HIGH BRIGHTNESS REMOTE CONTROLLED WHITE LED BULB By

Tzong-Yu Chan Justin Czarnowski

ECE 445, SENIOR DESIGN PROJECT SPRING 2009

TA: Paul Rancuret

5/5/2009 Project No. 27

ABSTRACT The goal of our project was to implement an RF remote controlled high brightness white LED light bulb. Current commercially available white LED light bulbs are not yet bright enough to replace traditional incandescent bulbs commonly in use (the brightest LED bulbs available top out at around 300 lumens). We set out to produce an LED light bulb that could produce as much light output as a 100W incandescent bulb (about 1700 lumens) through the use of Cree XR-E R2 high brightness LEDs. Commercial remote controlled LED light bulbs exist, but they are designed for the novelty market, as they produce a low brightness colored output. Additionally, the remote control system in these models utilizes IR, which makes it impossible to control multiple bulbs simultaneously unless they are in very close line-of-sight proximity. We design our product to use RF so that the end user could easily control multiple bulbs located throughout the room. Thus, a homeowner could quickly install a brightnesscontrollable room without any alteration to the homes existing electrical system. Attaining these goals would allow enhanced functionality as well as energy and associated cost savings for the consumer. While our current driver circuit did not provide as much current as designed, the major functionality of the circuit was in-tact and shows how the original goals could be readily achieved with more development time.

TABLE OF CONTENTS 1. INTRODUCTION ....................................................................................................................4 1.1 Review and Update Material ..............................................................................................4 1.2 Specifications......................................................................................................................4 1.3 Subprojects .........................................................................................................................4 DESIGN PROCEDURE...........................................................................................................6 2.1 Design Decisions ................................................................................................................6 2.2 Tools Used ..........................................................................................................................7 DESIGN DETAILS ..................................................................................................................8 3.1 Power Supply......................................................................................................................8 3.2 Wireless Transmitter...........................................................................................................8 3.3 Wireless Receiver ...............................................................................................................9 3.4 LED String........................................................................................................................10

2.

3.

4.

DESIGN VERIFICATION.....................................................................................................11 4.1 Testing ..............................................................................................................................11 4.2 Conclusions.......................................................................................................................12 COST ......................................................................................................................................13 5.1 Parts ..................................................................................................................................13 5.2 Labor.................................................................................................................................13 CONCLUSIONS ....................................................................................................................14 APPENDIX A BLOCK DIAGRAMS.................................................................................16 APPENDIX B SCHEMATICS............................................................................................17 APPENDIX C TEST DATA ...............................................................................................19 APPENDIX D PICTURES..................................................................................................20 APPENDIX E COST...........................................................................................................22

5.

6.

REFERENCES .......................................................................................................................23

1. INTRODUCTION For this project, we set out to create an RF controlled high brightness white LED light bulb. The motivation for this project was the lack of commercially available LED light bulbs that could produce sufficient light output to replace a traditional incandescent bulb. A typical 100W incandescent bulb can produce about 1700 lumens [1], so designed our project to at least meet this capability. Additionally, we chose to use RF technology for the remote control so that the end user could control the light bulb without having line-of-sight to the device. 1.1 Review and Update Material Our overall design goals remained the same compared to our original proposal. However, our specific implementation of the power supply portion of the project changed vastly as the original design was not feasible to produce. An updated block diagram of our system is shown in figure A.1 of the appendix. 1.2 Specifications Since we set out to build an LED light bulb that could replace a 100W incandescent light bulb, the final product had to produce a minimal light output of 1700 lumens. The resulting color temperature of the LED output must be between 2,600K and 10,000K to be close enough in color to a standard incandescent bulb. Additionally, we specified that the user could use the wireless remote control to dim or turn the bulb on or off within a 30 foot radius of the bulb. 1.3 Subprojects Our overall project can be broken down into smaller subproject units. These subprojects are organized as follows: 1.3.1 AC-DC Rectifier The rectification portion of our circuit is simply a bridge rectifier. The bridge rectifier takes in the 120V AC input from a household power outlet and outputs a rectified full wave signal. 1.3.2 LED Current Driver The LED current driver consists of the HV9931 chip which controls the gate of the MOSFET used in the power converter subcircuit. The current driver utilizes several sensing resistors that determine how to control the gate of the MOSFET in relation to the incoming high voltage rectified signal. 1.3.3 Power Converter The basic design of the power converter subcircuit is a buck-boost-buck topology. It utilizes several inductors, diodes, a capacitor, and a MOSFET to convert the high voltage rectified input into a current useable by the LED string.

