LED luminaire for retrofitting lighting system with LED lamp

Abstract

An apparatus for retrofitting an HID lighting system includes using existing components of a previously installed HID lighting system, such as a ballast thereof, while replacing some capacitors to regulate the power supplied to the retrofit LED lighting fixture. The unused ballast driver is removed and the independent ballast driver assembly is installed into the electronic control housing of the previously installed lighting system. Some retrofit LED lighting fixtures include upward illumination lenses, optics, or diffusers for providing upward illumination. The aiming support and the aiming plate can be used for setting the horizontal aiming angle of the lamp.

Description

[0001] This application is a divisional application of the invention patent application with application number 202480008925.2 filed on January 23, 2024, and the invention title is “Independent ballast driver for modifying lighting systems using LED lamps”.

[0002] CROSS-REFERENCE TO RELATED APPLICATIONS

[0003] This application is related to and claims the benefit of U.S. Provisional Application Serial No. 63 / 440,456, filed on January 23, 2023, and U.S. Provisional Application Serial No. 63 / 520,133, filed on August 17, 2023, the entire contents of which are incorporated herein by reference. Technical Field

[0004] The present disclosure generally relates to a system for replacing HID (high-intensity discharge) lamps in lighting systems with LEDs (light-emitting diodes). More specifically, the present disclosure enables such a system to be installed cost-effectively, utilize existing components of previously installed lighting systems, save energy costs during use, provide comparable or better lighting, and provide uplighting. Background Art

[0005] Direct replacement of a light source typically occurs when an existing light source, typically a faulty one, is replaced with another light source having similar power regulation and connection methods. For example, the light source of a residential lighting fixture (e.g., a desk lamp) may include a faulty 60W incandescent bulb that is replaced with a 100W incandescent bulb. This is not a typical retrofit scenario. A typical retrofit scenario occurs when the replaced light source is somewhat different from the light source it replaces, typically in terms of power requirements.

[0006] For example, if a failed 60W incandescent bulb in the same desk lamp is replaced with a 15W LED bulb (which has a light output comparable to a 100W incandescent bulb), this would be a typical retrofit scenario. The LED bulb requires an onboard driver system to adapt the available AC to the DC power requirements of the LED light source. However, it is important to note that this example is a simple retrofit scenario compared to other more complex lighting retrofit scenarios that lack this simple, market-wide accepted solution—no other modifications to the rest of the lighting system are required to address the different power requirements.

[0007] On the other hand, specialized lighting systems, such as sports or wide-area lighting systems, require more consideration to replace. Unlike the desk lamp example, there is no standard bulb shape or size, no standard bulb base, and no standard input wattage. Instead, all of these characteristics can vary from site to site and manufacturer to manufacturer. For example, the input voltage at a site may be 480V or 240V, or the input wattage may be three-phase or single-phase, or the existing lighting system may be a mix of HID and sodium lamps of different sizes and shapes, etc. In addition to the lighting technology, the power regulation devices, connection devices, and the non-lighting technology parts of the above-mentioned existing lighting systems, such as the poles, housings, wiring, and cross arms, may also vary. As an example, an existing lighting system may include a solid wood pole with exposed wiring or a hollow steel pole with internal wiring. As another example, the pole may be screwed to a plate on the ground, buried in the ground, or attached to some other feature in the lighting system (such as a truss system).

[0008] Therefore, the one-to-one replacement approach in the residential lighting retrofit market, such as taking out the old light source and installing a new one without making other changes, is impractical for the professional lighting retrofit market.

[0009] That said, some manufacturers have, to date, experimented with a one-for-one replacement approach for professional lighting system retrofits. These attempts have often encountered significant problems. For example, some manufacturers attempt to retain the existing crossarm even when the one-for-one retrofit fixture cannot fit within the existing crossarm footprint. This limits the retrofit fixture's achievable horizontal and vertical aiming range and often results in dark spots in the target area. This can affect lighting uniformity. Some manufacturers drill new holes in the existing crossarm to accommodate the one-for-one retrofit fixture's footprint. This often weakens the crossarm and introduces additional locations for moisture to penetrate, damaging wiring and potentially exacerbating corrosion.

[0010] Therefore, the art lacks a system for appropriately retrofitting specialized lighting systems, such as lighting systems covering large external areas, such as sports stadiums, ports, airports, railways, and the like. Summary of the Invention

[0011] An LED lighting fixture according to an embodiment of the present disclosure may include a lamp defining a lamp perimeter having a horizontal width and a vertical height, wherein a ratio of the horizontal width to the vertical height ranges from 0.90 to 1.25.

[0012] The details of one or more examples of the present disclosure will be set forth in the accompanying drawings and the following description. Other features, objects, and advantages of the present disclosure will be apparent from the description, drawings, and claims. BRIEF DESCRIPTION OF THE DRAWINGS

[0013] The following drawings are used to illustrate specific examples of the present disclosure and therefore do not limit the scope of the present disclosure. The drawings are not necessarily drawn to scale, but the examples may include the proportions shown and are intended to be used in conjunction with the description in the following detailed description, where like reference numerals represent like elements. Examples of the present disclosure will be described below in conjunction with the drawings.

[0014] Figure 1 shows a prior art system of an exterior lighting system comprising a light pole with HID (High Intensity Discharge) lamps attached thereto for lighting a sports field and the area above the sports field. As shown, a baseball field or other sports field can also be illuminated by this prior art system.

[0015] Figure 2 depicts a lamp post and its cross arm with HID lamps used in the prior art system of Figure 1. In addition, the electrical component housing and grounding equipment are clearly shown in the figure.

[0016] 3 is a side cross-sectional view of the top portion of FIG. 2 showing the wiring within the light pole and the cross arms leading to the lights.

[0017] Figure 4 is a top cross-sectional view of the top portion of Figure 3, more clearly showing the wiring within the top cross arm. Figures 3 and 4 also illustrate possible physical or photometric interference (indicated by lines A and B) between luminaires on the same pole, which can be avoided during retrofit design to allow full horizontal and vertical pivoting and avoid the generation of unwanted light, etc.

[0018] Figure 5 is a schematic diagram of the components within the electrical component housing of Figure 2. These components form the circuit for operating the single HID lamp shown in Figures 2 to 4.

[0019] FIG. 6 is a schematic diagram of the conventional power supply circuit of FIG. 5 for powering a single HID lamp.

[0020] Figure 7 The interior of an electrical component enclosure (ECE) is shown with the ballast removed and one or more independent ballast driver assemblies installed in the ECE for powering one or more LEDs, according to an embodiment of the present disclosure. The front cover of the ECE has been removed to reveal these internal components and assemblies.

[0021] Figure 8 is shown separately Figure 7 A perspective view of the independent ballast driver assembly.

[0022] Figure 9 Shown Figure 8 A standalone ballast driver assembly with its cover removed reveals a circuit board containing a power supply circuit for powering a single LED lighting fixture according to an embodiment of the present disclosure.

