LED Driver Circuit Self-Calibration for Manufacturing Cost Reduction
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Solution Overview
Problem
The high cost and complexity of manufacturing solid state light bulb assemblies due to process variance and the need for frequent redesigns to accommodate new LED components, which increases production costs and complexity in the supply chain.
Innovation Solution
A controller for a driver circuit that calibrates the light bulb assembly by determining a set of settings for the driver circuit to achieve pre-determined target illumination characteristics, using multiple test scenarios and modulated electricity supply signals to optimize the light source's performance without the need for transmitting settings via the electrical supply signal, thereby accelerating and robustifying the calibration process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If traditional incandescent light bulbs are used, then simplicity and low cost are maintained, but energy efficiency is poor and they are being phased out by legislation
Solution Approach 1:
The patent replaces the mechanical/incandescent lighting system with solid-state LED technology, substituting the traditional filament-based mechanical system with semiconductor-based light emission. This substitution dramatically improves energy efficiency while the modular driver circuit design with integrated calibration maintains manufacturing simplicity through automation.
2Use of energy by moving object
If LED-based light bulbs are used, then energy efficiency and lifetime are improved, but product cost increases up to 10 times that of CFL lamps
Solution Approach 1:
The LED lamp assembly performs self-calibration by automatically determining optimal driver circuit settings during initial operation. The system uses built-in sensors and processing to autonomously adjust parameters without external intervention or complex manual binning processes, thereby reducing manufacturing costs while maintaining high energy efficiency.
Solution Approach 2:
The patent dynamically adjusts driver circuit parameters (current, voltage, frequency) based on actual LED characteristics rather than using fixed parameters for all lamps. This parameter adaptation eliminates the need for expensive manual binning and allows a single manufacturing process to produce lamps suitable for various LED variations, reducing overall manufacturing cost.
3Power
If LED efficiency is improved, then luminous output increases, but device temperature increases causing efficiency degradation and reduced lifetime
Solution Approach 1:
The driver circuit incorporates temperature sensing and feedback control mechanisms that continuously monitor LED junction temperature and adjust drive parameters accordingly. When temperature rises, the system automatically reduces drive current or increases pulse width modulation duty cycle adjustments, maintaining optimal temperature levels while preserving high luminous output through dynamic parameter optimization.
4Manufacturing precision
If manual binning and calibration processes are used, then manufacturing precision is improved, but device complexity and production time increase heavily
Solution Approach 1:
The system performs preliminary self-calibration during initial power-up sequences before normal operation begins. The driver circuit automatically characterizes the LED parameters and stores optimal settings in memory, completing the calibration process in minutes rather than requiring complex external equipment and manual procedures. This preliminary action eliminates the need for complex supply chain binning processes.
Solution Approach 2:
The driver circuit is designed as a universal platform that can accommodate various LED types and specifications through software configuration rather than hardware redesign. The integrated calibration routine works across different LED manufacturers and batches, making the driver circuit universally applicable and eliminating the need for specialized calibration equipment or complex supply chain management for different LED variants.
5Adaptability or versatility
If driver circuit settings are transmitted via electrical supply signal, then adaptability is improved, but calibration time and robustness are reduced
Solution Approach 1:
The system performs preliminary self-calibration during initial power-up sequences before normal operation begins. The driver circuit automatically characterizes the LED parameters and stores optimal settings in memory, completing the calibration process in minutes rather than requiring complex external equipment and manual procedures. This preliminary action eliminates the need for complex supply chain binning processes.
Data Source
AI summary
A driver circuit for programmable solid state light bulb assemblies including light emitting diodes is operable to provide a drive current to a light source of the light bulb assembly. The controller comprises a data storage unit storing a test scenario for calibration of the light bulb assembly; wherein the test scenario indicates a sequence of states of the light source; wherein a state of the light source is associated with settings of the driver circuit; a data input unit receiving a command signal via a modulated electricity supply signal; and a data processing unit retrieving the test scenario from the data storage unit; in dependence of the received command signal, generating a control signal for operating the light source in at least one state of the sequence of states of the test scenario; and to output the control signal.