High-flux focusable color-tunable and efficient white-light-emitting diode light engine for stage lighting

Abstract

Abstract. A color mixing light-emitting diode (LED) light engine that can replace 2-kW halogen–Fresnel spotlight with high-luminous flux in excess of 20,000 lm is reported for applications in professional stage and studio lighting. The light engine focuses and mixes the light from 210 LEDs of five different colors through a microlens array (MA) at the gate of $Ø50mm$. Hence, it produces homogeneous color-mixed tunable white light from 3000 to 6000 K that can be adjustable from flood to spot position providing 10% translational loss, whereas the corresponding loss from the halogen–Fresnel spotlight is 37%. The design, simulation, and optimization of the light engine is described and compared to the experimental characterization of a prototype. The light engine is optimized through the simulated design of reflector, total internal reflection lens, and MA, as well as the number of LEDs. An optical efficiency of 59% and a luminous efficacy of $33lm/W$ are achieved, which is three times higher than the 2-kW halogen–Fresnel spotlight. In addition to having color rendering of color rendering index $Ra>85$ and television lighting consistency index $12>70$, the dimmable and tunable white light can be color controlled during the operational time.