LED usage and design is growing exponentially each year. There are a number of advantages for designing circuitry the uses LEDs as the illumination component. Below we’ll cover some of the best uses and reasons for use in your cabinet, PCB and signaling projects.

LEDs and Directional light emission

Traditional light sources that were used in the past, emitted light in all directions. This flaw resulted in parts of the light being scattered and luminance lost. Special optics and reflectors could be integrated into the system to create directional light sources, but they caused even further light losses. Because LEDs are mounted on a flat surface, they emit light hemispherically reducing lost and wasted light.

Low Profile/Compact Size LEDs

The small size and directional light emission of LEDs offer designers flexible options for low-profile, compact lighting design. Using either through-hole or SMT LEDs or LEDs coupled with a lite pipe, can eliminate system devices that protrude and cause less space to be available in cabinet or PCB housings.

Breakage resistance

LEDs are extremely resistant to vibration and damage because they do not have filaments or glass enclosures. Standard sginaling lamps may be affected by vibration in certain applications unless specialized vibration-resistant devices are implemented.

Other light and signaling sources are all based on glass or quartz envelopes. Product breakage is a fact of life during transport, storage, handling, and installation. LED devices usually do not use any glass. LED devices mounted on a circuit board are connected with soldered leads that may be vulnerable to a direct impact, but are significantly more stable than other lighting types.

Cold temperature operation

Cold temperatures present a challenge for other signal lamps. Many lamps will require higher voltages to start during colder temperatures, this is not true for LEDs lamps. LED performance actually increases as operating temperatures drop. This makes LEDs a natural fit for refrigeration product, cold storage facilities, and outdoor applications.

Instant on

Lamp types that are not LED based often requires additional time after system initiation before the full brightness level is reached. In contrast, come on at full brightness almost instantly, with no re-strike delay. This ‘Instant-On’ feature is desirable both for convenience and safety reasons.

Rapid cycling capability

Traditional light and signaling devices will burn out sooner if switched on and off frequently. In many cases, a timer is designed into the circuit for protection of the circuitry when the device has been in use that prevents further use until a cooling period has been met. LED life and lumen life cycles are unaffected by rapid cycling. In addition to flashing light displays, this rapid cycling capability makes LEDs the perfect device to integrate into your circuitry and with other electronic devices such as occupancy sensors or daylight sensors.

Controllability

Traditional, lighting and signaling sources present a number of challenges with regard to lighting controls. Dimming of the system lighting is readily available and effective, although at a substantial cost premium. LEDs offer benefits in terms of controlling light levels (dimming) and color appearance. As LED driver and control technology continues to evolve, this is expected to be an area of great innovation in a large variety of applications.

No IR or UV emissions

Today’s manufacturing and regulatory commissions are increasingly concerned about IR and UV emissions. The trend is to implement restrictions on power usage and circuitry Ir and UV emissions. LEDs emit virtually no IR or UV. This not only helps reduce carbon footprints but lowers circuit power requirements. In addition, it eliminates excessive heat (IR) from lighting that presents a burn hazard and also the UV rays that can be damaging to any unshielded devices.

Where can I get more information?

The experts at VCC Optoelectronics are available daily to help with your design requirements and also selection of the best LEDs for your project. Contact us today for advice, information, design assistance and superior LED devices.

Integrating LED components is most successful when the technology for the application is based on the specific device performance, quality, reliability and cost requirements. This includes taking the time to evaluate and design your LED system to cover the full range of optical quality, from high-precision lenses to basic plastic optical lenses and to match lens features, filters, lite pipes and other components to meet your design requirements.

There are two main application categories for LED applications: Visual LEDs and Non Visual LEDs.

Visual LEDs

Visual LEDs were once implemented simply as panel and device indicator lights with frequent implementation in flashing sign applications. Each aspect of the LED field has grown and now includes many additional uses such as lighting, coaxial and reflective illumination, linear assemblies, dome sources and smart lighting. Flashing LEDs are even used as attention seeking indicators without requiring external electronics. LED panel indication, automotive applications and signal communication are well on their way to being dominated by LED usage. In addition, industry insiders feel that LEDs will also completely replace present standard lighting sources like incandescent, halogen and even gas discharge lamps.

