A Report On

“
LED BULB”
Submitted In Partial Fulfilment of the Requirement
For The Award of second year ITI
In Electrician of
Techniche pvt ITI Hunsur
Submitted By

Guide

PPL. PUNEETH R

Department of Industrial training & institute

Techniche pvt ITI Hunsur
 Certificate

This is to certify that Mr. Nidhigowda B M has successfully completed his Report on
“LED BULB” for the partial fulfillment of the second year electrician in the as prescribed by
Department of Industrial training & institute
Techniche pvt ITI Hunsur
during academic year2024-2026.

Team member
Paramesha S C
Ravikumara
Rohith odisomastha
 DECLARATION

I hereby declare that the seminar report entitled, “DC motor” was carried out and written
by me under the guidance of [Link] R, Departmentof Industrial training &
institute Techniche pvt ITI Hunsur,.This work has not been previously formed the basis for
the award of any ITI or certificate nor has been submitted elsewhere for the award of any ITI.

Place:
Date:
 CONTENTS

1. INTRODUCTION
2. CHARACTERISTICS
3. METHODOFOPERATION
4EFFICIENCY
[Link]
[Link]
[Link]
[Link]
[Link]
10. RAWMATERIAL
11. ABOUTRAWMATERIAL
12. LEDBULBMANUFACTURINGPROCESS
 LEDBULB
INTRODUCTIO
N
Light Emitting Diode (LED) is a relatively old
technology,
circa1970,thathasadvancedfromnumericdisplaysandindicatorlightsto
a
rangeofnewapplications,includingexitsigns,accentlights,tasklights,traffic
lights,automobilelighting,signage,wallsconces,andoutdoorlightingand
downlighting.

LEDsofferbenefitssuchassmallsize,longlamplife,lowheatoutput,energ
y
[Link]
or
changing,dimminganddistributionbycombiningthesesmallunitsinto
desiredshapes,colors,sizesandlumenpackages.

Characteristics
[Link]
d
whenasemiconductorcrystalisexcitedsothatitdirectlyproducesvisible
lightinadesiredwavelengthrange(color).LEDunitsaresmall,typically5m
m (T1-3/4).

MethodofOperation
WhenanLEDunitisactivated,apowersupplyconvertsACvoltageinto
sufficientDCvoltage,whichisappliedacrossthediodesemiconductor
[Link](negativechargecarriers[N])inthediode’
s
electrontransportlayerandholes(positivechargecarriers[P])inthediod
e’s holetransportlayercombiningattheP-
Njunctionandconvertingtheirexcess
[Link]
providearangeofangulardistributionsofthelight.
Efficency
LEDsarelow-voltage,low-
[Link],
amber,yellow,greenandblueLEDs,newmaterialshavebeendevelopedt
hat
aremoreefficientthantraditionalmaterials,producingefficacies(lumens
per
watt)greaterthanincandescentlampsandrivalingfluorescentlamps.A.
Efficaciesashighas100LPWhavealreadybeenachievedinlaboratory
[Link],groupleaderoflightingresearchf
or
theLawrenceBerkeleyNationalLaboratory,“Itisnotunrealistictoexpectt
he efficacyofsolid-statesourcestoachieve150-
200lumensperwattinthe comingdecades.”

WhiteLightLEDs
Theutilizationofindiumgalliumnitride(InGaN)asasemiconduct
or
materialresultedinthebrightestLEDsandenableddevelopmen
tof whitelightLEDs.

WhitelightLEDsfeatureaphosphoraddedtoablueLEDthat
convertssomeofthelightemissionintoyellow,resultinginablui
sh-
[Link]
spectrumofcorrelatedcolortemperaturesof4,000-
11,[Link]
lightcanalsobeachievedbycolormixingthelightproducedbyre
d, blue andgreen LEDs.-END-
FlowofCurrent

LEDpowersupplyconvertstheincomingACvoltagetoaDCvoltagesuitable for
powering your LED lightingsystem. This processinvolves regulating the
output voltage and current to ensure a stable and consistent power supply,
[Link] supply
also provides protection against overvoltage, overcurrent, and short circuits,
ensuring the safety and longevity of your LED lighting system.

The efficiency of LED power supply is a crucial factor to consider when

[Link]-efficiency
power supply reduces power consumption, generates less heat, and extends
the lifespan of your LEDs. The efficiency rating of LED power supply is
expressed as a percentage and ranges from 70% to 95%. It's advisable to
choose a power supply with an efficiency rating of at least 80% to ensure
optimal performance and longevity of your LED lighting system.

