**The Simple Production Process of LED Energy-Saving Lamps**
LEDs, or light-emitting diodes, are semiconductor devices made from compounds such as gallium (Ga), arsenic (As), and phosphorus (P). Today, LEDs and their corresponding drive circuits are widely used in energy-saving street lamps, office lighting, and various electronic products. Among them, high-brightness white LEDs are commonly used as the light source in energy-saving lamps. These lamps offer numerous advantages, including high luminous efficiency, low power consumption, long lifespan, and environmental friendliness. They are considered an ideal cold light source for the future and are becoming the preferred choice for home lighting.
Compared to traditional incandescent and fluorescent lamps, LED energy-saving lamps have significant advantages. The luminous efficiency of LED lamps can exceed 90%, while ordinary incandescent bulbs only reach about 20%, and fluorescent lamps typically reach around 40%. This means that LED lamps are highly efficient and energy-saving. Moreover, since LEDs operate on direct current, the brightness remains constant without flickering, which is better for eye protection and reduces visual fatigue.
Another key benefit of LED lamps is that they do not contain harmful substances, making them easier to recycle and more environmentally friendly. Unlike fluorescent lamps, which emit ultraviolet and infrared rays, LED lamps produce pure light with no radiation and generate very little heat. This makes them safer and more efficient in terms of energy use.
**How LED Energy-Saving Lamps Work**
Figure 1 shows a schematic of the power supply circuit for 38 LED lamps. The lamp is powered by a 220V AC supply. The voltage is first stepped down using resistor R1 and capacitor C1, then rectified by a full-bridge rectifier consisting of D1 to D4. Resistor R2 provides a constant current to the 38 LEDs connected in series. Each LED has a rated current of 20mA and a power rating of approximately 2W. Since LEDs tend to generate heat when concentrated, the current must be carefully controlled during circuit design to prevent overheating.
In this circuit, R1 acts as a protective resistor, while R2 limits the current to avoid voltage spikes and temperature increases. This design is ideal for small power lamps, as it is compact and easy to install in limited spaces. It offers low power consumption, small size, and cost-effectiveness. For optimal performance, C1 should be a polyester capacitor rated at 400V or higher, and R2 is usually a 1/4W carbon film resistor.
**Component Parameters**
- C1: 474μF, 400V polyester capacitor
- R1: 1MΩ five-band resistor
- D1–D4: IN4007 rectifier diodes
- R2: 510Ω, 1/4W carbon film resistor
- LEDs: 38 high-brightness white LEDs in a straw hat type
**Production Process**
1. Before starting the production, all components must be tested with a multimeter to ensure they are working properly. This prevents faulty parts from causing circuit failures. Especially for LEDs, since they are connected in series, if one is damaged, the entire circuit will not work. To test LEDs, use the R×10k range on the multimeter, similar to testing regular diodes. Do not use other ranges for testing.
2. Solder the DC drive circuit board. Components like diodes and resistors are placed horizontally, while capacitors are installed vertically.
3. Solder the LED board according to the layout shown in Figure 3.
*Figure 3*
The arrangement of LEDs should be neat and orderly. Pay special attention to the polarity of the LED leads. The longer leg is the positive terminal, and the shorter one is the negative. One simple way to ensure correct installation is to align the LED with the notch and solder it with a suitable iron. Afterward, trim any excess leads with diagonal cutters.
4. Solder the AC power leads (marked with “ACâ€) and the LED power leads (marked with “+†and “−â€).
5. Fix the DC drive circuit board to the lamp housing using hot melt adhesive, and insert the LED board into the slot to secure the back cover.
This step-by-step guide ensures that the LED energy-saving lamp is assembled correctly and functions efficiently.
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