. Sandia National Laboratory estimates that if half of all lighting is based on LEDs by 2025, the world would use 120 GW less electricity, saving $100 billion a year and cutting the carbon-dioxide emissions from power plants by 350 Megatons annually. Innovations in photonics and solid state lighting will lead to trillions of dollars in cost savings, along with a massive reduction in the amount of energy required to light homes and businesses around the globe, the researchers forecast. In addition to the environmental and cost benefits of LEDs, the technology is expected to enable a wide range of advances in areas as diverse as healthcare, transportation systems, digital displays, and computer networking. To bring all these things into reality, there is urgent need to a. To develop mass level production to decrease cost b. To adopt new technologies to reduce production cost c. In many energy conscious states, government should enforce LED bulbs for street lighting and other public areas to bring savings to bloated energy bills. d. Need more R&D efforts towards nano techlogy crystal technology used for LED lighting As per study or survey carried out in this report, I am sure that LED is surely a drive towards green earth. So, GO GREEN BY ADOPTING LEDs
The need of the time says that, in the global world if we want to survive and move ahead in life then we have to be in the race to accept new technologies for organizational controls. Science has improved tremendously in every sphere of life. It has eases the life of human and have made this world a global village where there is no boundary to achieve success. So whenever we talk of the technology to be used for the functioning of a system, it does not indicate that it should compromise in any field. Some of the major points on which the choice stays are: The technology should be efficient and updated and need automation for control. The life of functioning should be more for less maintenance and carefree controls for long time. The technology should be safe for every one so that everybody should be aware of the principles and equipments used. The updated or new technology must be capital saving that is cost effective.
LED lights are the future of lighting due to many advantages. Hence they are used for the critical systems where the clear vision, distant vision, uniform Lux output is required and necessary.
Chapter 2: NEW TECHNOLOGY

LED- The Future of Lighting
Light Emitting Diodes, commonly called LEDs, are real unsung heroes in the electronics world. They do dozens of different jobs and are found in all kinds of devices like digital clocks, remote controls, watches and indicators in home appliances. Collected together, they can also form images on a jumbo television screen or illuminate a traffic light.
LED-At a Glance
Basically, LEDs are just tiny light bulbs that fit easily into any electrical circuit. But unlike ordinary incandescent bulbs, they don't have a filament that will burn out, and they don't get especially hot. They are illuminated solely by the movement of electrons in a semiconductor material, and they last just as long as a standard transistor.
LED is too a diode which is the simplest sort of semiconductor device. Broadly speaking, a semiconductor is a material with a varying ability to conduct electrical current. Most semiconductors are made of a poor conductor that has had impurities (atoms of another material) added to it. The process of adding impurities is called doping. In the case of LEDs, the conductor material is typically aluminum-gallium-arsenide (AlGaAs). In pure aluminum-gallium-arsenide, all of the atoms bond perfectly to their neighbors, leaving no free electrons (negatively-charged particles) to conduct electric current. In doped material, additional atoms change the balance, either adding free electrons or creating holes where electrons can go. Either of these additions makes the material more conductive.
A semiconductor with extra electrons is called N-type material, since it has extra negatively-charged particles. In N-type material, free electrons move from a negatively-charged area to a positively charged area. A semiconductor with extra holes is called P-type material, since it effectively has extra positively-charged particles. Electrons can jump from hole to hole, moving from a negatively-charged area to a positively-charged area. As a result, the holes themselves appear to move from a positively-charged area to a negatively-charged area. A diode comprises a section of N-type material bonded to a section of P-type material, with electrodes on each end. This arrangement conducts electricity in only one direction. When no voltage is applied to the diode, electrons from the N-type material fill holes from the P-type material along the junction between the layers, forming a depletion zone. In a depletion zone, the semiconductor material is returned to its original insulating state -- all of the holes are filled, so there are no free electrons or empty spaces for electrons, and charge can't flow.
At the junction, free electrons from the N-type material fill holes from the P-type material. This creates an insulating layer in the middle of the diode called the depletion zone.
To get rid of the depletion zone, we have to get electrons moving from the N-type area to the P-type area and holes moving in the reverse direction. To do this, connect the N-type side of the diode to the negative end of a circuit and the P-type side to the positive end. The free electrons in the N-type material are repelled by the negative electrode and drawn to the positive electrode. The holes in the P-type material move the other way. When the voltage difference between the electrodes is high enough, the electrons in the depletion zone are boosted out of their holes and begin moving freely again. The depletion zone disappears, and charge moves across the diode. The negative electrons in the N-type
material are attracted to the positive electrode. The positive holes in the P-type material are attracted to the negative electrode. No current flows across the junction because the holes and the electrons are each moving in the wrong direction. The depletion zone increases. When the positive end of the circuit is hooked up to the N-type layer and the negative end is hooked up to the P-type layer, free electrons collect on one end of the diode and holes collect on the other. The depletion zone gets bigger.
LED: How It Produces Light ?

