Large Format LED Controller For Outdoor Display 01052012

Large Format LED Controller for Outdoor Display
by Divya T L Mtech , IV Sem Power Electronics TOCE

Internal Guide Mrs.Raichel Ruby M Assistant Professor, EEE Dept. TOCE External Guide Mr. Ramachandran M Sr. Manager(R&D) Vignani Solutions Pvt Ltd
Contents
Introduction System Block Diagram
LED Panel
Display Driver Board Multiplexing
Microcontroller Board
Flowchart Linear Power Supply
Testing & Result

Conclusion Future Scope
M Tech, Power Electronics The Oxford College of Engineering 2
Large Format LED Display

The LED technology has become a key component in lighting LED has rapidly become commercially viable due to the following : Unidirectional lighting property over the conventional lighting instruments High luminous intensity
Low power consumption

Very long life High reliability LED is a popular choice in Large format Display boards and are widely used in: Sports Advertising Finance
Exhibitions
Transportation etc.

Proposal: Design & development of LED panel -12X8 matrix
Design & implementation of a driver for large format LED display

Design & develop an embedded system with associated software for controlling the display data
To derive and implement hardware, firmware for a master board which is used for
controlling moving display
Objective: Energy efficient lighting / display solution Minimize electricity consumption & thus reduce electricity generation cost
M Tech, Power Electronics
The Oxford College of Engineering

How this project is different?
Array Multiplexing- Reduces the number of I/O pin required to drive LEDs Three time slot multiplexer-To limit the LED pulsed current in safe peak level
Light Emitting Diodes (LEDs)

LED is a P-N junction solid-state semiconductor diode that emits light when a current is applied though the device
Detailed view of an LED

M Tech, Power Electronics The Oxford College of Engineering
LED & IV characteristics

6
Light Emitting Diodes (LEDs)

Light Emitting Diodes (LEDs) Energy Efficiency Incandescent Light Bulbs Compact Fluorescents (CFLs)
Life Span (average) Sensitivity to low temperature Toxic Mercury Sensitivity to humidity On/Off cycling Durability
50,000 hours
1,200 hours
8,000 hours
None
Some
Yes
No No No Effect Durable
No Some Some Not very Durable
Yes Yes Yes Not very Durable
450 Lumens Light output
4-5 watts
40 watts
9-13 watts
System Block Diagram

The system block diagram consists of following 3 major blocks 1. LED Panel 2. Display driver board 3. Microcontroller board Power Supply
UART
Personal Computer
Microcontroller Board
LED Driver Board
Display Panel
LED Panel
LED Panel 12 X 8 Matrix Block Diagram of LED
Vertical Driver Embedded system Horizontal Driver LED Driver LED Matrix
LED Panel
LED KWT803S
Features White colored SMT package InGaN material Suitable for all SMT assembly and soldering methods Pb-Free Reflow soldering application
RoHS compliant
Applications: Interior lighting General lighting Indoor and outdoor displays Architectural /Decorative lighting White Back-light
LED Schematic
12 X 8 LED Matrix
Parameter Power Dissipation Forward Current Peak Forward Current Reverse Voltage Operating Temperature Symbol Pd IF IFM VR TOPR Value 111mW 30mA 90mA 5V -40~+850C
Storage temperature Junction temperature

Parameter Forward Voltage Reverse current Luminous Intensity Symbol VF IR Iv Condition IF=20mA VF=5V IF=20mA
Tstg Tj
Min. 2.9V 1700mcd
-40~+1000C 1250C
Typ. 3.2V Max. 3.4V 10uA 2500mcd
11
LED PCB
The LED panel developed in FR4 grade PCB The images illustrate front & back side view of the PCB Front side view demonstrates:
LED positioning Connector positioning Copper positioning (light green)
Front side view of PCB Rear side view of PCB
Rear side view demonstrates:

Copper positioning (light green) Connections between LEDs & connectors
LED Board Testing
ROW1
ROW2
ROW3
LED ROW 1,4,7,10 testing when P1 is ON
13
Display Driver Board

Hex inverter
P I C 1 8 F 4 5 2 0
SN74HC04
P-MOSFET
Data bus
SN74HC374
N-MOSFET
L E D
P a n e l
SN74HC374
N-MOSFET
SN74HC374
N-MOSFET
SN74HC374
N-MOSFET
14
Timing Diagram
1/3 ON
Three time slot multiplexing Minimizes complexity
I P1 Mosfet
3.3ms
2/3 OFF 6.7ms
Minimizes Hardware circuit
P2 Mosfet
P3 Mosfet Time in milli second
with varying intensity
N channel duty cycle
15
Display Driver PCB

The Display driver board developed in FR4 grade PCB The images illustrate front & back side view of the PCB Front side view demonstrates:
Latch positioning Connector positioning Front side view of PCB
P channel MOSFET
Copper positioning (light green)

