JP5609243B2 - Light source device - Google Patents

Description

  The present invention relates to a light source device using a plurality of solid state light emitting elements such as light emitting diodes as a light source, and particularly to a light source device suitable for various industrial plants that require a large amount of light.

  In general, a solid-state light-emitting element such as a light-emitting diode (LED) can be handled as a point light source, and has an advantage of low power consumption and long life. Thus, in recent years, with the increase in the output of LEDs, many techniques for applying LEDs as light sources for various illumination devices have been proposed.

  For example, in Patent Document 1, as a technique for obtaining sufficient illuminance and wide directivity without increasing the size of the light bulb itself for LED lighting light bulbs (light source devices) used in place of heat-generating light bulbs, respectively. A technique for constructing a substantially spherical polyhedron by three-dimensionally assembling a large number of regular pentagonal substrates and regular hexagonal substrates mounted with chip-type LEDs is disclosed.

JP 2002-184207 A

  By the way, this kind of light source device using LED as a light source is expected to be applied to a wider range of fields without being limited to the general-purpose products as described above. For example, as a substitute for a high-output discharge tube or the like. It is expected to be applied to various industrial plants. In such a case, for example, it is conceivable to apply the technique of the above-mentioned Patent Document 1 to configure a light source device by finely arranging a plurality of LEDs on a plurality of substrates arranged in a regular polygonal cylinder shape.

  However, industrial discharge tubes and the like may require an extremely large amount of light compared to general-purpose products, and even if the above-described configuration is adopted, the absolute number of LEDs that can be mounted is insufficient. It may be difficult to obtain a sufficient amount of light.

  To cope with this, it is conceivable to increase the outer dimension of the light source device in order to increase the LED mounting area. However, in such a case, there is a possibility that application to existing equipment becomes difficult.

  An object of the present invention is to provide a light source device capable of efficiently concentrating and arranging a plurality of solid state light emitting elements in a limited region.

A light source device according to an aspect of the present invention is a light source device in which a plurality of solid state light emitting elements are mounted as light sources on a mounting surface of a base, and the mounting surface is formed by a plurality of mounting surface portions arranged in a zigzag manner. have been, said angle between the mounting surface forming the valleys on the mounting surface, and set the optical interference angle of more than an angle determined by the half-value angle of light emitted from the solid state light emitting devices, the mounting The surface is formed by connecting a plurality of the mounting surface portions arranged in a zigzag manner in a ring shape.

  According to the light source device of the present invention, it is possible to efficiently collect and arrange a plurality of solid state light emitting elements in a limited area.

Perspective view of light source device Exploded perspective view of light source device Cross section of light source device Sectional view showing the light source module Characteristic diagram showing directional characteristics of light-emitting diodes Enlarged view of the VI area in Figure 2 Schematic configuration diagram showing the cooling system of the light source device Schematic configuration diagram of light emitting system Flow chart showing lighting control routine of light source device (part 1) Flowchart showing the lighting control routine of the light source device (part 2) Sectional drawing which shows the modification of a light source device

  Hereinafter, embodiments of the present invention will be described with reference to the drawings. FIG. 1 is a perspective view of a light source device, FIG. 2 is an exploded perspective view of the light source device, FIG. 3 is a sectional view of the light source device, and FIG. 4 is a sectional view showing a light source module. 5 is a characteristic diagram showing the directivity characteristics of the light emitting diode, FIG. 6 is an enlarged view of the VI region of FIG. 3, FIG. 7 is a schematic configuration diagram showing a cooling system of the light source device, FIG. 8 is a schematic configuration diagram of the light emitting system, FIG. , 10 is a flowchart showing a lighting control routine of the light source device, and FIG. 11 is a sectional view showing a modification of the light source device.

  The light source device 1 shown in FIGS. 1 and 2 is a high-output light source device used in, for example, an industrial plant. The light source device 1 includes a plurality of light emitting diodes (LEDs) 12 that are solid-state light emitting elements. It has the base 2 mounted.