Light is a form of energy that can be released by an atom. It is made up of many small particle-like packets that have energy and momentum but no mass. These particles, called photons, are the most basic units of light. Photons are released as a result of moving electrons. In an atom, electrons move in orbitals around the nucleus. Electrons in different orbitals have different amounts of energy. Electrons with greater energy move in orbitals farther away from the nucleus. For an electron to jump from a lower orbital to a higher orbital, something has to boost its energy level. Conversely, an electron releases energy when it drops from a higher orbital to a lower one. This energy is released in the form of a photon. A greater energy drop releases a higher-energy photon, which is characterized by a higher frequency. As we saw in the last section, free electrons moving across a diode can fall into empty holes from the P-type layer. This involves a drop from the conduction band to a lower orbital, so the electrons release energy in the form of photons. This happens in any diode, but you can only see the photons when the diode is composed of certain material. The atoms in a standard silicon diode, for example, are arranged in such a way that the electron drops a relatively short distance. As a result, the photon's frequency is so low that it is invisible to the human eye. It is in the infrared portion of the light spectrum. This isn't necessarily a bad thing, of course: Infrared LEDs are ideal for remote controls, among other things. Visible light-emitting diodes (VLEDs), such as the ones that light up numbers in a digital clock, are made of materials characterized by a wider gap between
the conduction band and the lower orbitals. The size of the gap determines the frequency of the photon and in the other words; it determines the color of the light.
Led-latest version (Power Leds)
LED packages may contain just one chip or multiple chips (comprised of layers of semi-conducting material), mounted on heat-conducting material called a heat sink and usually enclosed in a lens. The resulting device, typically around 7 to 9 mm on a side, can be used separately or in arrays. LED devices are mounted on a circuit board, which can be programmed to include lighting controls such as dimming, light sensing and pre-set timing. The circuit board is mounted on another heat sink to manage the heat from all the LEDs in the array. The system is then encased in a lighting fixture, architectural structure, or even a light bulb package. The LEDs do not have any fusible filaments or elements. They also do not contain any gases such as Mercury or Sodium. When electricity passes through the LED, the electrons passing through the DIODE under goes an energy change and produces the light. Since it is a Solid State light production without any gas or heating LEDs last for a very long time. LEDs are diodes, which is a semiconductor device that will conduct electricity in only one direction. The device is fabricated from layers of silicon and seeded with atoms of phosphorus, germanium, arsenic or other rare-earth elements. The layers of the device are called the die and the junction between the materials is where the light is generated. The electricity enters from one side of the die and exits out the other. As the current
passes through the LED device, the materials that makes up the junction react and light is emitted. Different materials and designs have different colored lights and intensities.
Solid State Lighting

Lighting application that uses light-emitting diodes (LEDs), organic light-emitting diodes (OLEDs), or light-emitting polymers are commonly referred to as solid-state lighting. Technical advances have dramatically improved the reliability and the performance of the LEDs since they were invented in the 1960s. The lifetime for the new generation of LEDs is around 100,000 hours of use, or 30 to 40 years of normal operation. Because they are a semiconductor device, they are also very rugged and are not subject to fail when dropped or vibrated, as do incandescent and fluorescent lights. The original LEDs only emitted light of one frequency or color of light. These were blues, greens, yellows, oranges or reds and they were unsuited for domestic lighting. Recent innovations in materials, doping and die structure have developed high brightness LEDs that emit light in all visible frequencies to produce white light. LEDs are part of a family of lighting technologies called Solid-State lighting. This family also includes OLEDs (Organic Light Emitting Diodes). OLEDs (pronounced OH-leds) consist of sheets of carbon-based compounds that glow when a current is applied through transparent electrodes. While not yet market ready, OLEDs will function like a thin film on a wall or ceiling that illuminates a room. Like LEDs, OLED technology is advancing rapidly and can be referred as Future of LED Lighting
Advantages Of Leds
While all diodes release light, most don't do it very effectively. In an ordinary diode, the semiconductor material itself ends up absorbing a lot of the light energy. LEDs are specially constructed to release a large number of photons outward. Additionally, they are housed in a plastic bulb that concentrates the light in a particular direction. As you can see in the diagram, most of the light from the diode bounces off the sides of the bulb, traveling on through the rounded end. LEDs have several advantages over conventional incandescent lamps. Efficiency: LEDs produce more light per watt than incandescent bulbs as in conventional incandescent bulbs, the light-production process involves generating a lot of heat (the filament must be warmed). This is completely wasted energy, unless someone using the lamp as a heater, because a huge portion of the available electricity isn't going toward producing visible light.
LEDs generate very little heat. A much higher percentage of the electrical power is going directly to generating light, which cuts down on the electricity demands considerably. Color: LEDs can emit light of an intended color without the use of color filters that traditional lighting methods require. This is more efficient and can lower initial costs. Size: LEDs can be very small (smaller than 2 mm2) and are easily populated onto printed circuit boards. Lower Cost in Long Run: Up until recently, LEDs were too expensive to use for most lighting applications because they're built around advanced semiconductor material. The price of semiconductor devices has plummeted over the past decade, however, making LEDs a more cost-effective lighting option for a wide range of situations. While they may be more expensive than incandescent lights up front, their lower cost in the long run can make them a better buy. In the future, they will play an even bigger role in the world of technology. On/Off time: LEDs light up very quickly. A typical red indicator LED will achieve full brightness in microseconds. LEDs used in communications devices can have even faster response times. Cycling: LEDs are ideal for use in applications that are subject to frequent onoff cycling, unlike fluorescent lamps that burn out more quickly when cycled frequently, or HID lamps that require a long time before restarting. Dimming: LEDs can very easily be dimmed either by Pulse-width modulation or lowering the forward current. Cool Light: In contrast to most light sources, LEDs radiate very little heat in the form of IR that can cause damage to sensitive objects or fabrics. Wasted energy is dispersed as heat through the base of the LED. Slow Failure: LEDs mostly fail by dimming over time, rather than the abrupt burn-out of incandescent bulbs. Light Pattern : LED lights are having a straight/Linear/uniform illuminating effect rather than distributed illuminations. This property helps in long distance vision. Lifetime: LEDs can have a relatively long useful life. One report estimates 35,000 to 50,000 hours of useful life, though time to complete failure may be longer. They don't have a filament that will burn out, so they last much longer.
Additionally, their small plastic bulb makes them a lot more durable. They also fit more easily into modern electronic circuits. Shock Resistance: LEDs, being solid state components, are difficult to damage with external shock, unlike fluorescent and incandescent bulbs which are fragile. Focus: The solid package of the LED can be designed to focus its light. Incandescent and fluorescent sources often require an external reflector to collect light and direct it in a usable manner. Non Toxic: LEDs do not contain mercury, unlike fluorescent lamps.
Disadvantages Of Leds
High Initial Price: LEDs are currently more expensive, price per lumen, on an initial capital cost basis, than most conventional lighting technologies. The additional expense partially stems from the relatively low lumen output and the drive circuitry and power supplies needed. However, when considering the total cost of ownership (including energy and maintenance costs). Temperature Dependence: LED performance largely depends on the ambient temperature of the operating environment. Over-driving the LED in high ambient temperatures may result in overheating of the LED package, eventually leading to device failure. Adequate heat-sinking is required to maintain long life. Voltage Sensitivity: LEDs must be supplied with the voltage above the threshold and a current below the rating. This can involve series resistors or current-regulated power supplies. Light Quality: Most cool-white LEDs have spectra that differ significantly from a black body radiator like the sun or an incandescent light. The spike at 460 nm and dip at 500 nm can cause the color of objects to be perceived differently under cool-white LED illumination than sunlight or incandescent sources, due to metamerism, red surfaces being rendered particularly badly by typical phosphor based cool-white LEDs. However, the color rendering properties of common fluorescent lamps are often inferior to what is now available in state-of-art white LEDs. Area Light Source: LEDs do not approximate a point source of light, but rather a lambertian distribution. So LEDs are difficult to use in applications requiring a spherical light field. LEDs are not capable of providing divergence
below a few degrees. This is contrasted with lasers, which can produce beams with divergences of 0.2 degrees or less. Blue Hazard: There is increasing concern that blue LEDs and cool-white LEDs are now capable of exceeding safe limits of the so-called blue-light hazard as defined in eye safety specifications such as ANSI/IESNA RP-27.105: Recommended Practice for Photo biological Safety for Lamp and Lamp Systems. Blue Pollution: Because cool-white LEDs (i.e., LEDs with high color temperature) emit much more blue light than conventional outdoor light sources such as high-pressure sodium lamps, the strong wavelength dependence of Rayleigh scattering means that cool-white LEDs can cause more light pollution than other light sources. It is therefore very important that cool-white LEDs are fully shielded when used outdoors. Compared to lowpressure sodium lamps, which emit at 589.3 nm, the 460 nm emission spike of cool white and blue LEDs is scattered about 2.7 times more by the Earth's atmosphere. Cool-white LEDs should not be used for outdoor lighting near astronomical observatories.
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Chapter 3: LIGHTING FACTS
Lux And Lumens