[0023] Figure 10 yes Figure 9 Figure 2 is a bottom-oriented perspective view of the standalone ballast driver assembly, showing the bottom of the circuit board.

[0024] Figure 11 is shown separately Figure 9 Bottom-oriented perspective view of the cover of the standalone ballast driver assembly.

[0025] Figure 12 is shown separately Figure 8 Front oriented perspective view of the mounting bracket for the standalone ballast-driver assembly.

[0026] Figure 13 is a perspective view of a circuit board assembly with a heat sink. Figure 8 Part of the standalone ballast driver assembly shown by itself.

[0027] Figure 14 yes Figure 13 A top view of the circuit board assembly and heat sink.

[0028] Figure 15 yes Figure 7 An alternative to the ECE disclosed in , which has dual independent ballast driver assemblies.

[0029] Figure 16 is with Figure 8 A perspective view of a similar standalone ballast driver assembly, except with two PCBs and a driver for Figure 8 This component can be used to drive more lighting fixtures related circuits Figure 15 of ECE.

[0030] Figure 17 Shown Figure 16 A standalone ballast driver assembly with the cover removed showing the two PCBs (printed circuit boards) facing each other.

[0031] Figure 18 yes Figure 17 An alternative perspective view of a stand-alone ballast driver of FIG. 1 , more clearly showing the clamps that hold some components attached to the PCB against a thermally conductive and electrically insulating plate.

[0032] Figure 19 yes Figure 18 Figure 2 is a rear perspective view of a standalone ballast driver assembly showing the PCBs and heat sinks vertically adjacent to each other.

[0033] Figure 20 Contains separate display Figures 17 to 19 A perspective view of a single instance of a PCB.

[0034] Figure 21 yes Figure 20 Alternative perspective view of the PCB.

[0035] Figure 22 is a schematic diagram of a rectification and power supply circuit according to an embodiment of the present disclosure, which is configured to supply direct current (DC) to an LED lighting fixture.

[0036] Figure 23 Shown in more detail Figure 22 Some sub-circuits of the rectification and power supply circuit.

[0037] 24 discloses a cam timer assembly that is installed in some prior art HID lighting systems to gradually increase the wattage supplied to the HID lamp due to the loss of brightness the HID lamp experiences over time.

[0038] Figure 25 is a perspective view of the wire end bracket in an open configuration.

[0039] Figure 26 is a perspective view of the wire end bracket in a closed configuration.

[0040] Figure 27 1 is a perspective view of an LED lighting fixture having a visor with a top surface forming a top angle of approximately 12 degrees with respect to the horizontal according to an embodiment of the present disclosure. An optional uplighting lens is shown attached to the front of the visor.

[0041] Figure 28 yes Figure 27 Side view of an LED lighting fixture.

[0042] Figure 29 yes Figure 28 sectional side view of an LED lighting fixture showing the curved underside of the bezel, the optics, and the LEDs.

[0043] Figure 30 yes Figure 27 Front view of an LED lighting fixture with the outer lens removed, showing the secondary lens and internal optics holder.

[0044] Figure 31 Shown Figure 30 An LED lighting fixture where the bezel and uplighting lens have been removed, more clearly showing the square perimeter of the fixture.

[0045] Figure 32 is a perspective view of an LED lighting fixture according to another embodiment of the present disclosure, Figure 27 of similar or identical construction, except that the bottom side of the sunshade is as Figure 26 Straight as shown.

[0046] Figure 33 yes Figure 32 Side cross-sectional view of an LED lighting fixture.

[0047] Figure 34 is a perspective view of an LED lighting fixture according to another embodiment of the present disclosure, Figure 32 is similarly or identically constructed, except that the top surface of the sunshade forms a top angle of approximately 18 degrees with the horizontal.

[0048] Figure 35 yes Figure 34 Side view of an LED lighting fixture.

[0049] Figure 36 yes Figure 35 A side cross-sectional view of an LED lighting fixture showing the optics, LEDs, internal lenses, etc.

[0050] Figure 37 yes Figure 34 Front view of the LED lighting fixture.

[0051] Figure 38 Depicts Figure 37 LED lighting fixtures, showing the lamps, steering knuckles and radiators for Figures 27 to 34 All three embodiments shown are identical.

[0052] Figure 39 is a perspective view of an LED lighting fixture according to another embodiment, Figure 34 similar or identical construction except that the bottom surface of the visor Figure 40 Shown are undulating.

[0053] Figure 40 yes Figure 39 A side cross-sectional view of an LED lighting fixture.

[0054] Figure 41 Shown Figure 39 FIG. 1 shows an LED lighting fixture in which the uplighting lens is removed, thereby showing the mounting holes in the front panel of the sunshade. It should be understood that the uplighting lens, optics, or diffuser can be used with each of the sunshade embodiments disclosed herein, such that the front panel of each sunshade has the same mounting holes.

[0055] Figure 42 1 is a partially exploded assembly diagram of the LED lighting fixture disclosed in this article.

[0056] Figure 43 is a perspective view of an optical device having a four-LED array to produce a wide beam, which can be used with Figure 42 Used together with the lamps.

[0057] Figure 44 is a perspective view of a lens constructed in accordance with an embodiment of the present disclosure shown alone.

[0058] Figure 45 yes Figure 44 Front view of the lens.

[0059] Figure 46 yes Figure 44 Side view of the lens.

[0060] Figure 47 is a rear oriented perspective view of a circuit board and heat sink subassembly with a wire end bracket shown attached to its side.

[0061] Figure 48 is a perspective view of a lens constructed according to another embodiment of the present disclosure shown alone.

[0062] Figure 49 yes Figure 48 Front view of the lens.

[0063] Figure 50 yes Figure 48 Side view of the lens.

[0064] Figure 51 It is shown that the formation Figure 50 A graph of the curve of the side surface of the light redirecting portion of the lens.

[0065] Figure 52 Shows to Figure 50 The incident light on the lens, the refraction of light in the lens, and the redirection of light when it leaves the lens.

[0066] Figure 53 Shown with Figure 52 Shown are the same incident light incident upon lenses having different profiles, the resulting different refractions in the lenses, and the resulting different redirections of the light upon exiting the lenses.

[0067] Figure 54 A front perspective view of yet another embodiment of a lens of the present disclosure is depicted.

[0068] Figure 55 Include Figure 54 A rear perspective view of a lens showing one or more mounting pads of the lens.

[0069] Figure 56 yes Figure 54 Right side view of the lens.

[0070] Figure 57 shows a horizontal aiming bracket used on some HID lighting systems as well as some LED lighting systems found in the field.

