Shri Ramdeobaba College of Engineering and Management,Nagpur

(An autonomous College of Rashtrasant Tukadoji Maharaj Nagpur University)

Department of Electronics Engineering
Year 2014-2015

PROJECT REPORT
ON

LED DRIVER CIRCUIT

Submitted by
Roll No:79,81 Section:B Candidate name: SWAMI MUDGAL
SOUVIK DAS

Under the guidance of

Prof. S.R Pandey

Shri Ramdeobaba College of Engineering and Management,Nagpur

 (An autonomous College of Rashtrasant Tukadoji Maharaj Nagpur University)
Department of Electronics Engineering

Certificate
This is to certify that the project titled LED DRIVER CIRCUIT has been
Successfully completed by the following students under the guidance of Prof. S.R
Pandey in recognition to the partial fulfillment of the requirements for the
Electronic Product Design ENP-310 course work of Bachelor of Electronics
Engineering during academic year 2014-2015.

Students Name and Signature Students Name

SWAMI MUDGAL
SOUVIK DAS

Guide

Prof.S.R Pandey
 Shri Ramdeobaba College of Engineering and Management,Nagpur
(An autonomous College of Rashtrasant Tukadoji Maharaj Nagpur University)
Department of Electronics Engineering
Electronic Product Design ENP-310
Evaluation Sheet

Architectural Design

Hardware Design
Requirements2

Software Design

Implementation

Total out of 50
Project Report
Status Reports

Out of 25
Test Plan
Concept

Delivery
Roll No

Name

Name of Sign of Name of Sign of

Internal Examiner External Examiner
Sr.
Content Page No
No.
1. Abstract 1
2. Introduction,
Literature survey, Motivation,
3.
Problem statement
Working principle / architecture
discussion
4.
4.1 Sub topics Problem statement
4.2 Sub topics Problem Description
Hardware description, List of
5.
components
6. Software description/ Flow Chart
7. PCB Layout / Design Process
8. Front Panel/Enclosure Design
9. Product Cost Analysis
10. Applications of your project
11. Conclusion & Future Scope
12. References
Appendix : Data sheets of
13. components/IC sensors used in
project
Project report with additional
information if any should be submitted
16 in soft form i.e. CD/DVD .Put it in
cover and paste it to back cover page of
project report .

ABSTRACT
As the lighting industry continues to make the transition to LED technology, there
is an increasing need for more intelligent controllers and drivers. The rising price
of electricity presents a major operating cost to consumers and businesses;
however, efficient operation of LEDs can result in substantial savings. Many
applications need to produce consistent light quality while supporting advanced
control functionality such as dimming, balancing and accurate color mixing. Remote
connectivity is also becoming a regular requirement
in applications where high-maintenance expenses can be reduced through self-
diagnostics that allow technicians to make a service call only when there is an
actual reason to visit a site.

Bringing intelligence into many LED lighting applications may require moving from
fixed function LED drivers to microcontroller-based or programmable
architectures. For applications that need advanced functionality, using a
microcontroller enables many intelligent features such as native dimming control,
specialized color mixing, adaptive lighting control and even remote connectivity.
Specialized power electronics microcontrollers can even further benefit lighting
applications with the capability to efficiently and cost-effectively control the
luminaire power supply in addition to the lighting control and communications. Like
many modern electronics trends, moving to digital control opens up flexibility and
can bring new levels of intelligence and differentiation to lighting products.

INTRODUCTION
When it comes to lighting, it is quite easy to imagine the impact of globally
improving the efficiency of lighting sources by 10%. But what if it could be
improved by 1000%? The use of newly enhanced LEDs as lighting sources has the
potential to achieve these efficiency improvements while maintaining outstanding
performance and reliability that supersede many of the currently used sources

Regardless of type, color, size, or power, all LEDs work best when driven with a
constant current. LED manufacturers specify the characteristics (such as lumens,
beam pattern, color) of their devices at a specified forward current (IF), not at a
specific forward voltage (VF). Most power supply ICs are designed to provide
constant voltage outputs over a range of currents (see below); hence, it can be
difficult to ascertain which parts will work for a given application from the device
datasheet alone. With an array of LEDs, the main challenge is to ensure every LED
in the array is driven with the same current. Placing all the LEDs in a series string
ensures that exactly the same current flows through each device.

