Detailed Project Report on led bulb manufacturing unit

LED BULB MANUFACTURING UNIT

[code no.4110] 

Light-emitting diodes (LEDs) are semiconductor devices that emit visible light when electric current passes through them. Compared to conventional lighting systems, these are smaller, have a longer operating life and involve a lower cost of ownership. Available in a wide range of colours, LED light bulbs are more durable and offer comparable or better light quality than other types of lighting.

Residential LED lights, especially Energy Star rated products, consume at least 75 per cent less energy and last 25 times longer than incandescent lights. These also use significantly less power—a typical 84-watt fluorescent light can be replaced with a 36-watt LED to give the same level of light output. 

A light emitting diode (LED) is a device which converts electrical energy to light energy. LEDs are preferred light sources for short distance (local area) optical fiber network because they: are inexpensive, robust and have long life (the long life of an LED is primarily due to its being a cold device, i.e. its operating temperature being much lower than that of, say, an incandescent lamp),can be modulated (i.e. switched on and off) at high speeds (this property of an LED is also due to its being a cold device as it does not have to overcome thermal inertia),couple enough output power over a small area to couple to fibers (though the output spectrum is wider than other sources such as laser diodes).

A light-emitting diode (LED) is a two-lead semiconductor light source. It is a p–n junction diode, which emits light when activated.[4] When a suitable voltage is applied to the leads, electrons are able to recombine with electron holes within the device, releasing energy in the form of photons. This effect is called electroluminescence, and the color of the light (corresponding to the energy of the photon) is determined by the energy band gap of the semiconductor.

Types of LED

(1) Miniature

Photo of miniature surface mount LEDs in most common sizes. They can be much smaller than a traditional 5 mm lamp type LED which is shown on the upper left corner.

Very small (1.6x1.6x0.35 mm) red, green, and blue surface mount miniature LED package with gold wire bonding details. These are mostly single-die LEDs used as indicators, and they come in various sizes from 2 mm to 8 mm, through-hole and surface mount packages. They usually do not use a separate heat sink.[116] Typical current ratings ranges from around 1 mA to above 20 mA. The small size sets a natural upper boundary on power consumption due to heat caused by the high current density and need for a heat sink. Package shapes include round, with a domed or flat top, rectangular with a flat top (as used in bar-graph displays) and triangular or square with a flat top. The encapsulation may also be cleor tinted to improve contrast and viewing angle. Researchers at the University of Washington have invented the thinnest LED. It is made of two-dimensional (2-D) flexible materials. It is 3 atoms thick, which is 10 to 20 times thinner than three-dimensional (3-D) LEDs and is also 10,000 times smaller than the thickness of a human hair. These 2-D LEDs are going to make it possible to create smaller, more energy-efficient lighting, optical communication and nano lasers.

There are three main categories of miniature single die LEDs:

• Low-current: typically rated for 2 mA at around 2 V (approximately 4 mW consumption).

• Standard: 20 mA LEDs (ranging from approximately 40 mW to 90 mW) at around:

• 1.9 to 2.1 V for red, orange and yellow,

• 3.0 to 3.4 V for green and blue,

• 2.9 to 4.2 V for violet, pink, purple and white.

• Ultra-high-output: 20 mA at approximately 2 V or 4–5 V, designed for viewing in direct sunlight.

5 V and 12 V LEDs are ordinary miniature LEDs that incorporate a suitable series resistor for direct connection to a 5 V or 12 V supply.

(2) Mid-range

Medium-power LEDs are often through-hole-mounted and mostly utilized when outputs of just tens of lumens are needed. They sometimes have the diode mounted to four leads (two cathode leads, two anode leads) for better heat conduction and carry an integrated lens. An example of this is the Super flux package, from Philips Lumileds. These LEDs are most commonly used in light panels, emergency lighting, and automotive tail-lights. Due to the larger amount of metal in the LED, they are able to handle higher currents (around 100 mA). The higher current allows for the higher light output required for tail-lights and emergency lighting

(3) High-power

High-power light-emitting diodes attached to an LED star base (Luxeon, Lumileds)

See also: Solid-state lighting, LED lamp and Thermal management of high-power LEDs

High-power LEDs (HPLEDs) or high-output LEDs (HO-LEDs) can be driven at currents from hundreds of mA to more than an ampere, compared with the tens of mA for other LEDs. Some can emit over a thousand lumens. LED power densities up to 300 W/cm2 have been achieved.[120] Since overheating is destructive, the HPLEDs must be mounted on a heat sink to allow for heat dissipation. If the heat from a HPLED is not removed, the device will fail in seconds. One HPLED can often replace an incandescent bulb in a flashlight, or be set in an array to form a powerful LED lamp.