1.3.4 LED String The LED string consists of 10 Cree XR-E R2 LEDs which are soldered together in series. Each LED is rated for a light output of 228 lumens when driven with a current of 1000mA. Thus, the entire LED string is capable of producing an output of 2280 lumens when driven at 1000mA. [2] 1.3.5 Heat Dissipater The heat dissipater mechanism consists of star-shaped metal clad PCBs (MCPCBs) which are soldered onto each LED chip. The heat dissipater is designed to quickly remove heat from the LED string that results from driving the LEDs at high current. 1.3.6 RF Receiver The RF receiver provides the wireless interface between the remote control and the light bulb unit. The LINX LC receiver chip is used to receive a 315 Mhz wireless signal from the LINX LC transmitter which contains brightness data. [3] 1.3.7 RF Transmitter The hand-held RF transmitter allows the user to turn on and off the LED light bulb and control its brightness. The RF transmitter sends data over a 315 Mhz RF signal. [3]

2. DESIGN PROCEDURE 2.1 Design Decisions Our decision making process during design is broken down into the main sub-blocks of our circuit as follows: 2.1.1 Power Supply Our power supply was designed to convert voltage directly from the 120 VAC wall outlets to 33V and provide the LED circuit with 1 Amp maximum current. In order to reduce the size of the power supply, we decided to use a transformerless power supply design. We considered both resistive and capacitive transformerless power supply designs. [4] However, the former requires a large resistor which dissipates more than 100W of heat, and the latter involves a high voltage, high capacitance nonelectrolytic capacitor which is not commercially produced. Both designs also require prohibitively expensive and large high current capacity zener diodes in order to facilitate the required dimming functionality. Our final design utilizes a MOSFET controlled transformerless power supply. The size of the inductors in the power supply limits the peak current going towards the LEDs. The HV9931 Unity Power Factor LED Driver controls the MOSFET in the power supply which dictates the charge and discharge of current through the inductors. The benefit of using the HV9931 driver is that current only flows through the MOSFET, so the driver chip can be relatively small. Also, it easily interfaces with the PWM signal provided by the dimmer circuit. [5] When testing our power supply, we discovered that it consumed a large amount of reactive power. We added in a high voltage capacitor to the power supply to correct the power factor. We also included a fuse at the 120VAC line side for over current protection. 2.1.2 Wireless Control One major decision we had to make during the design process revolved around the type of wireless transmission we would choose for the remote control capability. While existing novelty LED light bulbs use infrared (IR) technology, we did not want to be limited by the line-of-sight transmission that IR technology requires. Consequently, we chose to us RF as our method of transmission, which frees us from the line-of-sight requirement. This could potentially allow the end user to control multiple bulbs simultaneously with only one remote. Another design issue concerned the method of encoding and decoding the brightness data. We chose to use PIC microprocessors as they are relatively inexpensive, easy to program, and can interface directly with the LINX RF chips. Using a microprocessor also allows us to verify that valid data is being sent and to keep a memory of the last known desired brightness before a remote loses power or goes out of range. 2.1.3 LED Units We based our design around the CREE XR-E white LED because it is the brightest white LED that is commercially available. The XR-E LED is capable of producing 228 lumens of light at 1 Amp current. By combining 10 of these LEDs, we should be able to output 2280 lumens which is greater than the 1700 lumens that a standard 100W incandescent bulb can deliver 6

2.2 Tools Used We used the following tools while designing and developing our project: 2.2.1 OrCAD/PSPICE We used PSPICE as a tool to carry out preliminary simulations on our initial resistive and capacitive power supply design ideas. Additional, we used the OrCAD schematic capture software to create schematics for our various subcircuits 2.2.2 MPLAB MPLAB Integrated Development Environment (IDE) was using for the development of the software for both the remote PIC and the receiving PIC. We used the CCS C compiler within the MPLAB IDE to compile our code for both PICs.