  Here, for example, as shown in FIGS. 2, 4, and 8, in the present embodiment, each LED 12 is modularized every predetermined number (for example, 100) to form the light source module 10. In this state, a plurality of pieces are arranged on the base 2.

  More specifically, the light source module 10 has a basic configuration in which a plurality of LEDs 12 are finely arranged in a matrix on an LED mounting substrate 11, for example.

  The LED mounting substrate 11 of the present embodiment is configured by a substrate having a substantially rectangular shape in plan view using, for example, a metal such as high thermal conductivity aluminum-based or copper-based metal or ceramics such as aluminum nitride as a base material. .

  Each LED 12 is a hemisphere, for example, as shown in FIG. 4, which is composed of a planar mounting type LED having a substantially rectangular shape in plan view of about 3 [mm] × 3 [mm], and is fixed to the emission surface. By the action of the lens 12a, light is emitted with a directivity characteristic of a half-value angle of about 45 degrees (light interference angle of about 135 degrees) (see FIG. 5). Each LED 12 is finely arranged, for example, in a matrix of 10 × 10 with respect to the LED mounting substrate 11. More specifically, each LED 12 is a minimum for not blocking the light emitted from the adjacent LEDs 12. Are mounted at an equal pitch while maintaining an interval of (for example, 0.2 [mm]).

  Here, in order to individually monitor the temperature of the LEDs 12 arranged densely and densely in units of the light source modules 10, for example, as shown in FIG. 8, the temperature sensor 13 is provided on the LED mounting substrate 11. . In addition, when one LED 12 is short-circuited or opened, the other LEDs 12 are turned on accurately, so that the power supply wiring 11a for each LED 12 is wired in a grid pattern on the LED mounting substrate 11, and each LED 12 Are connected in a so-called series-parallel state.

  As shown in FIGS. 2 and 3, the base 2 of the present embodiment is configured by an aggregate of a plurality of (for example, four) base blocks 20 having the same shape.

  If demonstrating it concretely, the base block 20 will be comprised by the elongate extrusion molded product which consists of an aluminum alloy etc. with favorable heat conductivity, for example. The base block 20 has a pair of side surfaces 21 extending along the longitudinal direction. These side surfaces 21 function as contact surfaces that contact other base blocks 20, and are configured by tapered surfaces that expand at a predetermined angle from the inner surface side to the outer surface side of the base block 20. .

  The outer surface of each base block 20 is set as a mounting surface 22 for mounting a plurality of LEDs 12 (light source modules 10). The mounting surface 22 has, for example, four rectangular mounting surface portions 22a extending in the longitudinal direction of the base block 20, and these mounting surface portions 22a are continuously arranged in a zigzag manner in the short-side direction. . For example, as shown in FIG. 1, each mounting surface portion 22a holds ten light source modules 10 in a line along the longitudinal direction thereof. At that time, each light source module 10 is fixed to the mounting surface portion 22a via, for example, an adhesive having heat resistance and good thermal conductivity. Thereby, each light source module 10 is thermally connected with respect to the base block 20, and heat exchange between each other is attained.

  For example, as shown in FIGS. 2 and 3, the base block 20 has a pair of through holes 23 extending in the longitudinal direction inside the base block 20. In the present embodiment, each through hole 23 is arranged in association with each other for each set of mounting surface portions 22 a that are continuous in a mountain fold shape, and each end portion of each through hole 23 corresponds to each longitudinal direction of the base block 20. Each end face has an opening.

  Each base block 20 configured in this manner is arranged in an annular shape by bringing the side surfaces 21 into contact with each other, for example, as shown in FIGS. And these base block 20 comprises the column-shaped base 2 which makes a cross-sectional substantially octagonal star shape, when the both ends are connected integrally through the nozzle | cap | die 25, respectively.