[0071] Figure 58 A perspective view of a main crossbar and an auxiliary crossbar attached to the main crossbar by an aiming bracket and an aiming plate (also referred to as an aiming shim) according to an embodiment of the present disclosure. One aiming bracket and one aiming plate are each attached adjacent to each end of the main crossbar, while one aiming bracket and one aiming plate are each attached adjacent to each end of the auxiliary crossbar.

[0072] Figure 59 yes Figure 58 A top cross-sectional view of the main and auxiliary cross-arms, showing the mounting holes and hardware used to secure the aiming brackets to the cross-arms. The middle aiming bracket is angled approximately 10 degrees relative to normal to the main cross-arm, the right aiming bracket is angled approximately 30 degrees relative to normal to the main cross-arm, and the left aiming bracket is angled approximately 40 degrees relative to normal to the main cross-arm.

[0073] Figure 60 yes Figure 58 A perspective view of the sight bracket, knuckle, sight plate, and mounting hardware with the cross arm removed.

[0074] Figure 61 is a perspective view of the intermediate aiming bracket, steering knuckle, mounting hardware, and intermediate aiming plate shown in isolation.

[0075] Figure 62 is a perspective view of the right aiming bracket, steering knuckle, mounting hardware, and right aiming plate shown in isolation.

[0076] Figure 63 is a perspective view of the left aiming bracket and left aiming plate shown alone.

[0077] Figure 64 is shown separately Figure 61 A perspective view of the intermediate aiming bracket and intermediate aiming plate.

[0078] Figure 65 It is shown by itself Figure 61 Bottom directional perspective view of the sighting bracket.

[0079] Figure 66 It is shown separately Figure 61 A top-oriented perspective view of the top portion of the steering knuckle.

[0080] Figure 67 is a top view of the sight plate, such as shown by itself with Figure 61 The aiming plate is used together with the intermediate aiming bracket.

[0081] Figure 68 is a top view of the sight plate, such as shown by itself with Figure 62 and 63 Aim plate used with the right and left aiming brackets.

[0082] Figure 69 is a top view of an aiming plate according to another embodiment of the present disclosure, the aiming plate and Figure 67 The sight plate is similarly or identically constructed, except the angle indicator has been removed.

[0083] Figure 70 is a top view of an aiming plate according to another embodiment of the present disclosure, the aiming plate and Figure 68 The sight plate is similarly or identically constructed, except the angle indicator has been removed.

[0084] Figure 71 is yet another embodiment of an aiming plate that lacks an angle indicator and may be used with other older style cross arms or in other locations in the cross arm not expressly disclosed herein.

[0085] Figure 72 is a perspective view of an aiming bracket for use with an aiming plate having an extended angle indicator portion so that smaller angles can be more easily read along a front flat portion of the aiming bracket in accordance with yet another embodiment of the present disclosure.

[0086] Figure 73 It is shown by itself Figure 72 A top view of the aiming plate.

[0087] Figure 74 is a flow chart describing a method for determining whether a HID lighting system and some of its components are suitable or ready for retrofitting with an LED lighting system.

[0088] Figure 75 Contains the use of Smart A method for adjusting the capacitance supplied to the power line and the resulting power supplied to the LED lighting fixture using a technique or similar technique.

[0089] Figure 76 A method of retrofitting a HID lighting system using an LED lighting system according to an embodiment of the present disclosure is shown.

[0090] Figure 77 A method for assembling a housing around a circuit board having a heat sink is included in accordance with another embodiment of the present disclosure.

[0091] Figure 78 A method of producing uplighting using a lens, optics, or diffuser according to an embodiment of the present disclosure is shown.

[0092] Figure 79 Depicted is a method of aiming the horizontal direction of a knuckle that may be attached to a lighting fixture, such as an LED lighting fixture, a HID lighting fixture, or the like. DETAILED DESCRIPTION

[0093] The following detailed description is illustrative in nature and is not intended to limit the scope, applicability, or configuration of the technology or systems described herein in any way. Instead, the following description provides some practical examples for implementing the technology or system examples described herein. Those skilled in the art will appreciate that many of the above examples have multiple suitable alternatives.

[0094] In order to further understand the present disclosure, specific exemplary embodiments according to the present disclosure will be described in detail. The accompanying drawings will be frequently mentioned in this specification. Figure numerals will be used to indicate specific components in the accompanying drawings. Unless otherwise specified, the same figure numerals will be used to indicate the same components in all drawings. In addition, similar figure numerals (e.g., 702, 802, 902, 1002, 1102) will be used to indicate similar components or functions between embodiments. Figure numerals with letters (e.g., 100, 100a) may represent the same or similar features, which may be symmetrical to each other, etc.

[0095] Regarding terminology, terms such as “device,” “element,” “component,” “part,” “portion,” “structure,” “assembly,” and “member” may be used interchangeably herein in the singular or plural for convenience and without departing from or limiting the aspects of the present disclosure unless expressly stated otherwise.

[0096] Furthermore, terms such as "having," "including," "with," and the like, or forms thereof, should be understood as open ended and not limiting the components that may be added to the structure. Terms such as "substantially linear," "linear array," and the like, or forms thereof, should be understood to include arrays of items, such as LEDs, that follow at least partially straight or slightly curved scan paths such that a tangent at one end of the array forms an angle of less than 40 degrees with a tangent at the other end of the array.

[0097] Furthermore, certain terms are used herein for convenience or explanation, but these terms should not be construed as limiting the scope of the invention described herein. For example, the terms "lighting fixture" and "luminaire" are used interchangeably herein, as they are commonly used in the lighting industry. Neither term is intended to constitute any specific limitation beyond the scope described herein.

[0098] As another example, this document refers to a "ballast" and a "driver." While both are power regulation devices in lighting technology, the former is used herein with respect to HID light sources, while the latter is used with respect to LED light sources. However, it should be noted that where aspects of the present disclosure are applied to other types of light sources (e.g., laser diodes), the corresponding terminology for the power regulation device may differ. It should generally be understood that various embodiments of the present disclosure are directed to lighting system modifications, and therefore any specific reference to a light source type or power regulation device should be interpreted in the broadest sense.

[0099] For example, the ballast may include an inductive ballast, an electronic ballast, and generally any AC power conditioning device; while the driver may include a universal driver (i.e., a simple DC power conditioning device), a so-called intelligent driver (i.e., a complex DC power conditioning device that may include programmable features, self-healing components, active feedback loops, etc.), or something in between. All of the above possibilities are considered within the scope of the present disclosure.

[0100] Finally, regarding terminology, this document may refer to terms such as "ray," "beam," "beam pattern," "beam shape," "compound beam," and "beam design." All of these terms refer to the light projected from a lighting fixture. It should be understood that the nature of light is complex, and the terms used herein may generally describe the shape of the light projected from a lighting fixture onto a target area, or the intensity in the airspace above the target area, or the general direction of the light as it exits the lighting fixture. While specific descriptions and illustrations are provided herein, it should be understood that none of these terms, descriptions, or illustrations should be considered exhaustive of all lighting issues that may be encountered during a retrofit situation; however, it should be noted that all of these terms, descriptions, or illustrations are well-known and well-understood terms in the lighting art.