3. DESIGN DETAILS 3.1 Power Supply The power supply module is designed so we can directly receive power from the wall outlets. The module uses an HV9931 Unity Power Factor LED Driver. This driver chip can interface with the PWM signal from the dimmer module and handle and input voltage up to 450V. The LED driver controls the on and off of the power MOSFET in the power supply, and the switching frequency is calculated by the following equation: [6]
Fs = 1 Rt + To (3.1)

Since current does not flow through the LED driver chip directly, the size of the chip can be relatively small. Also, the heat dissipation of the driver becomes less of an issue compared to a conventional current driver. The power supply module also includes two inductors which limit the amount of output current and serve as step down voltage converters. The inductor size is calculated base on the following equation: [6]
L= VAC * TOFF Io (3.2)

The transformerless power supply consists of two different buck-boost stages. The input voltage is stepped down by going through the discontinuous and continuous conduction modes. The total voltage step-down ratio of the power supply is the product of the step down ratios of these two stages. The capacitor in the first stage is charged up when the MOSFET is ON and continues to power the second stage when the MOSFET is OFF. The peak current flowing through the inductor is controlled by the reference resistors connected with the current driver. Thus, we are able to size the inductors to accommodate the current rating based on the following equation: [6]

IL =

Vref * Rcs Rref * Rs

(3.3)

The schematic for the power supply module can be seen in figure B.1 in the appendix.

3.2 Wireless Transmitter

When desiring the wireless transmitter, it was important to take into consideration not only the technical aspects of transmission, but also the feel from the users perspective. Since our goal was to replace a traditional light bulb, we chose to use a rotary potentiometer as the users method of controlling brightness. This would be a very familiar control to the end user, who would most likely be familiar with the rotary dimmer units that are common in many households. The rotary potentiometer is also a good choice due to its ease of integration with the PIC. The PIC16F877A has a built in analog to digital converter (ADC). By hooking up 5V to one side of the 8

potentiometer and ground to the opposite side, we were able to effectively turn the potentiometer into a voltage divider. The center contact was connected to the wiper of the potentiometer. Thus, as the user turns the potentiometer through its full range, the voltage on the wiper contact varies between 0V and 5V. This analog voltage level represents the desired brightness set by the user. We define 0V as corresponding to completely dark output and 5V as corresponding to maximum brightness output. Finally, we read in this analog voltage as a 10-bit digital value using the PICs ADC. Converting the desired brightness level from an analog voltage into a digital value facilitates a relatively robust and easy wireless transmission. Since the PICs serial port natively handles 8-bit data, we chose to ignore the 2 least significant bits from the digital value to simplify data transmission. Number of digital brightness levels = 2resolution (bits) (3.4)

Hence, even though we only use the most 8 significant bits, we have 2 8 = 256 brightness levels, which is plenty of levels to ensure smooth dimming appearance. The LINX TX-315-LC module was chosen to transmit serial data because it interfaces directly with the PIC16F877As UART serial transmission port and was available in the lab. The TX pin of the PIC is connected directly to the data pin of the LINX transmitter, where the encoded data (see 3.3 for a description of the encoding mechanism) is transmitted across the wireless link to the receiver module. In order to power the wireless transmitter, a type of battery needed to be chosen. For simplicity, we decided upon using a simple 9V battery as the power source. While we would probably choose a more economical battery type (such as AA alkaline or rechargeable) for a commercial product, using a 9V battery simplified construction for prototyping purposes. The LM7805 voltage regulator serves as a natural counterpart to the 9V battery to create a stable 5V output from the 9V source. Several filtering capacitors ensure that the PIC and the LINX transmitter receive clean voltage for proper operation. The schematic for the wireless transmitter module can be seen in figure B.2 in the appendix.