The concept of the brightness of visible light from an LED is fairly easy to
understand. Assigning a numerical value to the perceived brightness of an LEDs
output can simply be measured in units of luminous flux density, called candelas
(cd). The total power output of an LED is a measurement of the amount of Lumens
(lm). It is also important to understand that average forward LED current
determines the brightness of an LED. The relationships remarkably linear over
useable ranges of IF or forward current. Note the nonlinearity appearing as IF
increases. Reduced efficacy in Lumens per Watt arises as the operating current
exceeds the linear range.

Sources of input voltage for LED arrays come from batteries or power supplies
that have a certain tolerance. An automotive battery, for example, may supply 8V
to 16V depending on the load and the age of the battery. The "silver box" power
supply inside a desktop CPU may supply 12V 10%.High brightness (HB) LEDs also
give a range of forward voltage. A typical HB LED might be characterized at a
forward current of 350 mA. The forward voltage of the LED when IF = 350 mA is
specified with a range that includes a typical value as well asover-temperature
maximum and minimum values. To ensure that a true constant current is delivered
to each LED in an array, the power topology must be able to deliver an output
voltage equal to the sum of the maximum forward voltages of every device placed
in the string.

Working principle
If input voltage always exceeds the sum of the maximum forward voltages of every
LED in a string, then two options are available: linear regulators and buck
regulators. A linear regulator introduces efficiency and thermal drawbacks, but is
the simplest design option. In order to provide constant current, the linear
regulator must be an adjustable type that uses a pair of feedback resistors.
Replacing the top feedback resistor with the LED string and placing a current-
sensing resistor in the bottom position "tricks" the former constant voltage source
into adjusting the output voltage until enough current flows through the current
sensing resistor to equal the feedback voltage of the IC. Linear regulators have
the advantages of simplicity, low parts count, and very little Electromagnetic
Interference (EMI). They can deliver constant current as long as the VF in the
LED string does not exceed their dropout-limited output voltage. The disadvantage
lies in efficiency and thermal dissipation. Loss in a linear regulator LED driver is
approximately equal to (VIN n x VF) x IF , where "n" is the number of LEDs in the
string. At currents of 350 mA and above, the linear solution may require a heat
sink, adding cost and size to the design. The more efficient option when input
voltage always exceeds the LED voltage is a step-down or buck regulator. As with
linear regulators, this must be an adjustable type, and the same method can be
used to turn almost any buck regulator into a constant current source for LEDs.
Buck regulators enjoy high efficiency and eliminate the need for a heat sink, at the
cost of a more complex circuit and the addition of switching noise. Many recent
buck regulators switch at 1 MHz and above, making their external components so
small that at currents under 1A they may actually use less space than a linear
regulator.

The Buck Converter

The Buck Converter is used in SMPS circuits where the DC output voltage needs to
be lower than the DC input voltage. The DC input can be derived from rectified AC
or from any DC supply. It is useful where electrical isolation is not needed between
the switching circuit and the output, but where the input is from a rectified AC
source, isolation between the AC source and the rectifier could be provided by a
mains isolating transformer.
The switching transistor between the input and output of the Buck Converter
continually switches on and off at high frequency. To maintain a continuous output,
the circuit uses the energy stored in the inductor L, during the on periods of the
switching transistor, to continue supplying the load during the off periods. The
circuit operation depends on what is sometimes also called a Flywheel Circuit. This
is because the circuit acts rather like a mechanical flywheel that, given regularly
spaced pulses of energy keeps spinning smoothly (outputting energy) at a steady
rate.