  Here, in order to prevent a part of the emitted light from each LED 12 from being blocked by the other mounting surface portions 22a, an angle θv (which is formed between each pair of mounting surface portions 22a that are continuously folded in a valley shape on the mounting surface 22). And, it is desirable that the angle θv) between each set of mounting surface portions 22a that are continuous in a valley shape between the base blocks 20 is set to an angle that is equal to or greater than the light interference angle of the light emitted from the LED 12. That is, for example, as shown in FIG. 6, in the present embodiment in which the interference angle of each LED 12 is set to 135 degrees, it is desirable that θv ≧ 135 degrees. In particular, it is preferable that θv = 135 degrees.

  For example, as shown in FIGS. 2 and 7, a plurality of hole portions 26 corresponding to the respective through holes 23 are opened on the contact surfaces of the bases 25 with the base blocks 20. 26 is in fluid-tight communication with each through-hole 23 through a gasket 27. As a result, a series of cooling passages 3 are formed inside the base 2. As shown in FIG. 6, the cooling passage 30 is connected to a cooling device 30 that circulates a cooling liquid made of, for example, water or oil. The cooling device 30 includes a heat exchanger 31 and a pump 32, and the coolant cooled to a predetermined temperature (for example, about 10 ° C.) by the heat exchanger 31 is pumped into the cooling passage 3 by the pump 32. . Thereby, each base block 20 is always kept at a predetermined low temperature, and functions as a cooling member for each LED 12.

  According to such a configuration, the mounting surface 22 set on the base 2 is formed by the plurality of mounting surface portions 22a arranged in a zigzag shape, thereby limiting the outer dimensions and the like without increasing the size. A plurality of LEDs 12 can be efficiently and collectively arranged in the area. Therefore, the present invention can be suitably applied to various facilities such as industrial plants that require a large amount of light without significant changes.

  At that time, by setting the angle between the mounting surface portions 22a that form valleys on the mounting surface 22a by being arranged in a zigzag manner to an angle greater than the light interference angle, the emitted light from each LED 12 is Absorption by other mounting surface portions 22a and the like can be prevented accurately, and the emitted light from each LED 12 can be used as illumination light with suitable utilization efficiency. If the same angle is set, the size can be minimized without reducing the amount of light.

Next, the lighting control device 50 for controlling the lighting of the light source device 1 will be described.
As shown in FIG. 8, the lighting control device 50 is configured around a control unit 51 including, for example, a microcomputer.

  The input port of the control unit 51 is connected to the temperature sensor 13 of each light source module 10 and the operation panel 33 of the cooling device 30. The control unit 51 receives signals such as the temperature T detected by each temperature sensor 13 and various operation input information for the cooling device 30 performed through the operation panel 33. On the other hand, to the output port of the control unit 51, a power supply circuit 52 corresponding to each light source module 10, an alarm device 53, and the like are connected.

  The control unit 51 can control the power supplied to each LED 12 in units of the light source module 10 by controlling the current value through each power supply circuit 52 or switching the current at a predetermined on / off ratio, for example. It is possible. The control unit 51 basically turns on the light source device 1 by supplying preset rated power to each light source module 10 through each power supply circuit 52.

  At that time, the control unit 51 prevents the temperature of the LED 12 from being overheated (abnormally increased) due to a failure of the cooling device 30 or partial detachment from the mounting surface portion 22a of the LED mounting substrate 11. The temperature T detected by each temperature sensor 13 is monitored. For this reason, the control unit 51 has a relationship between the power supplied to the light source module 10 and the temperature rise allowed for the power supply (when the power supplied to each light source module 10 and each LED 12 are normally cooled). The relationship between the temperature and the temperature that can be increased is set and stored in advance based on experiments, simulations, and the like. When the control unit 51 determines that at least one of the light source modules 10 has abnormally increased the temperature of each LED 12 with respect to the current supply power, the control unit 51 outputs an alarm through the alarm device 53 and each light source module. Control to reduce the power supplied to 10 is performed.

