INDUSTRIAL TRAINING REPORT

ON
LUMIRISE PVT LTD
A REPORT WORK SUBMITTED IN PARTIAL FULFILMENT OF THE
REQUIRMENTS FOR THE AWARD OF

DIPLOMA IN
ELECTRONICS AND COMMUNICATION ENGINEERING
SUBMITTED BY BATCH MEMBERS
A. ROHIT KUMAR K. AKSHAY SK. ABDUL KHADARI
B. SRINIVAS TEJA M.C.V. ADITYA S.B.M. NAIDU
G.S.D. MANIKANTA M. SANTOSH KUMAR T. SATYA RAMU
I. TEJA P. BILLY PAUL V. DURGA SRI SAI
K. SIVA SHANKAR P.V.S.S. NARAYANA P. NITESH
K. SUDARSAN S. RISHYANTH

Sri.D.V.Subbarao,M.Tech(PhD)

S.M.V.M POLYTECHNIC
TANUKU-534211
2024-2025
STATE BOARD OF TECHNICAL EDUCATION AND TRAINING
MANGALAGIRI (A.P)
1
 CERTIFICATE

This is to certify that this report work is the bonafied work of

…………………………………………………………………. PIN-……………………………….
student of final year D.E.C.E along with his batch in partial fulfilment of the requirements
for the award of DIPLOMA IN ELECTRONICS AND COMMUNICATION ENGINEERING
of the STATE BOARD OF TECHNICAL EDUCATION AND TRAINING - MANGALAGIRI
(A.P.) during the academic year 2024-2025.

TRAINING INCHARGE HEAD OF THE DEPARTMENT

Sri. SUDHAKAR REDDY Sri. D.V. SUBBARAO, M. Tech
GENERAL MANAGER,LUMIRISE
L.POLAVARAM-533238

2
 ACKNOWLEDGEMENT

We would like to thank the company management from “LUMIRISE PVT LTD”
for giving us the opportunity to complete our industrial training.

We specially express our gratitude to Sri CH.AJAY KUMAR; Sri SUDHAKAR

REDDY for the encouragement during our industrial training period.

We express our thanks to all the staff of the department for guiding us and for our
valuable time.

We wish to express our sincere gratitude to “ Sri. Y. RAJENDRA BABU

M.TECH,FIE” Our beloved principal and “ Sri.D.V. SUBBARAO, MTech[PhD]”H.O.D,
Electronics and communication engineering. for giving us valuable suggestions and
guidance during our industrial training.

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 INDEX

S.NO NAME OF THE TOPIC PAGE NO.

1. Different types of LED PANEL lights 05

2. LED driver 09

3. Materials used for assembling LED panel light 13

4. Soldering of AC&DC wires to drivers 18

5. ASSEMBLING of surface round & square panel lights 22

6. ASSEMBLING of recess round & square panel lights 26

7. Soaking process 30

8. DOB flood light 33

9. Materials used for assembling flood light 36

10. ASSEMBLING of DOB flood lights 40

11. DOB bulb& Emergency bulb 47

12. Materials used for assembling DOB bulb 50

13. ASSEMBLING of DOB bulb 53

14. Materials used for assembling Emergency bulb 56

15. ASSEMBLING of Emergency bulb 60

16. Materials used for assembling 2x2 panel lights 64

17. ASSEMBLING of 2x2 panel lights 68

18. Raw material to high quality LED light 71

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DIFFERENT TYPES OF LED PANEL LIGHTS

5
 DIFFERENT TYPES OF LED PANEL LIGHTS

LED PANEL LIGHTS: LED panel lights are a type of lighting fixture that use light-emitting
diodes (LEDs) to provide bright, uniform illumination. They are a more energy-efficient alternative to
incandescent and fluorescent lamps, and are known for their durability, minimal environmental impact, and
long lifespan.

These are available in three categories:1. Surface mounted LED panels, 2. Recessed LED panels and 3.
2x2 panel lights

1. Surface-mounted LED Panels: These are directly mounted onto ceilings or walls without
requiring recessed installation. They are suitable for spaces with low ceilings or where recessing isn’t
possible. Key features of surface panel lights include:

1. Easy Installation: Since they don’t require a false ceiling, surface panel lights can be installed
directly onto any flat surface, making them suitable for both new constructions and retrofitting older
spaces.

2. Sleek and Modern Design: These lights have a slim profile, offering a clean and contemporary
appearance. They blend well with different interior styles while being visible on the ceiling.

3. Bright, Even Illumination: Surface panel lights offer uniform light distribution across the
room, reducing shadows and glare, which is ideal for homes, offices, and commercial spaces.

4. Energy-efficient: Like other LED lights, they consume less power and last longer, making them
a cost-effective and eco-friendly lighting option.

5. Versatility: Available in various shapes (round, square, rectangular) and sizes, surface panel lights
can be used in living rooms, kitchens, hallways, and workspaces.

Fig1.1. Surface round panel light Fig1.2.Surface square panel light

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 2. Recessed LED Panels: Installed into ceiling grids or plaster ceilings, these panels are
ideal for creating a sleek, modern look in spaces with suspended ceilings, like offices and conference
rooms. These are designed to provide a sleek, minimalist look, where the light fixture itself is hidden,
and only the illuminated surface is visible.

Here are some key features of recessed panel lights:

1. Slim and Compact: They are designed to fit into ceiling spaces without protruding, making
them ideal for low-ceiling areas.

2. Uniform Light Distribution: These lights use diffusers to spread light evenly across the
space, providing soft, glare-free illumination.

3. Energy-efficient: Like other LED lights, recessed panel lights are highly energy-efficient,
consuming less power compared to traditional lighting.

4. Versatile Applications: Commonly used in offices, hospitals, hotels, and retail spaces, they
create a clean, modern lighting effect.

5. Variety of Shapes and Sizes: Available in square, round, or rectangular designs, and in
various sizes, they can be selected to match the design aesthetics of a space.

Fig:1.3. Recess round panel light Fig:1.4. Recess square panel light

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 3. 2x2 panel lights: 2x2 panel lights are LED lighting fixtures designed in a square shape
with dimensions of 2 feet by 2 feet (approximately 600mm x 600mm). These panels are commonly used
in commercial, residential, and office spaces due to their energy efficiency, sleek design, and even light
distribution. Here’s an overview:

Fig:1.5. 2x2 panel light

Key Features:

1. Energy Efficiency: LED technology used in 2x2 panel lights consumes significantly less power
than traditional lighting options like fluorescent or incandescent bulbs, leading to reduced electricity
costs.