Non-Visual LEDs

Non-visual LEDs are used extensively in application where their main functions is not to serve as indicators or light sources. The easy modulation ability of LEDs has encouraged voluminous use in optical fiber and free space communication. The many uses for non-visual LEDs include infrared applications such as remote controls, barcode scanners and machine vision systems. LEDs are also combined with photo diodes or phototransistors to create an opto-isolator, providing electrical isolation between circuits.

Application Options

When designing your project selecting the right components often comes down to not only the device itself but also the options that make that device fit the critical parameters of your application. For LEDs there are several devices that will modify your LED component to meet the project requirements and achieve optimal system results. Color options, lenses, filters, diffusers and waterproofing are additional options that can be selected or added to generate desired system results.

Where can I find the right LEDs and the Right Application Specific Options?

VCC has been a leader in LED manufacture, design and implementation for many years. Our experience covers a diverse range of LED indicator light applications in which our products and their many options and variations are used. Contact us today for innovative design assistance combined with modern manufacturing practices. , VCC provides high-quality, high-performance LED lighting solutions that will help your design meet and exceed your expectations.

Factory automation projects are growing across the country, despite the economic times, leaving many to wonder why companies are choosing now to automate processes. Whether you have a discrete parts operation, a batch or continuous process, information flow, quality control and cost management are key elements to your success.  Implementing a factory automation process allows you to design and integrate a system to provide you with the appropriate level of information and products–on time and on budget.

Automation Isn’t Just for the Big Boys Anymore

Just a few years ago the majority smaller companies could not afford the initial investment cost for implementing an automation system. Today, companies are realizing the purpose of automation has expanded to issues broader than productivity and costs. Automation is now often applied primarily to increase quality in the manufacturing process, where automation can increase quality substantially. Smaller companies are also creating hybrid factory systems where specific time consuming or repetitive assemblies and products with high reject rates are automated to not only create a faster manufacturing process but also increase quality.

Why Automate?

There are a number of reasons to automate processes such as:

• Growth of Industry – Products that have sudden increases in demand that can’t be handled by the current workforce are prime candidates for automation.
• Increased Efficiency and Quality – Components and assemblies that are automated have proven increases in efficiency and quality.
• Faster Time to Market – Products and assemblies that are barely meeting schedules or tend to run late should be viewed as possible automation projects. Functions such as determining correct orientation, part identification, code reading, metal work and material handling, once automated, will experience exceptional reduction in manufacturing times resulting in product delivery times will increasing substantially.
• Health and Environment – The costs of automation to the environment are different depending on the technology, product or assembly being automated. Hazardous operations, especially those including industrial chemical handling or metalworking are prominent contenders for automation. Automating hazardous processes allow better health for workers, a safer manufacturing facility and reduced environmental effects.

What Automation Options are Available?

There are a number of different systems available for automating processes or entire manufacturing lines. Among those options are:

• Robotics
• Motion Control
• Drive Systems
• Machine Vision
• PLC Control

VCC has experienced personnel that can help you pinpoint possible products that are ripe for automation and specify indication and PCB components that will help make your automation plan successful.

As a semiconductor component, Light emitting diodes (LEDs) are best known for their amazing energy-saving abilities. As we know, LEDs have several applications, however, LEDs can also function as simple light sensors in a variety of applications, making them highly versatile and useful in many other systems and purposes.

How LEDs Function as Light Sensors

LEDs can be used as sensors where it can be configured to detect ambient light. Here’s how it works to use LEDs as light sensors:

First, you use two bidirectional CMOS I/O pins connected to an LED with both I/O pins set to output mode and LED in forward direction to emit light.

Second, you set up additional LEDs with I/O pins set to output mode but in the reverse bias direction. This charges the LED’s inherent capacitor by inhibiting the current. By reversing the current, the LED power pin reads the current leakage of the diode, which in turn charges relative to the ambient light, thereby detecting it.

Essentially, as you shine light of a similar color with a slightly shorter wavelength on an LED, it produces electricity, with the voltage of that electricity increasing with the intensity of the light. This turns a simple LED into a light sensor.

You can use a simple experiment to see its working as a LED sensor – just connect the LED–when illuminated–across a voltmeter, you can observe a reading.

