Simple Circuits
High Brightness LEDs
By Jeff Alder, CET
Hello and welcome to Simple Circuits. In this issue, I thought
it might be interesting to explore some of the aspects of driving
High-Brightness LEDs (HBLEDs).
We all know the benefits. 1/10th the power consumption of in-
candescent with many times the longevity, as well as the ability
to withstand shock and vibration, etc.
These advantages have indeed resulted in energy savings with
lower maintenance and longer replacement schedules, but is it
really as simple as putting a few strings of HBLEDs together in
an array, and providing them with an appropriate voltage?
As it turns out, it is not so simple as one might think. Companies
have been hard at work for several years striving to produce
consistent, quality, low cost lighting products for traffic, and
other industries, with varying degrees of success.
Initial complaints were to include such issues as premature
failure, blotchy appearance, and inconsistent light intensity
between the various colors (red, green and yellow “bulbs”),
among others.
Products have improved significantly over the last 5 years or
so, but what is it that makes replacing incandescent with LED
technology so challenging?
First, we must consider the environment in which these devices
are to operate. The traffic and transportation industry is one of
the most brutal environments for electronic circuits. This envi-
ronment involves temperature extremes, vibration, humidity,
vandalism, and many other challenges.
There are cabinets full of equipment that have operated in this
extreme environment for decades, but HBLEDs are a relatively
new technology. There are special considerations which must
be met when applying LEDs into any application, let alone
traffic.
HBLEDs are in fact very interactive devices and, unless certain
conditions are met, several parameters can vary, which will affect
everything from efficiency to life expectancy and even color.
When one considers the basic incandescent bulb, it is a mechani-
cal device that utilizes its entire physical structure to radiate
energy. The ratio turns out to be around 90% heat and 10%
light. Not particularly efficient.
By comparison, an LED is a semiconductor junction. This is a
very small area with which to dissipate excess energy. HBLEDs,
though more efficient, can still produce considerable heat
when being driven by the higher currents required for their
operation.
Microchip Technology Inc., a leading provider of microcon-
troller and analog semiconductors, currently manufactures
several electronic components which have been specifically
designed to drive, modulate, monitor and even communicate
Page 14
with HBLED circuits. These products ensure that HBLEDs op-
erate at their highest efficiency, achieve their greatest longevity,
and maintain their color integrity.
It is first important to note that while an LED is a PN junction
(diode), and thus has an associated forward voltage drop, this
parameter usually falls within a range of voltages and is incon-
sistent from device to device. It is therefore unwise to implement
voltage-drive circuits, which no doubt produce different light
intensities based upon a range of currents that are also affected
by current-limiting resistors, whose resistance will vary from
device to device.
A constant-current source is a much better method for consis-
tent light output between LED devices. These constant-current
sources are actually single-chip switching power supplies,
based upon the same technology as voltage-based switching
power supplies, but they have been specifically designed for
the purpose of driving LED arrays.
HBLEDs are specified with an optimal forward current for
luminous output. Therefore, constant-current sources provide
the following 3 benefits to LED drive technology:
1. Maximum efficiency (Lumens per Watt)
2. Maximum cost effectiveness per lumen (highest effi-
ciency/lowest maintenance)
3. Maximum chromaticity stability (consistent color tem-
perature and repeatability)
By driving an HBLED at its rated optimal current, one achieves
the most efficient light output and ensures the longest LED life.
The color temperature also remains extremely constant. I’m not
suggesting that an LED will change from green to red based
upon its forward drive current, but different color temperatures
of output light will be observed if varying currents are applied
to the device.
Microchip has produced an excellent application note (AN1138),
which describes a high current, HBLED control circuit. A Pro-
portional-Integral (PI) controller algorithm is used to regulate
the LED current to a constant value.
An 8 pin MCU (PIC12HV615) is the core of the circuit, which
samples the LED current across a 0.56 Ohm sensing resistor. The
sampled current is then amplified through an Op-Amp and used
to drive a PWM output, based upon the measured value.
Since an HBLED array presents a very constant load, the MCU
will never have to make significant adjustments. The sample
rate can therefore be quite low, freeing the MCU to perform
other tasks as required.
The circuit is designed to drive a 1W HBLED with a current of
350 mA, from a 12 VDC supply.
It should be noted that constant-current LED drive circuits
Continued on page 18
IMSA Journal
Simple Circuits . . . application, but too extensive to cover
within the scope of this article.
mote dimming or on-off control, although
this can be very important in the detection
Continued from page 14
of room occupancy and other factors.
can also be designed using linear com-
Pulse-width modulating a constant source
ponents. These too are low cost and
of optimal drive current will produce The very health of an array and/or fault
will achieve the lowest EMI output, but
controlled brightness of HBLED arrays conditions can be easily polled or alarmed
high efficiency will be sacrificed. See
