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Originally Posted by arunphilip So here's the part that puzzles me a bit: - In household lighting, I see LEDs as roughly 10x as efficient as incandescent lighting, and 2x as efficient as fluorescent lighting (tubelights & CFL), which means there is a noticeable drop in power consumed and heat emitted. The reason I make this point is just to set a scale of power drawn by different lighting technologies.
- However, in the automotive side, I see that halogens are rated 55/60W and LED 35W, let's call halogens as 2x that of LED. Yet I see that LED headlights come with cooling fans, while the good old legal halogens make do without any such forced cooling. What gives? Is it just the density of diode packaging and placement that results in higher thermals?
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There is a big difference between LEDs used for household and LEDs used for headlamps - the former is sitting in an extremely 'airy' constant ambient while the latter is sitting in an airtight, hot (engine radiation) ambient. Where am I going with this ?
Lets take a step back and examine what happens when current is passing through a resistor (halogen lamp) and a semiconductor with special implants (LED lamp) :
Heat is generated primarily because an army of electrons are punching through a narrow alley, jam packed with atoms of the material - this causes these atoms to sway violently about their positions, increasing their amplitude of vibration, which we call heat and the effect of which we call temperature. These oscillating atoms (packets of charges vibrating violently) generate electrical and magnetic fields that are also oscillating - and voila, we have EM waves. Imagine a team of cheetahs running through a huge field of thick tall grass - the grass which is already swaying in the wind will sway violently along the edges of the path the moving animals make, and this sway will be transferred outwards, radially.
For a resistor, most of the generated EM waves fall in the infrared spectrum (the heat which we 'feel at a distance' from the lamp) and a little bit fall in the visible light spectrum (that is used to light up the road ahead).
LEDs on the other hand are actually PN junction diodes made with carefully chosen semiconductor material, such that when the same effect occurs (described above) when electrons are made to flow through it, there is more of visible light and less of infrared, making LEDs less heaty and more lighty.
However, there is a crucial difference.
Resistors have a positive temp coefficient of resistance, ie forging a path is more difficult for the electrons when the material is having a higher temperature (cheetahs find it harder to run through, when the grass is already violently swaying from the wind). The 'resistance' increases with temperature. If the heat generated by a resistor (proportional to the square of the current passing through it) is not taken away quickly, then the temp of the resistor rises, and increases the resistance, which will reduce the current, which in turn, generates less heat. This is a self regulating equilibrium where once a stable temp is reached (generated heat = removed heat + heat required to maintain the same temp of the resistor) , a constant, steady state current is consumed.
On the other hand, PN junctions have a negative temp coefficient of resistance, ie the electrons find it easy to forge a path when the material is hotter (here the grass is such that as the wind gets stronger, the grass uproots readily, making it easy for the cheetahs). If the heat generated is not taken away quickly, then there will be more current, leading to more heat, leading to more current, more heat...... a thermal runaway - something which can cause exponential rise in the current, burn the LED lamp from the heat and cause a short (there is no grass to sway if it all gets burnt in a fire).
Many of the good quality LEDs for headlamps come with a 'driver' or 'adapter' circuit (a box which dangles behind, as part of the wiring kit) - this primarily contains a DC-DC power supply adapter and a constant current regulator, the constant current drive is to prevent thermal runaway.
Hence, even though LEDs generate lesser heat than halogens, the removal of generated heat is extremely crucial to the working and lifespan of the LED lamp. Thats why they have these complicated fin designs, fans etc ; and halogen lamps dont bother with this, since there is auto regulation (as long as the max heat generated is within the melting point of the filament material)
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The extra power consumption for LED headlamps vis-a-vis home LED lamps for similar lumens output, is attributed to the more 'lossy' DC-DC power adapter support circuitry in the headlamps , compared to the AC-DC power adapter for home LED lamps. This is my guess, not very sure about it.