3.3 Wireless Receiver

The LINX RX-315-LC module is the complementary receiver to the TX-315-LC chip discussed in 3.2. Upon receiving data over the wireless link, the LINX receiver chip forwards the serial data to the receiver PIC. The receiver PIC is programmed to accept the serial data on the RX pin using the PICs built in UART capability. In order to verify that the data being received is valid, a simple encoding scheme is used. The remote PIC is programmed to pad the 8-bit brightness value with a leading magic byte and a trailing magic byte. These magic bytes are hard-coded and were chosen arbitrarily during development. The receiver PIC has holds a variable that contains the current brightness level and only changes if the received data is preceded by the appropriate leading magic byte and followed by the appropriate trailing byte. This ensures that the light bulb does not turn on and off or change brightness levels erratically when the remote has gone out of range or is otherwise not transmitting valid data. Valid brightness data that is received is then stored into the 8-bit variable that holds the current output brightness value. Because the HV9931 current driver IC that we selected is designed to accept PWM input for dimming purposes, we chose to convert the digital brightness value into a PWM signal of varying duty cycle. A low duty cycle corresponds to dimmer light, and a higher duty cycle corresponds to brighter light. Since the PIC16F877A has built in PWM generator, we output a PWM signal that has 9

a duty cycle proportional to the value of the variable that stores the brightness data. An example of how the serial data is converted into a PWM signal can be seen in figure 3.1.

PIC (receiver) Serial data (8-bit) PWM signal

Figure 3.1 Conversion of serial data to a PWM signal

Another design consideration was the length of the period to be used in the PWM signal. The most convenient option was to use the native oscillator frequency to drive the PWM generator. This results in a PWM period of 20uS, which corresponds to a frequency of 50 kHz. 50 kHz is a frequency far faster than the eyes can detect, so this design ensures that there will be no perceptible flicker of the LED output while dimming. While we had originally designed the logic chips on the receiver circuit to be powered by the MAX611 120VAC to 5VDC converter chip, further research showed that the MAX611 had been discontinued and was no longer available. We were able to locate another functionally equivalent chip (the BIAS Power BPI 200-05-00) but we could not find a distributor that had the device for sale in low quantities. [7] For demonstration purposes, we simply chose to use another 9V battery paired with a 7805 regulator to supply power to the logic chips on the receiving side. While this solution would obviously not be practical for a commercial device, it was merely selected to show proof-of-concept. If we were to implement our design as a commercial product, it would be trivial to include the BIAS Power BPI 20005-00 as part of the final product. The schematic for the wireless transmitter module can be seen in figure B.3 in the appendix.

3.4 LED String

Each CREE XR-E LED is capable of producing 228 lumens of light flux at 1Amp. In order to have the equivalent light output as a 100W light bulb (about 1700 lumens), we need at least 8 XR-E LEDs. In our design, out LED light string consists of 10 CREE XR-E LEDs, so even when the circuit operates below 1Amp, it still can output more than 1700 lumens of light. We measured each individual LEDs forward voltage at 1Amp, and added these numbers to determine the required output voltage at the power supply. The LEDs also dissipate very large amount of heat, so we attached a star shape metal heat sink to each LED. Additional heat sinks can also be attached to the LED string if needed.

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4. DESIGN VERIFICATION 4.1 Testing 4.1.1 Power Supply

The output of the power supply was connected with the LED string and probed with the multimeter to verify the output voltage. Based on the measurement, the power supply is capable of providing at least 32.6V of voltage to the LEDs. However, we were unable to use either the multimeter or the oscilloscope to determine the current level. We desired to use an oscilloscope and a shunt resistor to determine the average current flowing through the LED string, but isolation issues between the oscilloscope and our power supply (neither of which were isolated) prevented us from completing our test plan. We ended up using a power meter to test and measure our power supply. By turning the potentiometer at the dimmer circuit, the power consumption and the output current at the power supply change corresponding to the PWM signal in a linear fashion. The test result shows that the maximum output of our power supply is about 100mA, which is relatively low compared to our expectation. Also, the results of the power meter showed that our power supply consumed a large amount of reactive power. In order to correct the power factor, we added in a 33uF, 250V capacitor. A picture of the completed power supply module can be seen in figure D.1 of the appendix.

4.1.2 Remote PIC

After prototyping the remote PIC circuit, we needed to verify that the ADC was correctly configured and operating properly. To accomplish this stage of verification, we programmed the PIC to read in the analog voltage value (derived from the potentiometer) via the ADC into an 8-bit value. We then programmed the PIC to output a PWM signal with a duty cycle proportional to the 8-bit digital value. We then probed the PWM output of the PIC with an oscilloscope and observed the resulting PWM signal as we twisted the knob of the potentiometer. The duty cycle decreased to 0% as we turned the knob on the potentiometer to one extreme, and increased to 100% as we turned the knob to the other extreme. This verified the proper configuration and operation of the ADC. We then probed the output of the remote PICs serial port to see if we could observe serial data being sent. While we did not attempt to manually decode the serial data we saw on the oscilloscope, we did see a serial data stream that changed as we turned the knob on the potentiometer.

