Why LED Lights are Such a Bright Idea

 

Thomas Edison had no idea that his 1879 light bulb invention would someday be used in another dramatic technological wonder. Almost since the beginning, airplanes and airports had constantly made use of the reliable and inexpensive incandescent light bulb. For 133 years, people have enjoyed the ease of use and near global benefit that incandescent lighting has to offer. Unfortunately, the U.S. Congress of 2007 has decided that we should no longer use this inexpensive U.S. invention. The original Energy Independence and Security Act mandated efficiency standards for bulbs between 40 and 100 Watts. Although this bill has been altered, and recent Congress sessions have tried to defeat it, the bill became enforceable in October 2012. Because of the passage of this bill, G.E. closed its last incandescent bulb plant in Winchester, Pa., in 2010. America suffered a double whammy. Not only were 200 jobs lost in Winchester, but America no longer had the ability to provide inexpensive lighting for North American use.

Since the replacement for incandescent bulbs was normally CFL (fluorescent) bulbs, American manufacturers found it near impossible to compete against Chinese factories in the manufacturing of CFL products. CFL bulbs are much more labor intensive to build and they require the use of hazardous mercury elements in the assembly process. Many economists like to believe that markets should be allowed to allow products to be built wherever they want, thus China is the cheapest source. Government officials and economists are now upset over Chinese manipulation of rare earth exports. The same mentality that eliminated incandescent bulb production in the U.S. is now somehow confused why incandescent bulbs coming from China are climbing in price at an accelerating rate. China has now also introduced a full ban of the importing and sale of incandescent bulbs by 2016.

I chose to write this article because sometimes our industry has severe product shortages due to impending FAA regulations, such as the recently-rescinded mandate for 406 MHz ELT replacement. Many of my friends and customers were in a near panic when they were told that the 406 ELT productions were backlogged from four to six months.

Similarly, I believe the coming shortage of aircraft light bulbs will take everyone in our industry by surprise. The days of an inexpensive 4509 landing light are nearly over. Several major industrial light bulb wholesalers are already sending letters to their top distribution partners to state that a shortage is coming. The reason? China is reducing rare earth materials used to make light bulbs in China, forcing prices to skyrocket. Reduce supply, and prices are driven up. DOMs should start taking immediate inventory of their bulbs. Evaluate your navigation light bulbs, beacon bulbs, landing lights and taxi lights. Have enough spares to last 12 to 24 months. Once you have established some inventory to cover your future needs, think about upgrading your lights.

Although some aircraft owners like the expensive high-intensity discharge (HID) lights, we are going to focus on light-emitting diode (LED) lighting, which is where most of the aerospace lighting companies are headed. I once looked at the price of LED lights and scoffed. Once I thought about aircraft operations, I began to look at this alternative more closely. A friend in Anchorage, AK, took me over to his Cessna 180 and showed me the lighting difference between LED landing lights and incandescent ones. All I could say is “wow.” The proof blew me away. Despite what I read from some aviation experts, the LED landing light was significantly brighter than the old one. Seeing the LED landing light in operation single-handedly changed my mind about how bright they could be. I also discovered that using these lights solves a long list of issues that have plagued aircraft maintenance operators for years.

Lifespan

Many FAA Part 135 operators tell me that they see life spans of 25 to 100 hours with their standard incandescent light bulbs. Some have been able to get longer life using halogen bulbs, but everyone agrees that the constant labor cost and downtime to address this universal issue is a pain. For example, Teledyne Lighting & Display Products’ ALPHABEAM LED landing/taxi light has a minimum life expectancy of 5,000 hours. That is extraordinary. If you’re charter operator or commuter air carrier, the life expectancy alone is enough to justify the purchase price.

