Our company was requested to make a high-quality stream lite design. The stream lite was a 30W dimmable daylight-balanced LED light that was to be used specifically for video streamers incorporating custom built-in diffusion and a 60-degree light spread for perfect talking head video and green screen lighting.
The main requirements set by the client included the followings:
– The size should have been the size of an iPad
– It was supposed to be one of the thinnest while using the most powerful LEDs in the market.
– Hidden magnetic connection points across the front of the light attach optional accessories in seconds.
– Designed to run off of both AC and DC power using a patented Power Stand.
– Some of the main technical requirements were as the following:
- Optical System: LED (must be flicker free for video)
- Light Aperture: 25” x 7.25” (23.49 x 18.14 cm)
- Beam Angle: 60 degrees
- Voltage Input: 19v
- Power Consumption: 30w
- Power: 110-240 VAC, 50-60 Hz 2.0 A
- Battery Connection: TBD
- Battery DC Voltage: 8 V DC
- Battery Light Output: 100% of Total Output
- Color Temperature: 5600 Kelvin (+/- 200)
- Color Rendition: CRI > 94
- Dimming: 0-100% Continuous
- Controls: Local On Board; Wireless through Bluetooth
- LED Lifetime: 50,000 hours
- Product Length: 5” (24.13 cm)
- Product Width: 5” (19.05 cm)
- Product Depth: < 1.3” (3.3 cm)
- Weight: < 2 lbs. (.9 kg)
– The built-in diffused plastic sheet covering LEDs eliminating LED shadows.
– Including of a power button and up and down dimming arrows. Also including a 2-digit power indicator to indicate dimming level (0-100 ((or FP for Full Power)). Continuous, 0, 1, 2, 3
– SOFTWARE REQUIREMENTS – General
- Power On and Off
- Quick power / pre-determined 25% 50% 75% 100%, (User can quickly pick a percentage and jump to that output)
- Dim From high to Low = 5 seconds, 7 seconds and 10 seconds. This technology is same as breathing light. The user can choose to dim the lights from high to low over 3 preset time periods.
Some of the main challenges in making the electronic design included the followings
- Choosing the best style LED considering cost considerations
- The product was requested to be as small as possible while its heat dissipation issue was to be resolved
- The design was to incorporate Bluetooth (Anaren A20737 or equivalent)
- Choice of the proper material and proper venting mechanism to minimize heat consideration while the device works for a long time
- Implementing a dimming mechanism without any flickering problem with LEDs
The electronic design was composed of three boards
- LED panel
- LED driver board
- LED control board
1. LED panel
Considering the requirements set for the LED panel, first, a research was done on the existing Power LEDs that could best meet the above condition and after that, the panel was designed. The size of the LED area was 18.14cm x 23.47 cm as compared to the screen Light Aperture area (18.14cm x 23.49cm). So the LEDs fit exactly in the aperture area. The board was sized as 20.11cm x 25.43cm which was greater than the aperture area (1cm at each side). This was considered to make the board adjustable with the size of the enclosure and fixing purpose.
Also, having considered the power consumption of the LEDs and the chosen power LED, for the 30 W design, the proper number of LEDs was calculated to be 167 LEDs.
Based on the designed LED driver, LEDs were powered on 7 serially connected columns. So, they were finally arranged in 12-row x 14-column matrix or 168 LEDs. This configuration guaranteed that there would be a minimum waste of power in the none-LED components.
2. LED driver board
Designing the LED driver board was the most challenging part. In order for the product to be a quality work meeting all the give requirements including dimming of LEDs without any flickering effect on the LED lights, being durable with a long lifetime, being thin enough to be enclosed in the existing thin space, etc., a special work was done. Having considered all the solutions, and for the first prototype aimed at checking the functionality of the design, an Arduino Nano based design was used. The choice of this board provided the designers with more flexibility in terms of designing and debugging the hardware and well as firmware for the first prototype. The board had three connections, one connection to the LED panel and one connection to the membrane switches on the board via a control board and one connection to the battery or AC supply.
In order to provide dimming for the design, a special PWM design was used that made the light lacking any flickering as requested in the request.
Also, regarding the heat dissipation issue, the design was tested on a 24/7 basis and no heat problem was detected.
3. Control board
This board was designed to connect the membrane switches on the enclosure to the driver board. The final design was a thin board that could be easily connected and replaced for troubleshooting and fixing.
The whole project took about 6 months to get completed and the final electronic design met all the requirements given by the clients. In a close cooperation and work between the CEO of the company who had a high and longtime skill in making different light design productions and the design team, all the problems faced during the design and prototyping was resolved. The client was satisfied and made the following feedback on the work.
“The project underwent some iterations with various parties involved and Norman’s constant communication and positive attitude helped streamline the process. Meee-services is very skilled and truly wants the best result for its clients. Highly recommend and plan on working with them again.”