at maximum efficiency. But this is only (and even logged) as the array performs
Microchip’s Web site (www.microchip.
the beginning… its day-to-day operations. Cooling fans
com) for further details.
can be activated and maintenance calls
Now that microcontrollers are involved, can be initiated, because of CPU control
Microchip also manufactures many volt-
highly sophisticated drive circuits can and the intelligent communication de-
age-based switching LED drive products,
be realized. vices now implanted within the array.
including:
It was mentioned earlier that thermal Microchip’s devices support many indus-
1. Single chip charge-pump devices,
management is also a potential concern. try standard communication protocols
which do not require external in-
Incandescent bulbs radiate energy, but including DMX512, a High Speed Se-
ductors or FETs. (Backlight applica-
LEDs must have their heat conducted rial protocol requiring a EUSART. This
tions with low voltage/low current
away from the semiconductor junction. hardwire-based protocol has been around
requirements)
These junctions are physically small and since the mid ‘80s and is becoming very
2. Buck mode devices, for converting
large numbers of LEDs are often placed in popular for LED lighting applications.
down from higher voltages
close proximity to one another, potentially
3. Boost mode devices, for “up” con-
compounding thermal issues. Couple this Communications can be either hardwire
verting lower input voltages in order
with the expectation of operation in high- or wireless, depending upon the applica-
to drive many LEDs
temperature locations e.g direct sunlight tion. Microchip has developed several
4. SEPIC configurations, which are
in hot climates and you have a recipe for fully-certified wireless modules, includ-
high-current drivers that adapt to
LED destruction. ing devices that contain an integral PCB
buck or boost - based upon the level
antenna, which literally take the RF com-
of input voltage, thereby extending
Heat is an electronic component’s worst ponent out of the wireless design. By this,
the useful life of the battery.
enemy. Without proper thermal manage- I mean that a designer can simply apply
ment, junction temperatures quickly rise, power and the communications interface
These circuits can be used when the
reducing the life of the LED and produc- from the CPU, and the miniature stand-
application will not push LEDs to their
ing variance in the chromaticity. alone RF modules will communicate via
limits of operation.
IEEE 802.15.4™ (2.4 GHz ISM) using
I am not privy to all thermal-management the ZigBee™, MiWi™, or MiWi P2P
For higher voltage, AC input require-
techniques in use by LED lamp replacement protocols in various network configura-
ments, Microchip provides reference
manufacturers, but the technology is avail- tions which include Star, MESH, P2P and
designs and evaluation boards for some
able to implement array temperature sens- Cluster Tree. (See Figure 1.)
very impressive 120VAC drive applica-
ing and responsive brightness control.
tions, including Power Factor Correction
(PFC).
Lamp manufacturers begin by carefully
laying out their printed circuit board,
All of these products and applications are
providing good thermal paths by which
discussed at length on Microchip’s Web
to conduct heat away from the semicon-
site and in its application notes.
ductor junction, as you would from any
power semiconductor device. Heat sinks
Let us get back to LED theory and more
can also be installed to help with the cool-
of the advanced drive techniques for
ing process.
these devices.
Temperature is then monitored in order
If we are always to drive the HBLEDs
to control the brightness of the LEDs. The
with a constant optimal current, then how
control circuits can even shut down an Figure 1: Complete RF Module, Including
do we control brightness? It turns out that
array if necessary when excess thermal Antenna (Part # MRF24J40MA)
as long as the LED is driven at the optimal
conditions exist. (Shutting down an LED
current, it can be switched on and off, at
lamp at an intersection for cooling pur- Imagine having all the LED lamps at an
high rates of speed, and by varying the
poses is obviously unacceptable.) intersection, wirelessly connected via
duty cycle brightness is controlled. By
Mesh network back to a coordinator
modulating the current driver circuit via
The ability to monitor and control tem- (the device that forms the network), at
Pulse Width Modulation (PWM) from a
perature can extend the life of an LED the cabinet. Lamps logging their hours
microcontroller, one can easily achieve
or array several times over. Microchip of operation, and monitoring for fault
programmable LED array brightness.
manufactures many types of tempera- conditions, while automatically compen-
ture-measurement devices with outputs sating for temperature excess. Detailed
Microchip provides several application
ranging from logic, to voltage and even information from every lamp could then
notes, schematics and PWM driver rou-
I2C™ interface depending upon circuit be made available to the Traffic Manage-
tines, including sophisticated color gen-
requirements. ment Center (TMC).
eration algorithms and development tools
such as the MiColor™ -Color Control
Micro controllers also provide the added The TMC would then have the ability to
GUI, used to help customers understand
benefit of communication. Communica- monitor, in real time, each lamp’s hours
the details of RGB open loop and closed
tions provide more than the means for re-
loop color generation. An interesting Continued on page 20
Page 18 IMSA Journal
Simple Circuits . . .
Continued from page 18
of operation and health. They would also
have the ability to monitor and control the
brightness and temperature of every de-
vice in the field. Maintenance schedules
would be easily defined and service calls
immediately dispatched.