LED power supply also comes in various types, including constant voltage,
constant current, and dimmable power supplies. Constant voltage power
supply is suitable for powering LED strips and modules, providing a stable
voltage output. Constant current power supply is ideal for powering LED
drivers and high-power LEDs, providing a constant current output. Dimmable
powersupplyallowsyoutocontrolthebrightnessofyourLEDlightingsystem,
making it suitable for applications that require adjustable lighting levels.

Installing LED power supply is simple and straightforward, with various

options for mounting, including surface mount and panel mount. LED power
supplyisalsoavailableinvarioussizesandcapacities,allowingyoutochoose the
best option that suits your specific LED lighting requirements.

In conclusion,LEDpower supplyis an essentialcomponent ofanyLEDlighting

system, providing the necessary electrical power, regulating the voltage and
current, and protecting your LEDs from damage. Choosing a reliable and
efficientLEDpowersupplyensuresoptimalperformanceandlongevityofyour
LED lighting system. With various types, sizes, and capacities available, LED
powersupplyoffersasolutionthatsuitsanyLEDlightingrequirement,making it a
crucial backbone of your LED lighting system.

ApplicationofLEDBulb

[Link]
colouredlightisneeded,LEDsthatinherentlyemitlightofasinglecolour
[Link]-lightLEDbulbhavelongerlife
expectancyandhigherefficiency(morelightforthesameelectricity)than
[Link]
e
compact,whichgivesflexibilityindesigninglightingfixturesandgoodcont
rol
[Link]
smallsizeofLEDs,controlofthespatialdistributionofilluminationis
extremelyflexible,andthelightoutputandspatialdistributionofanLEDarra
y [Link]-mixing
principlecanemitawiderangeofcoloursbychangingtheproportionsoflig
ht
[Link]
th LEDs of differ.

Energyconservation

Withthegrowingenergyneedsandshortagecoupledwithrisingenergyco
st,a
greaterthrustinenergyefficiencyinindustrialsectorhasbeengivenbyGo
vt.
ofIndiasince1980s.TheenergyConservationAct2001hasbeenenacte
don
18thAugust2001whichprovidesforefficientuseofenergyitsconservati
on
andcapacitybuildingofBureauofEnergyEfficiencycreatedundertheact.T
he
followingstepsmaybehelpforconservationofElectricalEnergy:i)Adopti
on
ofenergyconservingtechnology,[Link])
Efficientmanagementofprocess/manufacturingmachineriesandsyste
ms,
QCandtestingequipment’[Link]
i)
Optimumuseofelectricalenergyforheatingduringsolderingprocessca
nbe
obtainedbyusingefficienttemperaturecontrolledsolderingandDEsolder
ing
[Link])Periodicalmaintenanceofmotorscompressorsetc.v)Useof
powerfactorcorrectioncapacitors,properselectionandlayoutoflighting
systemstimelyswitchingon/offofthelights,useofCompactFluorescent
Lamps wherever possible.

DescriptionofLEDBulb

MachineMachineryforLEDBulbUnitincludesthefollowing:

>TikkiMakingMachine

> PunchingMachine

>Cutter

>Iron

>Solder

> Nuts
>HeatsinkPaste
 TIKKIMACHINE

ThisMachineassistyoutosuitMCPCBintohousingBody(lodging)at
quicker speed with more precision. Our LEDTikkiFittingMachineis
extremely low cost in value and high in quality, as we put very
low margin to form a relationship with clients and encourage
them to begin their own business with smaller investment.
Themosteffective methodtoUseTikkiFittingMachine:
TawangTikkiFittingMachinewillassist youtopressthealuminium plate (
heat sink) to the degree of your lodging (housing) [Link]
BulbTikkiFittingMachineusedforlodging(housing)likePhilipstype
(180 degree) and Syska type (270 degree). Other Name of
TikkiFitting Machine is LED Bulb Heat Sink Pressing Machine or Tikki
Pressing Machine.
LEDTikkiFittingMachinecomeswith5components
 (1).PressMachine
 (2).SmallSizelodging(housing)45MMTo 57MM
 (3).BigSizeBulblodging(housing)holder58MMTo95MM
 (4).PressureDieForSmallSizeHeatSinkPlate
 (5).PressureDieForBigSizeHeatSinkPlate
 (6). Fitand adjustthetiny size heat sinkpressure
diewithinthe Nozzle ofpowerPress Machine andplacethe
smallsize Bulb
lodging(housing)holderbeforethePressMachinenozzlefitt
ed
 with small size pressure die. Now, place the LED Bulb B22 part
ofhousinginthemiddleofhousingholderandplacetheheatsi
nkon
theupperpartofhousingandpressthenozzledownside.
currentlyyouwillseeyourhousingisfittedwiththeheatsinkplate.
BenefitsofTawangTikkiFittingMachine/LEDHeatSinkFitting
Machine

PUNCHINGMACHINE
Stampingistheprocessofforcingasteelpunchthroughaworkpiec
e to
[Link],thepunchingpr
ocess is to cut a shape of waste material from the finished
product. The diameter of the punch determines the size of the
hole formed on the workpiece.
ObservingtheLEDlightfixturesarounduscanactually revealthatthereare
some lighting components on the base or shell of some LED light
 fixtures.
ThesecomponentsareusuallyembeddedinthebaseorhousingofLED
batten lights. So it will be necessary to use punching processing
technology topunchaholeonthe baseorshell ofthe
LEDlamp,sothatthecomponent module can be embedded in the
base or shell.