2. Brightness and Uniformity: They provide uniform illumination, with no dark spots or
flickering, making them suitable for workspaces that require consistent lighting.

3. Slim Design: The slim, modern profile makes them easy to install in ceilings with limited space.
This design also contributes to a clean, professional look in interior settings.

4. Colour Temperature Options: Available in various colour temperatures (e.g., cool white,
warm white, daylight) to suit different environments and preferences.

5. Long Lifespan: LED panels have a longer operational lifespan compared to traditional lights,
reducing the need for frequent replacements.

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LED DRIVER

9
 LED DRIVER
INTRODUCTION:

An LED panel light driver is an essential component used to regulate and supply power to the
LED panel light. It converts the high-voltage AC power from the mains to low-voltage DC power required
by the LEDs. The driver ensures consistent current flow, preventing flickering and protecting the LEDs
from fluctuations in voltage, which can extend their lifespan. LED drivers also often include protections
against short circuits, over-voltage, and overheating.

Fig:2.1. LED panel light driver

An LED panel light driver plays a critical role in the performance, efficiency, and longevity of LED
panels. Here is a more detailed breakdown of its functions and characteristics:

1. AC to DC Conversion: LEDs require low-voltage DC (Direct Current) power, but the mains
supply provides high-voltage AC (Alternating Current) power. The LED driver converts this AC power to
the appropriate DC voltage needed by the LEDs.

2. Regulation and Control: The driver regulates the current and voltage to ensure the LEDs operate
within their specified limits. This is crucial because LEDs are sensitive to voltage changes, and small
variations can cause large changes in current, potentially damaging the LEDs or reducing their lifespan.

3. Longevity: Since LED panel lights are typically used for long hours, a reliable driver helps maximize
the LED's lifespan. High-quality drivers with good thermal management and robust protection circuits
extend the overall lifespan of the LED system. The LED panel light driver is vital for efficient, safe, and
long-lasting operation of LED panel lights. It ensures proper power delivery, protects against electrical
issues, and can offer additional features like dimming and energy efficiency.

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 4. Driver Efficiency and Power Factor:

Efficiency: LED drivers should convert as much of the input power as possible into usable light output
(lumens) while minimizing heat generation. The efficiency of a good driver typically exceeds 85%. Higher
efficiency translates to energy savings and better thermal performance, which is critical for LED longevity.

Power Factor (PF): A high power factor (close to 1) means that the driver uses power more
effectively from the electrical grid. A low power factor indicates wasted power and can lead to higher
electricity bills. LED drivers often come with Power Factor Correction (PFC) to improve the power factor,
reducing strain on the electrical system and enhancing overall efficiency.

5. Thermal Management in LED Drivers: Heat is a significant factor that affects both the
driver and the LED panel's performance and lifespan. High-quality drivers feature built-in thermal
management systems that monitor and regulate heat. Some use heat sinks or fans, while others employ
more sophisticated electronic thermal protection that reduces the power output when the temperature
exceeds a threshold, protecting the system from damage.

LED panel light drivers are rated according to the wattage of the LED panel they support. Wattage
refers to the amount of electrical power the LED panel consumes, and the driver must be able to supply the
necessary power consistently. Here's how wattage relates to LED panel light drivers:

1. Low-Wattage Drivers (6W-9W,8W-15W):

Use Case: These drivers are typically used in small LED panel lights, like those used for decorative
purposes, under-cabinet lighting, or small task lighting.

Features: Simple, low-power designs, often with minimal heat dissipation needs.

Common Types: Constant voltage drivers are commonly used in these low-power applications, where
the power requirement is straightforward.

Fig:2.2.6W-9W LED driver Fig:2.3.8W-15W LED driver

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 2. Mid-Wattage Drivers (18W-24W,36W-50W):

Use Case: These drivers are suitable for medium-sized LED panels used in residential rooms, small
offices, or hallways. They are the most common drivers used in standard-sized LED panels (e.g., 600mm x
600mm or 2’ x 2’ panels).

Features: More robust current regulation, efficient heat dissipation, and often feature dimming
capabilities.

Common Types: Both constant current and constant voltage drivers are used, depending on the LED
panel's design and requirements.

Fig:2.4.18W-24W LED driver Fig:2.5.36W-50W LED driver

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MATERIALS USED FOR ASSEMBLING LED
PANEL LIGHTS

13
 MATERIALS USED FOR ASSEMBLING LED PANEL LIGHTS

To assemble a surface-mounted LED panel light, you will need the following materials:

1. Aluminium Frame: Used to encase and mount the LED panel, providing heat dissipation and
durability. These are of two types: 1. Surface and 2. Recess

Fig:3.1. Surface round Fig:3.2.Surface square Fig:3.3.Recess square Fig:3.4.Recess round

2. LED strip: In LED panel lights, LED strips serve as the primary light source, offering flexibility,
energy efficiency, and uniform light distribution. They enable slim, sleek designs and are commonly
used in both commercial and residential settings where high-quality, even lighting is essential.

Fig:3.5. LED strip

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3. PS SHEET: PS (Polystyrene) sheets are commonly used in LED panel lights as light guide plates. It
spread the light evenly across the surface of the panel. It helps eliminate hotspots (bright spots where
individual LEDs are placed) and provides uniform, soft light output.

Fig:3.6. Round PS sheet Fig:3.7. Square PS sheet

3. Diffuser: A translucent or frosted panel to evenly distribute the light and reduce glare.

Fig:3.8. Round diffuser Fig:3.9. Square diffuser

5. Reflector sheet: A reflective material placed behind the LEDs to enhance light output and ensure
uniform light distribution.

Fig:3.10. Reflector round Fig:3.11.Reflector square

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 6. Metal back plate: The back plate in an LED panel light is essential for providing structural
integrity, enhancing thermal management, and improving light efficiency. It ensures that the LED panel
light operates reliably and efficiently while maintaining a sleek, modern appearance.

