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Kundapplikation 27 augusti 2021

Små plintar leder till stora framsteg

OSRAM bidrar till utvecklingen av den globala belysningsmarknaden med sin nya LED-driver, som bara är 11 millimeter tjock. En viktig komponent i denna innovation är de extremt kompakta, lättanvända 2060-seriens SMD PCB-plint från WAGO.

När tusentals besökare strosade runt i utställningarna på Light+Building 2016 bildades en folkmassa runt OSRAM-montern. "Vi har redan väckt en hel del uppmärksamhet med vår nya LED-driver", säger Nicolai Heber, produktchef för LED Drivers & Industrialization på OSRAM, och påminner om mässan. Detta är lite av en underdrift, med tanke på att OSRAMs nya innovation nästan stal showen från de andra producenterna.

Och det är inte konstigt – den nya linjära drivern från "OPTOTRONIC Intelligent"-serien heter "UltraFlat", och med en tjocklek på bara 11 millimeter är anledningen tydlig. Men trots sin miniatyrdesign ger föraren upp till 75 watt, är utrustad med ett motsvarande temperaturhanteringssystem, stöder DALI och kan även programmeras med trådlös teknik för Near Field Communication (NFC) – dock inte viaDALI eller LEDset.

Den München-baserade ljusspecialisten öppnar upp helt nya dimensioner med sin nya driver. Medan standardtjockleken på LED-enheter en gång var 30 millimeter, krympte den för cirka 15 år sedan till 21 eller 22 millimeter – och det är där standarden har legat kvar fram till nu. Med andra ord, medan LED-modulerna blev plattare och plattare, ändrades knappast formen på kontrollutrustningen.

OSRAM tillför nu ny dynamik på marknaden – och skapar stora konkurrensfördelar för belysningstillverkarna. Redan från början var vår idé att tillhandahålla en ultraplatt LED-driver för high-end belysningssegmentet. "Framför allt är vårt mål att imponera på kunder med attraktiv design, till och med mer än kostnader och energieffektivitet", säger Heber och beskriver marknadens krav från tillverkarnas synvinkel. Det var trots allt tillverkarna som sa till OSRAM att de ville ha en tunnare driver. Men i början av utvecklingsprocessen var det inte alls klart hur tunn den nya drivern faktiskt kunde vara, säger Heber. OSRAMs ljusdesigners ville erbjuda ett tydligt mervärde, så de satte upp ett mål att halvera drivertjockleken. Efter mer än ett år av att utforska möjligheter stod det klart att måltjockleken på 11 millimeter skulle vara genomförbar. Men det fanns ytterligare en begränsning: den tunna designen kunde inte tillåtas att äventyra funktionaliteten. Även i en platt kapsling måste höga krav upprätthållas vad gäller livslängd, temperaturbeständighet, ljuskvalitet och andra tekniska detaljer.

OSRAM och WAGO

  • Teknik för enkel anslutning
  • Automatiserad ledningsdragning är ett måste
  • Drivers kommer att erbjuda ännu fler funktioner i framtiden

Teknik för enkel anslutning

Halva tjockleken för dubbelt så stor designfrihet – att uppnå det innebar enorma utmaningar för de enskilda komponenterna i drivern. Det fanns dock ett område där FoU-teamet inte behövde oroa sig mycket: anslutningstekniken. Osrams ingenjörer kunde förlita sig på 2060 seriens SMD PCB plintar från Wago för deras ultratunna LED drivers. Dessa plintar från Minden i Nordrhein-Westfalen, som introducerades för cirka fyra år sedan, är bland de minsta som finns på marknaden. "WAGO-plintar var avgörande för att göra denna produktdesign till verklighet", säger Heber. Som han förklarar: "De kombinerar två viktiga fördelar: De är extremt små och möjliggör även praktiska, bekväma ledningar."

LED-Treiber.jpg

Automatiserad ledningsdragning är ett måste

Fem enpoliga radplintar är installerade på den interna sidan av OSRAM-drivern, med två trepoliga radplintar på den externa sidan. WAGOs plintar i 2060-serien är bara 4,5 millimeter tjocka. De är konstruerade för ledararea från 0,2 till 0,75 millimeter. "Det är idealiskt för att hålla PCB extremt platta. Plintarna tillåter även automatiserad kabeldragning. Nuförtiden är det ett absolut måste”, förklarar Heinz-Werner Hilgenberg, marknadschef för PCB Applications & Lighting på WAGO. Liksom i andra projekt var WAGO-experten nära involverad i utvecklingen av den nya drivern. Det är viktigt för anslutningstekniken att erbjuda en hög grad av flexibilitet så att tillverkarna har den frihet de behöver för produktdesign", säger Hilgenberg och sammanfattar kärnan i sin erfarenhet. Många tillverkare har redan börjat inse fördelarna med de små radplintarna och använda dem för att producera innovativa LED-moduler, till exempel. Nu spelar 2060-serien också en ledande roll i vidareutvecklingen av LED-enheter.

osram logo.jpg

Drivers kommer att erbjuda ännu fler funktioner i framtiden

Under strikt sekretess skapades andra helt nya komponenter till den nya OSRAM-drivern i nära samarbete med både leverantörer och flera belysningstillverkare. Det centrala styrchippet har till exempel, även om det är mindre än vanligt, ännu fler funktioner och spolen har också specialanpassats. De första förproduktionsmodellerna av den nya drivern var klara lagom till Light+Building. Ett antal OSRAM-partners kunde presentera ovanligt platta LED-armaturer på Light+Building. Även dessa företag väckte stor uppmärksamhet. Drivern genomgår för närvarande tester i olika länder för att få motsvarande certifiering. Drivern har varit tillgänglig sedan augusti 2016. Under de kommande månaderna kommer även en 11 millimeter tjock dagsljusskörd och närvarosensor att läggas till det ultraplatta systemet. Heber tror att LED-drivers kommer att bli ännu mer intelligenta inom en snar framtid. "Med den här produkten i sin nuvarande form är det redan möjligt att läsa ut data som förbrukningstimmar. Vi kommer definitivt att se fler och fler sådana här funktioner, särskilt med tanke på smarta nätapplikationer.” Och Heber förutser också att NFC kommer att bli en standardfunktion på vissa marknader på medellång sikt. "Detta visar hur stort ett steg framåt vi har tagit när det gäller modulstorlek", säger Heber sammanfattningsvis. Men vi har inte heller hört sista ordet i detta ämne.

Av Patrick Schirrmacher | 2016-08-30

Foto: Stephan Görlich/vor-ort-foto.de

Produktöversikt

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WAGO på arbetet

Kundapplikationer inom belysningsteknologi

Ekonomisk LED-teknik

På grund av föråldrad belysningsteknik är gatubelysning en energikostnadsfälla. Det modulära ljussystemet från Nordeon förändrar allt detta – med WAGO-teknik.

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Din WAGO kontaktperson

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Full fart framåt: Oavsett om det gäller skeppsbyggnad eller onshore/offshore-applikationer, kombinerar WAGO innovation med tillförlitlighet och flexibilitet för att göra det till den föredragna partnern för många fartygsleverantörer.

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In i den digitala framtiden: Energisektorn står inför stora utmaningar på alla områden. Intelligent nätverk och innovativa lösningar från WAGO hjälper till att möta dessa utmaningar.

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