Some well-known HPLEDs in this category are the Nichia 19 series, Lumileds Rebel Led, Osram Opto Semiconductors Golden Dragon, and Cree X-lamp. As of September 2009, some HPLEDs manufactured by Cree now exceed 105 lm/W(e.g. the XLamp XP-G LED chip emitting Cool White light) and are being sold in lamps intended to replace incandescent, halogen, and even fluorescent lights, as LEDs grow more cost competitive.

Evidence of Haitz's law which predicts an exponential rise in light output and efficacy of LEDs over time. For example, the CREE XP-G series LED achieved 105 lm/W in 2009 while Nichia released the 19 series with a typical efficacy of 140 lm/W in 2010.

(4) AC driven LED

LEDs have been developed by Seoul Semiconductor that can operate on AC power without the need for a DC converter. For each half-cycle, part of the LED emits light and part is dark, and this is reversed during the next half-cycle. The efficacy of this type of HPLED is typically 40 lm/WA large number of LED elements in series may be able to operate directly from line voltage. In 2009, Seoul Semiconductor released a high DC voltage LED, named as 'Acrich MJT', capable of being driven from AC power with a simple controlling circuit. The low-power dissipation of these LEDs affords them more flexibility than the original AC LED design.

Advantages

• Efficiency: LEDs emit more lumens per watt than incandescent light bulbs. The efficiency of LED lighting fixtures is not affected by shape and size, unlike fluorescent light bulbs or tubes.  

• Color: LEDs can emit light of an intended color without using any color filters as traditional lighting methods need. This is more efficient and can lower initial costs.

• Size: LEDs can be very small (smaller than 2 mm2) and are easily attached to printed circuit boards.

• On/Off time: LEDs light up very quickly. A typical red indicator LED will achieve full brightness in under a microsecond.[134] LEDs used in communications devices can have even faster response times.

• Cycling: LEDs are ideal for uses subject to frequent on-off cycling, unlike incandescent and fluorescent lamps that fail faster when cycled often, or high-intensity discharge lamps (HID lamps) that require a long time before restarting.

• Dimming: LEDs can very easily be dimmed either by pulse-width modulation or lowering the forward current. This pulse-width modulation is why LED lights, particularly headlights on cars, when viewed on camera or by some people, appear to be flashing or flickering. This is a type of stroboscopic effect.

• Cool light: In contrast to most light sources, LEDs radiate very little heat in the form of IR that can cause damage to sensitive objects or fabrics. Wasted energy is dispersed as heat through the base of the LED.

• Slow failure: LEDs mostly fail by dimming over time, rather than the abrupt failure of incandescent bulbs.

• Lifetime: LEDs can have a relatively long useful life. One report estimates 35,000 to 50,000 hours of useful life, though time to complete failure may be longer. Fluorescent tubes typically are rated at about 10,000 to 15,000 hours, depending partly on the conditions of use, and incandescent light bulbs at 1,000 to 2,000 hours. Several DOE demonstrations have shown that reduced maintenance costs from this extended lifetime, rather than energy savings, is the primary factor in determining the payback period for an LED product.

• Shock resistance: LEDs, being solid-state components, are difficult to damage with external shock, unlike fluorescent and incandescent bulbs, which are fragile.

• Focus: The solid package of the LED can be designed to focus its light. Incandescent and fluorescent sources often require an external reflector to collect light and direct it in a usable manner. For larger LED packages total internal reflection (TIR) lenses are often used to the same effect. However, when large quantities of light are needed many light sources are usually deployed, which are difficult to focus or collimate towards the same target.

Disadvantages

• High initial price: LEDs are currently more expensive (price per lumen) on an initial capital cost basis, than most conventional lighting technologies. As of 2012, the cost per thousand lumens (kilolumen) was about $6. The price was expected to reach $2/kilolumen by 2013 At least one manufacturer claims to have reached $1 per kilolumen as of March 2014The additional expense partially stems from the relatively low lumen output and the drive circuitry and power supplies needed.

• Temperature dependence: LED performance largely depends on the ambient temperature of the operating environment – or "thermal management" properties. Over-driving an LED in high ambient temperatures may result in overheating the LED package, eventually leading to device failure. An adequate heat sink is needed to maintain long life. This is especially important in automotive, medical, and military uses where devices must operate over a wide range of temperatures, which require low failure rates. Toshiba has produced LEDs with an operating temperature range of -40 to 100 °C, which suits the LEDs for both indoor and outdoor use in applications such as lamps, ceiling lighting, street lights, and floodlights.

• Voltage sensitivity: LEDs must be supplied with the voltage above the threshold and a current below the rating. Current and lifetime change greatly with a small change in applied voltage. They thus require a current-regulated supply (usually just a series resistor for indicator LEDs).

