80+ Watt LED Driver Circuit

I need to drive 18 3W Leds using a standard ATX power supply. Constant voltage needs to become constant current. Here are my requirements: I need a gerber file for two boards. One is the controller, which will contain all of the components except the LEDs and the main LED board - which really is just an arrangement of LEDs with some wire traces. The design goal here is to allow for swapping out of the LED driver circuit in the event I need to upgrade/replace the driver, while leaving the LEDs intact. Ergo, the gerber file for the LED board is pretty simple. The controller is a bit more complex but should be pretty simple for somebody who knows what they are doing.

## Deliverables

Here are the core requirements for the controller board: It needs an ATX power plug, thermal sensor to shut down the circuit if the cooling fans fail, a resettable power fuse in case the circuit spikes, 2x fan headers, a relay to turn the entire circuit on or off, removeable connections to the LED board and the LED driver circuitry. Options include a transistor based system, or some kind of boost LED driver. I am shooting for 80% efficiency here, and above all else, safety in the event of component failure, component overheat or over voltage/current. At the same time, this circuit should be as simple as possible. Less components = less chance of failure and tend to cost less and be more reliable as well. Here are the datasheets for the two similar (but slightly different) LEDs I am considering using: [url removed, login to view] [url removed, login to view] Here are the part numbers for the ATX supply and the Fan headers: The fan headers should be driven as if they were a normal motherboard header. 12v + and gnd, no sense needed - only two pins in use. ATX: 39-29-9202 Fan Headers: 22-23-2031 You are free to search for board to board connectors for connecting the two boards. Obviously make sure they meet specs but most importantly - keep the costs low - nothing fancy. If you can't find it in Mouser for under 2 bucks, it is too elegant of a solution to connect two wires. This LED to LED driver connection is a two wire connection. Wire terminal perhaps? KISS. Datasheets with pin layout should be pretty easy to come by. Check the LED pdfs for their layouts. The relay: This part is the only tricky part. Because a normal 400 watt ATX power supply has more than enough power for two of these boards, I will be splitting the power supply and powering two boards from it. I need feedback on this but if possible, I would prefer to run both LED daughter boards off of a single controller. That way, I will eliminate having to use a Y splitter and also be able to control the board with a relay, to either short the sense pin to ground (to turn the supply on) or leave it open to turn the circuit off. It would make sense to also tie the temperature overload sensor to this. Anyway, what I need the system to do is somehow interface with a computer to enter a low power mode. My thoughts were to simply use the USB port to sense and switch this relay. When the computer powers up, it trips the relay and on comes the circuit. When the computer enters S3 (not sure S1 standby will do it) then the USB power is cut and the LEDs turn off. All told, this circuit should be pretty straightforward but I need somebody who understands the nuances of driving high powered LEDs and knows how to reliably run them at 90% of rated power (so about 650 ma each). Small changes in voltage lead to large changes in current and driving these things past spec gets real expensive real fast, as the LEDs themselves run around 6 - 8 bucks each. Also, the voltage and internal resistance varies A LOT depending on Tj and other factors. I am not interested in a PWM solution unless you can give me a very good reason to justify that kind of implimentation. Please feel free to ask questions or to clarify this circuit. 1) Complete and fully-functional working program(s) in executable form as well as complete source code of all work done.

2) Deliverables must be in ready-to-run condition, as follows (depending on the nature of the deliverables):

a) For web sites or other server-side deliverables intended to only ever exist in one place in the Buyer's environment--Deliverables must be installed by the Seller in ready-to-run condition in the Buyer's environment.

b) For all others including desktop software or software the buyer intends to distribute: A software installation package that will install the software in ready-to-run condition on the platform(s) specified in this bid request.

3) All deliverables will be considered "work made for hire" under U.S. Copyright law. Buyer will receive exclusive and complete copyrights to all work purchased. (No GPL, GNU, 3rd party components, etc. unless all copyright ramifications are explained AND AGREED TO by the buyer on the site per the coder's Seller Legal Agreement).

## Platform

The Real World.

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Proje NO: #3438299

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