Fig:3.12.Back plate Round Fig:3.13.Back plate Square

7. Fasteners: Required for securing the frame, diffuser, and mounting brackets. Fasteners play a
crucial role in the functionality, safety, and aesthetic appeal of LED panel lights. Proper selection and
installation of fasteners can enhance the performance and longevity of these lighting fixtures.

Fig:3.14. Fasteners

8. Male DC wire: The DC wire in an LED panel light is a crucial component that transmits DC power
from the LED driver to the LEDs, ensuring efficient operation, safety, and support for additional features
like dimming or smart control. Proper wiring also helps improve the performance and longevity of the
LED panel light.

Fig:3.15.Male DC wire

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 9. DC wire holding cap: The DC wire holding cap is a small but crucial component in an LED
panel light, helping to ensure secure electrical connections, manage wiring, provide strain relief, and
improve safety. By preventing loose wires and ensuring organized cable management, the cap enhances
the durability, reliability, and safety of the LED panel light during operation and maintenance.

Fig:3.16. DC wire holding cap

10. Clips: Clips in LED recessed panel lights play a vital role in securing the fixture, simplifying
installation, allowing for adjustments, improving heat dissipation, and facilitating maintenance. They
enhance both the functionality and aesthetic appeal of recessed lighting, making them an essential
component of modern LED panel designs.

Fig:3.17. Clips

11. Earth wire: The earth wire in an LED panel light is essential for electrical safety, protecting
both the fixture and users from electrical faults. It ensures safe operation by grounding any stray currents,
reducing the risk of electric shocks, fires, and component failure.

Fig:3.18. Earth wire

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SOLDERING OF AC & DC WIRES TO LED
DRIVER

18
 SOLDERING OF AC & DC WIRES TO DRIVER

AC wire: The AC wire in an LED panel driver is used to supply power from the mains electricity
to the driver, which then converts it to a suitable DC voltage for the LED panel.

Fig:4.1.AC wire

Purpose of AC Wire in LED Panel Drivers:

1. Power Supply:

The AC wire connects the driver to the alternating current (AC) power supply, typically from the mains
(e.g., 110V or 230V AC). In this step, the LED driver receives the high-voltage AC input.

2. Conversion:

The primary function of the driver is to convert the AC power to the required direct current (DC) voltage
and current, which is compatible with the LED panel. LEDs operate on low-voltage DC power, so this
conversion is crucial.

3. AC Wire Connections:

There are typically two AC wires:

Live wire (L): Carries current from the power source.

Neutral wire (N): Completes the electrical circuit by carrying current back to the power source.

FEMALE DC wire: The female DC wire in an LED panel driver is used to provide a reliable
connection for delivering the converted direct current (DC) power from the driver to the LED panel or other
connected devices.

Fig:4.2. Female DC wire

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Purpose of Female DC Wire in LED Panel Drivers:

DC Power Output: After the LED driver converts the high-voltage AC input into low-voltage DC
power, the female DC connector serves as the output interface. It is where the LED panel or other devices
are connected to receive the required DC power.

When soldering AC and DC wires to LED panel drivers, it's essential to follow proper safety
protocols and ensure solid connections for both performance and safety. Here’s a step-by-step guide:

Materials:
Soldering iron (15W-30W)
Solder (preferably lead-free)
Wire strippers
AC and DC wires
LED panel driver

STEPS:

1. Preparation:

Turn off power: Ensure the LED driver is not connected to any power source.

Strip wires: Use wire strippers to remove about 10-12 mm of insulation from the ends of both AC and
DC wires.

Tin the wires: Before soldering, apply a small amount of solder to the exposed ends of the wires (tinning)
to improve the connection and make soldering easier.

2. Soldering the AC wires:

Identify AC input terminals: The LED driver will have clearly marked AC input terminals (L for live, N
for neutral).

Solder the live wire: Carefully solder the live (brown/black) AC wire to the "L" terminal.

Solder the neutral wire: Similarly, solder the neutral (blue/white) AC wire to the "N" terminal.

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 2. Soldering the DC wires:

Identify DC output terminals: These are usually marked with "+" for positive and "−" for negative.

Solder the positive DC wire: Attach and solder the positive wire (often red) to the "+" terminal of the
driver.

Solder the negative DC wire: Attach and solder the negative wire (often black) to the "−" terminal.

Fig:4.3. Soldering DC wire

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ASSEMBLING OF SURFACE ROUND& SQUARE
PANEL LIGHTS

22
 ASSEMBLING OF SURFACE ROUND&SQUARE PANEL LIGHTS

Assembling an LED Surface panel light involves several key steps, from preparing the components
to connecting and securing them for proper operation. Here’s a detailed breakdown of the process:

Materials Required:

➢ LED surface panel frame

➢ LED strip or panel module
➢ LED driver
➢ AC wires and DC wires (connectors)
➢ Diffuser and PS
➢ Mounting brackets
➢ Soldering tools
➢ Screws, screwdriver

Assembly Process:

1.Attach the LED Strips or Module: Secure the LED strips or the pre-made LED panel onto the
back of the frame. This can involve using screws, thermal paste, or adhesive, depending on the design.

Fig:5.1. Surface round Fig:5.2. Surface square

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 2. Soldering DC wire: The LED strips or modules require soldering, use a soldering iron to attach
the dc wires to the LED strips. Solder the positive and negative leads from the dc wire to the corresponding
terminals of the LED strip.

Fig:5.3.Surface round Fig:5.4.Surface square

4. Installing the Diffuser, PS and reflector: Position the Diffuser: Once the LEDs are secured
and tested, install the diffuser panel. This is typically a sheet of acrylic or polycarbonate material that
helps distribute the light evenly across the surface.

Fig:5.6. Installing diffuser, PS and reflector in surface round panel light

Fig:5.7. Installing diffuser, PS and reflector in surface square panel light

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 4. Mounting the Panel:

Install Mounting Brackets: Use the appropriate mounting brackets, screws, or clamps to secure the
panel in the desired location, whether it's ceiling-mounted, recessed, or surface-mounted.

Fig:5.8. Surface round Fig:5.9. Surface square

5. Final Testing: Once the panel is fully assembled and installed, turn on the power to check for proper
illumination, ensuring there are no flickering or brightness issues.

