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'[EE] 12V flexible LED strings for automotive use a'
2011\03\02@115949 by Patrick Moody

picon face
I have been using these (ebay link - http://bit.ly/hbiCF0 ) LED
strings as additional lighting for the front of my motorcycle for the
past 3 years.  I was looking for something to make me more obviously
visible to oncoming traffic in an attempt to reduce my likelihood of
having someone in pull out in front of me because they didn't see me
and when they do, to make sure they have absolutely no excuse.

Of all the options I've found so far these seemed the best because
they don't require any modification to be run from the 12V supply on
the bike, they are water-resistant due to the rubber moulding, they
are flexible so can be formed to the shape of the internal fairing
around the front wheel where I have them mounted, and because they
have a rectangular shape allowing them to be mounted with the lights
pointing along the tangent of the surface where they are mounted.  The
only similar products I have found are flatter strips with the lights
facing normal to the mounting surface which therefore don't suit my
application.  I want them facing forward towards the oncoming traffic
rather than inwards to the front wheel.

A holiday photo (800x600 jpg) showing what this looks like: http://bit.ly/e4L5ur

The problem is that after about a year they begin to lose brightness
and the flexible circuit seems to deteriorate so that some of the LEDs
(usually in groups of 3) begin to fail (as those with keen eyes might
spot in my picture).  Having replaced a set on one side of the machine
which had failed, it was quite noticeable that the new set were
brighter than the old set.  Perhaps the lesson to learn is to always
replace the whole lot at once but I'd rather find an alternative that
won't need replacing in the first place.

In summary I'm looking for:
Strings of white LEDs in a clear flexible waterproof housing
Run directly on 12V
LEDs are spaced approximately 1cm apart along the string
Can be mounted to face along tangent of mounting surface

Longer mtbf (mean time before failure AND before fading)
Better durability in automotive environment - vibration, moisture,
heat and cold.

Does anyone have any suggestions?

Patric

2011\03\02@122804 by Andre Abelian

picon face
Patrick,

The reason leds are failing or you see discoloration because of led resistance is dynamic it changes right
after turning it on (+ outside temp) and by applying fixed current led life becomes shorter.
the best way to use leds for lighting is by using constant current not voltage.

Andre



________________________________
From: Patrick Moody <spam_OUTpatrickmoody84TakeThisOuTspamgmail.com>
To: Microcontroller discussion list - Public. <.....piclistKILLspamspam@spam@mit.edu>
Sent: Wed, March 2, 2011 8:59:48 AM
Subject: [EE] 12V flexible LED strings for automotive use as daytime running lights

I have been using these (ebay link - http://bit.ly/hbiCF0 ) LED
strings as additional lighting for the front of my motorcycle for the
past 3 years.  I was looking for something to make me more obviously
visible to oncoming traffic in an attempt to reduce my likelihood of
having someone in pull out in front of me because they didn't see me
and when they do, to make sure they have absolutely no excuse.

Of all the options I've found so far these seemed the best because
they don't require any modification to be run from the 12V supply on
the bike, they are water-resistant due to the rubber moulding, they
are flexible so can be formed to the shape of the internal fairing
around the front wheel where I have them mounted, and because they
have a rectangular shape allowing them to be mounted with the lights
pointing along the tangent of the surface where they are mounted.  The
only similar products I have found are flatter strips with the lights
facing normal to the mounting surface which therefore don't suit my
application.  I want them facing forward towards the oncoming traffic
rather than inwards to the front wheel.

A holiday photo (800x600 jpg) showing what this looks like: http://bit.ly/e4L5ur

The problem is that after about a year they begin to lose brightness
and the flexible circuit seems to deteriorate so that some of the LEDs
(usually in groups of 3) begin to fail (as those with keen eyes might
spot in my picture).  Having replaced a set on one side of the machine
which had failed, it was quite noticeable that the new set were
brighter than the old set.  Perhaps the lesson to learn is to always
replace the whole lot at once but I'd rather find an alternative that
won't need replacing in the first place.

In summary I'm looking for:
Strings of white LEDs in a clear flexible waterproof housing
Run directly on 12V
LEDs are spaced approximately 1cm apart along the string
Can be mounted to face along tangent of mounting surface

Longer mtbf (mean time before failure AND before fading)
Better durability in automotive environment - vibration, moisture,
heat and cold.

Does anyone have any suggestions?

Patric

2011\03\02@145129 by RussellMc

face picon face
On 3 March 2011 06:28, Andre Abelian <abelian.andrespamKILLspamyahoo.com> wrote:
> The reason leds are failing or you see discoloration because of led resistance
> is dynamic it changes right
> after turning it on (+ outside temp) and by applying fixed current led life
> becomes shorter.
> the best way to use leds for lighting is by using constant current not voltage.