[0101] Overview

[0102] As previously mentioned, the present disclosure relates to lighting system retrofits, and more particularly, to retrofits of specialized lighting systems.

[0103] Figures 1 to 4 illustrate one such specialized lighting system. Here, a sports lighting system is described for illuminating a sports field 2 and a portion of the airspace above the field. As shown in Figure 1 , power is delivered to the field via a transformer 4 or other device. This power is then regulated and / or controlled at various points in the circuit, including a cabinet 10 (hereinafter referred to as an electrical component enclosure or ECE) on a light pole 12, a control cabinet 14, and a distribution cabinet 16.

[0104] Additional control, if desired, can be made from the off-site control center 18 (e.g., by wireless communication to an antenna and control module located in the control cabinet 14), such as disclosed in U.S. Patent No. 7,209,958 or otherwise. Most sports lighting systems operate on three-phase power and require a dedicated ground 20, but as discussed above, this varies greatly from site to site. The power supply wiring is typically isolated from the ground wiring (at least a portion of which can be integrated into the base 22) and routed as internally as possible to prevent theft and exposure to environmental influences.

[0105] In FIGS. 2-4, the wiring 8 is routed internally through the light pole 12, into the cross arm 24, through the adjustable armature 26, and to each HID fixture 6 arranged in an array 28. This is a sufficient description of a dedicated lighting system that can be retrofitted and benefit from the present disclosure, although additional background information can be found in U.S. Patent Nos. 6,250,596; 7,600,901; 8,163,993; 8,337,058; and 8,770,796, among others.

[0106] As discussed earlier herein, a retrofit situation occurs when the replaced light source is different from the light source it is replacing. Typically, LED lamps have different power requirements than HID lamps. In the context of retrofitting the sports lighting system in FIGS. 1-4 from HID to LED, this translates to some change in the power conditioning device at the pole cabinet 10. While the power is distributed at the pole cabinet 10 and controlled at the control cabinet 14 (e.g., turned on and off according to a preset schedule), the power is ultimately adjusted and conditioned at the pole cabinet 10 for the particular load (i.e., one or more HID sources 6) by the ballast 30 and capacitor bank 32, and thus, this power is an aspect of the present disclosure as shown in FIGS. 5 and 6.

[0107] Another aspect of the present disclosure is at the top of the light pole: the fixture level. Ideally, the retrofitted fixture will fit in the existing cross arm footprint such that it can pivot left and right (sometimes referred to as swing) or up and down (sometimes referred to as tilt) without creating a photometric or physical disturbance. A photometric disturbance occurs when light from one fixture (see light rays A and B in FIGS. 3 and 4) strikes another fixture in the system and causes a glare or other undesirable lighting effect on the field. This occurs, for example, if the top-most fixture 6 in FIG. 3 is pivoted down such that light ray A strikes the top of the bottom-most fixture 6a in FIG. 3 (i.e., the fixture associated with light ray B).

[0108] Physical interference occurs when certain aiming angles are eliminated because luminaires collide with each other or with some other part of the lighting system. This occurs, for example, if the leftmost luminaire 6b in Figure 4 (i.e., the luminaire associated with ray A) is pivoted sideways into the next luminaire 6c (i.e., the luminaire associated with ray B). Both photometric interference and physical interference reduce useful light: light that is useful for a particular application (in this case, illuminating stadium 2 and the airspace above it).

[0109] It might be tempting to assume that photometric and physical interference in retrofit systems are simply the result of poor aiming or lighting design, but it's important to note that extreme aiming is sometimes the only way to achieve the desired lighting design if the retrofit luminaire itself isn't a good match for the application in terms of required light levels, desired glare control, and existing pole location / weight load limitations. Other times, even if the luminaire design is excellent, the wiring quality is too low, the crossarm is bent, or the existing light levels being retained are too low for the retrofit situation, and the best approach is to retrofit a full-array LED luminaire on a new crossarm with a new wiring harness—which has the added benefit of being factory-tested for photometric and physical interference. All of this is addressed in some of the embodiments described herein.

[0110] Furthermore, retrofitting existing dedicated lighting systems to include LED luminaires on a one-to-one basis—current industry practice—such as the system just described, often results in a significant loss of glare control (on-site and / or off-site). To address the increase in glare, prior art LED retrofit luminaires are often capped, blacked out, attached with shading devices, etc.—which, while effective at reducing glare, also reduce overall light output, requiring more luminaires to achieve light levels comparable to the previous HID lighting system. This can create issues with the weight that existing light poles or crossarms can support and the space available on the crossarms (as discussed with respect to Figures 3 and 4). It might be argued that LEDs are always a better choice than traditional lighting technologies—and indeed, they have a very long lifespan if operated properly—but this may come at the expense of glare control (often, glare control isn't realized as an issue until a poorly constructed retrofit system is installed). Some of the embodiments described herein also address this issue.

[0111] Exemplary embodiments contemplate apparatus and methods for designing specialized LED retrofit lighting systems in a manner that addresses varying power requirements, meets desired lighting conditions, preserves most existing lighting systems, and is more cost-effective and customizable than prior art. These exemplary embodiments will be described herein using various aspects of the general examples already described.

[0112] Modification of electronic component housings

[0113] Now go to Figures 7 to 26 and Figure 47 Various embodiments will now be discussed in connection with using some of the existing components of the system to adjust the power provided by a previously installed lighting system utilizing HID lamps.

[0114] from Figure 7 and Figure 8 Initially, a modified ECE is shown in which some of the ballasts previously used to power HID lamps have been removed and replaced with independent ballast-driver assemblies that communicate with at least one of the remaining ballasts. In some applications, one such driver assembly and its associated ballast can power two LED lamps, but this is not required. In some embodiments, three ballasts can be removed and replaced with three ballast drivers installed in the ECE. The three existing ballasts and existing capacitors can still be used. In other embodiments, because LED lighting is inherently more efficient than HID lighting, the number of ballasts, capacitors, and ballast drivers can be reduced. Conversely, a dedicated or new ECE can be supplied with more ballasts and ballast drivers to increase the amount of lighting, such as brightness level or the area covered by the previously installed HID lighting system site.

[0115] The ECE 100 includes one or more ballasts 30 as described above and one or more independent ballast driver assemblies 200, which are in electrical communication with the one or more ballasts 30 for providing direct current (DC) to the LEDs. More specifically, the independent ballast driver assembly 200 may include a circuit board 302 and a circuit board housing 204 (which may be made of a metal sheet) surrounding the circuit board 302 for protecting the circuit board and securely mounting it in the ECE 100.