25
ASSEMBLING OF RECESS ROUND&SQUARE
PANEL LIGHTS

26
 ASSEMBLING OF RECESS ROUND&SQUARE PANEL LIGHTS

Assembling an LED Recess panel light involves several key steps, from preparing the components
to connecting and securing them for proper operation. Here’s a detailed breakdown of the process:

Materials Required:

➢ LED recess panel frame

➢ LED strip or panel module
➢ LED driver
➢ AC wires and DC wires (connectors)
➢ Diffuser and PS
➢ Mounting brackets
➢ Soldering tools
➢ Screws, screwdriver

Assembly Process:

1.Attach the LED Strips or Module: Secure the LED strips or the pre-made LED panel onto the
back of the frame. This can involve using screws, thermal paste, or adhesive, depending on the design.

Fig:6.1.Recess round Fig:6.2. Recess square

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 2. Soldering DC wire: The LED strips or modules require soldering, use a soldering iron to attach
the dc wires to the LED strips. Solder the positive and negative leads from the dc wire to the corresponding
terminals of the LED strip.

Fig:6.3. Recess round Fig:6.4. Recess square

3. Installing the Diffuser, PS and reflector: Position the Diffuser: Once the LEDs are secured
and tested, install the diffuser panel. This is typically a sheet of acrylic or polycarbonate material that helps
distribute the light evenly across the surface.

Fig:6.5.Installing diffuser, PS and reflector in recsess panel light

Fig:6.6.Installing diffuser, PS and reflector in recess panel light

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 4. Mounting the Panel:

Install Mounting Brackets: Use the appropriate mounting brackets, screws, or clamps to secure the panel
in the desired location, whether it's ceiling-mounted, recessed, or surface-mounted.

Fig:6.7. Recess round Fig:6.8. Recess square

5. Final Testing: Once the panel is fully assembled and installed, turn on the power to check for proper
illumination, ensuring there are no flickering or brightness issues.

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SOAKING PROCESS

30
 SOAKING PROCESS

The soaking process in LED panel light manufacturing is a testing phase designed to identify
potential failures or defects in the product. It involves subjecting the LED panel lights to stress conditions,
often for an extended period, to ensure reliability and performance stability before they are shipped to
customers. Here’s how it typically works:

1. Initial Setup: The LED panel lights are connected to a controlled power source. The current and
voltage are set to the required specifications to simulate normal or slightly increased operational
conditions.

Fig:7.1. Soaking of lights

2. Soaking Test Conditions: The lights are powered continuously for a specific period, often
between 8 to 24 hours or even longer, depending on the manufacturer’s requirements. During this period,
the temperature, humidity, and power conditions may be varied to simulate different environmental factors
the lights might face in real-world applications.

3. Monitoring: Throughout the soaking process, parameters like temperature, brightness, colour
consistency, and power consumption are closely monitored. Any changes in these parameters might indicate
underlying issues with the LED chips, drivers, or other components.

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 4. Evaluation: After the soaking period, the LED panel lights are evaluated for any failures or defects.
Common issues might include flickering, colour shifts, reduced brightness, or component failures.

5. Pass/Fail Criteria: Lights that pass this testing process are cleared for distribution, while those
that fail are either repaired or discarded, depending on the defect's nature.

This testing phase helps ensure that LED panel lights can withstand real-world usage, reducing the
chances of early failure and increasing customer satisfaction.

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DOB FLOOD LIGHT

33
 DOB FLOOD LIGHT

DOB (Driver-On-Board) flood lights are an advancement in LED lighting technology where the
driver circuitry is integrated directly onto the LED module, rather than having a separate driver. In
traditional LED systems, the driver converts AC power from the mains to the DC power that LEDs
need, while also regulating voltage and current to ensure stability and protect against fluctuations.
Integrating this driver on the board itself simplifies the structure and reduces the number of
components, making the light fixture lighter, more compact, and often more cost-effective.

Fig:8.1. DOB Flood light

Key Features of DOB Flood Lights:

1. Compact Design: Without a separate driver, DOB flood lights are more streamlined, allowing
for a slimmer and lighter build, which can be easier to install in various settings.

2. Cost-Effectiveness: The reduction in components generally lowers manufacturing costs,

making DOB flood lights more affordable compared to traditional LED flood lights.

3. Energy Efficiency: DOB technology is designed to use power efficiently, which translates to
lower energy consumption and, consequently, reduced electricity bills.

4. Maintenance: With fewer components, there’s potentially lower maintenance since there are
fewer parts to replace. However, if the driver fails, the entire unit might need to be replaced.

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5. Heat Management: Since all components are on a single board, these lights require good heat
dissipation mechanisms to avoid overheating, which can reduce lifespan if not properly managed.

6. Limitations: While they offer several advantages, DOB lights can be sensitive to power surges
and fluctuations, as they lack the more robust protection features found in external drivers. This can
make them less durable in areas with unstable power supplies.

Applications:
DOB flood lights are ideal for outdoor spaces, like parking lots, building exteriors, stadiums, and areas
that need wide-spread illumination. They are also popular in residential and commercial settings due
to their compactness and affordability.

35
MATERIALS USED FOR ASSEMBLING DOB
FLOOD LIGHT

36
 MATERIALS USED FOR ASSEMBLING DOB FLOOD LIGHT

Assembling a DOB (Driver-on-Board) floodlight requires specific materials designed to handle high
power, outdoor environments, and efficient heat dissipation. Here’s a list of essential materials:

1. DOB LED Board: The primary component, which integrates LEDs and the driver circuitry directly
on a single board, reducing the need for an external driver. The board is typically made from aluminium or
copper-clad PCB for improved heat dissipation.

Fig:9.1. DOB LED BOARD

2. Heat Sink: Often made from aluminium, the heat sink is crucial for absorbing and dissipating the
heat generated by the LEDs, keeping the floodlight cool and prolonging LED life. The frame is usually
weatherproof and resistant to corrosion.

Fig:9.2. Heat sink

2. Reflector: This component, usually made from reflective coated plastic or metal, focuses and directs
the light, maximizing output and improving the light beam's focus.

Fig:9.3. Reflector

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 4. Lens/Cover: A tempered glass or polycarbonate cover protects the LEDs and circuitry from
moisture, dust, and impact. It is often clear or lightly frosted to avoid light loss while maintaining a robust
enclosure.

Fig:9.4. Lens
5. Sealing Gasket: A silicone or rubber gasket that seals the frame to prevent water and dust from
entering the light, providing an IP65 or higher waterproof rating.