The strings are sold as "designed" for direct 12V operation.
Whetjer they have any sort of current control is uncertain.
They may have a series resistor but maybe not even that. They MAY have
a formal current control, but even less likely.

Yhe ONLY way to get long life is

- Drive LEDs correctly at constant current (As Andre says)

- Run them in accordance with manufacturers specs and know claimed
lifetimes under these conditions

- Use LEDs from a reputable "big 5" LED maker OR one using technology
from a maker who knows what they are doing. There are many small LED
makers worldwide but I am unaware of any that have managed long LED
lifetimes by themselves. I'd risk saying that ANY Asian LED maker who
cannot show a direct technology link from "big name" LED makers does
not make quality product.  There is now a substantial cross linking of
licences. Some (not all) competent LED makers are (in no order) Cree,
Osram, Lumiled/Luxeon. Nichia, Avago, Sharp, Seoul semi, ...

The best LEDs operated correctly can have lifetime in the 50k - 100k
hours range to 70% output.
The worst manage under to well under 1000 hours.

If you are REALLY serious then you may want to consider buying quality
LED's potting and mounting them to suut your needs and driving them
correctly. Replacement will not be necessary for the life of the
motorcycle.

BUT I have been hit head on by a car  when riding with my headlight
on. A few LEDs are unlikely to make a vast difference. A colimated
LASER may :-).


                  Russel

2011\03\02@145215 by Andre Abelian

picon face
I mean using fixed voltage not current.


________________________________
From: Andre Abelian <.....abelian.andreKILLspamspam.....yahoo.com>
To: Microcontroller discussion list - Public. <EraseMEpiclistspam_OUTspamTakeThisOuTmit.edu>
Sent: Wed, March 2, 2011 9:28:02 AM
Subject: Re: [EE] 12V flexible LED strings for automotive use as daytime running lights

Patrick,

The reason leds are failing or you see discoloration because of led resistance is dynamic it changes right
after turning it on (+ outside temp) and by applying fixed current led life becomes shorter.
the best way to use leds for lighting is by using constant current not voltage.

Andre



________________________________
From: Patrick Moody <patrickmoody84spamspam_OUTgmail.com>
To: Microcontroller discussion list - Public. <@spam@piclistKILLspamspammit.edu>
Sent: Wed, March 2, 2011 8:59:48 AM
Subject: [EE] 12V flexible LED strings for automotive use as daytime running lights

I have been using these (ebay link - http://bit.ly/hbiCF0 ) LED
strings as additional lighting for the front of my motorcycle for the
past 3 years.  I was looking for something to make me more obviously
visible to oncoming traffic in an attempt to reduce my likelihood of
having someone in pull out in front of me because they didn't see me
and when they do, to make sure they have absolutely no excuse.

Of all the options I've found so far these seemed the best because
they don't require any modification to be run from the 12V supply on
the bike, they are water-resistant due to the rubber moulding, they
are flexible so can be formed to the shape of the internal fairing
around the front wheel where I have them mounted, and because they
have a rectangular shape allowing them to be mounted with the lights
pointing along the tangent of the surface where they are mounted.  The
only similar products I have found are flatter strips with the lights
facing normal to the mounting surface which therefore don't suit my
application.  I want them facing forward towards the oncoming traffic
rather than inwards to the front wheel.

A holiday photo (800x600 jpg) showing what this looks like: http://bit.ly/e4L5ur

The problem is that after about a year they begin to lose brightness
and the flexible circuit seems to deteriorate so that some of the LEDs
(usually in groups of 3) begin to fail (as those with keen eyes might
spot in my picture).  Having replaced a set on one side of the machine
which had failed, it was quite noticeable that the new set were
brighter than the old set.  Perhaps the lesson to learn is to always
replace the whole lot at once but I'd rather find an alternative that
won't need replacing in the first place.

In summary I'm looking for:
Strings of white LEDs in a clear flexible waterproof housing
Run directly on 12V
LEDs are spaced approximately 1cm apart along the string
Can be mounted to face along tangent of mounting surface

Longer mtbf (mean time before failure AND before fading)
Better durability in automotive environment - vibration, moisture,
heat and cold.

Does anyone have any suggestions?

Patric

2011\03\02@145852 by RussellMc

face picon face
> I mean using fixed voltage not current.

Fixed current is correct.
LED voltage will vary between LEDs.
Voltage varies non linearly and semi exponentially over a small range
for very large variations in current.
So. increase voltage a little and current may go from OK to well over ratings.

Controlling the current allows the LEDs to function at a designed
operating point

2011\03\02@150802 by Jesse Lackey

flavicon
face
Hi - I don't have specific model suggestions, but there are some links to LED suppliers on my main DMX LED product page:
<www.celestialaudio.com/dmx_led/index.html>
in particular take a look as oznium.com, they specialize in 12V automotive oriented lighting.