Often LED sensors are “infrared” LEDs which infrared refers to light with longer wavelengths when compared to visible light spectrum.  Note that, when used as light emitters, the light projected from infrared LEDs is invisible to the human eye, though they can output a dull red glow when viewed directly.  The operating voltage is usually set to 1.4 v, and current less than 20mA for IR LEDs. A very common application of IR LED is remote controller for household appliances; where wavelength used is 940nm.

How LEDs are used in Sensors and Infrared Technologies

You may be surprised to know how frequently LED sensors are used in a long list of applications. LEDs can be used in a wide variety of sensor and infrared applications such as:

• Remote controls
• Traffic lighting
• Night vision web cameras for security
• Indicator lights on electronics
• Web or video conferencing
• Photo couplers
• License plate readers
• Factory automation
• Digital camera range finders
• Smoke detectors
• Night video production
• Treatments for sports injuries and burns
• Total darkness or near darkness video surveillance
• Motion sensors for light switches and controls

LEDs from VCC Optoelectronics

VCC offers a large selection of LED products that can be used in sensor and infrared applications, including automated and semi-automated production environments, instrumentation, networking equipment, and more. VCC’s custom design services further expand our offerings, allowing you to work with our technical staff to design and manufacture LED components for your project specifications.

Eltek Valere is a leading global supplier of energy conversion solutions within telecom, renewable energy, electric vehicles and industrial applications. When Project Lead, David Webb of Eltek Valere wanted to improve the quality of light emanating from their PC board, he turned to Advance Technical Sales Engineer Mary Perkins for help finding a bright and high quality led and lens assembly.

Mary suggested the HMC 461 series with 10mm LED. The HMC 461 has patented features that increases the apparent brightens of the LED as well as the increased viewing angle up to 180 degree. The HMC 461 threaded body with retaining nut provides added security to the panel by use of a locking washer. The HMC 461 can with stand vibration and direct impact providing extensive protection of the LED and internal enclosure electronics. David found them just what Eltek Valere was looking for. He was impressed by the versatility of the products, the flexibility of the mounting and the high luminosity of the LEDs.  VCC looks forward to growing our business with Eltek… Good job on the design in Mary…

Let VCC help you find a quality solution to your indicator application.

Connecting light-emitting diodes (LEDs) to circuit boards is a matter of some question if you ask the experts. There are those who swear by the age-old method of soldering with lead because of its simplicity and commonality. But VCC’s products are far from ordinary and our new techniques have created several alternatives that come with significant advantages not only for the manufacturing process, but also for the end user.

Problems with Traditional Soldering Techniques

Traditionally, LEDs have been constructed using time-tested soldering techniques. This type of construction method is especially popular for through-hole LEDs where the leads pass through the circuit board, as opposed to surface-mount LEDs that sit on the surface of the board. When LEDs are connected to circuit boards using this method, care must be taken to connect the LED in the correct direction with respect to the anode (a) or + and the cathode (k) or -.

Soldering works by melting an alloy – usually tin and lead in a 60% to 40% ratio – tinning the surface with the alloy and connecting the two components. But herein lies the first problem: lead is a heavy metal and is considered highly poisonous to humans and damaging to the environment as well. The second problem with this process is the potential for damage to the LED as a result of the high heat (200°C).

Damage can also occur when errors are made during the connection process. If an LED is incorrectly connected using soldering or otherwise needs to be removed from the board (a process called desoldering), the removal can often damage the LED.

Superior Interconnectors for LEDs

VCC uses state-of-the-art alternative techniques for connecting LEDs: either panel mount assemblies or locking header connectors. Panel mounting assemblies used by VCC are fast, simple, and highly advantageous. Not only is panel mounting a tool-free technique, but by using press-fit or threaded connections, VCC is able to provide a variety of LED connections to power source circuitry.

VCC’s locking header connectors are designed to provide positive locking for securing connectors to a printed circuit board using a male pin header design. Using existing friction header designs, VCC incorporated a finger release lever with a detent which creates a polarized positive locking header – our “click, it’s locked” feature. Removing the ramp connector from the locking header involves inserting a fingertip between connector and header lever to disengage the lock, which allows the connector to be extracted. This locking header also provides polarity protection by preventing the header connector from being inserted in the reverse position.

By choosing alternative interconnections to the standard soldering methodology, VCC is a leader in the field with simpler, easier mechanisms and a more environmentally-friendly outcome.