Lumen is the unit of light energy Lux is the unit of light intensity. Lumen values are required for engineers to decide the design of the luminnaire to ensure that the required LUX is available for the Purpose for which the light is used. For example, If you require 100 lux for comfortable reading over 1 sq meter, then you need 100 lumens. If the same 100 lux light is required over 0.25 sq meter area (0.5 x0.5 square), then you require only 25 lumens When the light is kept at a longer distance, the area covered by the light increases in proportion to the square of the distance and lux reduces inversely with the square of the distance. Most of the lights give lights at 360 degree sphere thus the light produced without reflectors to direct the light to a limited area gives lower lux than the same light with the luminnaire, designed to reflect at least part of the light to where required. One has to remember that the light reflected into the bulb, such as the CFL or the tube-lights gets absorbed into the light source itself.
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However, the light given by a single diode is very small say 0.3% to 0.5 of a 40 W incandescent bulb. In other words, only if 200 - 300 LED chips (integrated or single) are used, light equivalent to one normal bulb can be produced. In LED, the reflectors are built in and the light output is measured after taking into account all the losses. Thus, a 60 degree 1 watt LED (15 to 20 chips) can give more light within the cone of the 60 degrees than a 40 W incandescent (360 degrees). Thus, it can be used provide where the light is required with much higher efficiency Further, LED lights can be made at very low wattages 0.5 W or even 0.25W is an economical proposition compared to 15 W (commercial Zero watt) of the incandescent or 5 W of the CFL, or 20 W Tube-light. This enables the light to be brought near the application or the point of usage. Thus, even a 1W LED located at 450mm (1.5 feet) to provide light to a work table can give more lux than a 25 W CFL (or a 150 W incandescent) located at a distance of 3 meters. (distance factor of more than 18 times, and angle factor of more than 15 times making a total of 15x18 = 270 as a factor in lumen requirement if no focusing or diffusion is considered due to the reflectance from the roof/ reflectors etc., the actual factor would be lower). 1 W of electrical energy can produce about 683 lumens at 555nm. The white light being a spectrum, 400 lumens per watt is considered as the maximum efficiency. The early LEDs were producing only about 2-5 lumens per watt the present high bright single chip LED produce 90-110 lumens. Since energy can neither be created nor be destroyed, the unconverted energy is converted into heat. The temperature of the system is dependent on the area available for radiating the heat produced. Thus, if the heat has to be dissipated in a small area the temperature would be higher and vice versa. The temperature also depends on the ambient. Most of the LED chips are rated for maximum temperature of 80 degrees. Thus, in a tropical country like India, with summer ambient reaching 45 degrees in the shade, large area is required for ensuring the dissipation of heat. A single chip LED, dissipating 0.05 watts requires much less area for heat dissipation compared to a 1 W LED. High bright normal LEDs are made from single chip while the power LEDs are made from multiple diodes in a single chip. The diodes are arranged in series and parallel, at the time of doping. The chip manufacturing of the single chip is always more economical, than an Integrated chip. Higher efficacies are achievable in single chip, compared to multi-diode LED. This is because of the fact that when a single LED is not performing, it can be segregated and rejected, while in a multi-diode, the average LED performance is taken. Thus, for the
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same basic technology, the multi diode LED has marginally less efficacy than the single chip LED. In power LED higher heat dissipation takes place in a smaller area, compared to the total area available in a single chip LED. Thus, power LED always requires heat sink, while single chip LEDs normally does not require heat sink. The power LEDs have diodes in series and parallel internally, thus requiring higher voltage. The voltage current characteristics vary marginally between the diodes. Hence the single voltage control does not guarantee proper current control for each parallel string. In single diode strings, each string can be grouped for current limiting, eliminating the need for expensive driver circuits. a simple, reliable AC current limiting circuit using just passive component is sufficient for normal LEDs, thus providing very high reliability with low cost circuitry.
Color temperature and color Rendering index

