How to make LED TUBE LIGHT

Led tube light

LED TUBE LIGHT

Before making Led tube light we need know basic concept about led working .

Led is basic element for making led tube light and it's come in different form so we have difficulty that what type led we need to use in it and which  led is best can we use smd led or dip product.

Basically we can use any led in led tube light...

• If we wand cheaper tube light and esay to make than w can use dip led in 3 mm,5mm,8mm.because these led are easy to solder on pcb and easily available in market.But in Led light output/watt is less compare to smd and look not so great.
• If we go with smd led than may be our tube light price go little bit higher but it's looking is greet and light output also really greet.But problem with that led is about mounting because smd led mount by re flow soldering.also this led is not available in normal market it will come in 3000,4000 pic pack.smd led available in 3014.4014,2835,3528,5050,5630,5730 etc package

so now we have some knowledge about about led so how we select led we told you in the end of this blog.

Basically led tube light come in t-5,t-8 form in retro and battens type with transparent and milky cover.

retro type led tube light

battens type Led tube light

 also available in plastic and aluminum base.for good quality we prefer aluminum base tube because it's good for thermal management in led tube light which makes led life longer.

So now after some knowledge about led tube light  we go for it's basic element.

1. Housing(enclosure)
2. PCB and led
3. Driver

Housing - 

retro tube housing

battens type housing.

It's basic body of led tube light which content three part .

1. aluminum tube-its a holo tube which is use for pcb mounting and it's holo space use for led driver.If you want to make this part than you need  aluminum profile for high press aluminum  di casting .

2. Diffuser - it is use for diffusing or spiting light.it is two type  transparent and  milky white.we select diffuse quality so high  light transmittance and diffusion in diffsure for that we need to make it by good quality raw material so light output efficiency is maximum.

3.end cap- they are use for packing final finish ans supply input.

PCB AND LED -

PCB are use for led mounting.Due to high heat generate in led we need mcpcb for high heat transfer rate so led became cool and have long life.we design pcb according to our tube light wattage and driver conflagration.so for example - we have led driver 240 ma /50-80v in 18 watt  and we 2835 smd led 0.2watt with 60 ma current.so how we select that how much led we put in series and how much parallel.

so as our conflagration we have 240ma constant current led driver and our 1 led take 60ma current

so led in parallel =driver current rating/led current rating = 240/60 = 4 

as result we have 4 parallel line

  

one led voltage 3.2 v and we have limit of 80v as driver rating so

maximum led in series =driver maximum voltage rating/led voltage rating =80/3.2 =25

so we can put maximum 25 led in series and 4 led in parallel 

generally we use 24 series and 4 parallel combination in that led  tube light for best result.

 

Driver-

It is use for give supply to led.so what type of supply and property we need in led driver?because we can operate led in different method but which is safe and best.

Led driver types

1. rc ckt driver -it's only constant resistance and capacitor in driver.It's cheapest led driver but having low power factor and no constant current so input operating voltage range is also law.so in power fluctuation your led may be burn.. 

 2. liner constant current led driver- they are also use for operating led but driver current is very low so need to connect led all in series.It's input voltage range also very law.

3. non-isolated led driver- this type of driver is widely use in led tube light because it's price is good and having wide input range 85-265v.It's a constant driver and having high power factor more than 0.9 and it's efficiency is more than 90% its really good driver which we use in led tube light in domestic purpose

non isolated led tube driver

4. Isolated Led tube driver-It's best driver but little bit costly.It's having high input voltage range 85-265v,high power factor,short ckt,open ckt protestation .It is having secondary supply isolated so it's shockproof so widely use in industrialist.

so after knowing about led driver we can use it as our comfort.but we prefer use only constant current driver and  if possible  use isolated driver for safety resigns.

Now we know all about Led  tube part and working so i think now you can make led tube light

1. mount led in mcpcb  make sure your led positive and negative point is correct

2.connect mcpcb to led driver 

3.connect led driver input point to tube end cape.

4. connect supply to end cap and check all led glowing well if have any problem plz check connection and led polarity.
5.put pcb on aluminum housing by using thermal past.

5.assemble all part your tube light is ready.

If you have any trouble to purchase tube parts from market than you can purchase that parts from us.we supply that parts many companies in India.for that contact nitin@mysunlight.co.in

Thanks for reading this blog if you like my blog plz like and share we will soon post other led product making concepts. If you have any doubt and know more about that plz comment