[0116] Pay attention to Figure 7 , the ECE may be described below as a separate and sellable item. The ECE 100 may include a side wall 102, a bottom wall 104, a first ballast 106 attached to the side wall 102 or the bottom wall as shown, and a first ballast driver (e.g., a separate ballast driver assembly) attached to the side wall 102 as shown or attached to the bottom wall adjacent to the first ballast 106.

[0117] Similarly, the second ballast 106a and the third ballast 106b can be attached to the side wall 102, and the second ballast driver 200a and the third ballast driver 200b can be attached to the side wall 102 as shown or to the bottom wall. The first, second, and third ballasts can be arranged in a linear array, and the first, second, and third ballast drivers can form a linear array adjacent to the array of ballasts.

[0118] In a retrofit application, the first ballast driver, second ballast driver, and / or third ballast driver may occupy the space vacated by removing multiple previously installed ballasts. This may not be the case when the ECE is supplied as a brand new assembly.

[0119] More specifically, the ECE can take the form of a polygonal sheet metal housing (e.g., can be rectangular) such that the side wall 102 includes a plurality of panels 108, 108a forming a polygonal perimeter 110 and the bottom wall 104 is adjacent to or even attached to the plurality of panels 108, such as when the ECE is folded into shape.

[0120] like Figure 7 As shown, the plurality of panels may include a first panel 108 and a second panel 108a parallel to the first panel 108, and the first ballast 106, the second ballast 106a, and the third ballast 106b may be attached to the first panel 108, while the first ballast driver (e.g., see 200), the second ballast driver 200a, and the third ballast driver 200b may be attached to the second panel 108a. In addition, the first ballast driver, the second ballast driver, and the third ballast driver may be identically constructed (i.e., within a manufacturing tolerance of + / - 0.020 inches). In other embodiments of the present disclosure, other configurations and arrangements of the ECE and these components are possible.

[0121] As mentioned previously herein, the first ballast may be in electrical communication with a first ballast driver, the second ballast may be in electrical communication with a second ballast driver, and the third ballast may be in electrical communication with a third ballast driver, eg, via electrical wires (not shown).

[0122] The first and second panels 108, 108a can be parallel to each other, but this is not required. The ballast can be attached to the first panel, while the ballast driver can be attached to the second panel. In other embodiments of the present disclosure, this may not be the case. For example, the ballast and ballast driver can alternate along one of the panels, etc.

[0123] Still refer to Figure 7 A DIN (German Institute for Standardization) rail 112 may extend from the panels 108, 108a below the third ballast 106b and the third ballast driver 200b. A plurality of fuses 114 or circuit breakers may be attached to the DIN rail 112. Fuses or circuit breakers that are no longer used may also be removed when the ballast is removed, but this is not required.

[0124] As will be discussed in further detail later in this article, A cam motor assembly 34 or manual cam assembly may be positioned below the DIN rail 112 and adjacent to the panel 108. A capacitor bank 116 may be positioned below the DIN rail 112 and adjacent to the panel 108a and adjacent to the cam motor assembly 34 or manual cam assembly. The cam motor assembly 34 or manual cam assembly may include a lever configured to rotate one or more cams to connect selected capacitors in the capacitor bank to power lines leading to one or more ballasts, etc. A wire inlet and a wire outlet may be formed in the bottom wall 104 (which may be implemented as a single aperture 118). In other embodiments of the present disclosure, the number and location of the capacitors, cam assemblies, wire inlets, and wire outlets may vary.

[0125] One or more independent ballast driver assemblies 200 may be attached via a fastener and bracket combination 120 and a toe 124 that mates with a flange 122 used in previous ECEs to attach the ballast to the sidewall. Other attachment methods are possible in other embodiments of the present disclosure.

[0126] Now see Figure 15 , an alternative ECE 100a is shown that is constructed similarly or identically to ECE 100, except that a separate ballast driver assembly 200c having dual PCBs is used to power more lighting fixtures, as will be described in further detail below. In addition, the driver assembly 200c is positioned lower on either side in the ECE (e.g., on a first side or bottom wall and on a second side or bottom wall, directly adjacent to the DIN rail 112, opposite each other) to promote efficient cooling of the PCBs. For example, heat generated from one driver will not rise to the next driver via natural convection. In addition to or in lieu of this effect, the driver assembly can be located away from conventional ballasts that generate heat that rises away from the now lower located driver assembly. The fact that the driver assembly 200c has two PCBs instead of just one allows for the elimination of Figure 7 Two higher placed driver assemblies 200, 200a.

[0127] Circuit board housing

[0128] Now refer to Figures 8 to 12, the circuit board housing 204 may include a five-sided cover 206 and a three-part mounting bracket 208. The five-sided cover 206 may include a front panel 210 defining a plurality of connector receiving windows 212, a top panel 214 defining a plurality of ventilation openings 216, and a bottom panel 218 defining a plurality of ventilation holes 220. The five-sided cover 206 may also have a first side panel 222 and a second side panel 224. The first side panel 222 may define a plurality of first side apertures 226, while the second side panel 224 may define a plurality of second side apertures 228. These apertures may allow for the attachment of wire end retainers to the housing, as will be described in more detail below.

[0129] like Figure 8 and Figure 11 As shown, the top panel 214 may include a first pair of attachment flanges 230, 230a extending downward from the top panel 214 and defining a first pair of attachment apertures 232, 232a, and the bottom panel 218 may include a second pair of attachment flanges 230b, 230c extending upward from the bottom panel 218 and defining a second pair of attachment apertures 232b, 232c.

[0130] In addition, the top panel 214 can be connected to the front panel 210 via a plurality of top bends 234, 234a, 234b, each separated by a top notch 236, 236a. Similarly, the bottom panel 218 can be connected to the front panel 210 via a plurality of bottom bends 234c, 234d, 234e, each separated by a bottom notch 236b, 236c. These notches facilitate bending the panels without tearing or applying excessive force. In other embodiments of the present disclosure, these notches can be omitted.

[0131] refer to Figure 9 、 10 12, the three-part mounting bracket 208 can include a first side circuit board mounting portion 238, a second side circuit board mounting portion 238a, and a top housing attachment portion (also referred to as a handle portion 240) for connecting the first side circuit board mounting portion 238 to the second side circuit board mounting portion 238a. The top housing attachment portion or handle portion 240 can include an elongated aperture 246 (e.g., racetrack-shaped or oval-shaped, which can be used for mounting to the ECE using the fastener and bracket combination 120 described earlier herein). The handle and aperture can be covered with a cover (not shown) until ready for installation. The cover can also protect the back surface of the heat sink and / or the thermally conductive and electrically insulating material until the installation steps are complete.

[0132] The handle portion 240 can be coupled to the first side circuit board mounting portion 238 via a first side bend 248, and the top housing attachment portion or handle portion 240 can also be coupled to the second side circuit board mounting portion 238a via a second side bend 248a. The first side bend 248 can be separated by a first side cut 250, and the second side bend 248a can be separated by a second side cut 250a.