AC or DC Input
The buck converter is a form of DC to DC converter that can take an input directly
from a DC source, such as a battery. The input could also be DC derived from the
AC mains (line) as shown in Fig. via a rectifier/reservoir capacitor circuit. The AC
input to the rectifier circuit could be AC at high voltage directly from the AC
mains supply, or alternatively at a lower voltage via a step down transformer.
However the DC applied to the Buck Converter is obtained, it is then converted to
a high frequency AC, using a switching or chopper transistor, driven by a (usually
pulse width modulated) square wave. This results in a high frequency AC wave,
which can then be re converted to DC.

Buck Converter Operation

As shown in Fig. the buck Converter circuit consists of the switching transistor,
together with the flywheel circuit (Dl, L1 and C1). While the transistor is on,
current is flowing through the load via the inductor L1. The action of any inductor
opposes changes in current flow and also acts as a store of energy. In this case the
switching transistor output is prevented from increasing immediately to its peak
value as the inductor stores energy taken from the increasing output; this stored
energy is later released back into the circuit as a back e.m.f. as current from the
switching transistor is rapidly switched off.

Transistor Switch on Period

In Fig. therefore, when the switching transistor is switched on, it is supplying the
load with current. Initially current flow to the load is restricted as energy is also
being stored in L1, therefore the current in the load and the charge on C1 builds up
gradually during the on period. Notice that throughout the on period, there will be
a large positive voltage on D1 cathode and so the diode will be reverse biased and
therefore play no part in the action.

Transistor Switch off Period

When the transistor switches off as shown in Fig the energy stored in the
magnetic field around L1 is released back into the circuit. The voltage across the
inductor (the back e.m.f.) is now in reverse polarity to the voltage across L1 during
the on period, and sufficient stored energy is available in the collapsing magnetic
field to keep current flowing for at least part of the time the transistor switch is
open. The back e.m.f. from L1 now causes current to flow around the circuit via the
load and D1, which is now forward biased. Once the inductor has returned a large
part of its stored energy to the circuit and the load voltage begins to fall, the
charge stored in C1 becomes the main source of current, keeping current flowing
through the load until the next on period begins. The overall effect of this is that,
instead of a large square wave appearing across the load, there remains only a
ripple waveform, i.e. a small amplitude, high frequency triangular wave with a DC
level of:

VOUT = VIN x (On time of switching waveform (tON) / periodic time

of switching waveform( T))
Therefore if the switching waveform has a mark to space ratio of 1:1, the output
VOUT from the buck Converter circuit will be VIN x(0.5/1) or half of VIN.
However if the mark to space ratio of the switching waveform is varied, any output
voltage between approximately 0V and VIN is possible.

Hardware description
The LM3406 is a buck regulator controlled current source designed to drive a
series string of high power, high brightness LEDs (HBLEDs at forward currents of
up to 1.5A. Theconverter's output voltage adjusts as needed to maintain a constant
current through the LED array.

The LM3406 is a step-down regulator with an output voltage range extending from
a VO-MIN of 200 mV (the reference voltage) to a VO-MAX determined by the
ratio of the minimum off time (typically 230 ns) to the switching frequency. The
regulator can maintain the output current through any number of LEDs as long as
the combined forward voltage of the array does not exceed VO-MAX. VO-MAX
can be calculated with the following formula:
VO-MAX = VIN-MIN x (1 - fSW x tOFF-min)

Output voltage is calculatedwith the following formula:

VO = n x VF + 0.2V

Setting the LED Current

The default forward current IF delivered to the LED array when no program
jumper is installed on J2 is 0.35A, set by resistor R.35. The higher LED currents
are set when the program jumper puts resistors R.7, R1 or R1.5 in parallel with
R.35. For users that wish to program a current other than one of the four default
levels, or for users who want the best accuracy at a given current, the program
jumper J2 should be removed, and R.35 changed according to the following
equation:
R.35 = 0.2 / IF

This resistor should be rated to handle the power dissipation of the LED current.
For example, the closest 5% tolerance resistor to set an LED current of 0.35A is
0.56. In steady state this resistor will dissipate (0.352 x 0.56) = 69 mW,
indicating that a resistor with a 1/8W rating is more than capable of dissipating
the power.