Many optical energy applications require high intensity, spatially uniform, white light that does not significantly heat the surrounding environment in the near field and/or far field. More specifically, many applications require correlated color temperatures (CCT) between 4100-4900K (i.e., white light) with a color rendering index (CRI) between 90 & 100. Correlated color temperature (CCT) is a numerical assignment of the apparent color of a light source (i.e., as viewed by the human visual system) and is measured in degrees Kelvin. Color rendering is how well a light source renders color (i.e., in the course of interacting with an object) as compared to how well daylight renders color (i.e., in the course of interacting with the same object). Traditional light sources, however, suffer from, for example, but not limited to, combinations of a poor CRI, poor CCT, poor intensity, short usage life, large power electrical consumption, large package size, thermal energy, and/or are electrically and; or optically inefficient. Tungsten filament lamps for example, while providing high intensity optical energy with high CRI values, emit optical energy that has a poor CCT (i.e., about 3000K. which correlates to the color yellow) for white light applications. In addition tungsten filament lamps have a low electrical to optical efficiency and, thus, require large amounts of electrical power to generate high intensity optical energy, which results in large quantities of thermal energy. Furthermore high power tungsten lamps have a low lamp lifetime, usually operating for about 500 hours.
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LAMP TYPE Standard Incandescent Tungsten Halogen Compact Fluorescent Mercury Vapour Metal Halide High Pressure Sodium LED Based
LUMEN/W CRI 5-20 15-25 20.55 25-50 45-100 45-110 90-110 100 100
CCT (K) 3000 4000
LIFE 750-1000 20004000 10000 24000 20000 24000 >50000
EFFICIENCY 3-10 7-12 10-27 20-40 36-80 36-88 25-60
80 15-30 60-90 5000 9-70 904100100 4900
Comparison to contemporaries
Energy efficiency proponents are accustomed to comparing light sources on the basis of luminous efficacy. To compare LED sources to CFLs, for example, the most basic analysis should compare lamp-ballast efficacy to LED + driver efficacy in lumens per watt. Data sheets for white LEDs from the leading manufacturers will generally provide typical luminous flux in lumens, test current (mA), forward voltage (V), and junction temperature (Tj), usually 25 degrees Celsius. To calculate lm/W, divide lumens by current times voltage. As an example, assume a device with typical flux of 45 lumens, operated at 350 mA and voltage of 3.42 V. The luminous efficacy of the LED source would be: 45 lumens/ (.35 amps 3.42 volts) = 38 lm/W. To include typical driver losses, multiply this figure by 85%, resulting in 32 lm/W. Because LED light output is sensitive to temperature, some manufacturers recommend de-rating luminous flux by 10% to account for thermal effects. In this example, accounting for this thermal factor would result in a system efficacy of approximately 29 lm/W. However, actual thermal performance depends on heat sink and fixture design, so this is only a very rough approximation. Accurate measurement can only be accomplished at the luminnaire level.
Application Efficiency
While there is no standard definition of application efficiency, manufacturers use the term here to denote an important design consideration: that the desired illuminance level and lighting quality for a given application should be achieved with the lowest practicable energy input. Light source directionality and intensity may result in higher application efficiency even though luminous efficacy is lower relative to other light sources. Due to the directional nature of their light emission, LEDs potentially have higher application efficiency than other light sources in certain lighting applications. Fluorescent and standard bulb shaped incandescent lamps emit light in all directions. Much of the light produced by the lamp is lost within the fixture, reabsorbed by the lamp, or escapes
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from the fixture in a direction that is not useful for the intended application. For many fixture types, it is not uncommon for 40-50% of the total light output of the lamp(s) to be lost before it exits the fixture. LEDs emit light in a specific direction, reducing the need for reflectors and diffusers that can trap light, so well-designed fixtures, like the under cabinet light shown below, can deliver light more efficiently to the intended location
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Chapter 4: HOW TO PRODUCE LEDs

Raw Materials
Diodes, in general, are made of very thin layers of semiconductor material; one layer will have an excess of electrons, while the next will have a deficit of electrons. This difference causes electrons to move from one layer to another, thereby generating light. Manufacturers can now make these layers as thin as .5 micron or less (1 micron = 1 tenthousandth of an inch).Impurities within the semiconductor are used to create the required electron density. To complete the device, it is necessary to bring electricity to it and from it. Thus, wires must be attached onto the substrate. These wires must stick well to the semiconductor and be strong enough to withstand subsequent processing such as soldering and heating. Gold and silver compounds are most commonly used for this purpose, because they form a chemical bond with the gallium at the surface of the wafer. LEDs are encased in transparent plastic, the plastic can be any of a number of varieties, and its exact optical properties will determine what the output of the LED looks like.
Making Semiconductor Wafers