Hope it helps.
J


Patrick Moody wrote:
{Quote hidden}

> Patric

2011\03\02@222823 by Denny Esterline
picon face
Everything mentioned so far is good, but let's not loose sight of the
fact that a motorcycle is _far_ from an ideal 12 volt system.
I'd actually be quite concerned about the health of the charging
system and battery if it actually measured 12 volts while running.

The picture on ebay is a bit fuzzy, but I believe I see what looks to
be a SM resistor visible in the string. Assuming it is, and assuming
"they" have correctly valued it for 12 volts - both big assumptions -
you could be putting nearly twice the rated current through it.

Based on more assumptions, previous experience, and your "groups of
three" comment.... I'll assume that it's three LEDs in a string with a
current limiting resistor. That resistor should be sized by Ohms Law;
R=E/I, where "E" is actually (supply voltage - sum of LEDs Vf).

Making up some numbers for this, let's assume 12v, 50mA current and an
individual Vf of 3.4v. this becomes

(12 - 3.4 - 3.4 - 3.4) / 0.05 = 36 ohms

But putting that in an automotive system with a 13.8v nominal supply gives you
(13.8 - 3.4 - 3.4 - 3.4) / 36 = 0.1A or 100mA.

There's lots of reasons for LEDs to fail, too much current is pretty
high on everybody's list.

And don't forget that any automotive application has very dirty power
with lots of spikes and surges and other nasties, all of which have
negative effects on your LED life.

-Denn

2011\03\03@034520 by RussellMc

face picon face
In any serious application I would not consider driving LEDs other
than with constant current drive.
Exception might be if maximum current worst case was under LED
acceptable max and the brightness was acceptable in all cases.

With Denny's 3 LED example of 3 x 3.4V LEDs = 10.2 V you have  enough
headroom to run down to 11V or less using electronic constant current
circuitry.

At eg 350 mA (slightly over 1 Watt per 3.4v block*) you get about 1/3
Watt dissipation in the regulator per Volt of "headroom" with a linear
regulator. So at say 14V you get about (14-10.2)/3 = ~~~ 1.5 Watt
dissipation. A switching regulator will reduce this substantially for
higher power LED strings.

I say "3.4V block" as, while the system may LOOK like 3 LEDs in series
most strings of N LEDs  will effectively be 3 groups each of N LEDs in
parallel. If a simple series resistor is used for current limiting
then ideally each group of 3 physical LEDs should have its own series
resistor. Using only one resistor per system and placing N/3 LEDs in
hard parallel (as is very very very commonly done in these or similar
LED arrays, then differences in LED Vf:I charateristics can lead to
massive differences in individual LED currents. MOST Asian sourced LED
products using multiple LEDs use inferior or no LED current balancing
or control.

Unfortunately, you cannot rely on claims of "long life" without other
supporting evidence. Data sheet specs are only as good as the
reputation of the manufacturer or the independent test house who
verifies them. (A tour of a manufacturer's test lab and demonstration
of their instrumentation may be impressive - but is utterly no
guarantee that the supplied test data will be accurate - or indeed
bear any relationship to reality. (Ask me how I know :-) ).

..

            Russel

2011\03\03@042635 by Patrick Moody

picon face
Thanks everyone for your input so far.

Everyone's comments so far are suggesting that the short life of my
LEDs is caused by over-current/spikes.  A constant current supply has
been recommended by a few people so I duly went to wikipedia the great
source of information and mis-information to get some ideas in that
vein. Before I ask for advice on how to implement this idea I should
provide some more information on the set up as it is, and why I put it
together that way.

The LEDs are powered from the side-lights circuit on the bike by
splicing the line coming in just under the headlight assembly.  This
means they are only powered when the ignition is on and they can be
switched on and off using the normal handlebar switch along with the
other lights.
There are 2 each of white and yellow LED strings each with 24LEDs,
24cm long mounted on the sides.  There are also 3 strings of 12 white
LEDs mounted around the top.
The top strings are driven directly from the light supply and the
white and yellow side strings are driven via a pair of relays.  When
the turning indicator is inactive, the white string is lit (normal).
When the turning indicator is lit, the yellow string is lit and the
white string is not.
I set it up this way because I thought having lots of white lights
facing forward and very little area of indicator visible from the
front, it might be difficult for oncoming traffic to see when I'm
indicating to turn.
If anyone has a better idea than the relays for the indicators part
I'd be glad to hear it, by the way.

