Sweeping LEDS
1. Introduction:
LED Configuration:
Total of 10 LEDs arranged in a line, each 5mm apart.
LEDs should be orange in color.
LEDs will light up sequentially in a sweeping pattern (i.e., LED1 ON → LED2 ON →
LED3 ON, etc.), with each LED ON for 50ms.
Power Supply:
The product will be powered from a 24V AC source.
An appropriate AC to DC conversion circuit is needed (e.g., a rectifier and smoothing
capacitor) to provide a suitable DC voltage for the LEDs.
LED Driver Circuit:
A hardware-based timing circuit (e.g., using a 555 timer or other discrete components)
can be employed to create the sweeping effect without needing a microcontroller.
A series of transistors can be used to switch the LEDs ON and OFF based on the timing
circuit outputs.
Component Placement:
LEDs will be mounted on the top side of the PCB.
All other components (resistors, capacitors, diodes, transistors) will be placed on the
bottom side of the PCB to meet the design requirement.
Surface Mount Technology (SMT):
All components should be SMT compatible for efficient mass manufacturing.
Choosing standard package sizes (e.g., 0805 for resistors/capacitors, SOT-23 for
transistors) can facilitate sourcing and assembly.
AC to DC Conversion:
o Use a bridge rectifier circuit to convert the 24V AC input into DC voltage. Use
diodes (e.g., 1N4007 in SMT packages) and a smoothing capacitor (e.g., 470µF)
to filter the DC output.
o To step down the rectified DC voltage to a suitable level, use a voltage regulator
(e.g., LM7812 in SMT) to provide 12V DC.
Timing and Control Circuit:
o Add a 555 Timer IC in astable mode to generate a clock pulse with a period of
100ms (50ms per LED in the sweeping sequence). Set the values of the timing
resistor and capacitor based on the desired output frequency.
o Connect the 555 Timer’s output to a 4017 Decade Counter IC. This IC will
sequentially activate each of its 10 outputs with every clock pulse, enabling the
sweeping effect for the LEDs.
LED Driver Circuit:
o Each output of the 4017 is connected to a current-limiting resistor (SMT, e.g.,
470Ω) and then to the base of an NPN transistor or N-channel MOSFET
(depending on current requirements) to drive each LED.
o Each transistor or MOSFET will switch its respective LED ON for 50ms before
moving to the next LED in the sequence.
LED Arrangement:
o Connect 10 orange SMT LEDs (arranged 5mm apart) on the output side of the
transistors.
2. Simulation in Proteus
After creating the schematic, run a simulation in Proteus to ensure:
o The 555 Timer generates the correct frequency.
o The 4017 counter sequences each LED ON for 50ms before moving to the next.
o Verify that all LEDs light up sequentially, creating the sweeping effect.
Troubleshooting: Adjust timing components or verify connections if the LEDs don’t light up as
expected.
3. PCB Layout Design
Component Placement:
o Place all LEDs on the top layer in a straight line with 5mm spacing.
o Place the remaining components (rectifier, capacitors, 555 Timer, 4017 IC,
resistors, and transistors) on the bottom layer to satisfy the design requirements.
Routing and Spacing:
o Route all signal and power traces, ensuring wide traces for the main power lines
to handle current requirements.
o Keep the traces for the 555 Timer and 4017 IC as short as possible to maintain
signal integrity.
o Add test points for input voltage, 555 Timer output, and 4017 counter outputs to
facilitate easy testing during manufacturing.
4. Design Report with DFT, DFM, and BOM
Design for Manufacturing (DFM):
o Select components that are standard SMT packages (e.g., 0805 resistors, 1206
LEDs) for ease of sourcing and automated assembly.
o Use widely available components to reduce costs and ease procurement for large-
scale manufacturing.
Design for Testability (DFT):
o Include test points for power, ground, and key signal lines.
o Ensure the design includes a simple method to test each LED and verify that it
lights up in sequence.
Bill of Materials (BOM):
o Create a detailed BOM listing all components, including component values,
package types, and quantities.
Sr Components Quantit Price
y
1 Timer 555 1 10usd
2 Ic counter 1 10usd
3 LEDs 10 10usd
4 Resistors 10 10usd
5 Rectifier diode 1 20usd
6 Capacitors 2 5usd
5. Testing Plan and Pass/Fail Criteria
Test Method:
o Power on the circuit and verify that each LED lights up sequentially in the
sweeping pattern.
o Measure the voltage and timing at each test point:
Confirm the 12V DC output from the power conversion stage.
Check the output frequency of the 555 Timer to ensure it is around 10Hz
(100ms period).
Verify that each LED turns ON for 50ms as expected, using an
oscilloscope if possible.
Pass/Fail Thresholds:
o LEDs should sequentially light up in the correct order with a 50ms interval. Any
deviation from this pattern (e.g., incorrect sequence, LEDs remaining ON)
indicates a failure.
o The circuit should maintain consistent functionality over time, with each LED
remaining ON for 50ms and the entire sequence restarting continuously.