4.1.3 Receiver PIC

In order to verify proper operation of the receiver PIC, we simply connected the TX port of the remote PIC to the RX port of the receiver PIC using a signal wire and ensured that both PIC chips shared the same ground. We probed the PWM output of the receiver PIC and observed that the duty cycle of the PWM signal decreased to 0% as we turned the potentiometer knob to one extreme and to 100% as we turned the knob to the other extreme. Thus, we were able to verify the serial link between the PIC chips and the PWM output of the receiver PIC.

4.1.4 Wireless transmission

11

In order to verify the functionality of wireless transmission, we first disconnected the physical wire that linked the serial ports of the two PIC chips and connected each PIC to its proper LINX chip as outlined in section 3. We then used the oscilloscope to probe the data input to the transmitting LINX chip and simultaneously probe the data output of the receiving chip. As can be seeing in figure C.1, the data streams match exactly, which confirms that the LINX RF chips were operating. Additionally, the oscilloscope screenshot in figure C.1 confirms that the transmission rate is 9600 bps. To perform a test on the entire remote control system, we turned the potentiometer on the remote module as we observed the PWM output from the receiver module. As can be seen in figure C.2, the duty cycle of the PWM signal decreased to 0% as we turned the potentiometer knob to one extreme and to 100% as we turned the knob to the other extreme. Thus, we were able to verify complete operation of the wireless remote portion of our project. We repeated the tests at various distances, and determined that the remote would not operate more than about 3 inches away. To simulate a loss of wireless transmission, we suddenly disconnected the battery for the remote and observed the duty cycle of the receiver PICs PWM output. The duty cycle remained unchanged, and only could be changed once again when power was restored to the remote module. This proved that our encoding method succeeded at ensuring predictable behavior in the bulb despite a loss of valid communication with the remote. A picture of the completed wireless transmission modules can be seen in figure D.2 of the appendix.

4.1.5 LED string

In order to verify the output of the LED string, we connected the LEDs to a lab power supply which was programmed to provide a constant current of 1A. The brightness of the LED string was observed and compared with the brightness of a 100W incandescent bulb. With our naked eyes, we can determine that the LED string driven at 1A is a significantly brighter than the 100W incandescent light bulb.

4.1.6 Heat dissipation

We used an IR thermometer to determine the temperature of the LED string. The LED junction temperature remained stable at about 150 F when driven at 1A.

4.2 Conclusions
Our tests of the power supply demonstrated very disappointing results. We designed the power supply to output 1000mA of current to the LED string in order to achieve the minimum of 1700 lumens output brightness that we originally specified. Instead, our testing showed that the power supply was only able to output a maximum of about 100mA to the LED string. While we did verify operation of wireless transmission, the wireless transmission range was extremely limited. In our tests, we were not able to transmit data further than about 3 inches. We suspect that either improper wiring or a damaged LINX chip led to this problem. We would have required more time to debug the circuit to find the root cause for this issue. A picture of the completed project can be seen in figure D.3 of the appendix.

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5. COST 5.1 Parts

A table describing the parts cost for this project can be found as table E.1 in the appendix. According to our calculations in table 5.1, the total parts cost for this project was $146.80. As can be seen in table 5.1, the cost of LEDs contributes to almost half of the cost of the entire project. While the cost of the LEDs in our prototype causes the cost of the bulb to be prohibitively expensive for a commercial product, the efficiency and cost of LEDs continues to decrease as further developments are made in LED semiconductor technology. Considering that the LEDs that we purchased were the brightest commercially available LEDs on the market, they carry a high price premium. It is conceivable that LEDs with equivalent performance may be available for as little as 10% of this cost in the near future, which could allow our project to be competitive at a commercial level. The PIC microprocessor we used turned out to be overkill for our application. For our application, we only used 1 I/O pin plus 1 serial port pin on each PIC. The PICs we used had 40 pins, so we did not utilize most of the PICs functionality. A smaller PIC would have performed the same function just as well and cost significantly less money. The Linx RF transmitters were also overkill for our application. We did not need the high data transfer rate that these chips supported, and likely could have found a more cost effective solution for the limited data bandwidth that our project required. Additionally, purchasing the components for our project in single digit quantities contributes to a high cost per device. If our product were to be scaled up to production level, costs of many of the components could be at least cut in half.