Light-emitting diodes (LED) have exceptionally long lives, low failure rates, and therefore low maintenance and replacement requirements. Not only does this result in hassle-free applications in instrumentation, telecom and networking equipment, and even toys and other consumer products, but because of their efficiency, they save significant amounts of energy as well.

LED Life Expectancy

Most manufacturers publish lifespans for LEDs close to 25,000 hours each, with some lasting as long as 100,000 hours. Most LEDs have life expectancies that are upwards of 50 times longer, for example, for tungsten halogen lamps that are used in various applications such as instrumentation for microscopy applications. Additionally, because LEDs put out little to no heat at all, they avoid complications from excess heat such as noise and vibrations from fans.

Causes of LED Failures

Life expectancy of LEDs is extremely good, as is the rate of failure. There are, however, several factors that impact whether an LED lamp will fail prematurely, including the following:

• Capacitors: This component is used in the circuit of every LED driver and has the potential to fail sooner than the rest of the system if quality is inferior. With high-quality materials, this should not be a problem.
• Heatsinks: Necessary for dispersing heat away from the bulb, heatsinks are essential for long lasting high power LEDs. They can fail, however, if the surface area is inadequate, the gaps between fins are inappropriate, or the fins are positioned incorrectly. Again, with high-quality components, LEDs should not experience such problems.
• Temperature: Though LEDs generally function well under normal conditions, when used in enclosed or high-heat areas, they can experience a shorter lifespan due to overheating. Extreme cold conditions can also shorten the life of an LED, causing it to flicker, dim, or cease functioning.

Early failure is rare, but can happen if not properly designed and operated.

Replacement Benefits of LEDs

Long lifespans makes LEDs ideal for many installations Because LEDs last for many, many years; they can be installed in enclosed and difficult to maintain components, thereby decreasing labor and maintenance costs significantly.

LEDs from VCC Optoelectronics

VCC offers a wide selection of LEDs and LED indicator products for commercial applications. Our high-quality, high-performance LED products are leaders in the field, with custom system designs available. Our team of highly qualified technical staff will use cutting edge technology and computer modeling to design and manufacture LED components for your project that meet your requirements for intensity, accuracy, and spatial needs.

A light-emitting diode (LED) is generally made with the same basic components. In the simplest sense, the LED circuit consists of two components connected in a series—an LED and a current limiting resistor—that are powered by a voltage source. The basic components of an LED include the following:

• Die: Includes a top contact that is wire-bonded to the frame terminal called the post
• Lead frame: This houses the die
• Encapsulation epoxy: This protects the die and disperses the light
• Conductive epoxy: Recessed in one half of the frame
• Anvil: A recess in the frame which is specifically shaped to throw light forward

At the heart of LED construction is the p-n junction which functions as a semiconductor diode. Every LED contains a p-type semiconductor (electron rich) and n-type semiconductor (electron deficient) with a transition layer between them known as the p-n junction. Connecting the LED to an energy source results in the flow of current from the p-side (anode) to the n-side (cathode). When the volt passes through an LED circuit, it encourages electrons to recombine with electron holes, which then releases energy as photons or light. The voltage across the p-n junction must be in the correct direction (forward-biased) in order for an LED to illuminate. A reverse-biased polarity will result in little current and no illumination.

LEDs are considered solid state lighting, which gives them several advantages. They are naturally shock resistant, have significantly long life spans, can withstand quick on/off cycles without damage, and can be formed to crease highly focused illumination.

Extra Features Built into LEDs: Color, Size, Shape, Angle

Sizes of LEDs vary quite significantly depending on the desired end product. Though the standard size is approximately 5 mm in diameter, they can also be made in smaller and larger sizes. LED shapes (determined by cross-section configuration) range from round to square to rectangular to triangular.

Though it might be assumed that creating LEDs with color occurs by modifying the plastic body or package of the LED, colored LEDs are actually constructed by changing the semiconductor material using things such as gallium phosphide, indium gallium nitride, silicon carbide, diamond, or aluminum nitride. They are available in basic colors, including red, amber, orange, green, blue, yellow, and white. Tri-color and bi-color LEDs are created by combining mixing more than one type of lead in the same LED to create more complex colors such as orange-red, pure emerald green, bluish green, near UV, infrared, and far UV.