N channel MOSFET Copper positioning (light green)
Rear side view of PCB

Testing of Display Driver Board
Testing of 1010 pattern using clocked latch when P3 is ON

Testing of 0101 pattern using clocked latch when P3 is ON

17
Microcontroller board
18
PIC18F4520 Special Features

Power on Reset Sleep mode WDT ICSP In Circuit Debugger
19
Microcontroller PCB
The Master board developed in FR4 grade PCB The images illustrate front & back side view of the PCB Front side view demonstrates:
PIC Microcontroller Relimate connectors
PIC18F4520 DB9
Front side view of PCB
DB9 Connector
AT24C64 IC

Max 232 LM 7805
MAX 232
Rear side view of PCB

Flow Chart
21
Flow Chart Contd.
22
PC Communication Mode Flowchart

Start
No If Interrupt occurs?
Yes
Read 96 bytes of data from UART (Serial Port)
Store data in EEPROM in assigned location (through microcontroller)
End
23
Timer interrupt mode Flowchart

No
Start
Is first time System boot?

Yes P1 MOSFET Initialization 3.3ms on and 6.7ms off
Initialization of N channel MOSFET from N1 to N32
P2 MOSFET Initialization 3.3ms on and 6.7ms off
Initialization of N channel MOSFET from N1 to N32 P3 MOSFET Initialization 3.3ms on and 6.7ms off
The N channel MOSFET from N1 to N32 Initialization ofOxford College of Engineering
Any update from EEPROM? Yes
No B
24
Timer interrupt mode Flowchart contd..

A
Read EEPROM data for Intensity value
Set the N channel MOSFET according to the EEPROM data
Display data continuously
End
25
Linear Power Supply Block Diagram & its Schematic
26
Concept Test Result

Below figure shows a block diagram of testing a single LED
Linear power supply Microcontroller Board Single P and N channel MOSFET LED
Micro Controller Board
Development Board
Linear Power Supply

LED
27
Concept Test Result

P channel MOSFET
N channel MOSFET
28
Simulation Result of Single LED Testing
29
Simulation Result of Single LED Testing
30
12 x 8 LED Panel Test Result
Complete experimental set up of 12 X 8 LED panel

HEX code for LED display

ASCII TABLE
DEC OCT HEX BIN Symbol A B C HTML Number A B C Description Uppercase A Uppercase B Uppercase C 83 123 84 124 85 125 86 126 87 127 88 130 89 131 53 01010011 54 01010100 55 01010101 56 01010110 57 01010111 58 01011000 59 01011001 S T U V W X Y Z S T U V W X Y Z Uppercase S Uppercase T Uppercase U Uppercase V Uppercase W Uppercase X Uppercase Y Uppercase Z 65 101 41 01000001 66 102 42 01000010 67 103 43 01000011
68 104 44 01000100
69 105 45 01000101 70 106 46 01000110 71 107 47 01000111 72 110 48 01001000 73 111 49 01001001 74 112 4A 01001010 75 113 4B 01001011 76 114 4C 01001100 77 115 4D 01001101 78 116 4E 01001110 79 117 4F 01001111 80 120 50 01010000
D
E F G H I J K L M N O P
D
E F G H I J K L M N O P
Uppercase D
Uppercase E Uppercase F Uppercase G Uppercase H Uppercase I Uppercase J Uppercase K Uppercase L Uppercase M Uppercase N Uppercase O Uppercase P
90 132 5A 01011010
81 121 51 01010001
82 122 52 01010010
Q
R
Q
R
Uppercase Q
Uppercase R The Oxford College of Engineering 33
Programming
Void DispCleanRay(void) DISP_DATA_BUF[0]= (0xE0 | 0x0E); //Col1 DISP_DATA_BUF[0]= (0xA0 | 0x0C); //Col2 DISP_DATA_BUF[0]= (0xA0 | 0x0A); //Col3 DISP_DATA_BUF[0]= (0x00 | 0x00); //Col4 DISP_DATA_BUF[0]= (0xE0 | 0x06); //Col5 DISP_DATA_BUF[0]= (0x20 | 0x0C); //Col6 DISP_DATA_BUF[0]= (0x20 | 0x06); //Col7 DISP_DATA_BUF[0]= (0x00 | 0x00); //Col8 0x11100000 | 00001110 0x10100000 | 00001100 0x10100000 | 00001010
0x11100000 | 00000110 0x00100000 | 00001100 0x00100000 | 00000110
DISP_DATA_BUF[0]= (0xE0 | 0x08); //Col9 DISP_DATA_BUF[0]= (0x40 | 0x06); //Col10 DISP_DATA_BUF[0]= (0xE0 | 0x08); //Col11 DISP_DATA_BUF[0]= (0x00 | 0x00); //Col12
M Tech, Power Electronics The Oxford College of Engineering
0x11100000 | 00001000 0x01000000 | 00000110 0x11100000 | 00001000
34
LED with 0% intensity or OFF
LED panel showing 25% intensity
35
LED showing 50% brightness
LED with full intensity
36
LED data moving pattern
37