SOLDERINGIRON
Solderisaconductivematerialthatmeltsaround400degreeFahren
heit and allows two pieces of metal to connect in a circuit. A
standard ‘point-to-point’connection is two leads,letssaythe
cathodeofanLED andthe anode of a second LED twisted and
soldered together; this is more efficient than simply just
twisting leads together. Another common type
ofsolderconnectionisfoundonPCBsandMCPCBs,wherethereare
conductive traces in a board that lead to components where a
solder connectionismade. Most ofthe soldering we encounter is
withLEDs on
MCPCB,which youcanseeontheright

HEATSINKPASTE
A heat sinkis a part with alarge surface areaconsisting of thermally
[Link]
ard components,including power transistors and switching
devices. The purpose of this part is to absorb and dissipate heat.
[Link],
heattransfersfromareasofhighthermalresistancetoareasoflowtherm
al resistance, and areasof high heat to areasof low heat. Because
heat sinks are made of aluminum or copper, which both have
excellent thermal
conductivityandlowthermalresistance,theheatwillnaturallymovefro
m PCB components to the heat sink.
LEDMARKETANALYSIS

The LEDLightingMarketsizeisestimatedat46.54billion
USDin2024,and is expected to reach 65.13 billion USD by 2030,
growing at a CAGR of 5.76% during the forecast period (2024-
2030).
RAWMATERIALS
> MCPCB
> DRIVER
> B22NICKLERIVIT
> BODY OF BULS
> HOUSING OF BULBS
> SCREWS

MCPCB
Metal-Core Printed Circuit Boards (MCPCBs) are designed to
provide high-poweroutputina
[Link] LED that has
been soldered to an MCPCB.
DOBMCPCB
A DOB lighting system uses only solid state driver components
which are available in surface-mount packages capable of being
assembled on circuit boards with a single-sided copper
construction. This makes it possible to
mountdrivercomponentsametal-
coreprintedcircuitboard(MCPCB)where LEDs are mounted.
Typically, the driver is designed as a linear power supply. Since
there is no high frequency switching, electromagnetic interference
(EMI) is practically absent in linear power supplies. The complete
absence of EMI radiation allows linear power supplies to be
designed with asignificantly reduced parts count. The small circuit
parts count and small form factor of circuit components contribute
a small footprint of the driver, which introduces minimal impact on
the LED assembly when it comes to photometric performance. The
drive current is regulated by small driver ICs without using
electrolytic capacitors. The weakest component with the shortest
life expectancy determines the life of the driver. The removal of

electrolytic capacitors translates to significantly improved driver

reliability.
LEDDRIVER
AnLEDdriverisaselfcontainedpowersupplywhichregulatesthepower required
for an LED or array of LEDs. The light emitting diodes are low
energy,lightingdeviceswithalonglifespanandlow energyconsumption, hence
the requirement for specialized power supplies.
 Provideslow voltage
IndividualLEDbulbsoperateatvoltagesrangingfromabout1.5to3.5 volts
and currents of up to a maximum of 30mA. The domestic bulbs may
consist of several bulbs, in series and parallel combinations and which
requires a total voltage of between 12 and 24 V DC. The LED driver
rectifies the AC and lowers the level to suit the requirements.
ThismeansconvertingthehighACmainsvoltagewhichrangesfrom 120
Volts to 277Volts, to the required low DC voltage.

 ProvidesprotectiontotheLEDbulbs
The LED drivers provide protection to the LED bulbs against current
and voltage fluctuations. The drivers ensure that the voltage and
current to the LED bulbs remains within the operating range of the
LEDs regardless of fluctuations in the mains supply. The protection
avoidsprovidingtoomuchvoltageandcurrentthatwoulddegradethe LEDs
or too low current that would reduce the light output.
 SEMIDOBDRIVER
AC DOB (Driver-On-Board) LED chips are a pivotal innovation in
lighting technology, designed to operate directly from alternating
current(AC)[Link] LED
chips is prevalent in various lighting applications due to their integrated
design and ease of use

ACDOBLEDlightsareefficientandlonglastingfor upto50,000hours which

means you do not incur the cost of replacement. In total, a user can
save about 3 times the regular amount by switching to AC DOB.