  Incidentally, problems such as failure of the cooling device 30 and partial peeling of the LED mounting substrate 11 are particularly likely to occur when the light source device 1 is replaced. Therefore, problems such as overheating of each LED 12 are more likely to occur at the time of startup after replacing the light source device 1 rather than at the time of steady lighting. Therefore, when starting the light source device 1, the control unit 51 first starts each light source module 10 with a starting power sufficiently lower than the rated power, and particularly in relation to the starting power. It is determined whether or not the temperature of each light source module 10 (each LED 12) has risen abnormally. And when the temperature of all the light source modules 10 exists in a normal temperature range, and the abnormal raise is not determined, each light source module 10 is made to light all light with predetermined rated power. In addition, it is preferable that the transition from lighting with such starting power to all-light lighting with rated power is performed in stages while monitoring the temperature rise of each light source module 10.

  Thus, in this embodiment, the control unit 51 implements each function as a power supply control unit and an abnormality determination unit.

  Next, lighting control of the light source device 1 executed by the control unit 51 will be described according to the flowchart of the lighting control routine of the light source device shown in FIGS. In the following description, in order to simplify the description, it is assumed that a light source device that is subject to lighting control uses 100 light source modules 10 each including 100 LEDs 12 of 1 [W]. In addition, if the total amount of supplied power is less than 2 [KW], the equipment to which the light source device 1 and the light source module 10 are applied will not be damaged even if the cooling device 30 is stopped. To do.

  When the main switch (not shown) is turned on and the lighting control routine starts, the control unit 51 first determines in step S101 whether or not the cooling device 30 is being driven based on a signal from the operation panel 33 of the cooling device 30. Check out.

  If it is determined in step S101 that the cooling device 30 is stopped, the control unit 51 proceeds to step S102, issues an alarm through the alarm device 53, and then exits the routine. That is, if each LED 12 is turned on while the cooling device 30 is stopped, the temperature of each LED 12 may rise abnormally. Therefore, when the cooling device 30 is stopped, the control unit 51 supplies power to each LED 12. The lighting control itself is forcibly terminated without supply.

  On the other hand, if it is determined in step S101 that the cooling device 30 is being driven, the control unit 51 proceeds to step S103, and the first light source module (N = 1) as the light source module 10 to be controlled. After selecting the module 10, the process proceeds to step S104.

  In step S104, the control unit 51 sets, for example, a current value to 50% of the total light time ratio as a starting power control value for the selected light source module 10, and an on / off ratio of the current of 25%. Set to.

  In step S105, the control unit 51 starts energizing the selected light source module 10 based on the control value set in step S104 described above. That is, the control unit 51 drives and controls the power supply circuit 52 corresponding to the selected light source module 10 based on the set control value of the starting power. Thereby, the said light source module 10 is started by the electric power of 12.5 [W], for example, and is intermittently lighted.

  When the process proceeds from step S105 to step S106, the control unit 51 checks whether or not the set time t0 has elapsed since the activation of the light source module 10 described above. If it is determined in step S106 that the elapsed time from activation is less than the set time t0, the control unit 51 waits as it is.

  On the other hand, if it is determined in step S106 that the elapsed time since activation of the selected light source module 10 is equal to or longer than the set time t0, the control unit 51 proceeds to step S107, and the temperature of the selected light source module 10 is reached. (That is, the temperature of each LED 12) It is checked whether or not T is abnormally increased with respect to the above-mentioned supply power of 12.5 [W].

  If it is determined in step S107 that the temperature T of the selected light source module 10 has not risen abnormally, the control unit 51 proceeds to step S108, where the control value of the power supplied to the selected light source module 10 is For example, the current value is set (changed) to 12.5% of the total light time ratio, and the on / off ratio of the current is set (changed) to 100%. Thereby, the light source module 10 determined to have no abnormality at the time of activation is subjected to aging by continuous lighting with a supplied power of 12.5 [W], for example.

  When the process proceeds from step S108 to step S109, the control unit 51 checks whether or not the currently selected light source module 10 is the last (100th: N = Nmax) light source module 10 that can be selected. If it is determined that it is not the module 10, the process proceeds to step S110, and after selecting a new light source module 10 as an activation target (N ← N + 1), the process returns to step S104.

