Solar power, also known as photovoltaic or PV power, has been around for quite some time but despite its potential to produce clean energy, PV systems were not commonly implemented until recent years. The main reasons in the past for limited use were a high initial cost, system inefficiencies and low power production. Also, PV systems produce DC electrical power, which cannot be power many traditional loads without conversion and battery storage, which also introduce efficiency losses.

The current pattern of rising conventional energy consumption cannot be sustained in the near future has led to growing need to promote the use of renewable energy technologies in an environmentally sustainable manner. Among others, solar photovoltaics has gained wider acceptance due to proven maturity of the technology and ease in use. One major area of recent growth and expansion in the PV field has been in the implementation of solar powered LEDs for lighting applications.

Why should I use PV LED systems?

Unlike many standard electrical loads, LEDs can work effectively off DC electrical power. Solar LED lighting products also come with the added benefits of energy savings, meeting environmental goals, power reduction, safety, reliability, long life, easy installation and virtually no maintenance. Photovoltaic LED applications can be widely used in green lighting, road lighting, marketing and signage applications, traffic signaling, automotive and aerial panels, urban landscape lighting, home lighting systems and more.

Solar LED lighting has other benefits as well, including, a small opening angle, point size, high brightness, light scattering that is highly directional, good optical uniformity and other factors that are fostering its application in the lighting field.

Solar LED Innovations

Through the structure of traditional solar lighting, intelligent controllers, the angle of light reflection and technical improvements are making LED usage more conducive to photovoltaic applications.

In recent years, solar PV has been coupled with LEDs to provide more energy efficient light. Recent advancements in LED technology have led to the development of white light emitting diodes WLEDs. WLEDs provide a bright white light that’s ideal for domestic lighting. The advantage of using LEDs with solar PV systems is that the LED requires much lower wattage, therefore the size and the cost of the solar system is much reduced for each system. For indicator and signaling applications, use of a filter, diffuser or lens allows use of WLEDs in other areas as well as standard PV lighting applications.

VCC has LEDs, lenses, lite pipes and all the components you may need to implement LEDs into your photovoltaic powered system. Contact us today and talk to our LED experts!

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.

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.

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.

VCC panel lenses are made from polycarbonate of optical grade U.L.94V2 and are designed for superior output in comparison to industry comparables.  The VCC range remains attached firmly to the display panel even as the entire LED removal and insertion from the mount is possible.

In conventional LED lens mounts, the LED will simply protrude from the hole in the panel or is glued to the panel. This limits the viewing angle as well as increases the possibility of damage to the circuit board components because of increase in electro-static discharge.  The possibilities of a push-thorough happening also increase the risks of the lens falling down.

The availability of various configurations of the LED lenses from a mere 3mm to 10mm increases the scope of the final design of the display. Besides, the lenses only need to be inserted into the LEDs hole and the installation is complete. This therefore, increases the scalability as the LEDs mounted on PCBs as it is very easy to insert and remove a panel from its mount.

The factor that sets the VCC’s LED panel apart from the rest of the available products in this segment is the multiple choices in the lenses themselves. Round and square, low and  high profile, plain and Fresnel  types of lens with diffusion or threaded capabilities define the final illumination as well the viewing angle of the display. Adapting diffused light technology a new series of glow lenses are also available now. The panel lenses made from thermoplastic material allow uniform glow with almost full angle viewing capabilities.

VCC’s LED panel lenses are easy to insert in standard display panel, saving on logistics of installation and commissioning, besides being technically more sophisticated. Available in multiple configurations, VCC LEDs are the ultimate choice for ultimate illumination.

LEDs and their offshoots, OLEDs (organic LEDs) and PLEDs (polymer LEDs), can be manufactured to display a stunning range of colors.  Different manufacturing methods and materials usage makes each particular type of LED suited to specific applications and lighting strategies.  The overall desired color effect will determine which LED is best suited for a particular project.

Solid-state LEDs produce light in a variety of wavelengths, from the infrared to the ultraviolet range, and create this light through the use of a semiconductor material.  Color variations are produced by the use of different materials to create the needed semiconductors.  Materials as diverse as gallium arsenide and diamond can be used to produce a range of intense colors, and the semiconductor material determines the given wavelength of emitted light.

The three “primary” or main colors for LEDs are red, blue and green (RGB). When a new LED color is designed, it begins with a combination of RGB light and any hue can be created with the correct color mixture.  It is difficult for engineers to accurately model these colors in advance as computer modeling software cannot match the full spectrum of colors available with LEDs.

White LEDs are the sole exception to the standard RGB process. Typically, white LEDs are created using the color combination process; however, they can also be created via use of a phosphor coating over a blue LED.  The phosphor coating forces the light wavelengths emitted by the blue LED to undergo a wavelength shift and appear as bright, white light.  This wavelength shift is referred to as the Stokes shift.  Phosphor coated LEDs are less expensive to produce than the RGB combination but, due to the Stokes shift, their overall efficiency is adversely affected.

OLEDs and PLEDs are variants on the original LED design.  OLEDs make use of organic compounds to replace the LED’s inorganic semiconductors.  PLEDs use the same design as OLEDs, but make use of a polymer film in place of the organic electrolumiscent compound. OLEDs can be manufactured as thin, flexible films, and they are widely used for items such as computer monitors and television screens due to their high contrast ratios.  PLEDs are also manufactured as films rather than as individual light elements, and are best for low area lighting or presenting a full color spectrum for displays.

VCC’s engineers can assess individual project requirements and develop appropriate colors and lighting solutions for any application. Cutting edge technology and design innovation ensure that each LED will meet customer needs for intensity and reliability while providing a high level of efficiency.  VCC offers in-house consultancy, design and manufacturing processes to cover LED production from start to finish.

Branson is the industry leader in the design, development, manufacture, and marketing of plastics joining, precision cleaning, ultrasonic processing and metal welding equipment. When Branson decided to develop a new line of Ultrasonic welders they looked to improve the user’s ability to easily operate and view the process using indicators as a means of identifying the stage at which the welder is operating. Since this is an extremely important feature they wanted to trust a company that could provide a customized solution in short time. VCC was called to duty, with our CNX C series LED panel socket that easily configures to a single four pin connecter allowed two LEDs to be panel mounted with one connection. This time saving feature is important to Branson since the majority of their products involve hand assembly which is very labor intensive.

Features of the CNX C series includes multiple of lens styles and mounting options with a relampable LED for easy service and replacement. Configurable to multiple of connections and options allows for a solderless alternative solution from more standard methods used to mount LED’s to a panel. Labor saving, easily configurable, short time to a custom design, This is why Branson Ultrasonic selected VCC as a partner for their panel indication requirements. To learn more about VCC custom LED cable interconnects visit www.vcclite.com.