5.2 Labor
In order to calculate labor cost, we used equation 5.1 shown below: Total labor cost = (Salary $/hr)*(Total hours of labor)*(2.5) Based on our records, we estimate that we spend a total of 160 hours working on the project. Thus, using equation 5.1 with a salary of $45/hr, we arrive at a total labor cost of $18,000. (5.1)

5.3 Overall Cost

We calculated the overall project cost using equation 5.2 as shown below: Overall prototype cost = Total parts cost + Total labor cost Thus, with a total parts cost of $146.80 and a total labor cost of $18,000, our total cost to produce a prototype was $18,146.80. (5.2)

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6. CONCLUSIONS
Even though our project did demonstrate proof-of-concept of all of our original design objectives, we were disappointed with the overall result of our final product. One key aspect of the project was to ensure that our LED light bulb at least provided as much light output as a traditional 100W incandescent bulb. White LED technology is now finally advanced enough to make this feasible. We were able to find an LED model, the Cree XR-E R2 series, that was more than up to the task when used in a modest group of about 8 units. Subjective testing by hooking a 10-LED string up to a bench power supply confirmed that the LEDs themselves were capable of surpassing the brightness output of a 100W incandescent bulb. Unfortunately, our power supply was not up to the task. Our semester was plagued with power supply design problems. Since a commercially product would not be viable with the weight, bulk, and cost of a transformer, we were required to consider transformerless power supply designs. We spent a great deal of our time researching designs that turned out to be dead ends, including the resistive and capacitive power supply designs. We finally did find a design, which we used for our final product, which showed promise as a solution to our design constraints. Unfortunately, we were left with little time to debug and optimize the circuit as the end of the semester neared. With more time, we are confident that we could have improved the power supply circuit to provide the current level that we originally specified. Application notes from Supertex (the manufacturer of the LED driver IC that we chose) confirmed that what we intended to achieve was feasible, but we merely ran out of time for analysis and debugging of the circuit. An additional issue was the limited range of our wireless transmitter. Many other engineers who have used the same model of LINX RF transmitters and receivers have reported that they achieved far greater ranges than we originally required even without using proper antennas. The fact that we were only able to achieve about a 3 inch range with the recommended antennas suggests that there was either a wiring issue that we failed to debug, or simply that one of our RF chips was defective (this is not unlikely since many other ECE445 students have used and potentially abused the RF transmitter/receiver chips). In the final product that we built, we did include several safety measures. We included a 2A fuse on the AC input side to the power supply. We did actually blow this fuse several times during the build and debug process when we had misconnected wires. We also included a 1A slow blow fuse in-line with the LEDs in case a malfunction in the current driver caused too much current to pass through the LEDs. This would prevent burn-out of the costly LED units. If we were to put our design into commercial production, there are a few safety additional safety measures that would need to be implemented. First, we could use a simple circuit with a zener diode to protect our circuit from an undervoltage input, which could cause unpredictable and potentially dangerous operation of our current driver circuit. Also, another simple zener-diode based circuit would need to be used on the output stage of our current driver to protect against an over-voltage condition that might arise during an open-circuit condition on the output LED string. Finally, we would need to ensure that all circuit parts would be electrically insulated from the user. This measure would be necessary because our power supply circuit is not isolated from the AC line voltage, and thus any exposed contacts would pose an electrocution hazard to the end user. Even though our final product failed to perform at the level we desired, we are confident that our design would be commercially viable if we had more time to debug and improve the circuit. If the circuit could 14

be made commercially viable, our design would save a great deal of energy when used to replace traditional incandescent bulbs as well as offer enhanced functionality to the consumer.

