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please help me design a constant current regulator for led

03/26/2010 3:35 PM

i've got a project where a constant current regulator to drive a led of 3V and 300mA,150lumens/W is to be designed.there will be a 6V,4.5Ah rechargeable lead acid battery to power the led and this current regulator should turn off when the battery voltage reaches 3V.the problem is whichever circuit i searched eats up atleast 1V excluding the led and this is what i do not want to happen.i want to have a circuit which can virtually change its resistance or such effect so that 3V is measured across led and 300mA current flows through it no matter what the battery voltage is.and all this should come at ultra low cost as this is beingmade for the rural people so that they can afford this. can anyone help me with this problem?

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#1

Re: please help me design a constant current regulator for led

03/26/2010 4:56 PM

Ok, lets just think about this a little bit. If you want a constant current source to still work with the identical source voltage as the load voltage, then your regulator circuit must be capable of having an impedance of 0V/300ma= 0 ohms. A little difficult to achieve at room temperature. So accept that your lowest battery voltage will drop out of regulation range at some slightly higher voltage than the LED's rated voltage. (I suspect this will be fine option.) Or you could accept an LED output voltage that is less than 3.0 volts like maybe 2.5 volts. The LED will be dimmer but the battery should last longer.. Lastly and the most complicated, you could design a boost buck switching voltage regulator that will provide a constant voltage as the battery drops in voltage.

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#2
In reply to #1

Re: please help me design a constant current regulator for led

03/26/2010 5:06 PM

thanks sir,i got ur point.i just thought of minimising the voltage drop in the circuit so that i can get almost same voltage across led.this will help increase the battery life, i thought.anyway thanks for ur help.

i've another thought.why not use a n channel jfet in series with led and let the gate voltage be monitored by connecting it to the emitter of a bjt which comes in parallel with the led.would this work?

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#3
In reply to #2

Re: please help me design a constant current regulator for led

03/26/2010 6:45 PM

That and a whole host of other linear arrangements can be made to work. But to actually maximize battery life you should use a switch mode configuration. This way the power draw from the battery remains constant and not the current draw.

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#4

Re: please help me design a constant current regulator for led

03/26/2010 7:40 PM

Instructables might be a good place to start:

http://www.instructables.com/id/Circuits-for-using-High-Power-LED_s/

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#5

Re: please help me design a constant current regulator for led

03/27/2010 2:29 AM

Dear Vishu

Your question has to be split into two parts.

(a) Charger for the battery.

(b) Constant current driver for LEDs.

Charger for battery - Should be capable of charging battery upto 6.9 V at a max. current of 0.9 A, lower current is also acceptable but charging time will increase. I am presuming that this battery is sealed maintenance free. There is NO WAY you can allow battery to be discharged till 3V, as mentioned by you. So even if battery voltage reaches 5.4 V then also 4.4 V is still available for driving LEDS. This voltage is high and reply to this is in second part.

Constant current driver for LEDs - Single chip switching regulators are available which can be operated in constant current mode also. Advantage with switching regulators is that as battery voltage increases, current drawn from battery keeps falling, while maintaining constant current output. Thus Ah drawn from battery is reduced & it can be used for longer time, as compared to series pass regulator which draws steady current from battery irrespective of its voltage. Thus differential voltage ( therefore power & energy ) of battery & load is lost constantly, making the system inefficient. Battery will therefore last for shorter duration compared to switching converter.

Being constant current source, voltage across LED will depend on LED characteristic. 150 lumen/W has got nothing to do with current regulator. It depends exclusively on LED.

Thanks and regards

Ashok Toshniwal, Bangalore, India.

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#8
In reply to #5

Re: please help me design a constant current regulator for led

03/27/2010 7:09 AM

A GA as to the point technically.

I like to point out:

. Why to to use LeadAcids .... Why not the Li-Ion or latest type ... Costwise better propsition and also maintenance-wise a better choice. Less charging time ... In Power shutdowns areas.

