Engineering
Circuit Strategy
We focus on efficient power conversion, protection and thermal management while ensuring reliable operation and ease of integration with other systems.
Our designs include a variety of components from full wave bridge rectifiers that convert AC through to additional capacity and into to smooth DC.
The input AC undergoes filtering and regulation twice: once at the 240V input stage and again at the 40V stage, ensuring an ultra-low ripple output.
Component Design and Selection
We carefully choose the finest components, leveraging our understanding of material lifespans and using long term established data to accurately predict their longevity.
PCB Design
We utilise double-sided PCBs where the components are soldered on both sides of the board. Many competitors often use single-sided PCBs, which are prone to fail from dry joints. Dry joints can form due to mechanical vibrations and thermal cycling over time. We also use 2 oz copper content to enhance the heat dissipation.
Terminal Blocks
Most of our drivers use terminal blocks with a press system using high tensile springs. This innovation has allowed us increased production efficiency, effectively reducing assembly time.
NTC Thermistors
When the lights are first switched on, there is an initial power surge that can stress components, especially in systems with multiple lights (e.g., multiple track spots). Our drivers incorporate these NTC (Negative Temperature Coefficient) thermistors to suppress these inrush voltage spikes, thus prolonging component life.
Capacitors
The capacitors typically have the lowest life expectancy of any electronic device. We use larger-sized mains capacitors rated at 450V and higher, while most competitors use lower 400V types. Most of our drivers incorporate four output capacitors, compared to the one or two used by most competitors.
Component Spacing
We use proper spacing of components to facilitate better heat dissipation.
Flicker-free circuitry
Our circuits were some of the first on the market with a dedicated ripple and flicker-free IC. These circuits are now becoming mandatory in LED drivers.
Assembly and Testing
We rigorously test for reliability by running the drivers in harsh conditions and over extended periods to observe their performance and identify any potential issues.
Overheating
- Each component undergoes thermal testing to identify any overheating issues.
- Any Indicators signify overheating, prompting a feedback loop for improvement.
Thermal Management
- We test our fittings at 45°C, while most of our competitors test them at 25°C.
- These tests include placing fittings in an oven and logging the results with thermal probes.
- We also test some of our driver models in high heat environments of up to 75°C.
Quality Control
We focus on identifying any issues related to driver failures and maintain a continuous feedback loop for checks and improvements directly to our production process.
