Sunday, January 10, 2016

Sustainable Design - Electronics – IR LED Illuminator – Voltage regulation

In the mechanical world, like an automobile, bicycle, pumps, drilling equipment or a wind turbine, overbuilding is accomplished by very high safety to failure ratios, heavier grade and corrosion resistant materials, proper cooling, etc. In the electronic world, many of the same practices are put into place. However in the name of efficiency and production costs, they are not respecting the guidelines of sustainable design.


The circuit is composed of LED in series of 6 groups of 6 ( 36 LEDs ), a light dependent resistor ( https://en.wikipedia.org/wiki/Photoresistor ) with a infrared or IR mask which bears a greenish tint, a transistor 2SD2150, some current limiting resistors and another resistor marked as M6 which corresponds to PNP 2SA812.
What is missing in this circuit to make it durable or sustainable? LEDs are sensitive to voltage and current. Too much of either will burnout the resistor and eventually the whole of the series will stop functioning. If the LEDs are limited to 20mA (http://www.alibaba.com/product-detail/850nm-5mm-round-IR-color-led_60377496110.html?spm=a2700.7724838.30.18.puVDe3&s=p ) they should last about 50000 hours or about 5.5 years. If used withing operating conditions - 20mA at 1.3 to 1.5V. Increase the voltage and current, the LEDs may only last a few days, or even seconds. Decreasing the voltage would result in less illuminaton, but the LEDs would last much longer.
What would be a low cost solution to ensure that the circuit would last much longer? A simple voltage regulator. How much would it cost? Is there room for it?
  1. How: The voltage regulator can be a simple as a resistor and a zener diode. The resistor will limit the whole of the current to the circuit and the 12V Zener would limit the voltage. This is one example of a low cost http://www.alibaba.com/product-detail/MMSZ5242B-500mw-Axial-Lead-12v-Zener_765722089.html?spm=a2700.7724838.0.0.iFVnuj&s=p
  2. Cost : A few hundreds of a cent. Some board redesign, but the benefits would outweigh the costs to the environment and to the users.
  3. Space : The circuit in on a double sided Printed Circuit Board (PCB). There is plenty of room.
I recently installed a rear view camera on my car. The IR LEDs burnt out before I even got the chance to try it at night.
Who is at fault with these cost optimized designs? Engineers, technicians, accountants, stock holders, consumers who want to pay the least possible? I think it is everyone's fault, however regulatory bodies, and consumer protection advocates, could ensure that our devices last much much longer.

PS. A 9V battery can be connected to these units. They work, but the lighting isn't very strong. 



1 comment:

  1. I need help on how to power up such led board to be used as a stand-alone illuminator. Thanks You all

    ReplyDelete