Regards

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#10
In reply to #5

Re: please help me design a constant current regulator for led

03/27/2010 5:22 PM

I've reread the OP problem and I don't see where he/she is asking for a battery charger circuit. I interpreted the question that this was for some form of a rechargeable battery driven LED sign. This would explain the desire for such a high wattage LED instead of the tiny wattage that one can achieve with an indicator LED like a T 1-3/4. Depending on the number and configuration of the LEDs one might even be possible to pulse the LED's so that the apparent brightness can be much higher than the actual brightness due to the latency effect in the human retina. But this gets into a lot more detail than what the OP has offered on how this is going to be used.

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#11
In reply to #10

Re: please help me design a constant current regulator for led

03/28/2010 12:52 AM

hi,

i'm sorry that i didn't get to the detail of my problem.actually i'm using this led for home lighting in villages where power outage is very common.now i thought of having a battery driven led with more lumens compared to incandescent so that all the light that is required could come from a low wattage device which obviously saves cost and gives the luxury of having light anytime they want.U were correct in guessing that this led would be driven by rechargeable battery.now to charge this battery we thought of having a chopper.this chopper would be connected to solar pv and also mobile phone charger output(which is already connected to ac mains).this is to make it easy for user to switch between two source if anyone is not available.i hope i've made it clear about my problem.right now i'm very much concerned about the current regulator than the battery charging part.so,it would be a great help if u can help me with this.

thank u,

vishwanath

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#12
In reply to #11

Re: please help me design a constant current regulator for led

03/28/2010 3:38 PM

There are a multitude of switch-mode LED circuit diagrams available on the web. Many IC manufacturers provide very good application notes along with complete schematics and occasionally circuit board patterns. Look and you shall find.

One thing that can significantly save you power is to change your design goal from a constant current source to a pulsed current source. You'll be using the natural latency of the chemical reaction that happens in the eye while saving power by not having the LED ON all of the time but still flashing faster than people can see.

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#6

Re: please help me design a constant current regulator for led

03/27/2010 6:33 AM

If the LED is just an indicator you might consider running it at a lower voltage. I tested a lot of LEDs to select the best load resistor and found that most LEDs with a suitable resistor will operate below their rated current at 32V and yet still operate with good brightness and much reduced current at 4V. Get hold of a bench dc power supply and a selection of resistors/LEDs and find a pair that does what you want; select-on-test used to be the way we made up circuits many moons ago!.

If you read the manufacturers specification you will see that LEDs are fairly short lived if you run them at the rated current so this is another consideration - how long will your piece of kit be used and what do you want from the LED.

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#7

Re: please help me design a constant current regulator for led

03/27/2010 6:45 AM

Hi from Sleepy.

I do not know your precise requirement.

I would not accept a requirement for both a constant voltage and a constant current.

An LED is , in efffect, a diode and a look at the V/I Characteristic and the lumens vs Amperes and lumens vs voltage characteristic reveals that the output lumens will be dependent upon the current through it, the voltage will have a considerable effect but it will be difficult to control luminosity and life through voltage, use that as just a an absolute maximium. but it will be easier to stabilise the LED with a constant current drive.

LEDs often require a constant curent drive in order to maintain stability of lumen output; and to keep the LED below the rated maximum and a life rated maximum - ask the supplier. Read the Philips information if nothing else is available.

Good Luck

Sleepy

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#9

Re: please help me design a constant current regulator for led

03/27/2010 12:13 PM

Dear all,

use a LM317 regulator. Connect 6V to input terminal. between output terminal (pin 2) and the third pin connect a resistance

(1.25/0.35)ohms about 3.3 ohms of 0.35x0.35x3.3 watts.

This gives constnt current. Resistance may vary in the commercila products but small current variations are tolerable with LEDs. This is a practical circuit used by me.

written by

shreeramachandran,

AGM Telecom(REtd)

04428474099

sudarsanajyothi@gmail.com

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#13

Re: please help me design a constant current regulator for led

03/30/2010 2:40 AM
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