The viewing angle at which the LED is manufactured can also be customized. The options for LED viewing angle include standard 60° but narrower viewing angles at 15° or less are also possible.

The core competency of VCCs product range for the LED display units is ourits high performing technology and technical features which optimizes the accessory for the function it has to perform.  An excellent example is the manner in which VCC has evolved a simple solution to protect the lens from moisture or dust by using the gasket to create a vacuum around the lens.

Discussion on the engineering capabilities of VCC is incomplete without mentioning its patented PCH 175 right angled circuit board that will allow both the bi-lead as well as the tri-lead LEDs to be mounted simultaneously in combination as well as in color arrays. The main feature of the PCH 175 is the tabs will lock the LED leads into position within the housing. Additionally the interlocking of the dovetail helps in banding leads together in to arrays. The standoffs coming as part of the manufactured device, will allow for easy soldering and clearing of flux after they are fixed.

Another example of inner engineering that establishes VCC as the market leader is the addition of a retaining ring to hold the mount that is passed through the hole in the LED to easily install the panel mount. This ease and  simple design which makes them efficient accessories are what make these superior to other products.

The difference in technologies is actually apparent by looking at the traditional method of mounting of the PCB on the display panel.  Conventionally the LED simply protrudes or hangs out form a hole in the panel. Sometimes the LED is glued to the panel and this is monumental risk as the results of ungluing for various reasons could be disastrous. Secondly, the LED because of lack of protection could result in it being pushed through and falling off besides increasing the emissions thus damaging the components of the circuit board. Third, the viewing angle becomes very restricted and the LED light is dull.

Superior engineering and design of the VCC enhances the ultimate illumination that the brand values!

In the last few years we have seen the evolution of the Light Emitting Diode (LED) and its usage in various areas. Even though it has yet not been able to dislodge traditional lighting technologies, LED has been posing a threat for quite a few years now. There are numerous benefits of LEDs; you would find that the LED lights are brighter and they have a greater longevity. Even if the benefits that we mentioned were only a couple, in fact there are hundreds of such benefits, but in reality even today getting LED lights everywhere isn’t very easy. The pricing of these light emitting diodes is high enough for companies of all-sizes to manufacture and that is one of the primary reasons for it not being able to meet up to its expectations.

Previously, big companies used to manufacture LEDs and other associated equipments. However, with the sales of such equipments increasingly rapidly, we have observed a change in the trend.  There are companies that specialize in each attribute of LED manufacturing; these companies together make a complete lifecycle in LED manufacturing which is known as Supply Chain of LED manufacturing. Before we go into the reasons for having various companies forming a supply chain, we classify some of the important segments of the Supply Chain:

1)    Research & Development,

2)    Exipathy,

3)    Manufacturing,

4)    Packaging,

5)    Testing &

6)    Backend Processing.

It is true that the sales of LED has increased more than 50% in the US over the last few years, yet it isn’t enough to meet the huge amount of capital involved in buying equipments, so as to setup a unit capable enough to manufacture a LED unit on its own. For some of the companies apart from the capital, what matters is attaining various kinds of unique skills that are involved in the lifecycle of a diode development. These are two most important reasons why there exists a Supply chain for manufacturing LEDs.

The advantage of having such Supply Chain are again many, just like there are hundreds of advantages associated with LEDs. The day LEDs prices go down, it would replace various other forms within months. The strength of the supply chain is such that it has the capability to support and meet such a requirement. In a supply chain, the company that does the R & D only researches and formulates ways by which their researches can be developed. However for the company that manufactures, is no way related to research and it works only on the research provided by the R & D Company. In this way a small company that specializes in any particular aspect makes the most of its potential in this growing market. This whole concept applies to all the units present in the Supply Chain.

The benefit for companies that are a part of supply chain is quite evident, but how do general consumers benefit from all this? If you recall, we mentioned the increase in LED sales and the benefits associated with the usage of LEDs. Taking a very small example, we would see that if the prices of traditional lights and LED lights are the same then it is quite normal for one to choose LED lights. With the supply chain, competitive pricing is possible and that is what’s happening recently. If the trend stays the way it is, soon we would see affordable LED lights replacing traditional lights at every instance of our lives.