• Light quality: Most cool-white LEDs have spectra that differ significantly from a black body radiator like the sun or an incandescent light. The spike at 460 nm and dip at 500 nm can cause the color of objects to be perceived differently under cool-white LED illumination than sunlight or incandescent sources, due to metamerism, red surfaces being rendered particularly badly by typical phosphor-based cool-white LEDs. However, the color-rendering properties of common fluorescent lamps are often inferior to what is now available in state-of-art white LEDs.

• Area light source: Single LEDs do not approximate a point source of light giving a spherical light distribution, but rather a lambertian distribution. So LEDs are difficult to apply to uses needing a spherical light field; however, different fields of light can be manipulated by the application of different optics or "lenses". LEDs cannot provide divergence below a few degrees. In contrast, lasers can emit beams with divergences of 0.2 degrees or less.

• Electrical polarity: Unlike incandescent light bulbs, which illuminate regardless of the electrical polarity, LEDs will only light with correct electrical polarity. To automatically match source polarity to LED devices, rectifiers can be used.

• Blue hazard: There is a concern that blue LEDs and cool-white LEDs are now capable of exceeding safe limits of the so-called blue-light hazard as defined in eye safety specifications such as ANSI/IESNA RP-27.1–05: Recommended Practice for Photobiological Safety for Lamp and Lamp Systems.

• Blue pollution: Because cool-white LEDs with high color temperature emit proportionally more blue light than conventional outdoor light sources such as high-pressure sodium vapor lamps, the strong wavelength dependence of Rayleigh scattering means that cool-white LEDs can cause more light pollution than other light sources. The International Dark-Sky Association discourages using white light sources with correlated color temperature above 3,000 K.

• Efficiency droop: The luminous efficacy of LEDs decreases as the electric current increases. Heating also increases with higher currents which compromise the lifetime of the LED. These effects put practical limits on the current through an LED in high power applications.

• Impact on insects: LEDs are much more attractive to insects than sodium-vapor lights, so much so that there has been speculative concern about the possibility of disruption to food webs.

• Use in winter conditions: Since they do not give off much heat in comparison to traditional electrical lights, LED lights used for traffic control can have snow obscuring them, leading to accidents.