Fig:9.5. Sealing Gasket

6. Mounting Bracket: Typically made from stainless steel or aluminium, the bracket allows the
floodlight to be securely installed and adjusted at different angles.

Fig:9.6. Mounting bracket

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 7. Thermal Paste or Pad: This is applied between the DOB LED board and the heat sink to enhance
thermal conductivity, ensuring efficient heat transfer from the LEDs to the heat sink.

Fig:9.7. Thermal paste

8. Wiring and Connectors: High-quality insulated copper wiring is used to connect the DOB board
to the AC power source. Waterproof connectors are preferred to maintain a secure, weather-resistant
connection.

Fig:9.8.AC wire

9. Screws and Fasteners: Rust-resistant stainless steel or coated screws are used to secure various
components in place, ensuring durability and resistance to outdoor conditions.

Fig:9.9. Fasteners

39
ASSEMBLING OF DOB FLOOD LIGHT

40
 ASSEMBLING OF DOB FLOOD LIGHT

Assembling a DOB (Driver on Board) flood light involves several key steps, from mounting the LED
board to securing the housing and connecting the necessary components. Here’s a detailed step-by-step
process:

1. Prepare the Housing:

Purpose: The housing is the structure that holds all components of the floodlight.

Process: Clean the housing to remove any dust or debris that may interfere with the assembly. Inspect it
for any defects or damage.

Material: Usually made of aluminium for durability and heat dissipation.

Fig:10.1. Preparing housing

2. Install the Heat Sink:

Purpose: The heat sink is essential for dissipating heat generated by the LEDs.

Process: Attach the heat sink securely to the back of the LED board mounting area, often using thermal
paste or thermal pads to improve heat transfer. This helps maintain the LEDs at optimal temperature during
operation.

Material: Aluminium or copper heat sink.

Fig:10.2. Installing heat sink

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 3. Apply Thermal Paste or Pad:

Purpose: Thermal paste or pads enhance heat transfer from the DOB board to the heat sink.

Process: Apply a thin layer of thermal paste between the DOB LED board and the heat sink (if not applied
in the previous steps). This ensures efficient heat dissipation, preventing overheating.

Material: Thermal paste or pad.

Fig:10.3. Applying thermal paste

4. Mount the DOB LED Board:

Purpose: The LED board with the driver circuitry integrated onto it (DOB) is the light-emitting
component.

Process: Place the DOB LED board onto the designated area in the housing, often over the heat sink.
Secure it with screws or mounting clips to ensure it stays firmly in place.

Material: LED board with built-in driver circuitry

Fig:10.4. Mounting DOB LED board on heat sink

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 5. Connect the Power Input Wires:

Purpose: The power wires provide electricity to the DOB board.

Process: Connect the AC input wires (usually live and neutral wires) from the power source to the
designated terminals on the DOB board. Secure them with a soldering iron or connectors as required.

Material: AC power wires.

Fig:10.5. Connecting AC wires

6. Attach the Earth Wire:

Purpose: The earth wire ensures electrical safety by grounding the light fixture.

Process: Attach the earth wire to the designated grounding terminal on the housing, if applicable. This
wire helps prevent electrical shocks and damage due to faults.

Material: Grounding/earth wire.

Fig:10.6. Attaching earth wire

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 7. Position the Lens and Reflector:

Purpose: The lens and reflector shape and enhance the light output.

Process: Place the reflector over the LED board and secure it to the housing. Next, position the protective
lens (often glass) over the reflector to protect the LEDs from dust and moisture. The lens is usually fixed
with screws or a sealing gasket.

Material: Glass or polycarbonate lens, aluminium or plastic reflector.

Fig:10.7. Position of lens and reflector

8. Seal with a Waterproof Gasket:

Purpose: The gasket ensures that the floodlight is waterproof and dustproof, suitable for outdoor use.

Process: Place a waterproof gasket around the edge of the lens or housing. This prevents moisture, dust,
and debris from entering the floodlight and damaging the internal components.

Material: Silicone or rubber gasket.

Fig:10.8.sealing with gasket

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 9. Close and Secure the Housing:

Purpose: Securing the housing protects the internal components from the environment.

Process: Close the housing and fasten it with screws to ensure it’s tightly sealed. For additional
protection, some assemblies may use silicone sealant around the edges.

Material: Screws and, if necessary, silicone sealant.

Fig:10.9. fastening with screws

10. Test the Floodlight:

Purpose: Testing ensures the floodlight is working correctly before installation.

Process: Connect the floodlight to a power source and verify that it turns on and operates without issues.
Check for brightness, colour temperature, and potential flickering.

Material: Power supply for testing.

11. Install the Mounting Bracket:

Purpose: The mounting bracket allows for easy installation and adjustment of the floodlight.

Process: Attach the mounting bracket to the housing if it hasn’t been attached already. This bracket should
be adjustable to allow for different angles.

Material: Metal mounting bracket and screws.

Fig:10.10. Installing the mounting brackets

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 12. Final Inspection:

Purpose: Ensure all components are securely fastened and that there are no exposed wires or loose
parts.

Process: Double-check each step to confirm everything is correctly assembled, sealed, and secure

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 DOB BULB
&
EMERGENCY BULB

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 DOB BULB&EMERGENCY BULB

DOB BULB:
A DOB (Driver-On-Board) bulb is an LED bulb with the driver circuitry directly integrated
onto the LED circuit board. Unlike traditional LED bulbs, which use an external or separate driver to
regulate power, DOB bulbs combine all necessary components in a single, compact unit. This design
makes DOB bulbs more affordable, compact, and easier to manufacture, as fewer materials are
needed.

Key Characteristics of DOB Bulbs:

1. Simplified Design: By embedding the driver on the LED board, DOB bulbs are lighter and have a
more streamlined design.
2. Cost Efficiency: Fewer components mean reduced production costs, making DOB bulbs an
affordable choice.
3. Energy Efficiency: DOB bulbs maintain efficient energy usage, consuming less electricity while
providing high brightness.
4. Limitations: They can be more sensitive to power fluctuations, which may impact durability in
areas with unstable voltage.

Fig: 11.1.DOB Bulb

DOB bulbs are widely used in household and commercial settings, offering a budget-friendly
lighting option with efficient performance. However, they are best suited for environments with
stable power supply to ensure a longer lifespan.

