Technological revolution in the high-power LED market

Resonance switch-mode power supply units without a PFC layer, designed and manufactured in Germany

Although there are many R&D offices for switch-mode power supply units in Germany, we tend to think that they are not manufactured in Europe, but automatically assume they are produced abroad, notably in Southeast Asia (SEA), due to cheaper manpower costs. This last is true to a certain extent, but a workbench located far away is not always cost-effective. On the one hand, it can be of immense advantage if development takes place in Europe, where we are familiar with all the particular demands on a modern lighting switch-mode power supply unit. Crucial decisions regarding the power factor or harmonic waves, for example, can be taken and their layout implemented making the most of the shortest possible channels of communication. These clear benefits to development can be put at risk if subsequent manufacturing takes place in SEA, due to long transport routes and communication difficulties. This applies particularly to small and medium quantities and can put serious obstacles in the path to success.

When structural components are manufactured by machine, manpower costs are not necessarily a decisive factor. The short distance between workshop and design department can be more important as this translates into the ability to react quickly to the market. In addition, the degree of automation in this country plays a crucial role in cutting costs.

exscitron (development) and inpotron (development and manufacturing) can be seen as an example of successful symbiosis between design and manufacturing. Should changes in a structural component be necessary, these can be developed and tested within a very short period of time at our development company exscitron in Chemnitz and then put directly into production at our manufacturing plant inpotron, located near Lake Constance.

exscitron

With its team of highly specialized engineers, exscitron has established itself in Germany as a committed developer of customized switch-mode power supply units. As a subsidiary of "inpotron Schaltnetzteile", exscitron benefits from the rich resources available in the German "Silicone Valley" in Chemnitz with regard to power electronics.

inpotron

The well-known company "Spaun Schaltnetzteile" changed its name to "inpotron Schaltnetzteile GmbH" with its head office in Hilzingen in 2008. inpotron supplies switch-mode power supply units as customized solutions for all areas of application, from industrial electronics via automotive electronics to solar technology. Up to 1 000 000 switch-mode power supply units can be manufactured annually in our modern 3 000m² plant.

The newly-developed LED control gear currently demonstrates the successful symbiosis between exscitron and inpotron.

 

Electronic LED control gear

The electronic LED control gear has undergone a completely new development to satisfy all the modern requirements made of today's high-power LEDs and, thanks to its revolutionary topology, sets a new benchmark, particularly with regard to its efficiency in the lighting sector, plus it has no PFC layer. The latest semiconductors made by ST TM and InfineonTM take over the active part of the circuit. EPCOS, as manufacturer, has lent strong support to the young company exscitron throughout the development phase by supplying samples from its wide-ranging portfolio of passive components, such as inductors, current sense transformers, EMC inductors, aluminum capacitors, film capacitors that meet EMC regulations and varistors. All these structural components supplied by EPCOS ensure the robust, durable functioning of this electronic control gear. Further advantages are the result of dispensing with the "hard" switching PFC layer. The size of the line filter has been minimized and easily meets class B requirements or EMC standards for conducted emission system perturbation and beamed disturbances.

A starting current limiter is no longer necessary as the capacity at input is minimal as a matter of principle. The positive aspects of this light construction obviously also influence two other crucial factors of a successful product: size and price.

The 100 Hz current ripple that is transmitted is minimized on the secondary by high capacity. It is equipped with high-quality aluminum Elkos to achieve the required durability. These are not stressed by the HF ripple so almost no self-heating occurs.

A selection of our top of the range self-ballasted electronic LED lamps

• Adherence to the power factor and harmonic waves in accordance with EN61000-3-2 class C for the whole load range
• The starting current inrush is limited to a minimum, this applies to cold and warm starts as, thanks to the technology, no starting current inrush is generated
• 93% efficiency under real loading conditions, never below 91% in the whole dimming range
• 100W power output (max. 130W), without forced ventilation, even under extreme thermal loads of over 50°C ambient temperature. Via processor controlling, the current generator adjusts the power output automatically when the casing temperature reaches 70°C
• 3" x 5" form factor, including casing. Optional open-frame up to IP67 on request
• Various dimmer/actuator alternatives: infinitely variable current regulation via a resistor, by 1-10V analog input signal, primary controlled night setback via phase detection as well as DALI and POWERLINE control system
• Real lifetime of 100 000 hours thanks to top quality components, optimal thermal management and waiving of switching units, which reduce durability

Digital features

Thanks to the use of a micro-controller, a whole range of possibilities presents itself that would not be easy to realize if at all feasible using only analog technology.

• Night setback for the street lighting sector. In the systems existing at the moment, night setback in sodium vapor lamps is mostly achieved by an additional lamp being switched on or off during a second phase. We simulate this function in our device. This is not actually easy to do with a high-power LED as its luminous efficiency is not linear to the current. Our control system allows us to program output current according to the client's requirements and, for example, to reduce LED power at night setback from 100% to 30%, which results in a 50% reduction in brightness.

• Dimming on the secondary. Thanks to galvanic isolation, the simple means of using a normal potentiometer to regulate output current manually is possible. An extremely wide, infinitely variable setting range of 25 to 100% means optimal satisfaction of client requirements.

• Illuminant recognition via a resistor. If a fixed resistor is integrated in the dimmer, the device is able to recognize different illuminants and can supply the appropriate current parameters. This allows the client to use illuminants of varying performance categories using one sole intelligent control gear.

• LED protection device via lagging contacting. This special feature aims to allow a LED illuminant unit to be changed while the system is running during servicing. The output current in conventional current generators would first boost the output current to the upper limit at load throw-off, the next time it was plugged in this static current would discharge unchecked onto the LED and have a significant negative effect on its lifetime. The lagging contacts inform our power supply unit that the load has been removed. Output is immediately reduced to a level that presents no risk to the LED. When plugged in, voltage increases gradually to the level required for the desired current value.

EPCOS offers support to all leading manufacturers and designers of semiconductors via its Reference Design Department.
Please contact Mr Wolfgang Dreipelcher for more information.

Company links:
www.exscitron.de
www.inpotron.com

Presscontact:
exscitron GmbH - Stephan Gruber - Uhlichstr. 13 - 09112 Chemnitz
Fon.: +49 3 71 / 35 58 60 10 –

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