INVETERDRIVER
InverterLEDBulbDriver, ACDCLEDBulbMCPCB,
Rechargeable LED
[Link]-quality
varietyofACDCRechargeable/
InverterLEDBulbRawMaterialatwell-timed delivery.

OurpresenteddriversareperfectformakingLEDRechargeableInverter
Lights for their unique quality and high [Link] bulbs emit
soothing light and are energy efficient. They use both direct current and
alternating current for conveying their ideal working.

B22NICKLERIVIT
B22isatype oflampcap.AB22lampmeansalampwiththeB22cap -22mmdia with 2 pins
to hold the lamp in the lamp socket. Also known as Bayonet cap. In normal Indian
term we call it a 2pin cap. Most of our household lamp holders are B22. The
numbers after B indicate the diameter of the lamp cap.
LEDBulbManufacturingProcess
>TakeBody&diffuserofBulbseparately.
>Adjustinthetikki machine.
>NowsolderingthePCBwithdiffuseswire.
>CuttheextrawireinthePCBunit.
>PutB22caponthe PCB.
>Nowpressitwithpunchingmachine.
>Packaging
Machinery&Equipment’srequired
NAME COST

MACHINE 11670RS
G.S.T@16% 1780RS
TOTAL 13450 RS

>CostofthemachineisexclusiveofGST&valueofthemachine
varies with the change in batch size.

Labour Requirement:
4-7ManpowerisrequiredfortheLEDBulbunit. Includes:

2skilled Labour

4UnskilledLabour

RawMaterialRequirementofChalk

>Housing(body,Diffuser,tikky)

>DOB(PCB)
 >B22capwithwire

Preamiumbulbs

Rawmaterials Costperunit
Housing 11.0RS
[Link] 26.5 RS
B22Nicklerivit 2.5 RS
PackingandLeaserprint 3 RS
Totalcost 43RS

Gold bulbs
Raw materials Costper unit
Housing 11.00RS
[Link] 19.00RS
B22Nicklerivit 2.50 RS
PackingandLeaser print 3.00RS
Totalcost 35.5RS

Silverbulbs
Raw materials Costperunit
Housing 11.00RS
M.C.P.C.B 5.5RS
B22nicklerivit 2.5RS
PackingandLeaserprint 3.00RS
Total cost 22.00RS

Inverterbulbs
Rawmaterials Costperunit
Housing 22.00RS
 [Link] 76.00RS[battery=75]
B22nicklerivit 2.5RS
Packingandleaser 6.00RS
Total cost 181.5RS

LEDBulbLicense&registration For
Proprietor:
>ObtaintheGSTregistration.
> Fire/PollutionRegistrationasrequired.
> ChoiceofaBrandNameoftheproductandsecurethenam
e with Trademark if required.
ImplementationSchedule

S.N Activity TimeRequired(in

Months)
1 AcquisitionOfpremises 1
2 Construction(ifApplicable) 1-2Months
3 Procurement&installationofPla 1
nt & Machinery
4 Arrangement ofFinance 1
5 RequirementofrequiredManpow 1
er
TotaltimeRequired(someactiviti 2-3Months
es shall run concurrently)
Conclusion:
Aftercompletionofmanufacturingprocess,productisreadyto
sell in the market. This machine can be installed with low
investment & one can earn a good Margin of profit by
doing this business.

COMPUTATIONOFPRODUCTIONOFLEDBULB

COMPUTATIONOFPRODUCTIONOFLEDBULB

Items tobe Manufactured

LED BULB
Machinecapacity 300BULBFOR
DAY
Machinecapacityperannum 90000PIECE

ProductionofLEDBulb
PRODUCTION CAPACITY BULB
1st YEAR 70% 63,000
2 YEAR 75% 67,500
3 YEAR 80% 72,000
4 YEAR 85% 76,500
5 YEAR 90% 81,000

RawMaterial
 year CAPACITY RATEPER AMOUNT
UTILISATION BULB [[Link]]
1STYEAR 70% 43RS 27.09LAKH
2 YEAR 75% 43.50 29.02LAKH
3 YEAR 80% 43.70 30.96LAKH
4 YEAR 85% 43.80 32.89LAKH
5 YEAR 90% 43.90 34.83LAKH

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reportisforeducationalpurposeandreflecttheviewsoftheindustrywhi
ch are drawn from various research material sources from
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capacity and type of plant and other specific factors/cost directly
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guidance only and must not be considered a substitute for a
competent legal advice provided by a licensed industry
professional.
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