A look at Chinese Value Engineering

Seventy cents doesn’t buy you a lot these days. Maybe some sweets or candies at most. How about a string of LEDs that you can use to decorate your home during the festive season? [Amaldev] was curious to know what was, or wasn’t, inside these blinky LED strings which made them so cheap. He’s done a Christmas LED Light Teardown and shows how blinky LED string lights can be built with the bare minimum of components.

The string he purchased had 28 LEDs – seven each in four colors, a controller box with one push button and a  power cord. Without even knowing what is inside the controller box, the cost of the product seems astonishing based on this BoM. The single push button cycles through eight different light patterns for each press. It even has a faux CE mark for the supply plug. Cracking open the case, he finds that the controller board is sparsely populated with just seven through hole components and a COB (chip on board) module. A simple, 8-bit, 8-pin microcontroller is possibly what controls the device.

[Amaldev] sketches out a schematic to figure out how it works. There are two arms with 14 LEDs of alternating colors, each of which is controlled by an SCR. Two GPIO output pins from the COB control the gates of each of these SCR’s. The button is connected to a GPIO input, and a second input is connected to the AC supply via a current limiting resistor. Most likely, this is used to determine the zero crossing of the waveform so that the COB can generate the appropriate trigger signals for the gate outputs.

It is unlikely that these products are manufactured using automated processes. The PCB production could be automated, but soldering all the wires, fitting it all in the enclosure and preparing the LED string itself would require manual labor. At US$ 0.7 retail on the street, it is difficult to imagine the cost breakdown even when the quantities are in large numbers. Maybe a combination of cheap components, recycled or rejected parts (mains cord/enclosure), lack of safety and protection measures (no fuses, no strain reliefs) and reducing the component BoM to an absolute, bare minimum, coupled with very high volumes lets them pull it off? What are your thoughts – chime in with comments.

Filed under: Teardown