The specifications of the 12 x 8 single colour LED Display system:
Item Pixel pitch LED Configuration Panel Size Refresh Time of Display Transmission Interface Power Source Average Power Consumption Heat Sink
12 x 8 single colour LED Display system 11mm x 11mm White colour SMD 130mm x 130mm 10ms RS232 AC 220V/50 Hz 6.5 W Natural Air
38
Conclusion
We have designed, built and evaluated LED panel, microcontroller and display driver board. The average power consumption of the circuit is calculated which gives lesser power intake around 6.5 W. The embedded board is developed using PIC18F4520 microcontroller which is readily available in market, manufactured by MICROCHIP. It has got several features such as it supports RS232, RS485 communication and hence a data transfer from PC to PIC microcontroller can be readily achieved. The driver circuit is developed by using MOSFETs. Since MOSFETs have higher switching frequency they are best suited for applications which requires greater speed. The MOSFET switch was not provided with any heat sink. Array multiplexing is used, hence the number of drivers required to drive LED is also considerably less. 96 LEDs can be controlled by using only 35 MOSFETs and also each LEDs intensity control can be achieved individually.
Future Scope
The above concept can be extended to a colour LED outdoor display board with 32 bit ARM Microcontroller using FPGA technique ARM has good characteristics of small size, low power consumption, powerful data processing ability to meet different size, full-colour image display requirement Programmable logic devices such as FPGA provide high speed data transmission
The LED Matrix could be developed for video display

Each LED represents a pixel. By the intense packing of LEDs video display is possible The wireless LED board could also be developed
40
Reference
R.E Brown, LED displays past, present and future, in Proc. IEEE transactions on consumer electronics, Vol. C.E-24, No. 3, August 1978 Why multiplex LEDs? David M Barton, IEEE spectrum , November 1972 PIC Microcontroller and Embedded systems by Mohammed Ali Mazidi, Rolin D
MCkinlay, Danny Cause

Influence of visual feature for applications of high light-emitting diode arrays by Chen Shuwang, Ma Hongxia, Wang Congcong, IEEE spectrum 2009 Digital Fundamentals by Thomas L Floyd The Art Of Electronics by Paul Horowitz, Winfield Hill
42

Large Format LED Controller For Outdoor Display 01052012

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Large Format LED Controller For Outdoor Display 01052012

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Large Format LED Controller for Outdoor Display

by Divya T L Mtech , IV Sem Power Electronics TOCE

Testing & Result

Large Format LED Display

Low power consumption

Large Format LED Display

Design & implementation of a driver for large format LED display

M Tech, Power Electronics

The Oxford College of Engineering

Large Format LED Display

M Tech, Power Electronics

The Oxford College of Engineering

Light Emitting Diodes (LEDs)

Detailed view of an LED

LED & IV characteristics

Light Emitting Diodes (LEDs)

No Some Some Not very Durable

Yes Yes Yes Not very Durable

450 Lumens Light output

M Tech, Power Electronics

The Oxford College of Engineering

System Block Diagram

LED Driver Board

M Tech, Power Electronics

The Oxford College of Engineering

M Tech, Power Electronics

The Oxford College of Engineering

Storage temperature Junction temperature

M Tech, Power Electronics

The Oxford College of Engineering

Rear side view demonstrates:

LED Board Testing

LED ROW 1,4,7,10 testing when P1 is ON

LED ROW 2,5,8,11 testing when P2 is ON

LED ROW 3,6,9,12 testing when P3 is ON

M Tech, Power Electronics

The Oxford College of Engineering

Display Driver Board

M Tech, Power Electronics

The Oxford College of Engineering

Three time slot multiplexing Minimizes complexity

2/3 OFF 6.7ms

Minimizes Hardware circuit

P3 Mosfet Time in milli second

M Tech, Power Electronics

The Oxford College of Engineering

with varying intensity

N channel duty cycle

Display Driver PCB

Rear side view demonstrates:

Rear side view of PCB

Testing of Display Driver Board

Testing of 1010 pattern using clocked latch when P3 is ON

Testing of 0101 pattern using clocked latch when P3 is ON

The Oxford College of Engineering

M Tech, Power Electronics

The Oxford College of Engineering

PIC18F4520 Special Features

M Tech, Power Electronics

The Oxford College of Engineering

Front side view of PCB

Rear side view demonstrates:

Rear side view of PCB