First, a semiconductor wafer is made. The particular material composition is determined by the color of LED being fabricated. Single semiconductor wafer is formed with the help of encapsulation method, thing like baking of a cake.
To make the semiconductor wafers, gallium, arsenic, and/or phosphor are first mixed together in a chamber and forced into a solution. To keep them from escaping into the pressurized gas in the chamber, they are often covered with a
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layer of liquid boron oxide. Next, a rod is dipped into the solution and pulled out slowly. The solution cools and crystallizes on the end of the rod as it is lifted out of the chamber, forming a long, cylindrical crystal ingot. The ingot is then sliced into wafers- liquid encapsulation method. The bowl is then sliced into very thin wafers of semiconductor, approximately 10 mils thick, or about as thick as a garbage bag. The wafers are polished until the surfaces are very smooth, so that they will readily accept more layers of semiconductor on their surface. The principle is similar to sanding a table before painting it. Next, the wafers are cleaned through a rigorous chemical and ultrasonic process using various solvents. This process removes dirt, dust, or organic matter that may have settled on the polished wafer surface. The cleaner the processing, the better the resulting LED will be.
Adding Epitaxial Layers

Additional layers of semiconductor crystal are grown on the surface of the wafer, like adding more layers to the cake. This is one way to add impurities, or dopants, to the crystal. The crystal layers are grown this time by a process called Liquid Phase Epitaxy (LPE). The deposited layers will become a continuation of the wafer's crystal structure. To make the semiconductor wafers, gallium, arsenic, and/or phosphor are first mixed together in a chamber and forced into a solution. To keep them from escaping into the pressurized gas in the chamber, they are often covered with a layer of liquid boron oxide. Next, a rod is dipped into the solution and pulled out slowly.
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The solution cools and crystallizes on the end of the rod as it is lifted out of the chamber, forming a long, cylindrical crystal ingot. The ingot is then sliced into wafers. LPE creates an exceptionally uniform layer of material, which makes it a preferred growth and doping technique. The layers formed are several microns thick. After depositing epitaxial layers, it may be necessary to add additional dopants to alter the characteristics of the diode for color or efficiency.
Adding Metal Contacts

Metal contacts are then defined on the wafer. The contact pattern is determined in the design stage and depends on whether the diodes are to be used singly or in combination. Wafer bonding Technology, the metal and the semiconductor bond together chemically so the contacts don't flake off.
Mounting
& Packaging
Individual dies are mounted on the appropriate package. A tiny gold wire is soldered to the other lead and wire-bonded to the patterned contacts on the surface of the die. In wire bonding, the end of the wire is pressed down on the contact metal with a very fine needle. The gold is soft enough to deform and stick to a like metal surface. The entire assembly is sealed in plastic. The wires and die are suspended inside a mold that is shaped accordingly. The epoxy is cured, and the package is complete.
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Chapter 5: MARKET POTENTIAL

Lighting Industry Review
Total Electricity Consumption for India 1, 20, 000 MW Total Consumption from Lighting Sector 30, 000 MW (19%) Total Electrified households at present 112 millions (5% growth rate) Total non Electrified households at present 78 millions LED lighting products' market is still at a nascent stage in India. As per the industry estimates, Indian lighting industry LED lighting products market is still at a nascent stage in India. Its share is mere 200 Crores in the Rs 6,500 crore Indian lighting industries.
Market Potential In India

SEGMENT AND TOTAL VALUE STREET LIGHTING FACTORY LIGHTING DOMESTIC & COMM LIGHTING HOARDING SIGNAGE INDOOR LIGHT In Crores 1376 522 143 5 86 4158 5000
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Market Survey In India

VALUE OF TOTAL LIGHTING INDUSTRY IN INDIA (CRORES)
Category GLS Lamps FTL CFL Special Lamps Total Luminaires Control Gears and High Masts Accessories Components Total LED LIGHTING
2005 600 1100 700 400 3700 900 200 200 200 4300
2006 690 1210 830 440 4170 1000 210 205 220 4805
2007 725 1270 1162 560 4837 1120 248 236 260 5581
2008 762 1333 1627 713 5689 1254 293 272 307 6561 197
2009 2010 2011 800 841 1399 1468 2278 3189 907 1155 6789 8226 (CRORES) 1405 1574 346 408 313 360 363 429 7811 9424 (CRORES) 213 231 250 CAGR 8.03%
2012
271 (CRORES)
CRORE S
CRORE
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PRODUCTION TRENDS IN INDIA
PRODUCTION TRENDS IN INDIA (MILLION PIECES) Category Incandescent Lamps Fluorescent Lamps Compact Fluorescent Lamps Special Lamps Total LED LAMPS Total 2005 711 180 67 10 968 0 968 0 2006 757 186 100 14 1057 0 1057 0 2007 779 190 140 17 1126 0 1126 0 2008 734 186 199 21 1140 0 1140 0 2009 2010 2011 2012 551 275 0 0 156 109 77 0 299 448 672 1007 27 35 46 60 1033 868 794 1067 313 719 1079 1143 1345 1587 1873 2210 23% 45% 58% 52% TOTAL SHARE OF LED MARKET
A B C D TOTAL E E
2005 2008 TRENDS
2009 2012 TRENDS
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Chapter 6: CASE STUDIES