[0133] More specifically, the first side circuit board mounting portion 238 may include a first pair of cover mounting holes 242, 242a and a first pair of attachment flange receiving recesses 244, 244a disposed proximate to the first pair of cover mounting holes 242, 242a. Similarly, the second side circuit board mounting portion 238a may include a second pair of cover mounting holes 242b, 242c and a second pair of attachment flange receiving recesses 244b, 244c disposed proximate to the second pair of cover mounting holes 242b, 242c.

[0134] Furthermore, the first side circuit board mounting portion 238 may define a first circuit board receiving slot 252, and the second side circuit board mounting portion 238a may define a second circuit board receiving slot 252a. The first side circuit board mounting portion 238 may also define a first side heat sink receiving aperture 254, and the second side circuit board mounting portion 238a may also define a second side heat sink receiving aperture 254a.

[0135] Focus on Figure 12 , the first side radiator receiving aperture 254 can be spaced apart from the first circuit board receiving slot 252, and the second side radiator receiving aperture 254a can also be spaced apart from the second circuit board receiving slot 252a. The first side circuit board mounting portion 238 can also define a third circuit board receiving slot 252b that communicates with the first side radiator receiving aperture 254, and the second side circuit mounting portion 238a can also define a fourth circuit board receiving slot 252c that communicates with the second side radiator receiving aperture 254a. The first side radiator receiving aperture 254 can be L-shaped, and the second side radiator receiving aperture 254a can be L-shaped. These apertures are generally complementary in shape to receive the heat sink of the circuit board. Other configurations are possible in other embodiments of the present disclosure.

[0136] like Figures 8 to 10 As shown, the housing 204 may be adapted to hold and accommodate a circuit board and heat sink assembly 300, which may include the aforementioned circuit board 302. Methods of forming a housing around the circuit board and heat sink assembly will be discussed in further detail below.

[0137] Now see Figures 16 to 19 , it can be seen that the driver assembly 200a and Figures 8 to 10 The drive assemblies shown are similarly or identically constructed except for at least the following differences. Housing 204a is larger than Figures 8 to 10 The housing 204 in FIG is taller (perhaps 50% to 100% taller). More specifically, the mounting bracket 208a is proximate to the lower edge 209 of its toe 124a (see FIG. Figure 17 ) is below the lower edge of the housing 204, and the remainder of the mounting bracket 208a and the cover 206a are about Figure 19 The plane 211 in the mirror image can accommodate two PCBs (see 300a). Due to the increased height, additional bends 234c and cutouts 236b can be provided (see Figure 16 ) to allow the cover to be folded during manufacturing. In addition, the bottom edge 213 of the handle portion 240a of the mounting bracket 208a has also been moved upward to accommodate the taller cover 206a. In addition, an additional connector receiving window 212a is provided to connect wires to the top PCB.

[0138] Other changes to the cover include an additional top flange 256 extending from the handle portion 240a to provide greater stability when the driver assembly 200a is seated in the ECE 100a. In addition, the vent 216a has been moved from the top of the cover to the side panel of the mounting bracket and enlarged (possibly in a pie or wedge shape, see FIG. Figure 17 ) to provide additional ventilation, as the use of two PCBs may result in double heat generation.

[0139] Since no wire retainer is required, the side apertures 226a are configured differently (using a rounded shape rather than a polygonal shape). These apertures can also provide additional cooling, etc. In addition, a lateral support 258 is provided connecting the toe portion 214a to provide rigidity to the housing after the housing has been assembled. The lateral support can also help prevent one or more PCBs from being squeezed or damaged.

[0140] Circuit board and heat sink assembly

[0141] like Figure 13 and 14 As shown, the circuit board and heat sink assembly 300 may include a circuit board 302 having a top circuit mounting surface 304 and a plurality of side mounting tabs 306 configured to fit within slots in a housing, as previously described. Furthermore, a plurality of circuit components 308 may be attached to the top circuit mounting surface 304, as well as a heat sink 314 attached to the top circuit mounting surface 304, the heat sink being in thermal communication with but electrically isolated from one or more of the plurality of circuit components 308. To this end, a thermally conductive and electrically insulating material 312 may be disposed between one or more of the plurality of circuit components 308 and the heat sink 314. Specifically, the thermally conductive and electrically insulating material may include silicone, aluminum oxide, and the like. For example, the aluminum oxide may be 96% pure Al204. Other types of thermally conductive and electrically insulating materials may be used in other embodiments of the present disclosure.

[0142] As previously mentioned, the heat sink 314 can be L-shaped as previously described herein and can be made of aluminum (e.g., an aluminum alloy). For example, extruded 6063-T5 aluminum can be used. Other configurations and materials can also be used, as long as the appropriate amount of heat is removed from the electrical components, etc.

[0143] See also Figure 8 and 13 A plurality of connectors 316 may be provided near the front of the top circuit mounting surface, which communicate with the various circuit components. This allows wires from the ballast, etc., already in the ECE to be quickly connected to the circuit board and heat sink assembly, and also allows wires from that assembly to be easily connected to the LED light fixture, or vice versa.

[0144] Now go to Figures 17 to 21 , the circuit board and heat sink assembly 300a will now be discussed, which is Figures 8 to 13 are similarly or identically constructed, except for at least the following differences.

[0145] focus on Figure 20 and 21 , the heat sink 314 can define a clamp receiving slot 318 that is at least partially defined by a top ridge 320 and a bottom gripping rib 322. One or more clamps 324 can be disposed in the clamp receiving slot 318 and contact at least one of the plurality of circuit components to press it into contact with the electrically insulating and thermally conductive material.

[0146] The plurality of side mounting tabs include a front mounting tab 306a, a rear mounting tab 306b, and a middle mounting tab 306c located therebetween. The front mounting tab is added to provide an abutment surface against the cover, making assembly 300a less susceptible to twisting. A chassis 326 for receiving heat sink 314 can be positioned between heat sink 314 and circuit board 302. The chassis is made of an electrically insulating material, a thermally insulating material, or both. For example, the chassis can be in the form of an electrically insulating injection-molded plastic component. The specific material can be polybutylene terephthalate (PBT), among others.

[0147] Circuit

[0148] Figure 22 and 23 Contains one or more circuits for rectifying and powering LED lighting fixtures. Figure 22 Such a circuit 400 may include one or more ballasts 106 and capacitor banks 116, as previously described with reference to Figure 7 As stated.

