Hi,
Now THIS is a great area of interest for me.
@Petrus: I know I sent most of this info via PM, but I'll try to include some of the more practical stuff here...
The following is NOT a complete project guide, but it gives a general outline of what I used to build my LED projector...
(Please let me know if I'm bombarding people with too much typing.)
Modifying a DLP projector with high-power LEDs was the project which got me started with FPGAs about 6 years ago. I needed a way of sequencing the RGB LEDs so that the colour switching would match the original (removed) colour wheel...
I bought an old Proxima projector at first, then wrote my first Verilog code to interpret the serial data being sent to the projector's colour wheel motor drive chip. Many DLP projectors use the Allegro A8902 (or similar) motor chip...
http://www.datasheetarchive.com/pdf-dat ... 60607.html" onclick="window.open(this.href);return false;
I did try to monitor the serial data using a PIC chip initially, but I think the serial speed was too fast. The FPGA worked perfectly after some minor bugfixes.
Of course, many projectors have an opto sensor to sense when the colour wheel rotates, so that signal is generated too.
Some projectors (like the Proxima) also require a "tachometer" signal, which is just a square wave which toggles each time the wheel rotates. (I had to cut a small track on the PCB, then input the tacho signal from the FPGA directly to the CPU on the projector).
More modern projectors use a different method to detect the wheel rotation - there is often a photodiode with a yellow filter on it - this acts as a colour sensor to tell the projector when the blue segment of the colour wheel has just past (and Red / Green is about to start). This signal was also simple to generate.
If the LEDs are bright enough, you wouldn't need to connect this signal because the PJ would sense the colour changes directly. I did find it to be a huge help when aligning the lenses though (the image wouldn't freeze or go blank etc.)
I looked far and wide for the brightest LEDs around at the time (many years ago). I soon found out about the "Archilles heel" of optical design - Etendue...
http://en.wikipedia.org/wiki/Etendue" onclick="window.open(this.href);return false;
Basically, the light source(s) need to have a very narrow angle of emission in DLP projectors. The point from where the light is emitted also needs to be kept very small. If you don't do this, any light outside of this "cone" will be wasted.
In other words, the LEDs you use need to have very high brightness output from a very small surface area. (You can't just bunch many LEDs next to each other without loosing massive amounts of light efficiency.)
With LCD projectors, the Etendue problem generally isn't as bad because the LCD panels are often bigger than DMD chips. The DMD requires a narrow-beam light source too (because of the way the light is reflected off the mirrors).
Then, for full-colour you of course need to combine your RGB LEDs using a dichroic prism block or filters (also in a small angle). The article which Petrus posted is an excellent example of how an LED projector "should" be built (great Web site).
So, I had to find some suitable lenses with a narrow output angle, then build an RGB combiner using the dichroic prism from an old LCD projector. It looks like this (FPGA board removed for another project)...
http://img31.imageshack.us/img31/9523/file0085.jpg" onclick="window.open(this.href);return false;
I used the brightest LEDs that I could find for the money (a few years ago) which had a small emitter surface. I won't mention the name, you can see them in the photo.
They are rated at 15 Watts per LED!
The image brightness with this setup was pretty impressive. I wasn't expecting spectacular results because I'm not an optical engineer and I just used whichever lenses gave the best results. The image was perfectly watchable in a dark room, especially if you keep the image size around 4 to 5 feet wide.
I also had to build my own high-current LED drivers (top-left in photo). They basically use KA350 adjustable regulators (higher power versions of the LM317) and some low-ohm resistors for current feedback. My drivers are only ON / OFF switchable, but you can actually adjust the relative brightness of each LED colour using PWM anyway.
The power supply for the LED drivers can be a simple laptop PSU provided it has sufficient current output.
Another point is that you'll need to bypass the PJs original lamp ballast signals. This is usually fairly straightforward, but some projectors need specific timings to work properly.
So, here are my ancient project files for Altera Quartus. Remember, this is the first Verilog code I ever wrote and much of the design is done as a block diagram. The code would be FAR neater and more compact if I was to tidy it up now...
http://www.mediafire.com/?8eda3p7mx1m7p1z" onclick="window.open(this.href);return false;
The code needs to be modified to match the specific timings of YOUR original colour wheel. I tried to keep the angles in Degrees, so you'll need to measure the angles of your colour wheel segments as accurately as you can. The code is quite well commented, so you'll see how basic it is.
You'll need to see how your donor projector detects the colour wheel rotation too. Many PJs still use an opto sensor next to the wheel itself.
I can't guarantee that this code will work with your specific projector - there are probably many different clock speeds used for the motor chip (which would affect the speed of the wheel rotation). Modern PJs can also have some rather complex colour wheel sequences and many use a dynamic Iris etc. Lots of issues may arise depending on the projector you use.
I added some PWM code blocks to the design so that the LED colours can be "tweaked". I found that this almost always made the image worse - you can only ever reduce the overall brightness when tweaking the colour too.
A few months ago, I "stole" the FPGA board from the LED projector for another project - I couldn't afford to buy another FPGA at the time, but I'm tempted to put it back together now.
btw, the PJ in the photo is an IBM iL2215 (re-badged InFocus LP335). It was one of the more light-efficient PJs I could find (ANSI Lumens vs lamp wattage).
Important note!...
Unfortunately it is very difficult to modify the original firmware of a commercial projector to speed up the colour switching (unless you have the original source code
). So, even though the LEDs can be switched MUCH faster than your average colour wheel can spin, you will still have a similar amount of rainbow effect etc.
Also, I'm not sure how much brightness a DIY LED DLP can achieve, but please don't expect miracles. With the newer high-power LEDs it might just be possible to get very impressive brightness - you bank account will start to suffer though.
Speeding up the actual frame rate that a projector can display is almost impossible. The only method I could think of which doesn't involve trying to modify a projector is ColorFlipping (still work-in-progress after a six-month break!)...
http://www.mtbs3d.com/phpBB/viewtopic.p ... P&start=60" onclick="window.open(this.href);return false;
OK, I think that's enough info for now; My typing fingers are aching.
OzOnE.