Some of this is already in practice, today.

We have only scratched the surface as
to what HBLED technology and its as-
sociated interface and drive circuitry can
bring to our industry.

LED manufacturers such as Dialight

have predicted that LED efficiency is in
its infancy and that greater lamp efficien-
cies will continue to be achieved until the
year 2020. At that time, improvements
in efficiency are expected to plateau due
to the physical aspects and limitations of
light emitting PN junction based devices.
(See Figure 2.) Figure 2: Source - Dialight June

While other lighting technologies ma-

tured long ago, the humble LED is coming
into its’ own, and we will continue to see
new benefits for years to come.

Companies such as Microchip Technol-

ogy literally provide all the necessary
interface and intelligence to drive these
devices and exploit them to their highest
potential. The only components Micro-
chip doesn’t provide are the LEDs them-
selves. With CPUs priced at under $1.00,
adding intelligence has never been more
economical, so look for great innovations
- imagination is now the limiting factor.
(See Figure 3.)

I would like to thank Microchip Tech-

nology Inc. for supplying pictures and
graphics contained within this article.
Visit the direct links listed in the Refer-
ences section to access Microchip’s Web
site and the various data sheets and appli-
cation notes specific to LED and lighting
driver technology.

Let’s take our hats off to the manufactur-

ers of LED replacement lamps and gen-
eral lighting products. They truly operate
on the cutting edge of technology and
continue to overcome many hurdles, as
they bring us quality and energy-efficient
sources of light.
Until next time, take care out there!
Note: The Microchip name and logo are
registered trademarks of Microchip Technology
Inc. in the U.S.A. and other countries. MiWi
is a trademark of Microchip Technology Inc.
in the U.S.A. and other countries. All other
trademarks mentioned herein are property of
their respective companies.
Page 20
Figure 3: Wireless LED Monitor and Control
References
Discovering New Opportunities in Lighting Applications 12 (Microchip Technology Inc. PPT
Presentation)
WWST_RFPD_2008 (Microchip Technology Inc. PPT Presentation)
MCP1252 pdf Data Sheet (Microchip Technology Inc.)
Evolution of Lighting Graphic (Dialight Corporation)
Microchip Technology AN1138
www.microchip.com/lighting
www.microchip.com/smartled
IMSA Journal