Yet another LED

[ssw]

Looked in DIY section of this site I was really impressed... a lot of people with hands. Cool.

Let me describe our way to build LED fixture, will be glad if somebody find something useful.

So I'm started to build LED fixteres 6 years ago, and step by step come to:
1. Using regular FR4 PCBs
2. FR4 with some additions can provide good thermal interface
3. All electronics should be located on same PCB

Last (not really, but) LED lighting PCB:

As you can see 4 LED blocks located in corners, 12 drivers in center line, upper block is DC-DC and opto couplers, bottom - 2 controllers, clock, bluetooth.

Back side:

Back side with copper heatplates.

Small holes filled during heatplates soldering.

Assembled PCB (components placed by hand, then to special oven)

It is works!

Sorry for my English, it is not native for me. Will be glad if written above push somebody in same direction in LED building.

Good luck.

 

[saikumar]

thats a cool build, and tell you what- I just registered here to ask you couple of questions.
Is that an ESP-12E that you are using? is there any dedicated circuit you are using to keep it stable from noise?

and are the drivers A6211? also just wondering if you have a Atmega328 there, if so what purpose?

Thank you in advance!

 

[ssw]

thats a cool build, and tell you what- I just registered here to ask you couple of questions.
Is that an ESP-12E that you are using? is there any dedicated circuit you are using to keep it stable from noise?

No, on picture you can see HC 05 bluetooth adapter, also we have a possibility to mount on same place ESP8266 board but never try, just have no time to change software.

and are the drivers A6211? also just wondering if you have a Atmega328 there, if so what purpose?
Thank you in advance!

Drivers are ON Semiconductors 30160, for me it is best, but when we using it we must recalculate some parameters (cutoff R C circut) based on LED's current, dropped voltage, input voltage and so on.
And Yes, we have AtMega328 as main controller with 6 PWM onboard + ATTiny for 4 PWMs as slave controller. Sure Mega used for thermo control (i2c LM75AD) as well as controller for PWM fan. Also Mega handles connection between fixtures (something like RS485 network) so all of them can works based on same program or controlled separately.

Here you can see PC software for controller.

 

[dorky]

Do u sell the board separately?

 

[ssw]

Sorry, but not. Actually it is not a business it is a hobby. All these things made by only two mans, me and my friend and we just have not enough to sell. Moreover as I understand these boards not for selling in USA due to LED's manufacturer restriction (something about patents between Cree and Semileds).

 

[saikumar]

Thank you so much for the details! I am planning to get mine done too, and plan to start with esp chip as its quite capable for multi channel too. I am still doing some finding online on how to make it safe from noise.

Can you also tell us more about how you are able to maintain the fixture so slim, what is the fan and are you using 4 pieces of heatsink?

 

[ssw]

Some guys around already have ESP8266 + PCA9685 controller with soft. (PCA9685 - ic2 16 channels PWM)

one heatsink - 222x222x14mm, place for fan milled in it. Fan itself 12mm.

Whole sandwich is:
Acrilic black with windows for LED 3mm
Acrilic clear 12mm
Heatsink 14mm
Acrilic cover for fan 4-5mm

 

[ssw]

Another fixture based on similar PCB, but really compact (60x60mm):

Then we made based on that PCB a lot of different fixtures.
Passive cooling

or with active cooling:

 

[knukles55]

Very nice sleek light

 

[ssw]

Thanks, we are always trying to made something pretty. Will post photos of our latest fixtures soon...

 

[saikumar]

thats really really cool!! especially the smaller PCB foot print, is it the same PCB inside the disc shaped fixture too?

How many layer PCB did you use in your second one?
And wont the vias/terminals get short with the aluminum heatsink at the base?

how about adding some space on PCB to add a lens on each of diode, or may be one lens for all led together, this way that light spread is more contained.