Led Based Street Light
If you look at the spectral content in a HPSV lamp you will find that it has fairly poor color rendering. While this may not be very important for outdoor lighting of the streets (street lights), the LED lamps may offer a wider range of spectral content making it a preferred lamp due to superior color rendering. So, even if it turns out that it takes nearly the same amount of power to operate a LED cluster for 14,000 lumens as it does for one 150 Watt HPSV lamp, the real question is which lamp is going to give the best performance over time. The light output used for various street light sources are compared below: Typical Lamp Lumen output in lumens/watt is as follows:
HPSVL Halogen lamp Fluorescent Tubular Lamps T12 Fluorescent Tubular Lamps T 8 Fluorescent Tubular Lamps T 5 LED Lamp
80-90 15-20 50-60 55-60 80-90 90-114
The Recommended Light Levels for Street Lighting as per IS 1944 (Part I & II) -1970 are as follows: Classification Type of Road of Lighting Installation Group A1 Group A2 Group B1 Group B2 Average Level of Illumination on Road Surface Important traffic routes carrying fast 30 Lux traffic Other main roads carrying mixed 15 Lux traffic, like main city streets, arterial roads, throughways, etc Secondary roads with considerable 8 Lux traffic like principal local traffic routes, shopping streets, etc Secondary roads with light traffic 4 Lux Ratio Minimum /Average Illumination 0.4 0.4 0.3 0.3
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Recent advances in LED technology have made LED streetlamps more viable than ever. When typical LED output was 40 to 50 lumens per watt at 350 mA, a fixture would require so many LEDs, around 150, to meet the roadway lighting illumination standards, it would be oversized (and therefore potentially unstable and unsafe) not to mention cost-prohibitive. But now that LEDs provide outputs of 80 to 100 lumens at 350 mA, the same streetlamp fixture would only require about 75 LEDs to satisfy the roadway pattern specifications, resulting in a more compact, stable fixture design that is also much more cost efficient than traditional lighting technologies. The power supply to the light is 220V AC 50 Hz. Inside the fixture, there are several SMPS that provide an output of 24 V DC and 350 mA. Each SMPS drives a chip consisting of 7 one watt high powered LEDs. So approximate LEDs required will be around 65, it can vary as per the capacity of street light and lm/w of LED. The life of the LEDs is 100000 hours. The equivalent LED Luminaries to the conventional luminaries are as follows: Type HPSV HPSV HPSV Halogen Lamp 50 W Halogen Lamp 150 W Wattage 150W 250W 70 W 50 W 150 W To be replaced by 24 LED with consumption of 40 W 36 LED with consumption of 55 W 12 LED with consumption of 20 W 5 LED with consumption of 8 W 24 LED with consumption of 40 W
Now, we will consider only first two cases:
Comparison of 150 W sodium Vapour Lamp with 24 LED systems

Watt 150w + 25w 175 w 175 Load (ballast) Lux Level 175x12x365 20 25 x6/1000= Rs.4599/ fixture 40 w 40x12x365x LED Based 40w 6 /1000 Lux Level Lamp =Rs.1051 / 10 12 Pole Ht 6 m fixture Sodium Vapour Lamp Electric Bill Saving for 100 =3548/- per poles for fixture 1year Rs.4,59,900/ Electric Bill for 100 poles for 1 year Rs.1,05,100/ -
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Comparison of 250 W sodium vapour lamp with 36 LED systems

Watt 250w + 35w 285 w 285 Load (ballast) Lux Level 285x12x365 25 30 x6 /1000 =Rs.7490/ fixture 55 w 55x12x365x LED Based 55w Lux Level 6/1000 Lamp 15 18 =Rs.1445 Pole Ht 8 m /fixture Sodium Vapour Lamp Electric Bill for 100 Saving poles for 1 =6045/- per year fixture Rs.7,49,000/ Electric Bill for 100 poles for 1 year Rs. 1,44,500/-
Note: Rs. 6/- is considered as Energy rate per unit.
SAVING CALCULATION FOR DELHI STREET LIGHTS