Pulse Width Modulation (PWM) Dimming

The DIM1 terminal on the PCB provides an input for a logic-level pulse width
modulation signal for dimming of the LED array. In order to fully enable and
disable the LM3406 the PWM signal should have a maximum logic low level of 0.8V
and a minimum logic high level of 2.2V. Graphical representations of minimum and
maximum PWM duty cycle are illustrated in figure. The interval tD represents the
delay from a logic high at the DIM pin to the rise in output current. The quantities
tSU and tSD represent the time needed for the output current to slew up to
steady state and slew down to zero, respectively. It is important to note that tD is
a property of the LM3406 and remains fixed in all applications. The slew rates tSU
and tSD are a function of the external circuit parameters VIN, VO, IF, inductance
(L) and the LM3406 parameter tOFF-MIN.
The logic of DIM1 is active low, hence the LM3406 will deliver regulated output
current when the voltage at DIM1 is high, and the current output is disabled when
the voltage at DIM1 is low. Connecting a constant logic low will disable the output.
Note that an internal pullup esnures that the LM3406 is enabled if the DIM pin is
open-circuited. The DIM1 function disables only the power MOSFET, leaving all
other circuit blocks functioning to minimize the converter response time, tD.

Output Open Circuit

The LM3406 will begin to operate as soon as VIN is greater than 6V and the DIM
and RON pins are not grounded. If the regulator is powered and enabled but no
LED array is connected, the output voltage will rise to VIN. The output of the
circuit is rated to 50V (beyond the maximum input voltage) and will not suffer
damage, however care should be taken not to connect an LED array if the output
voltage is higher than the target forward voltage of the LED array in steady state.
If the LEDs are disconnected or one of the LEDs fails open-circuit while the
LM3406 is operating, the output voltage will experience a surge as the current in
the output inductor seeks a discharge path. The
output capacitor (if present) can absorb some of this energy, however circuits with
little or no output capacitance can experience a voltage spike that exceeds the
rating of the VOUT pin.
Bill of materials as generated by Orcad

SRNO Qn Name Valu

t e
CIN1,CI
1 2 N2 6.8uf
2 1 Cb5 22nf

Cf3,Cc
3 2 4 100nf

4 1 C6 C
1N58
5 1 D1 22

6 1 J1 VIN
7 1 J2 DIM
8 1 J3 IND
9 1 J4 VOUT
10 1 J5 R.7
11 1 J6 R.1
12 1 J7 R1.5
13 1 RON1 143k
14 1 Rout6 10k
15 1 Rs2 0.56
16 1 Rs3 0.62
17 1 Rs4 0.3

18 1 Rs5 0.16
LM34
19 1 U1 06
 Software description

Schematic
PCB Layout
 PRODUCT COST ANALYSIS

Sr No Component Cost(Rs) Quantity Total(Rs)

1 LM3406 140 1 140
2 4.7ufcapacito 2 3
r
3 100nf 5 2 10
capacitor
4 1N5822 20 1 20
5 Relimate 2 8 16
connector
6 143k resistor 10 1 10
7 10k resistor 10 1 10
8 Transformer 120 1 120
1N4001 diode 2 5 10
9 LM7824 10 1 10
10 Inductor Self Made 1 Free(20)
11 Led 5W 50 6 300
12 TOTAL COST 666
 Applications

High-Brightness LED Applications LED Bulbs

This circuit is designed to drive a 1.5A high-brightness LED from an input of 12

VDC for MR16 lamp replacement applications.

The two-wire dimming feature of LM3406 enables PWM dimming over the power
input line.
 Conclusion & Future Scope

LEDs represent the most significant development in Lighting since the invention
of the electric light more than a century ago.

They allow us to create unique, low energy lighting solutions, not to mention their
lower maintenance costs and as investment continues and volumes increase, the
price of LEDs should come down by 10% or more a year.