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EMERGENCY BULB:
An emergency bulb is a type of LED light bulb that includes a built-in rechargeable
battery, allowing it to automatically provide light during a power outage. It functions like a regular
bulb when connected to a power source, charging the battery while in use. When the power goes out,
the bulb instantly switches to battery power, offering emergency lighting for several hours.

Fig:11.2. Emergency bulb

Key Features of Emergency Bulbs:

1. Battery Backup: Comes with a built-in rechargeable battery that can last 2-5 hours during an
outage.
2. Dual Functionality: Works as a regular bulb under normal conditions and switches to battery
mode during a power cut.
3. Easy Installation: Fits standard bulb sockets, making it convenient to install and use.
Emergency bulbs are ideal for homes, offices, and areas prone to power outages, ensuring reliable
backup lighting without needing additional fixtures.

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MATERIALS USED FOR ASSEMBLING DOB
BULB

50
 MATERIALS USED FOR ASSEMBLING DOB BULB

To assemble a DOB (Driver-on-Board) bulb, you need materials that are compatible with the
compact design and efficient heat management that DOB technology requires. Here’s a breakdown of
the essential materials:

1. DOB LED Board: This is the core of the bulb, where LEDs and driver circuitry are integrated
on a single board, typically made of aluminium or copper-clad PCB for improved thermal
management.

Fig:12.1 DOB PCB

2. Bulb Housing/Base: Typically constructed from aluminium or plastic with a reflective coating.
The housing provides structure, dissipates heat, and protects the internal components.

Fig:12.2.DOB Housing

3. Bulb Cover/Diffuser: A frosted polycarbonate or acrylic dome is used to diffuse the light for a
softer, more uniform glow, reducing glare and spreading light evenly.

Fig:12.3.DOB diffuser

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4. Cap/Base: The screw or pin cap that connects the bulb to the socket, typically an B22 base made
of metal (aluminium or brass) with an insulated inner component. The base is connected to the wiring,
allowing for AC power.

Fig:12.4. B22 cap

5. Insulated Wiring and Connectors: High-temperature resistant copper wires insulated with
silicone or PVC connect the DOB board to the cap/base for power.

Fig:12.5.Insulated resistor

6. Surge Protection Component: A small surge protector can be added on the board to protect
the LEDs from sudden voltage spikes, especially for regions with unstable power.

Fig:12.6. MOV

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ASSEMBLING OF DOB BULB

53
 ASSEMBLING OF DOB BULB

Assembling a DOB (Driver-on-Board) bulb involves several steps, from preparing the main
components to final assembly and testing. Here’s a step-by-step process:

1. Prepare the DOB LED Board:

The DOB (Driver-on-Board) LED board is designed to house both the LEDs and the driver circuitry on
a single board, which reduces the need for separate drivers. This board is typically made from aluminium
or copper-clad PCB to improve heat dissipation. Ensure that the LED chips, resistors, capacitors, and other
driver components are securely soldered onto the board.

Fig:13.1. Preparing DOB LED board

2. Connect the Bulb Base (Cap):

The bulb cap, typically an B22 base, connects the bulb to the power socket. This is usually made from
metal like aluminium or brass.

Connect insulated resistor from the LED board to the base. These wires should be securely soldered to
ensure a stable connection.

Ensure the wiring is insulated and heat-resistant to handle the high temperatures inside the bulb.

Fig:13.2. Installing B22 base cap

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 3. Assemble the Housing and Diffuser:

The bulb housing, made of plastic or aluminium, encases the entire assembly. Place the heat sink and
DOB LED board inside the housing, aligning it to keep it stable.

Attach the diffuser (often made of polycarbonate or acrylic) to the housing. This dome-like cover softens
and distributes the LED light evenly, reducing glare and creating a smooth light output.

Secure the diffuser tightly to the housing to protect the internal components from dust and minor impacts.

Fig:13.3. Assembling PCB in housing Fig:13.4. Installing diffuser

4. Testing:

Connect the bulb to a power source and test it under both low and high voltages to ensure stability and
proper function.

Check for uniform light output, ensuring there are no flickers or malfunctions.

Test for heat dissipation to ensure the heat sink and thermal interface materials are working effectively,
preventing overheating.

5. Packaging:

Once the bulb has passed quality checks, it’s ready for packaging. Place each bulb in protective packaging
to prevent damage during shipping.

Fig:13.5. Packaging of light

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MATERIALS USED FOR ASSEMBLING
EMERGENCY BULB

56
 MATERIALS USED FOR ASSEMBLING OF EMERGENCY BULB

Assembling an emergency bulb involves materials that enable the bulb to operate normally when there
is power and switch to battery power during a power outage. Here’s a list of essential materials:

1. LED Board: This board, usually made from aluminium or FR4 PCB, contains LEDs for light
emission. LEDs are chosen for their low power consumption and long life, which is ideal for
emergency lighting.

Fig:14.1. EMB PCB

2. Battery: A rechargeable lithium-ion or lithium-polymer battery is included to provide power when the
main power source is unavailable. Battery capacity varies but typically ranges between 1200mAh to
2600mAh.

Fig:14.2. Lithium ion Battery

3. Driver Circuit: Manages power flow, switching between AC mains and battery power when needed.
It ensures stable voltage and current for the LEDs to operate correctly.

Fig:14.3. Driver circuit

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 4. Heat Sink: Made of aluminium, the heat sink dissipates the heat generated by the LEDs and circuitry,
ensuring longevity and safe operation.

Fig:14.4. Heat sink for EMB

5. Bulb Housing/Base: Usually made of plastic or aluminium, the housing provides structure and protects
the internal components. It also has slots for airflow to aid in cooling.

Fig:14.5. EMB housing

6. Diffuser: A polycarbonate or acrylic dome to soften and distribute the light, making it more
comfortable for the eyes and ensuring uniform brightness.

Fig:14.6. EMB Diffuser

7. Cap/Base: The screw base (B22) connects the bulb to the socket and is typically made of metal
(aluminium or brass) with an insulated portion.

Fig:14.7. B22 Base

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 8. Insulated Wiring and Connectors: High-quality copper wires with heat-resistant insulation connect
the LED board, battery, driver, and base.

9. Screws and Fasteners: Small screws or clips secure the bulb's internal components, keeping
everything aligned and in place.

