LED Lighting Industry Case Study
More Than a Fan: Solving Lamp Safety and COB Cooling for an Entertainment Lighting Manufacturer
An entertainment lighting manufacturer came to YS Tech with two distinct thermal problems that needed to be solved within tight space, noise, and timeline constraints.
The first was a safety issue. The client needed a mechanism to cut power to a high-voltage lamp if the cooling fan failed - without the risk of electrical arcing that would come from a mechanical air vane or metal switch solution. YS Tech supplied a 120mm axial fan with a tach signal output on a third wire, used to trigger a relay that would cut lamp power if the rotor stopped. The solution required only a single additional component - an inexpensive quarter-watt resistor - to implement, and eliminated the arcing risk entirely. The fan also delivered 160 CFM of airflow at 50 dB(A), improving on the existing unit's performance.
The second problem arose from a product upgrade. The client was developing a new fixture using a higher-power Chip on Board (COB) LED that ran significantly hotter than the previous model - hot enough that a heat sink alone was no longer sufficient. Active cooling was needed, but the available space was extremely tight (approximately 70 x 70 x 40mm), the required airflow was high (50 CFM minimum), and the application was theatrical - meaning noise had to stay below 40 dB(A).
No single fan on the market met all three constraints simultaneously. YS Tech's solution was to run two 70 x 15 mm fans in series, a configuration that delivered over 55 CFM while keeping noise below 38 dB(A).
The client then faced a third constraint: they needed temperature-based fan speed control but had no time to design and validate a PWM controller circuit before their production deadline. YS Tech supplied a fan variant with an integrated thermistor and built-in control circuitry, eliminating the need for a custom circuit board and allowing the client to meet their schedule without compromising the design.
More Information on Thermal Management for LED Lighting
What thermal management products does YS Tech USA supply for LED lighting applications?
YS Tech USA supplies DC axial fans, heat sinks, and custom thermal assemblies for LED lighting manufacturers. Applications include high-power COB LED fixtures, entertainment and stage lighting, architectural and industrial luminaires, outdoor lighting systems, and LED grow lights. Standard catalog products cover most common requirements; custom configurations are available for applications with specific size, airflow, acoustic, or control requirements.
Why is thermal management critical in LED lighting systems?
LED junction temperature directly affects light output, color consistency, and service life. Sustained operation above the rated junction temperature accelerates lumen depreciation and shifts the color point, reducing both the fixture's quality and lifespan. Active cooling with fans and heat sinks maintains junction temperature within the LED manufacturer's rated range, preserving output quality and extending the time between replacements.
Can YS Tech USA supply fans with built-in speed control for LED applications?
Yes. YS Tech USA offers fan variants with integrated thermistor-based speed control, allowing fan speed to vary automatically with temperature without requiring an external PWM controller or additional circuit development. This is particularly useful for LED lighting programs where thermal management needs to be addressed quickly, and the engineering team doesn't have bandwidth to design and validate a custom control circuit.
Which fan configurations work best for cooling high-power COB LEDs?
COB LEDs at higher power levels often require airflow volumes that exceed what a single small fan can deliver within the application's acoustic limits. Running two fans in series - where the second fan draws air through the first - can significantly increase airflow and static pressure while keeping noise output within acceptable limits. YS Tech USA's engineering team can model fan configurations to identify the right approach for a specific fixture geometry and thermal load.
Does YS Tech USA offer fans with tach signal outputs for lamp safety applications?
Yes. Fans with tach signal output on a third wire are available from YS Tech USA's catalog. The tach signal can be used to trigger a relay or control circuit that cuts power to a lamp or other heat-sensitive component if the fan rotor stops - providing a reliable, low-cost failsafe without the arcing risk associated with mechanical air vane switches.
What IP-rated fans does YS Tech USA offer for outdoor LED lighting?
YS Tech USA's fans are available with IP ratings from IP43 through IP68 for outdoor LED lighting applications where exposure to moisture, dust, and environmental contaminants is a design consideration. IP rating selection should reflect the specific installation environment and any applicable ingress protection standards for the fixture class.
How do I specify a fan for an LED lighting application?
Key inputs include available envelope dimensions, target airflow (CFM), static pressure imposed by the heat sink and enclosure, acoustic limit (dB(A)), operating voltage, temperature range, and any IP rating or regulatory requirements. Contact YS Tech USA to discuss your application with an engineer.
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