Providing a single constant-current source for the whole set up might
be problematic when indicating as I expect my relay will have a breif
moment of not powering either of its connected 24LED strings meaning
the current source(tuned for normally driving 84 LEDs) would be shared
between 60 instead.  Is this something I should be concerned by?
 If so, perhaps I should have 3 separate constant-current sources.
One for the top 36 LEDs and one each for the side sets with their
relays.  The next thing I need to know is what's the correct constant
current.  I plan to determine this by measuring the current drawn
using a clean 12V supply prior to re-installation.

I'll also need to build and weatherproof the new circuit(s) and
preferably have them all together in as compact a package as possible
along with the relays.  This will be tucked into the space just under
the headlight and secured with cable-ties. This package would have 10
connections, 2 for the incoming supply, 2 for top LEDs and 3(x2) for
white/yellow/ground on each side. I plan to use the standard 2 and 3
way connectors similar to those found all over the rest of the bike

2011\03\03@051819 by RussellMc

face picon face
> Everyone's comments so far are suggesting that the short life of my
> LEDs is caused by over-current/spikes.

That was one of the reasons.
But also note:

>> The best LEDs operated correctly can have lifetime in the 50k - 100k
>> hours range to 70% output.
>> The worst manage under to well under 1000 hours.

This is when driven properly.

And

> - Use LEDs from a reputable "big 5" LED maker OR one using technology
> from a maker who knows what they are doing. There are many small LED
> makers worldwide but I am unaware of any that have managed long LED
> lifetimes by themselves. I'd risk saying that ANY Asian LED maker who
> cannot show a direct technology link from "big name" LED makers does
> not make quality product.  There is now a substantial cross linking of
> licences. Some (not all) competent LED makers are (in no order) Cree,
> Osram, Lumiled/Luxeon. Nichia, Avago, Sharp, Seoul semi ...

ie - you can drive them as well as you want, but if they are junk they
will still be junk.
Essentially any LED without a traceable path to the technology of the
big-few is Junk.

If you were rolling your own then a trivially easy current source can
be made with an LM317 + one resistor.
BUT The LM317 requires 1.25V output drop plus about 2.5V "headroom" for the IC.
Too much for 3 LEDs on 12V.

A 4 channel current source can be made with eg an LM324, 4 x MOSFETS,
1 x TL431, 4 x current sense resistors and a few other r's and c's.
Very cheap.
LED current flows to ground via MOSFET and  sense resistor.
Op amp section monitors resistor voltage wrt reference voltage and
drives MOSG\FET gate to maintain V_R_sense at same voltage as Vref.
Works well.

   R



A constant current supply has
{Quote hidden}

>

2011\03\03@060003 by Patrick Moody

picon face
On 3 March 2011 10:17, RussellMc <KILLspamapptechnzKILLspamspamgmail.com> wrote:
>> Everyone's comments so far are suggesting that the short life of my
>> LEDs is caused by over-current/spikes.
>
> That was one of the reasons.

I should have said many, rather than everyone.

{Quote hidden}

If fixing the current source doesn't improve the situation then I'll
assume the parts are junk and follow up on some of the links Jesse
provided to try to source better quality.  The oznium.com one looks
promising. Thanks Jesse

{Quote hidden}

Cheap sounds good.  I'll have to spend some time working out how to
put all that together but that's a learning exercise for me.
Thanks again.

Patrick

{Quote hidden}

>> -

2011\03\03@081803 by Olin Lathrop

face picon face
RussellMc wrote:
> A 4 channel current source can be made with eg an LM324, 4 x MOSFETS,
> 1 x TL431, 4 x current sense resistors and a few other r's and c's.
> Very cheap.
> LED current flows to ground via MOSFET and  sense resistor.
> Op amp section monitors resistor voltage wrt reference voltage and
> drives MOSG\FET gate to maintain V_R_sense at same voltage as Vref.
> Works well.

I'm sure that will work fine, so fine that there may be simpler ways.  In
this case a little current error or temperature dependency isn't a big deal..
As I understand it, these LEDs aren't for illumination but just for
indication.  They shouldn't need to be run at full current.

Bipolar transistors make easy current sources since their collector current
is independent of collector voltage to good enough first approximation.  If
you've got multiple strings, than make a single voltage source of maybe 1.5V
once.  Each string gets a single NPN transistor and resistor.  For each
string, 1.5V to base, resistor between emitter and ground, and LED string
between power and collector.  Let's say you want to aim for 10mA nominal.
Assume the B-E drop is 700mV, which leaves 800mV accross the emitter
resistor.  800mV / 10mA = 80 Ohms, so the common value of 82 Ohms should be
fine.  Let's say it gets hot and the B-E drop goes down to 500mV leaving
1.0V accross the resistor.  That gives you 1.0V / 82 Ohms = 12mA, which is
20% brighter (very hard for humans to notice 20% brightness change) but
still well within LED current for long lifetime.

As Russell said, get decent LEDs and they will last longer than your
motorcycle.


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