But when will LEDs become more mainstream? Assuming LED lighting continues to
develop as expected, it is now possible to predict the future with some certainty.

For some time now LED lighting systems have been used to light up buildings,
bridges and monuments. Due to their flexibility and the possibility to set any
desired color, LEDs offer lighting solutions, which are not possible with any other
existing technologies, such as color wall washing, sharp light/shadow lines and
avoiding light pollution on windows.

LED Lighting For Business

Offices are already seeing the first niche LED applications with desk lights and
particularly emergency lighting. However, as replacements for conventional
general lighting LEDs are still some years off because the cost/lumen ratio is still
too high performance will have to improve (at least >80 lmW at a system level)
to compete.

Nevertheless, the next few years should see the first effective LED solutions in
specialised areas of the office, such as, reception and meeting areas, where more
decorative effects are required. Within three to five years the first solutions
should become available which can compete with compact fluorescent technology
on total cost of ownership criteria and within a decade LEDs should become a
viable option for general lighting solutions.
LED Lighting in Industry

LED replacements/retrofits are already making a small impact in industrial niche

areas mainly concerned with lighting in fire hazard and explosion risk areas. LEDs
are ideal because they operate at Safety Extra Low Voltages (SELV) typically
12V or 24V. Their reliability, long life and instant flickerfree turn on are also
major selling points. But similar to the commercial market, general LED lighting
solutions are still some years away.

LED Lighting For The Leisure Industry

In the leisure sector, hotels and restaurants are installing LED lighting for
decorative purposes in bars plus reception and dining areas. Hotels are also
beginning to use LED bedside and standing lamps and effective 3W LED
downlighters, (designed to replace 20W halogen versions), are expected within a
year or so.

LEDs are also being used in hotel signage to replace fluorescent, incandescent and
neon lamps. Their low energy consumption, bright clear colours and long life make
them ideal.

LED Lighting In Retail

Its an application that is frequently utilised within the retail sector. LEDs are
also finding an ideal application in commercial freezers since they are unaffected
by the cold and have already replaced traditional TL flourescents in some areas.

Elsewhere, expect new LED shelf lighting within a year and compact LED mini
spotlights soon after. Within three to five years, LEDs should start to appear in
general retail lighting applications.
The potential for LEDs in the fashion and high end of the retail market is also
significant, where they are already being used for ambience creation and dynamic
effects.

The first display LED lighting systems are also starting to appear on the market,
but it will be at least five to ten years before effective LED lighting solutions will
start to appear in mainstream shop lighting.

The Future of LED Lighting

In the coming years, the light output of LEDs will continue to increase, enabling
massmarket general lighting applications from approx 2010 onwards. The first
effective general LED solutions to replace incandescents will appear on the
market over the next two to three years, but initially they will be relatively
expensive.

However, as development continues the main question is not when they will replace
what, but what new developments will be made possible.
 REFERENCES

Texas Instruments Website www.ti.com

ST Microelectronics Website www.st.com

Wikipedia

Electronics For You Magazine

 ACKNOWLEDGEMENT

It is indeed a matter of great pleasure to be able to present this project

on LED DRIVER before you. We have tried our level best to place all the

theoretical as well as practical aspects about the project in our project report.

It is indeed our privilege to express our indebtness and sincere gratitude

to our project guide, Prof.Mr. S.R Pandey, for his precious support, able guidance,

encouragement, whole hearted cooperation and constructive criticism throughout

the duration of project.

In all our endeavors, we have always been kindly directed and supported by

our respected principal MR.Rajesh Pandey. We express our sincere gratitude to

our Head of Department Prof Dr. Mrs.A.Khursid for providing us with necessary

facilities in the laboratories.

We take this opportunity to thank all our lecturers who have directly or

indirectly lent a helping hand for our project. We pay our respect and love to our

parents for their love and encouragement throughout our career. Last but not

the least we express our thanks to our friends for their cooperation and support.