Reduced Load

Over the years, the aviation community has done a good job of installing more and more electronic equipment on aging airframes. We have added more lighting systems, GPS and entertainment systems to aircraft without increasing the availability of electrical power. This has become a widespread issue. One of the big pluses to LED lighting is that it requires a small fraction of power to operate properly. Whelen Engineering, which has long displayed extensive leadership in aviation lighting, has a large and expanding list of LED aviation products. Many of Whelen’s LED products are being used on new product fixed- and rotary-wing aircraft. The Whelen Parmetheus product line has several PMA/STC landing and taxi lights that are available. Several of its 14v units use barely one amp, whereas a standard 14v 4509 bulb may use up to eight amps. This is a monumental reduction of load. While we are talking about electrical load, the LED landing and taxi lights can be installed without a new power supply. They are just plug and play. I have noticed several of the HID systems require that a new power supply be purchased, which increases cost.

LEDs are very bright

The Teledyne ALPHABEAM advertises 170,000 maximum candlepower. When you compare this to the 110,000 advertised candlepower of the old 4509 bulb, or 150,000 candlepower of a 4596 bulb, that is bright! Designers are able to control the diodes by adjusting the flow electrons, which in turn releases photons. This event creates an electroluminescent light, which can be adjusted and controlled to address light color and brightness.

Significantly Increased Durability

Incandescent light bulbs use a filament, which often becomes damaged or broken during the operational cycle of aircraft operations. I have seen landing lights go out more than once while landing at night. The jar of hitting the pavement is enough to end a bulb’s life. LED lights do not have this issue. The LEDs are held firmly to the circuit board, creating a stable and rigid platform for the light to operate from. LED lights are more durable because they use a polycarbonate lens which is much more impact resistant than incandescent glass bulbs. LED lights are also more resistant to moisture. Recently, Aero LED posted a video on YouTube to demonstrate that its LED lighting would operate even under water. If you have doubts about the durability of LEDs, you might consider Aero LED’s recent success with its aircraft position lights and strobes that were successfully launched on the SpaceX Dragon capsule. This capsule recently docked with the International Space Station. While the Dragon capsule was nearing the station, astronauts onboard where able to see the Aero LED lights flashing long before they could visually see the approaching spacecraft.

I have made mention mostly of using LED for the external lighting of aircraft. If you work with business jets or with transport category aircraft, you are most likely aware of the exploding options that are coming available with the use of LED lights inside the cabin. Any visit to a major aircraft interior convention or business jet show such as the NBAA annual meeting and convention will leave you impressed with the array of customizable lighting options available. In addition to the reduced electrical load, LED lighting technology offers interior designers with the ability to expand lighting solutions while also reducing weight. When LED lighting is used, designers are also able to eliminate other problematic electrical components such as ballasts, dimmers and power supplies. LEDs were implemented much earlier in aircraft interiors, as interiors are normally highly customized to begin with. LED lighting solutions are being used to power emergency exit signs, air gaspers with lights, cabin flood lighting, floor lighting and even cockpit map lights. Luma Technologies recently announced STC-approved LED annunciator panels for Beech King Air and 1900 series aircraft. It seems as though engineers are finding new applications for LED technology for aircraft on a steady basis.

There are two cons that should be discussed when considering LED technology. LEDs, as a rule, give off a lot of heat when they are bright. The Teledyne ALPHABEAM has a beefy metal backside that serves as a heat sink. The Alpha Beam instructions mention that if a rubber liner were used with the older incandescent bulb, it may be best to dispense with the gasket. The Alpha Beam has an internal circuit that will temporarily reduce the power of the bulb if it gets too hot. When the bulb cools down, it returns the bulb to full power. Since LEDs often also require better input current management, the ALPHABEAM also controls all input voltages for 14v and 28v systems. It is impressive the Teledyne has been able to address several issues for PAR36 bulbs with just one unit.

Although the old yellow and blue bulb box may go the way of the dodo bird, we are fortunate that several aerospace companies are offering U.S.-made LED products that can address this approaching need. Fortunately, new LED technology will reduce aircraft maintenance costs while offering relief to overburdened electrical systems.  

 

Norman Chance is president and CEO of Chance Aviation, an international aircraft parts distributor headquartered in Indianapolis. He has a degree in aircraft maintenance from Vincennes University and a degree in aeronautics from Embry-Riddle University. He holds an FAA A&P certificate.

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