Fig:14.8. Heatsink Screws

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ASSEMBLING OF EMERGENCY BULB

60
 ASSEMBLING OF EMERGENCY BULB

The assembly of an emergency bulb involves combining several key components that allow the bulb
to light up during a power outage. Here’s a step-by-step breakdown of the assembly process:

1. Gather Components:

LED: Provides illumination; LED bulbs are energy-efficient and long-lasting.

Battery: A rechargeable battery, often lithium-ion, to store power.

Charging Circuit: Converts AC mains power to DC for charging the battery.

Control Circuit: Detects power failure and switches the light to battery power automatically.

Enclosure: Holds all the components, typically made of plastic.

Fig:15.1. Gathering components

2. Prepare the LED Circuit:

Solder the LEDs in series or parallel as per the required brightness.

Connect a current-limiting resistor to prevent excess current from damaging the LEDs.

Secure the LED module onto a heat sink if necessary, to manage heat.

Fig:13.2. Preparing LED circuit

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3. Assemble the Battery with the Charging Circuit:

Connect the battery terminals to the charging circuit.

Make sure to include a protection circuit for overcharging and deep discharge.

The charging circuit is generally designed to stop charging once the battery is full.

Fig:13.3. Connecting battery to charging circuit

4. Set Up the Control Circuit:

The control circuit monitors the AC mains input.

When power is available, it allows charging and keeps the LEDs off.

If there’s a power cut, the circuit immediately switches to battery power, turning the LEDs on.

5. Install Components into the Enclosure:

Place the LED, battery, and control circuits securely inside the enclosure.

Route wires neatly to avoid short circuits and interference.

Ensure that the LEDs are aligned correctly for optimal light dispersion.

Fig:13.4. Installing components in housing

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 6. Connect the Bulb Base (Cap):

The bulb cap, typically a B22 base, connects the bulb to the power socket. This is usually made from
metal like aluminium or brass.

Connect insulated copper wiring from the LED board to the base. These wires should be securely
soldered to ensure a stable connection.

Ensure the wiring is insulated and heat-resistant to handle the high temperatures inside the bulb.

Fig:15.5 Installing B22 base cap

7. Testing and Final Assembly:

Test the assembled bulb by charging it and then simulating a power cut.

Check for proper switching from mains to battery and confirm that the battery is charging as expected.

Fig:15.6. Final assembly

8. Labelling and Quality Check:

Label the bulb with specifications, including battery capacity and charging time.

Perform quality checks to ensure all units meet safety standards.

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MATERIALS USED FOR ASSEMBLING
2X2 PANEL LIGHTS

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 MATERIALS USED FOR ASSEMBLING 2X2 PANEL LIGHTS

To assemble a 2x2 LED panel light, you’ll need several key components. Here’s a list of the
materials required:

1. 2x2 Back Plate:

The back plate serves as the base for the panel light, holding all other components in place.

It provides structural support and is typically made of aluminium or another heat-dissipating material,
which helps manage heat generated by the LEDs.

Acts as a mounting surface for the FPCBs, diffuser, and frame.

Fig:16.1.2x2 back plate

2. FPCBs (Flexible Printed Circuit Boards):

FPCBs are flexible, thin boards that house the LED chips.

They allow for compact designs and can be shaped or arranged to cover the entire back plate, providing
even light distribution across the panel.

Fig:16.2. FPCB

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 3.MCPCB:

The MCPCB can handle higher power levels, distributing current to the LEDs more effectively without
risk of overloading. This is especially useful in panel lights where multiple LEDs are connected in series or
parallel on the same board.

Fig:16.3. MCPCB

4. DC Wires:

DC wires connect the LED driver to the FPCBs and distribute power evenly across the LEDs.

They help ensure stable current flow, which prevents flickering and improves the panel’s overall
efficiency. Proper insulation on DC wires also helps prevent short circuits and electrical hazards.

Fig:16.4. Round male DC wire

5. Glue:

Glue is used to secure components like FPCBs and the diffuser sheet to the back plate.

It provides a stable hold without adding significant weight or thickness, keeping the panel light and thin.

Adhesives should be heat-resistant to withstand the slight heat generated by the LEDs over time.

Fig:16.5. Glue

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 6. Diffuser Sheet:

The diffuser sits over the LEDs, softening the light output to reduce glare and ensure even illumination.

It helps create a smooth, uniform light appearance across the panel, enhancing visual comfort.

Diffusers are usually made from acrylic or polycarbonate, which are effective at scattering light while
being lightweight and durable.

Fig:16.6. 2X2 Diffuser

7. 2x2 Frame:

The frame holds all components in place and provides the panel light with its finished shape.

It protects the internal components from dust, moisture, and damage, making the light more durable.

Typically made of aluminium or other lightweight metal, the frame also helps dissipate heat, which keeps
the LEDs operating efficiently.

Fig:16.7.2X2 frame

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ASSEMBLING OF 2X2 PANEL LIGHTS

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 ASSEMBLING OF 2X2 PANEL LIGHTS

To assemble a 2x2 LED panel light, you need several components, including a back plate, Flexible
Printed Circuit Boards (FPCBs), LED driver, DC wiring, diffuser sheet, frame, and any protective layers.

Steps to Assemble a 2x2 LED Panel Light:

1. Attach the Back Plate:

Place the 2x2 back plate on a flat surface; this will be the base of your panel.

Ensure it’s clean and ready to hold the components.

2. Mount the MPCBs on the Back Plate:

Attach the Metal Printed Circuit Board (MPCBs) to the back plate using glue.

Arrange the MPCBs evenly to cover the surface and ensure consistent light distribution. Make sure each
MPCB is securely glued down.

Fig:17.1. Sticking PCBs on back plate

3. Connect the LEDs on the FPCBs:

If the FPCBs already have LEDs soldered on, skip this step. If not, solder LEDs onto the FPCBs in a
pattern that provides even lighting.

Fig:17.2. Connecting the LEDs to FPCB by soldering

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 4. Wiring:

Use DC wires to connect the LED segments on the FPCB to the LED driver, ensuring all connections are
solid and insulated.

Fig:17.3. Soldering DC wire on FPCB

6. Attach the Diffuser Sheet:

Place the diffuser sheet on top of the LEDs to evenly spread light and reduce glare.