  If it is determined in step S107 that the temperature T of the selected light source module 10 has abnormally increased, the control unit 51 proceeds to step S111 and issues an alarm through the alarm device 53.

  Then, when the process proceeds from step S111 to step S112, the control unit 51 keeps the intermittent lighting of the selected light source module 10 and the control value of the power supplied to the other light source modules 10 that are already turned on and are aging, for example, After the current on / off ratio is set (changed) to 12.5%, the routine is exited. As a result, the normal light source module 10 that has already been turned on is intermittently turned on with a smaller amount of light and a shorter lighting time than the light source module 10 that has been determined to be abnormal. In this way, the light source module 10 in which the abnormality is detected and the normal light source module 10 are turned on in different forms, so that the user can easily identify the light source module 10 determined to be abnormal. It becomes.

  If it is determined in step S109 that the currently selected light source module 10 is the last (N = Nmax) light source module 10, the control unit 51 proceeds to step S112, and supplies power to all the light source modules 10. As the control value, for example, the current value is set (changed) to 50% of the total light time ratio, and the on / off ratio of the current is set (changed) to 50%. Thereby, each light source module 10 is intermittently lit with electric power of 25 [W] (2.5 [KW] as a whole), for example.

  Then, when the process proceeds from step S112 to step S113, the control unit 51 checks whether or not the set time t1 has elapsed since the control value of the power supplied to each light source module 10 was changed. If it is determined in step S113 that the elapsed time from the change of the control value is less than the set time t1, the control unit 51 stands by as it is.

  On the other hand, if it is determined in step S113 that the elapsed time from the change of the control value is equal to or longer than the set time t1, the control unit 51 proceeds to step S114, and the temperatures T of all the light source modules 10 are 25 [W] It is checked whether or not there is an abnormal increase with respect to the supplied power.

  If it is determined in step S114 that the temperature T of at least one of the light source modules 10 has abnormally increased, the control unit 51 proceeds to step S120.

  On the other hand, if it is determined in step S114 that the temperatures T of all the light source modules 10 have not abnormally increased, the control unit 51 proceeds to step S115, and the control values of the power supplied to all the light source modules 10 are, for example, Set (change) the current value to 100% of the total light time ratio. Thereby, each light source module 10 is intermittently lit with electric power of 50 [W] (5 [KW] as a whole), for example.

  Then, when the process proceeds from step S115 to step S116, the control unit 51 checks whether or not the set time t2 has elapsed since the control value of the power supplied to each light source module 10 was changed. If it is determined in step S116 that the elapsed time since the change of the control value is less than the set time t2, the control unit 51 waits as it is.

  On the other hand, when it is determined in step S116 that the elapsed time from the change of the control value is equal to or longer than the set time t2, the control unit 51 proceeds to step S117, and the temperatures T of all the light source modules 10 are 50 [W] described above. It is checked whether or not there is an abnormal increase with respect to the supplied power.

  If it is determined in step S117 that the temperature T of at least one of the light source modules 10 has abnormally increased, the control unit 51 proceeds to step S120.

  On the other hand, if it is determined in step SS117 that the temperatures T of all the light source modules 10 have not risen abnormally, the control unit 51 proceeds to step S118, and the control value of the power supplied to all the light source modules 10 is, for example, Set (change) the on / off ratio of the current to 100%. Thereby, each light source module 10 is fully lit with power (rated power) of, for example, 100 [W] (10 [KW] as a whole).

  Then, when the process proceeds from step S118 to step S119, the control unit 51 checks whether or not the temperature T of each light source module 10 is abnormally increased.

  If it is determined in step S119 that the temperatures T of all the light source modules 10 have not abnormally increased, the control unit 51 repeats the determination in step S119. Thereby, as long as the temperature T of the light source module 10 does not rise abnormally, the full lighting state by the rated power is maintained.

  On the other hand, if it is determined in step S119 that the temperature T of at least one of the light source modules 10 has abnormally increased, the control unit 51 proceeds to step S120.

  When the process proceeds from step S114, step S117, or step S119 to step S120, the control unit 51 issues an alarm through the alarm device 53.