COST ESTIMATION

Plant Capacity                           80,000 Nos/Day  

Land & Building (2000 sq.mt.)  Rs. 2.96 Cr    

Plant & Machinery                       Rs. 1.78 Cr 

Working Capital for 1 Month    Rs. 12.36 Cr 

Total Capital Investment            Rs. 17.36 Cr 

Rate of Return                              30%

Break Even Point                          44%

• INTRODUCTION
  
• TYPES OF LED
• (1) MINIATURE
• THERE ARE THREE MAIN CATEGORIES OF MINIATURE SINGLE DIE LEDS:
• (2) MID-RANGE
• (3) HIGH-POWER
• (4) AC DRIVEN LED
• ADVANTAGES
• DISADVANTAGES
• TECHNOLOGY OVERVIEW OF LED BULB
• LED LAMPS BULB
• WHITE LIGHT LEDS
• COLOR CHANGING LED LIGHTING
• LED DRIVERS
• THERMAL MANAGEMENT
• EFFICIENCY DROOP
• HOUSEHOLD LED LAMP
• LAMP SIZES AND BASES
• HOW LEDS PRODUCE LIGHT
• WHITE LIGHT LED TECHNOLOGY FOR GENERAL ILLUMINATION
• THE MANUFACTURING OF WHITE LIGHT LEDS
• MANUFACTURING PHASES OF PACKAGED WHITE LIGHT LED ASSEMBLY
• SUBSTRATE PRODUCTION
• 1. PREPARATION OF THE SEMI-CONDUCTOR WAFERS
• 2. ADDING EPITAXIAL LAYERS
• LED DIE FABRICATION PROCESS
• PACKAGING THE LED ASSEMBLY
• FINISHED PACKAGED LED, THE PHILIPS LUXEON REBEL: AN ILLUSTRATION
• RAW MATERIALS
• VARIOUS MATERIALS USED FOR MULTI-COLOUR LEDS
• LED LAMP CHARACTERISTICS
• TREND FOR LED RETROFIT LAMP CHARACTERISTICS IN INDIA
• USES AND APPLICATION
• USES
• (1) POWER SOURCES
• (2) ELECTRICAL POLARITY
• (3) SAFETY AND HEALTH
• APPLICATIONS
• LED USES FALL INTO FOUR MAJOR CATEGORIES:
• B.I.S. SPECIFICATIONS
• FOR MORE INFORMATION CONTACT AT:
• MARKET OVERVIEW OF LED BULBS IN SAUDI ARABIA
• MANUFACTURERS/SUPPLIERS OF LED BULB
• METHOD OF MANUFACTURING LED BULBS
• ASSEMBLY OF LED LAMPS
• PROCESS FLOW CHART
• MANUFACTURING PROCESS IN DETAILS
• (A) MANUFACTURING OF LED
• SUBSTRATE MANUFACTURING
• INORGANIC SEMICONDUCTOR MANUFACTURING
• EPITAXIAL PROCESS
• PHOSPHOR MANUFACTURING
• LIGHT-EMITTING DIODE ASSEMBLY AND PACKAGING
• LED MOUNTING ON PCB
• 1: THROUGH HOLE COMPONENT MOUNTING
• 2: SMD PICK AND PLACE MACHINE
• 3: SOLDER PROCESS
• 4: REFLOW SOLDERING PROCESS
• 5: REPAIR AND REWORK
• LED BULB ASSEMBLY PROCESS IN DETAILS
• DETAILS OF DIE CASTING
• TWO TYPES OF DIE CASTING MACHINES
• HOT CHAMBER DIE CASTING MACHINES
• COLD CHAMBER DIE CASTING MACHINES
• CASTING MUST INCLUDE A PART-REMOVAL DESIGN
• CASTING PARTS WITH CAVITIES
• CASTING FOR LIGHT WEIGHT AND STRENGTH
• THE PROCESS OF CASTING ALUMINUM
• DIE CASTING
• TYPES OF PRESSURE DIE CASTING
• TYPES OF PRESSURE DIE CASTING
• HIGH PRESSURE DIE CASTING
• HIGH PRESSURE DIE CASTING PROCESS
• TYPES OF HIGH PRESSURE DIE CASTING:
• HOT CHAMBER PROCESS
• COLD CHAMBER PROCESS
• LOW PRESSURE DIE CASTING
• LOW PRESSURE DIE CASTING PROCESS
• PRESSURE DIE CASTING
• ADVANTAGES OF PRESSURE DIE CASTING:
• MANUFACTURING STEPS IN DIE CASTING
• PREPARATION
• FILLING
• INJECTION
• SHAKE OUT
• DEFECT INSPECTION
• MANUFACTURING MACHINES
• MACHINES FOR LED MANUFACTURING
• MACHINES FOR LED ASSEMBLY
• DRILL MACHINE: FOR VARIOUS DRILLING JOBS
• TESTING EQUIPMENT FOR LED
• ELECTRONIC COMPONENT TESTING EQUIPMENT
• EQUIPMENT FOR ASSEMBLY
• ENVIRONMENTAL ASSES REPORT ON LED TUBE AND BULB
• FIGURE 4-1 LED PACKAGE
• FIGURE 4-2. LED LAMP
• LIFE CYCLE FLOWS AND PROCESSES
• OVERVIEW
• FIGURE 4-3. MATERIALS FLOW FOR LIGHT-EMITTING DIODE LAMP
• RAW MATERIALS EXTRACTION AND PROCESSING
• LED CHIP
• CRYSTALS AND SUBSTRATES
• TABLE MATERIALS BY COLOR PRODUCED
• LED PACKAGE (HOUSING)
• THE TYPICAL LED PACKAGE CONTAINS:
• LED LAMP
• MATERIALS INVENTORY FOR LED LAMP FROM THE OSRAM STUDY
• LED PACKAGE (HOUSING)
• LAMP
• SUPPLIERS OF PLANT AND MACHINERY [IMPORTED]
• SUPPLIERS OF PLANT AND MACHINERY
• SUPPLIERS OF PLANT AND MACHINERY FOR LED TUBE 
•    AND BULB [IMPORTED]
• SUPPLIERS OF RAW MATERIAL FOR LED TUBE AND BULB
• 
  

APPENDIX – A:

01. PLANT ECONOMICS

02. LAND & BUILDING

03. PLANT AND MACHINERY

04. OTHER FIXED ASSESTS

05. FIXED CAPITAL

06. RAW MATERIAL

07. SALARY AND WAGES

08. UTILITIES AND OVERHEADS

09. TOTAL WORKING CAPITAL

10. TOTAL CAPITAL INVESTMENT

11. COST OF PRODUCTION

12. TURN OVER/ANNUM

13. BREAK EVEN POINT

14. RESOURCES FOR FINANCE

15. INSTALMENT PAYABLE IN 5 YEARS

16. DEPRECIATION CHART FOR 5 YEARS

17. PROFIT ANALYSIS FOR 5 YEARS

18. PROJECTED BALANCE SHEET FOR (5 YEARS)