Secure the sheet onto the FPCB with glue if needed, ensuring it covers all LEDs.

Fig:17.4. Attaching diffuser to frame

7. Install the Frame:

Fit the 2x2 frame around the edges to encase all components. The frame should hold the diffuser and
FPCBs in place. Secure the frame with screws or glue, depending on the design.

Fig:17.5. Installing the frame by using screwing machine

8. Final Testing:

Connect the LED driver to the power source and test the panel to ensure all LEDs light up evenly.

If there are any issues, check the wiring connections and ensure the FPCBs and diffuser are correctly
positioned.

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RAW MATERIAL TO HIGH QUALITY
LED LIGHT

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 RAW MATERIAL TO HIGH QUALITY LED LIGHT

Here's a detailed explanation of each stage in the light manufacturing process, from material intake
to final product dispatch:
• Material Intake and Storage:

Introduction: This is the initial stage of the manufacturing process where raw materials, components,
and packaging materials are received into the warehouse. These materials are crucial for the production of
panel lights
Process: Upon arrival, materials are checked against the purchase orders to ensure the correct items and
quantities have been delivered. A basic inspection for visible damage is carried out. Approved materials are
then labelled and organized in storage locations according to their type and usage frequency. This helps
maintain inventory control and ensures easy accessibility during production.

• Incoming Quality Control (IQC) in the Lab:

Introduction: IQC is a critical step where the quality of incoming materials is assessed to ensure they
meet predefined standards and specifications.

Process: Samples from each batch or lot of material are selected for detailed testing in the lab. Tests
may include durability checks, dimensional accuracy, electrical properties, and any other specifications
critical to the quality of the final light product.

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 Materials that pass the IQC tests are approved for production, while those that don’t meet standards are
either returned to the supplier or held for further review. This stage helps prevent defective materials from
entering the production process.

• Production Planning:
Introduction: Production planning coordinates all resources, schedules, and workflows to meet
manufacturing targets efficiently.

Process: Production schedules are created based on factors such as sales forecasts, current orders, and
available inventory. The production planning team calculates the quantity of materials required, allocates
workforce, and sets timelines to meet deadline.

• Material Transfer to Production and Assembly:

Introduction: Once production is scheduled, materials are transferred from storage to the production
floor, where they are assembled into final products.

Process: Warehouse staff or material handlers move the necessary components to the designated
workstations or assembly lines. The assembly process typically involves multiple steps, such as soldering
connections, attaching components, wiring, fitting, and securing all parts according to design specifications.
Each workstation is equipped with the tools and resources required to complete specific assembly tasks.

• In-Process Quality Control (IPQC):

Introduction: IPQC ensures quality standards are maintained throughout the assembly process by
performing checks at critical points.

Process:
Visual inspection: Checking for any assembly errors or defects. Functional testing: Verifying that the
panel lights turn on and operate correctly.

Electrical testing: Measuring voltage, current, and power consumption.

Thermal testing: Assessing the temperature of the components to ensure they are within safe limits.

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 • Printing of product specifications and company logo on light:

Laser printing on LED lights is a process used to add precise markings, logos, or designs onto
LED light components, typically the outer casings or lenses. This technology utilizes laser beams to etch
or engrave patterns, creating a permanent and high-quality finish on the surface.

One key advantage of laser printing is its durability; the printed marks are resistant to wear,
fading, and environmental conditions, making it ideal for long-lasting branding or labelling. The process
is also highly customizable, allowing for intricate designs, barcodes, and product details to be added
without additional materials, unlike ink-based methods. Additionally, laser printing is efficient and
environmentally friendly, as it does not require inks, solvents, or chemicals, reducing waste and emissions.
It’s commonly used in LED manufacturing for serial numbers, technical specifications, and certification
marks, helping improve traceability and compliance with industry standards.

By integrating laser printing, LED light manufacturers can enhance the product’s aesthetic appeal
while ensuring it meets both branding and regulatory requirements.

• Packing:
Introduction: After final assembly and IPQC checks, products are sent to the packaging area, where they
are prepared for safe storage and shipping.

Process: Each light is placed in a protective packaging material, such as foam or bubble wrap, to prevent
damage during handling and transit. Labels, user manuals, warranty information, and other required
documentation are included in the package.
Packaged products are sealed and marked with necessary identification and handling instructions.

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 • Final Goods Storage:
Introduction: Packaged products are then moved to a finished goods storage area, where they are
organized and stored until ready for dispatch.
Process: The storage area is organized based on criteria like product type, customer order priority, and
shipping schedules.

This organization allows for quick and efficient retrieval of products when they are ready to be shipped,
reducing delays in order fulfilment.

• Pre-Delivery Inspection (PDI):

Introduction: PDI is the last quality check before the product is dispatched to customers, ensuring that
only high-quality products leave the facility.
Process: Quality inspectors conduct random sampling of finished goods to check for any defects, such
as operational issues, cosmetic imperfections, or deviations from specifications.
Tests may include functional testing (ensuring the light works correctly), visual inspection, and verifying
that all accessories, labels, and packaging materials are present. Products that pass the PDI are cleared for
shipment, while any defective items are held back for further inspection or rework.

• Product Out (Dispatch):

Introduction: This final stage involves shipping the completed products to the customer.
Process: Products are retrieved from storage based on customer orders and loaded for transport. Shipping
documents, such as invoices, packing slips, and tracking information, are prepared to ensure accurate
delivery. Proper documentation also aids in inventory tracking and ensures accountability until the product
reaches the customer.

Each of these stages plays an essential role in ensuring the production of high-quality,
reliable light products, optimized production efficiency, and customer satisfaction.

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 CERTIFICATE

This is to certify that this report work is the bonafied work of

…………………………………………………………………. PIN-……………………………….
student of final year D.E.C.E along with his batch in partial fulfilment of the requirements
for the award of DIPLOMA IN ELECTRONICS AND COMMUNICATION ENGINEERING
of the STATE BOARD OF TECHNICAL EDUCATION AND TRAINING - MANGALAGIRI
(A.P.) during the academic year 2024-2025.

TRAINING INCHARGE HEAD OF THE DEPARTMENT

Sri. SUDHAKAR REDDY Sri. D.V. SUBBARAO, M. Tech
GENERAL MANAGER,LUMIRISE
L.POLAVARAM-533238

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