  Then, when the process proceeds from step S120 to step S121, the control unit 51 sets (changes) the current value to, for example, 50% of the total light time ratio as the control value of the power supplied to the light source module 10 that has detected the abnormality. Then, the on / off ratio of the current is set (changed) to 25%.

  Then, when the process proceeds from step S121 to step S122, the control unit 51 sets the current value to 12.5% of the total light time ratio, for example, as the control value of the power supplied to the light source module 10 other than the abnormality detected (normal). After setting (changing), the current on / off ratio is set (changing) to 12.5%, and then the routine is exited.

  According to such an embodiment, when starting the light source device 1 in which the plurality of LEDs 12 are mounted at high density, the start-up is lower than the rated power set in advance for each light source module 10 in which a predetermined number of LEDs 12 are modularized. By supplying power to each light source module 10 and turning on each light source module 10 at full power at the rated power, provided that the temperature of all the light source modules 10 does not increase abnormally in relation to the starting power. In the unlikely event that the cooling device 30 is deficient or the light source module 10 is partly peeled off from the base 2, the operating temperature of the light source device 1 is prevented from rapidly increasing and the LED 12 is turned on safely. be able to.

  At that time, by sequentially starting each light source module 10 with a predetermined time difference, the LEDs 12 can be turned on more safely than when all the light source modules 10 are simultaneously started, and a part of the light source modules 10 is given to the operator. It is possible to easily confirm the abnormality such as short circuit or open of the LED 12 by visual observation or the like.

  Furthermore, when the abnormality of the light source module 10 is determined, by turning on the light source module 10 in a form different from that of the other light source modules 10, an operator or the like can easily recognize the abnormal part.

  In the above-described embodiment, an example using a light emitting diode has been described as an example of a solid light emitting element. However, the present invention is not limited to this, and a light source device using other various solid light emitting elements. Of course, the present invention can also be applied.

  Further, the configuration of the mounting surface 22 on the light source device 1 is not limited to a configuration in which a plurality of mounting surface portions 22a are arranged in a zigzag manner while being connected in a ring shape. For example, as shown in FIG. Of course, the mounting surface 122 may be formed in a flat shape while arranging the plurality of mounting surface portions 22a in a zigzag manner.

  DESCRIPTION OF SYMBOLS 1 ... Light source device, 2 ... Base, 3 ... Cooling passage, 10 ... Light source module, 11 ... Mounting board, 11a ... Wiring, 12 ... Light emitting diode (solid light emitting element), 12a ... Hemispherical lens, 13 ... Temperature sensor, DESCRIPTION OF SYMBOLS 20 ... Base block, 21 ... Side surface, 22 ... Mounting surface, 22a ... Mounting surface part, 23 ... Through-hole, 25 ... Base, 26 ... Hole part, 27 ... Gasket, 30 ... Cooling device, 31 ... Heat exchanger, 32 ... Pump, 33 ... Operation panel, 50 ... Lighting control device, 51 ... Control unit (power supply control means, abnormality determination means), 52 ... Power supply circuit, 53 ... Alarm device, 122 ... Mounting surface

Claims (3)

A light source device in which a plurality of solid state light emitting elements are mounted as light sources on a mounting surface of a base,
The mounting surface is formed by a plurality of mounting surface portions arranged in a zigzag shape,
The angle between the mounting surface forming the valleys on the mounting surface, and set the optical interference angle of more than an angle determined by the half-value angle of light emitted from the solid state light emitting devices,
The mounting surface is formed by connecting a plurality of mounting surface portions arranged in a zigzag manner in a ring shape. A plurality of through-holes provided for each set of mounting surfaces that are continuous in a mountain fold shape of the base;
A cooling device for circulating the coolant,
The said each through-hole is connected to the said cooling device in the state where the connection location was aggregated by comprising a series of cooling passages by the edge part communicating, The cooling device of Claim 1 characterized by the above-mentioned. Light source device.   The light source device according to claim 1, wherein the base is divided into a plurality of base blocks in each predetermined valley portion.

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