LED driver design for high power LED bulb replacement applications

This article describes an LED driver reference design for high power LED bulb replacement applications. The driver provides the power required for a 100W A19 incandescent bulb replacement lamp. It is a non-isolated, high efficiency (about 93%), high power factor (PF) LED driver that fits into the A19. The bulb not only meets the EN61000-3-2 C(D) standard, but also easily meets the THD limit. The power factor (PF) value exceeds 0.95, making it suitable for both commercial and consumer applications.

According to estimates, China's lighting electricity accounts for about 12% of the total electricity consumption in the whole society. If you replace all the incandescent lamps in use with energy-saving lamps or LED lamps, you can save 48 billion kWh per year, which is equivalent to reducing carbon dioxide emissions by 48 million tons. It can be seen that the market potential of LED lighting is huge. The National Development and Reform Commission issued the "China Roadmap for Phased Elimination of Incandescent Lamps", which also indirectly promotes the development of the LED lighting market.

Figure 1: 100W incandescent lamp elimination route

100W A19 incandescent bulb replacement market potential for LED driver applications

Andrew Smith, Product Marketing Manager of Power IntegraTIons: "All countries start with high-power 100W incandescent lamps, followed by low-power incandescent lamps such as 75W. The EU eliminated 100W incandescent lamps in 2010, the United States. China, etc. began to phase out in 2012. Therefore, there is a very strong market demand for high-power LEDs that can replace 100W incandescent lamps."

Nowadays, 100W incandescent lamp replacement LEDs generally need to adopt PAR38, and LEDs with A19 specifications have not appeared yet. PI has now introduced the industry's first LED driver design for the 100W A19 incandescent bulb replacement application, the DER-322, which provides the power required for a 100W A19 incandescent bulb replacement lamp, the industry's first such design. The introduction of PI high-power LED driver design has greatly promoted the rapid entry of 100W incandescent high-power LED into the market.

The DER-322 driver fits into the A19 bulb and not only meets EN61000-3-2 C(D) standards, but also easily meets THD limits. Its power factor (PF) value exceeds 0.95, making it suitable for both commercial and consumer applications. Since the PFC and CC conversions are integrated into the same switching stage, the number of components in the design is very small, which contributes to miniaturization of the driver, reduction in cost and reliability. In addition, it uses ceramic capacitor components, eliminating the need for short-lived large-capacity input electrolytic capacitors, which greatly contributes to the improvement of product life.

Figure 2: Power IntegraTIons DER Series LED Driver Development Route

The applicability of DER-322 is also outstanding. It is not only suitable for LED replacement lamp drivers for A19 incandescent bulbs, but also for LED replacement lamp drivers for T8 lamps, so for high-end LED lighting designers and designers who are committed to optimizing retail low-cost designers, It is very attractive. The reference design is slightly modified to support TRIAC dimming.

Of course, objectively speaking, there are still many technical problems to be solved in high-power LEDs. In addition to the LED driver parts that PI prioritizes, other heat sinks, high-power LED granules, etc., require other related manufacturers to work together to have the final product. .

Andrew Smith pointed out: "As long as there is a clear market demand, the corresponding manufacturers will increase the investment in specific technologies. I think that high-power LED terminal products capable of replacing 100W incandescent lamps by the end of 2012 are expected to appear." After the corresponding products, under the promotion of national government policies, I believe that high-power LEDs will have good development potential.

100W high reliability LED bulb drive power supply design

This design is made with DER-305 PCB board, making maximum use of the area of the LNK460VG device heat sink.

Table 1: Power Supply Specifications Schedule (The following table is the minimum acceptable performance design requirements. The actual output is listed on the right.)

Figure 3: Main circuit diagram of LED driver for 100W high power A19 incandescent bulb replacement application