[0149] However, if Figure 23As shown, circuit 400 may also include a rectifier subcircuit 402, an open-circuit protection subcircuit 404, an output regulation subcircuit 406, and a surge protection subcircuit 408. In a specific embodiment, surge protection subcircuit 408 may include a gas discharge tube (GDT1). (Fuses such as F1 and F2, other external surge protection devices, etc. may also be provided, but are not required.) Furthermore, metal oxide varistors (MOVs) labeled Z1, Z2, and Z3 are provided. Z1 and Z2 provide surge suppression when the common-mode voltage reaches a maximum, while Z3 provides surge suppression when the differential-mode voltage reaches another maximum. Compared to MOVs, gas discharge tubes have different failure modes, providing an additional level of protection or safety. Specifically, MOVs typically fail due to a short circuit, while gas diodes typically fail due to an open circuit. According to the illustrated configuration, if either the MOV or the gas discharge tube fails, the current is most likely diverted to ground.

[0150] The rectifier circuit 402 includes a diode bridge D1, which is a commercially available full-wave bridge rectifier diode bridge. Other rectifier circuits may also be used.

[0151] The open circuit protection subcircuit 404 may include Zener diodes labeled D3, D4, and D5, which are electrically connected in parallel with a thermistor labeled R5 and a switching thyristor labeled D2. When the voltage is too high, the current from the rectifier subcircuit will be directed to ground. In some embodiments of the present disclosure, the voltage values ​​of D3, D4, and D5 can range from 100 volts to 600 volts.

[0152] Turning now to the output regulation subcircuit 406, which includes a capacitor regulation bank C1, C2 designed to reduce the electrical ripple (or resulting light flicker) of the AC component provided by the rectifier D1. In some embodiments of the present disclosure, the values ​​of these capacitors C1, C2 range from 100 μF to 4000 μF. In some embodiments, zero capacitance or near zero capacitance may be required, while in other embodiments, capacitance values ​​even greater than 4000 μF may be required to reduce light flicker to a desired level, etc. Resistors R6 and R7 are provided to discharge the capacitors C1, C2 when the power is turned off to enable safe interaction during maintenance, troubleshooting, etc. Another fuse F3 can be provided to prevent damage to the lighting fixture if the current is too high, but this is not required. In addition, a MOFSET (not shown) can be inserted between the open circuit protection subcircuit and the output regulation subcircuit to provide another level of protection.

[0153] Any component can be a "through hole" component or a "surface mount" component (see, for example, Figure 13 and 14 )part.

[0154] In some embodiments, an HID ballast capacitor circuit having a capacitance of 32 μF producing a constant wattage of approximately 1500 W may be replaced with a capacitor bank having a capacitance of approximately 28 μF to produce a constant wattage of approximately 900 W, which is sufficient to drive 224 XM-L LEDs (available from Cree LED, Inc., located in Durham, North Carolina) wired in parallel in two strings of 112 LEDs within an LED retrofit fixture, etc.

[0155] Further imagine that you can use Smart Nos. 7,675,251, 7,956,551, and 8,098,024 to regulate the power or wattage supplied to one or more light poles, which may have been installed in previous HID lighting systems. For example, as shown in FIG. Figure 7 24 , the light pole cabinet 10 may include a cam timer assembly 34 , 34 a that includes various cams and contactors to vary the capacitance and therefore the power supplied to the HID lamps over time to compensate for the loss in lumen efficiency such lamps experience over time.

[0156] More specifically, the motor 36 is powered to rotate a cam causing certain contactors to make contact and then close, allowing different capacitors with different capacitances to enter the circuit, thereby varying the wattage.

[0157] When creating a retrofit LED lighting system, the motor can be disconnected and reset by means of the reset wheel 38 (or Figure 7 The cam is manually rotated by a lever (e.g., a lever shown) to change the capacitance and, thereby, the power applied to the light pole. This system or method may not be available in other embodiments of the present disclosure.

[0158] Wire retainer

[0159] As previously mentioned, after removing the ballast, the various ECEs may need to be rewired. Ballasts still in use will plug into connector 316 on the circuit board. However, ballasts or other electrical or electronic components no longer in use will have loose ends that need to be handled to prevent short circuits, etc. In some cases, wire nuts or the like may be used to cover the exposed ends of the wires. In other cases, a wire end bracket may be provided and attached to the interior of the ECE, other cabinets, or to the housing of the circuit board and heat sink, as will be described later.

[0160] In some embodiments, the right-angle connector is unplugged from the unused ballast and secured in a wire holder, as will be described in more detail later. The bare strand wires can be disconnected from the timer motor as previously described and capped with closed end fittings crimped onto each wire for insulation. The wire ends are then secured in a wire holder (also known as a wire end bracket), which is then secured to the ECE's DIN rail.

[0161] like Figure 25 As shown, such a wire end bracket 500 may include a first half 502 defining a first wire connector receiving cavity 504 disposed within an outer wall 506. This cavity may be at least partially defined by a square or rectangular entrance for receiving a crimped right-angle wire connector (sometimes referred to as a faston). Furthermore, a first wire receiving slot 508 may extend through the outer wall 506 to allow the wire to enter the first half when the wire connector is placed into the first wire connector receiving cavity. Due to this configuration, the first wire connector receiving cavity and the first wire receiving slot form a first L-shaped path 510. This path generally represents the path formed when the wires and connectors are stored in the wire end bracket.

[0162] The first half 502 also forms an internal snap feature 512 in the form of a snap receiving slot 514 for receiving a male snap protrusion 516 of the second half 518. It is contemplated that in other embodiments of the present disclosure, these snap features of the first and second halves may be interchanged.

[0163] See together Figure 25 and 26 , there is an external snap feature 520 extending from the outer wall 506 of the first half 502. More specifically, the external snap feature 520 may include a pair of male snaps 522 and 524. The male snap 522 may be configured to flex through the slit 526, while the male snap 524 may not be so configured. These snaps may include inwardly extending protrusions 528 and 530 of different configurations. The protrusion 528 may be rounded, while the protrusion 530 may be more angled, so as to more effectively grasp the structural member than the protrusion 528, which is intended to be more flexible due to the slit.

[0164] Due to this structure, the wire end bracket can be attached by these clips and inserted into the first and second side openings 226, 228 of the independent ballast driver assembly 200, as shown in FIG. Figure 8 、 11 and as 47 understood.

[0165] As this article references Figure 25 and 26As shown, the second half 518 can include a second half snap feature 515 that is configured to engage the internal snap feature 512 of the first half 502. Additionally, the second half 518 can be coupled to the first half 502 via a living hinge 532, but this is not required.

[0166] like Figure 26 As best shown, the first half 502 may also define a second wire connector receiving receptacle 504a, and a second wire receiving slot 508a forming a second L-shaped path 510a. These paths 510, 510a are nested adjacent to one another, but need not be.

[0167] exist Figure 25 and 26 , first half 502 can define a first window 534 extending from first wire connector receiving cavity 504 through to the exterior of first half 502, and a second window 534a extending from second wire connector receiving cavity 504a to the exterior of second half 518. These windows can allow a user to see the connectors within the bracket and also allow these cavities and retention features to be molded with a mold core that exits through the windows after the plastic cures.