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APPENDIX A BLOCK DIAGRAMS

Power Supply Circuit Bridge rectifier AC Power Source LED Current Driver PIC RF Receiver Wireless Remote 9V Battery 5V regulator RF Transmitter LED Circuit Power Converter Heat Dissipater

Potentiometer and switch

PIC

Figure A.1 Block diagram of entire light bulb and remote system

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APPENDIX B SCHEMATICS

Figure from Supertex HV9931 datasheet [5] with added calculated component values Figure B.1 Schematic of the LED current driver power supply

17

Figure B.2 Schematic of the Remote Transmitter Module

Figure B.3 Schematic of the Remote Receiver Module

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APPENDIX C TEST DATA

Baud rate = 9600 bps => 104us period

Data input to transmitter

Data output from receiver

Figure C.1 Verification of wireless data transmission

Duty cycle = 0% (completely dark)

2%

25%

T = 20uS

50%

75%

98%

Duty cycle = 100% (maximum brightness)

Figure C.2 Verification of wireless remote PWM duty cycle control

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APPENDIX D PICTURES

Figure D.1 Picture of the power supply module

Receiver Remote Linx RF receiver Linx RF transmitter PWM output to LED current driver

Brightness control potentiometer

Figure D.2 Picture of the wireless transmission modules

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Remote Control

Receiver

Power Supply

LED units

Figure D.3 Picture of the entire completed project

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APPENDIX E COST
Part Cree XR-E R2 LED on star heat sink Screw-type bulb base Bulb casing material Wireless remote case Cost per Unit $6.56 $4.00 $5.00 $5.00 $0.15 $0.59 $0.10 $2.57 $2.97 $1.24 $0.10 $0.10 $11.91 $0.78 Quantity 10 1 1 1 1 2 4 1 1 1 6 1 1 1 Total Cost ($) $65.60 $4.00 $5.00 $5.00 $0.15 $1.18 $0.40 $2.57 $2.97 $1.24 $0.60 $0.10 $11.91 $0.78

43V power supply parts

1 ohm 1W resistor 33uF 250V capacitor MUR120 diodes 1.2mH 3.0A radial inductor 270uH toroid inductor HV9931 Off-line LED Driver 1/4W resistors for LED driver 1/4W resistors for remote 3N100E N-MOSFET W-02G bridge rectifier

Wireless remote control parts

Small capacitors for bulb Toggle switch for remote 5.125 x 1.875 inch breadboard 9V battery clip 0.1uF 50V ceramic capacitor 10uF 6.3V electrolytic capacitor 100uF 16V electrolytic capacitor 25k single-turn potentiometer 7805 Voltage Regulator 25 MHz oscillator PIC 16F877A microcontroller Linx TXM-418-LC-P RF transmitter Linx RXM-418-LC-P RF receiver

$0.25 $0.56 $1.96 $0.80 $0.06 $0.21 $0.34 $5.48 $0.75 $1.77 $5.44 $6.90 $9.95 Overall Parts Cost:

2 1 2 2 2 2 2 1 1 2 2 1 1

$0.50 $0.56 $3.92 $1.60 $0.12 $0.42 $0.68 $5.48 $0.75 $3.54 $10.88 $6.90 $9.95 $146.80

Table E.1 Parts Cost

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REFERENCES
[1] Natural Resources Canada, Household Lighting: Lumens and Watts, April 2009, http://oee.nrcan.gc.ca/publications/infosource/pub/home/Household_Lighting_Section5.cfm

[2]

Cree XLamp XR-E LED Data Sheet, Cree, Inc., 2009, http://www.cree.com/products/pdf/XLamp7090XR-E.pdf
Linx Technologies, LC Series Low Cost RF Transmitter and Receiver Modules, March 2009, http://www.linxtechnologies.com/Products/RF-Modules/LC-Series-Low-Cost-Transmitter-andReceiver-Modules/

[3]

[4]

AN954 Transformerless Power Supplies: Resistive and Capacitive, Microchip Technologies Inc., 2004, http://ww1.microchip.com/downloads/en/AppNotes/00954A.pdf Supertex Unity Power Factor LED Lamp Driver Datasheet, Supertex, Inc., 2008, www.supertex.com/pdf/datasheets/HV9931.pdf Supertex Application Note AN-H52, Supertex, Inc., 2009, www.supertex.com/pdf/app_notes/ANH52.pdf
Bias Power LLC, Low Power AC-DC Switching Power Supplies, April 2009, http://www.biaspower.com/LowPowerACDC.asp

[5]

[6]

[7]

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