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a design of replacement led fluorescent tube bulbs

With the LED products, technological innovation, led fluorescent tube lights bulbs has gradually in the home, office, public facilities and other lighting areas are widely used. Straight tube lamp as a major feature of traditional lighting products, has a high market share in the large-scale development trend of led fluorescent tube lights bulbs products, straight tube LED lamp research and development is also in full swing.

With the LED products, technological innovation, led fluorescent tube lights bulbs has gradually in the home, office, public facilities and other lighting areas are widely used. Straight tube lamp as a major feature of traditional lighting products, has a high market share in the large-scale development trend of led fluorescent tube lights bulbs products, straight tube LED lamp research and development is also in full swing. This paper introduces a LED lamp can replace the traditional design of the lamp, through the mass production of verification, the process is simple, high reliability, can be extended and applied, which can replace the traditional straight tube Fluorescent lamps, the market prospects are very broad.

1, straight tube LED product classification and characteristics

1.1, product structure characteristics of classification

From the tube structure characteristics of point of view, the current market more common straight LED products are the following categories: ① semi-aluminum plastic; ② plastic bag aluminum; ③ plastic type; ④ all-glass tube and so on.

1.2, all-glass LED straight tube lamp characteristics

All-glass straight tube LED with its own characteristics: shape and the traditional T8 (T5) light source consistent, light color soft, high luminous efficiency, easy to replace the advantages of increasing acceptance in the market, market share Also steadily. Although the current glass tube LED has a certain market share, but the real can directly replace the traditional fluorescent lamps, direct point in the original fluorescent lamp products, we based on the replacement of convenience considerations, design and appearance of a traditional straight Tube consistent with the LED lamp.

2, LED lamp design

Combined with the traditional fluorescent lamp shape, replaceable LED lamp components are divided into: drive design, shell glass selection, plug head, light-emitting devices.

2.1, the drive circuit design

Driver circuit is the key to replace the design of LED lamp, the circuit connected to simulate the traditional filament fluorescent lamps. Driving power from the main circuit for the step-down current limiting, rectifier filter and has a normal light LED lamp and protect the LED tube from the impact of instantaneous high voltage impact of the analog filament resistance circuit. The design includes an overvoltage and overcurrent protection circuit for preventing the lamp from being damaged due to overcurrent and / or overvoltage, a frequency detection circuit for generating an induced voltage only at a high frequency current input, a frequency detecting circuit for applying a low frequency alternating current or a high frequency A rectifying filter circuit for converting the alternating current into a clutherless direct current, a BUCK step-down circuit for reducing the DC voltage outputted by the rectifier filter circuit to obtain the operating voltage of the LED lamp bead group in the LED fluorescent tube for shielding said The PWM switch circuit in the BUCK step-down circuit is used to directly control the high-frequency straight-through circuit of the BUCK step-down circuit; the input end of the over-voltage and over-current protection circuit is connected with the output of the low-frequency alternating current or electronic ballast An output end of said frequency detecting circuit is connected with the input end of said rectifying and filtering circuit, and the output end of said frequency detecting circuit is connected with the input end of said frequency detecting circuit, The output end of said rectifying filter circuit is connected with the input end of said BUCK step-down circuit, and said output terminal of said high-frequency straight-through circuit is connected with said input terminal of said high-frequency straight-through circuit, And the output end of the BUCK step-down circuit is connected with the LED lamp bead group in the LED fluorescent lamp tube, and the output end of the BUCK step-down circuit is connected with the control end of the BUCK step-down circuit. The drive line is as follows

2.2, LED straight tube lamp with glass performance requirements

a design of replacement led fluorescent tube bulbs

The performance of the glass tube of the straight tube type LED lamp shell mainly includes the appearance effect, transmittance, atomization, temperature and humidity resistance, moisture resistance, hardness, conductivity, swelling rate, curvature, and the whole light color parameters. influences.

Key indicators are as follows:

① Appearance: color is generally milky white, smooth surface, no bubbles, no scratches, no miscellaneous points;

② transmittance: test calculation method, with the same light source in the specified voltage and power were applied to the same specifications of the transparent glass tube and milky white glass tube, with an integrating sphere to test the photoelectric color parameters, milky and transparent light effect Ratio is the light transmittance, usually the light transmittance requirements of 92% or more;

③ atomization: the matching of the light source (lamp beads) device on the glass tube, the rated voltage, power, the lamp will light, do not see the light-emitting point (lamp beads), the whole glass tube uniformity, Performance, consistent, no significant difference between light and dark;

④ temperature performance: the glass tube on the 150 ℃ high temperature box, 200 hours later, no color change, no burst, no deformation and other anomalies;

⑤ Water resistance: the glass on the 60 ℃ constant temperature water bath box, 24 hours later, no color change, no burst, no deformation and other anomalies;

⑥ expansion coefficient fluctuations: the same batch of glass tube expansion coefficient fluctuations in the control requirements ± 1 × 10-7 / ℃;

⑦ conductivity: the glass tube inner and outer walls are required non-conductive;

⑧ light color effects: milky white glass tube and transparent glass tube with the same light source test light color parameters, spectrum, color temperature, color rendering index can not be significantly different;

⑨ Hardness: T8 glass, for example, the use of general pressure test glass pressure gauge generally require greater than 300N, the specific subject to the manufacturer’s customers.

⑩ bending degree: T8-1.2 meters long glass tube, for example, generally require bending of not more than 3 °.

The above properties, light transmittance, atomization, temperature and humidity, light color effect is most manufacturers pay more attention.2.3, lamp design

Replacement led fluorescent tube lights bulbs mainly by: plug 1, the end of the first circuit board 2, power-driven, light-emitting module 3, the shell composed of glass tube 4. The light emitting module has a substrate material and a chip led fluorescent tube lights bulbs bead, and the led fluorescent tube lights bulbs beads are evenly distributed in the middle part of the substrate. Figure 2 below

2

(Click image to view larger image)

3, LED glass lamp production program

3.1, led fluorescent tube lights bulbs production process when there are difficulties

Under normal circumstances, the glass tube light-emitting devices and glass tube with glue for bonding, first of all, there are difficulties in curing the glue. LED glass tube in the production process is generally silicone glue, curing process takes a long time, so that the entire production process to increase the number of product cycles, the various links in the production process of fluency are affected, the production efficiency is low. Second, the dispensing equipment, LED glass lamp in the production process, PCB and plug the installation of fixed-point equipment are required to complete the dispensing equipment, the current development of the technology matures, the process is relatively difficult; , In the entire installation of the led fluorescent tube lights bulbs , the power and plug installation is the most complex, to achieve the greatest resistance to the flow of water.

3.2, lamp production process automation program considerations

To solve the LED production process in the existing problems, to achieve its systematic flow of production operations, we must focus on solving the above-mentioned problems in the production process. In addition, the LED glass tube production process automation solutions should also focus on the development of automation technology in the LED glass tube production process to reduce costs and improve production efficiency of the role of enterprises in the relevant production process, The introduction of automation technology to make the appropriate provisions, of which the introduction of automation must simplify the production process, fixed product structure, protect the production of a substantial increase. Therefore, the introduction of automation technology to improve product yield in the process must be in accordance with the fixed product structure, simplify the production process of the process carried out.

4, concluding remarks:

In this paper, the design scheme of a full replacement LED glass lamp is described, and the technical difficulties are analyzed. The method of simulating the design of filament resistance and the arrangement of lamp beads is proposed to solve the technical difficulties. At the same time, Glue, automatic assembly process program, in order to optimize the LED glass lamp design, process plan, the LED glass lamp production promotion has a certain significance.

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