SODIUM VAPOUR LIGHT TO BE REPLACED No. of Lamps 400000 Wattage of Lamps 250 Power Consumption in Watts 250 No. of hours of Operation per 8 day PRICE COMPARISON Cost of Fixture 1000 Cost of LED Light 7000 6 Power consumed/Day Power consumed/Year 2190 Power cost/Annum 13140 Savings with LED Lamps per Year Cost of Maintenance Total savings/Year ROI for new Installation EMISSIONS CO2 (0.85/unit) 297.84 S02 (0.00795/unit) 2.79 No2 (0.00356/unit) 1.25 Total GHG Emissions 301.87 LED LIGHT 400000 40 40 8 2000 13000 0.96 350.4 2102.4 11037.6 0 14191.2 0.94608
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Chapter7:ASSIGNMENT UNDERTAKEN
ASSIGNMENT 1
AIM : To do comparison between three different types LEDs. EDISON 1 W Part no.EDEW-ILA5 SEOUL 1 W Part no. 42180U2 ( LOT 1) SEOUL 1 W part no.42180U2 (LOT 2)
APPARATUS : 3 different LEDs, metal PCB, solder, soldering iron, heat sink, multimeter, Lux meter, power supply. PROCEDURE : First all 3 LEDs are mounted on the metal PCB with the help of solder & soldering iron & paste on heat sink. Supply is given through an AC to DC converter. Measure Voltage & current using multimeter. Now go in Dark Room for measuring Lux & Spread Angle. Take a screen at a distance of 1 meter from the source ( LED ). Now with the help of Lux Meter, observe different different readings at different different positions. Where you get a maximum value, mark it as C. Now calculate the half of the measured value and observe that half value at both upward & downward directions from A using Lux Meter. Also mark those points as B & D. Calculate the distance between B & D in cm using Measuring-Tape. We know that BC=CD=BD/2.Using formula tan(/2)=BC/AC where AC=1 meter & BC=BD/2. Total spread angle=/2+/2=.
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SOURCE SCREEN
/2 C A /2
OBSERVATIONS:
LED PARAMETER FORWARD VOLTAGE (V) CURRENT TAKEN (mA) SPREAD ANGLE () LUX (lx) @ 1 M
EDISON EDEW-ILA5 3.1 360 135 21.9
SEOUL SEOUL 42180U2 (LOT 42180U2 (LOT 2) 1) 3.3 360 127 27.1 3.1 360 127 25.2
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ASSIGNMENT 2
AIM : To do comparison between four different types LEDs. OSRAM 1 W Part no. LUWWSAM-LxLy AVAGO 1 W Part no.ASTM-MW009-NMM00 CREE 1 W Part No.XREWHT-L1-0000-A01 PHILIPS REBEL LUXEON 1 W Part no. LXML-PWC1-0090
APPARATUS : 4 different LEDs, metal PCB, solder, soldering iron, heat sink, multimeter, Lux meter and power supply. PROCEDURE : First all 4 LEDs are mounted on the metal PCB with the help of solder & soldering iron & paste them on heat sink. Supply is given through an AC to DC converter. Measure Voltage & current using multimeter. Now go in Dark Room for measuring Lux & Spread Angle. Take a screen at a distance of 1 meter from the source ( LED ). Now with the help of Lux Meter, observe the different different readings at different different positions. Where you get a maximum value, mark it as C. Now calculate the half of the measured value and observe that half value at both upward & downward directions from A using Lux Meter. Also mark those points as B & D. Calculate the distance between B & D in cm using Measuring-Tape. We know that BC=CD=BD/2.Using formula tan(/2)=BC/AC where AC=1 meter & BC=BD/2. Total spread angle=/2+/2=.
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OBSERVATIONS: PHILIPS REBEL LUXEON LXMLPWC1-0090 3.29 350 57 36.2
AVAGO OSRAM LUWWSAM- ASTMMW009LxLy PARAMETER NMM00 3.26 3.16 FORWARD VOLTAGE (V) 350 350 CURRENT TAKEN (mA) 74 70 SPREAD ANGLE () 21.9 27.8 LUX (lx) @ 1 M LED
CREE XREWHTL1-0000A01 3.26 350 62 40
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ASSIGNMENT 3
AIM : To compare two bunches of Nine LEDs on the basis of three parametersLux, Spread & Spread Angle. First of EDISON make EDEW-ILA5 & second of SEOUL make 42180U2 . To calculate Lux, Spread & Spread angle of a Focus Light using LUX Meter. APPARATUS : Nine EDISON EDEW-ILA5 LEDs, Nine SEOUL 42180U2 LEDs,2 nine LEDs Metal PCBs, solder, soldering iron, multimeter, Lux meter and power supply. PROCEDURE : First we mount all LEDs on their respective metal PCBs using solder & soldering iron. Now we have two different groups of LEDs-one is of EDISON make LEDs & second is of SEOUL make LEDs. Now give them power supply through an AC to DC converter. Now go in Dark Room for measuring Lux & Spread Angle. Take a screen at a distance of 1 meter from the source (Bunch of 9 LEDs). Now with the help of Lux Meter, observe the different different readings at different different positions. Where you get a maximum value, mark it as C. Now calculate the half of the measured value and observe that half value at both upward & downward directions from A using Lux Meter. Also mark those points as B & D. Calculate the distance between B & D in cm using Measuring-Tape. We know that BC=CD=BD/2.Using formula tan(/2)=BC/AC where AC=1 meter & BC=BD/2. Total spread angle=/2+/2=. Similarly follow the same procedure for calculating all three parameters of the Focus Light & note down in observation table.
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OBSERVATIONS: BUNCH OF PARAMETER LUX ( lx ) @ 1 M SPREAD ( Cm ) SPREAD ANGLE( ) EDISON EDEWILA5 (Without Lens) 190 149 73 EDISON EDEWILA5 (With Lens) 3316 35 19 SEOUL 42180U2 (Without Lens) 198 153 74 SEOUL 42180U2 (With Lens)
2734 40 22
Complete track light readings with the lot one Seoul W42180 U2 2916 LUX ( lx ) @ 1 M 20 SPREAD ( Cm ) 11 SPREAD ANGLE ( )
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ASSIGNMENT 4
AIM : To connect 10 LEDs in series & to mount them on a heat sink. To test 4 channel output NEC LED driver 40 W DC-DC boost driver. APPARATUS : 10 LEDs, metal PCBs, solder, soldering iron, multimeter, NEC LED driver, DC power supply & connecting wires. PROCEDURE : First we mount all LEDs on their respective metal PCBs using solder & soldering iron. Now paste all metal PCBs on a heat sink & join them all in series with one another using connecting wires. Now connect a DC supply to NEC LED driver & connect its output as input power supply to bunch of 10 LEDs. Using Multimeter, measure input voltage & input current of DC power supply. Now measure voltage & current at the four different channels of the NEC LED driver & record in observation table.
OBSERVATIONS : BATTERY INPUT VOLTAGE - 13.46 V BATTERY INPUT CURRENT - 1.53 A CHANNEL No. 1 2 3 4 VOLTAGE ( V ) 31.5 31.7 31.8 31.8 CURRENT ( mA ) 530 530 530 540
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ASSIGNMENT 5
AIM : To compare two High Bay lights models on the basis of their Lux output. Highbay models : Super flux LEDs model Triton Power LEDs model- Nebula APPARATUS: 2 High bay light (One is made up of 60 Power LEDs & second one is made up of 792 Super Flux LEDs), Lux meter, measuring tape & power supply. PROCEDURE: This experiment should be done only after sunset. First mount the light at a height of 9m from the ground. Make it glow by connecting it to the normal 230 V AC supply. Mark the centre as C on the ground & mark the positions exactly above & below the Centre measuring a distance of 1m using measuring tape. Name these points as A & B. Now from A & B, mark exactly 5 points at a distance of 1m from each other & on both the sides (Left & Right). Now with the help of Lux Meter, take readings at all these points.
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LUX LEVEL ANALYSIS:

Mounting height 9 M
100 lux @ centre
86 lux @ 1 M 50 lux @ 2 M 29 lux @ 3 M 17 lux @ 4 M 10 lux @ 5 M
LUX READINGS OF HIGH BAY PL-NEBULA Mounting height 9 M

37 lux @ centre
35 lux @ 1 M 31 lux @ 2 M 25 lux @ 3 M 19 lux @ 4 M 14 lux @ 5 M
LUX READINGS OF HIGH BAY SFL- TRITON
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ASSIGNMENT 6
AIM : To make a LED Street Light using 12 AVAGO 1 W part no.ASTMMW009-NMM00 LEDs & observe its Lux & Spread using Lux Meter. APPARATUS : Twelve nos AVAGO 1 W part noASTM-MW009-NMM00 LEDs, Star Metal PCBs, solder, soldering iron, multimeter, power supply & connecting wires. PROCEDURE : First we mount all LEDs on their respective Star Metal PCBs using solder & soldering iron. Connect them in series with one another. Place the light at a distance of 9 Feet, 12 Feet & 15 Feet one by one from the screen (wall) & connect an AC supply to it. Using Lux Meter, measure its Lux & Spread Angle. Note in observation table.
OBSERVATIONS: DISTANCE(ft) 9 12 15 LUX(lx) 50 35 21 SPREAD(cm) 450 480 502 SPREAD ANGLE() 79.6 67.3 58.3
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APPENDIX: PHOTO GALLERY
Photo 1: Types of Watt LEDs with Star MC PCB
Photo 2: Thermal bonding compound from Electro lube
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Photo 3: LEDs Testing Arrangement ( Heat sink)
Photo 4: Complete LEDs Testing Arrangement

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Photo 5: Temperature Controlled Soldering Station for soldering the LEDs without damaging
Photo 6: Chromo Meter cum Lux meter for measurement of Lux
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Photo 7: Complex LUX Meter shows reading with coordinates
Photo 8: Simplest LUX Meter
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Photo 9: Dark Room for Lux readings and testing
Photo 10: Testing in Dark Room ( Assignment no 3)
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Photo 11: LEDs Testing Arrangement
Photo 12: 12 W LED based Street Light
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Photo 13: Focus Lights LEDs with Lens & Diffuser ( Assignment no 3)
Photo 14: Testing of Lens & Diffusers Effect on Light ( Assignment no 3)
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Photo 15: Track Light Prototype (view 1)
Photo 16: Track Light Prototype (view 2)
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Photo 17: Track light Prototype (view 3)
Photo 18: Sealed IP65 constant current SMPS Driver Used in Track Light
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Under the Guidance of Mr. Aditya Tyagi & Mr. Manish Mohan Sr.

Jatin Sharma Roll No :277264 CE (Eve)

(Authorized signatory) Mr. Arun Bhatia V.P. Business Development

TRAINING REPORT ON LED LIGHTING

In total the motto of the report is Power Saved is Power Earned.

GND POLYTECHNIC, ROHINI, NEW DELHI

TRAINING REPORT ON LED LIGHTING

GND POLYTECHNIC, ROHINI, NEW DELHI

TRAINING REPORT ON LED LIGHTING

GND POLYTECHNIC, ROHINI, NEW DELHI

TRAINING REPORT ON LED LIGHTING

GND POLYTECHNIC, ROHINI, NEW DELHI

TRAINING REPORT ON LED LIGHTING

GND POLYTECHNIC, ROHINI, NEW DELHI

TRAINING REPORT ON LED LIGHTING

Chapter 2: NEW TECHNOLOGY

GND POLYTECHNIC, ROHINI, NEW DELHI

TRAINING REPORT ON LED LIGHTING

TRAINING REPORT ON LED LIGHTING

LED: How It Produces Light ?

GND POLYTECHNIC, ROHINI, NEW DELHI

TRAINING REPORT ON LED LIGHTING

Led-latest version (Power Leds)

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TRAINING REPORT ON LED LIGHTING

Solid State Lighting

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TRAINING REPORT ON LED LIGHTING

GND POLYTECHNIC, ROHINI, NEW DELHI

TRAINING REPORT ON LED LIGHTING

GND POLYTECHNIC, ROHINI, NEW DELHI

TRAINING REPORT ON LED LIGHTING

GND POLYTECHNIC, ROHINI, NEW DELHI

TRAINING REPORT ON LED LIGHTING

Chapter 3: LIGHTING FACTS

Lux And Lumens

GND POLYTECHNIC, ROHINI, NEW DELHI

TRAINING REPORT ON LED LIGHTING

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TRAINING REPORT ON LED LIGHTING

Color temperature and color Rendering index

GND POLYTECHNIC, ROHINI, NEW DELHI

TRAINING REPORT ON LED LIGHTING

CCT (K) 3000 4000

LIFE 750-1000 20004000 10000 24000 20000 24000 >50000

EFFICIENCY 3-10 7-12 10-27 20-40 36-80 36-88 25-60

80 15-30 60-90 5000 9-70 904100100 4900

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TRAINING REPORT ON LED LIGHTING

GND POLYTECHNIC, ROHINI, NEW DELHI

TRAINING REPORT ON LED LIGHTING

Chapter 4: HOW TO PRODUCE LEDs

Making Semiconductor Wafers

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Adding Epitaxial Layers

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TRAINING REPORT ON LED LIGHTING

Adding Metal Contacts

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TRAINING REPORT ON LED LIGHTING

Chapter 5: MARKET POTENTIAL

Market Potential In India