[0168] The wire end brackets may be molded from any suitable thermoplastic, such as nylon, polypropylene, ABS (acrylonitrile butadiene styrene), and the like.

[0169] like Figure 7 As shown, the wire end bracket may have features (eg, slots disposed between external snap features) so that it may be mounted on a standard DIN rail of the ECE as well as the side of the ballast driver housing.

[0170] In some embodiments, a straight wire nut can be attached to the free end of one or more wires that is not placed into the connector receiving cavity forming the L-shaped path but just passes through the outer wall, so that the entire interior of the first half of the wire end bracket serves as the connector receiving cavity. The second half can then be attached to the first half to close the one or more wire ends, etc.

[0171] LED lighting fixtures

[0172] Next, from Figures 34 to 35 Now, let's discuss LED lighting fixtures that can be installed within the "footprint" of previously installed HID lamps without causing physical and / or photometric interference as previously described. These various LED lighting fixtures can also provide sufficient illumination to achieve a reduction in the number of lamps or lamps compared to previous HID lighting systems. Furthermore, these various LED lighting fixtures can also utilize existing lamp components, but this is not required.

[0173] Now refer to Figure 34and 38 , LED lighting fixtures 600, 600a, 600b, 600c may include a luminaire 602 defining a luminaire perimeter 604 having a horizontal width 606 (measured along the X-axis of the illustrated Cartesian coordinate system) and a vertical height 608 (measured along the Y-axis of the illustrated Cartesian coordinate system). In some general embodiments, the ratio of horizontal width 606 to vertical height 608 may range from 0.90 to 1.25. In more specific embodiments, the ratio of horizontal width 606 to vertical height 608 may range from 0.97 to 1.17. A nominal value for this ratio may be approximately 1.07, resulting in a luminaire perimeter that is substantially square or more generally rectangular. In embodiments of the present disclosure, horizontal width 606 may range from 14.0 inches to 15.5 inches (e.g., approximately 14.75 inches), and in some embodiments of the present disclosure, vertical height may range from 11.0 inches to 13.0 inches (e.g., approximately 12.0 inches). In other embodiments of the present disclosure, the width may be approximately 14.25 inches to 15.25 inches (e.g., approximately 14.76 inches), and the height may be 11.5 inches to 12.5 inches (e.g., approximately 12.0 inches). These ranges may vary in other embodiments where the existing HID lamp footprint is different, if a larger downwardly extending knuckle is used, etc.

[0174] Focus on Figure 38 , LED lighting fixtures 600, 600a, 600b, 600c may include a hexagonal LED array 610 comprising 10 horizontally extending rows 612 and 23 diagonally extending rows 614, for a total of 230 LEDs. In other embodiments of the present disclosure, the array may be rectangular or have other configurations. For example, in other embodiments of the present disclosure, more or fewer LEDs may be used.

[0175] The LED lighting fixtures 600, 600a, 600b, 600c may further include a front fixture frame 616 defining a window opening perimeter 618, and a plurality of light sources (eg, optics and / or LEDs) disposed within the window opening perimeter 618. The plurality of light sources are spaced a maximum vertical distance 620 from the fixture perimeter 604.

[0176] In some embodiments of the present disclosure, the ratio of the vertical height 608 of the fixture perimeter 604 to the maximum vertical distance 620 ranges from 1.70 to 2.45. In more specific embodiments of the present disclosure, the ratio of the fixture's vertical height 608 to the maximum vertical distance 620 ranges from 1.85 to 2.24. These ranges can allow LED lighting fixtures to fit within the "footprint" of conventional HID lamps and position the LEDs low enough to cause minimal photometric interference to nearby LED lighting fixtures. In other embodiments of the present disclosure, this may not be necessary.

[0177] See also Figure 28 and Figure 35 , different visors 622, 622a that can be attached to the headlight frame 616 can include top surfaces 624, 624a that form top angles 626, 626a with a horizontal plane 628 (which can be coincident with or parallel to the XY plane) that range from 10.0 degrees to 20.0 degrees. Specifically, Figure 35 The top angle 626 of the light shield 622 is about 12.0 degrees, and Figure 35 The top angle 626a of the light shield 622a in FIG. 5 is approximately 18.0 degrees.

[0178] Similarly, these visors 622, 622a can extend a horizontal projection distance 630, 630a, which is measured perpendicular to the horizontal width 606 (e.g., along the Y axis) and extends the vertical height 608 of the light fixture 602, as shown. Figure 31 As shown. In some embodiments of the present disclosure, the ratio of the horizontal projection distance 630, 630a to the vertical height 608 ranges from 0.96 to 2.07. In more specific embodiments, the ratio ranges from 1.05 to 1.90. In addition, these visors 622, 622a can form a front angle 632 (in the XZ plane) that allows the visors to extend far enough downward to prevent or limit side glare while also providing sufficient top clearance to avoid physical or photometric interference with adjacent lighting fixtures / visors.

[0179] exist Figure 28 , the front angle 632 (in the YZ plane) may range from 20.0 degrees to 28.0 degrees (e.g., may be approximately 24.0 degrees), and Figure 35 In the embodiment of the present disclosure, the front angle 632a can range from 32.0 degrees to 40.0 degrees (e.g., approximately 36.0 degrees). In other embodiments of the present disclosure, the top angle can be only 0 to 5.0 degrees so that the top of the visor does not reach the top of the luminaire. Even so, the bottom angle of the visor can be approximately 10.0 to 20.0 degrees to limit side glare, etc.

[0180] like Figures 27 to 30, 32 to 37, 39 and 40, the upward lighting lens 700 can be attached to the free ends of the light shielding plates 622, 622a, 622b, 622c.

[0181] like Figure 29 、 30 , 33, 36, 37 and 40, when the uplighting lens 700 is lowered (along the Z axis) to its bottom-most position as viewed along the Y axis, the uplighting lens 700 can vertically cover 0% to 40% (e.g., approximately 30% to 40%) of a series of top rows of the hexagonal LED array 610. The diffuser can scatter light upward to provide upward illumination for viewing a ball or sporting event while it is in flight. In some embodiments of the present disclosure, the uplighting lens can be moved completely upward to minimize the upward direction of light and maximize the amount of light directed downward onto the playing field, or can be omitted entirely.

[0182] like Figure 41 As shown, the visors 622, 622a, 622b, 622c may include a front panel 634 having a plurality of mounting holes 636. Additionally, the uplighting lens 700 may include a plurality of mounting holes 702 (see also FIG. Figure 44 and 45 ), which mounting holes are configured to align with the plurality of mounting apertures 636.

[0183] See also Figure 27 、 28 , 29, 31, 35, 39 and 405, the LED lighting fixtures 600, 600a, 600b and 600c may include a lamp back plate 638 and a front lamp frame 616 attached to the lamp back plate 638. In addition, a steering knuckle 640 (or armature, such as models LED-3875-1, LED-5454-1, etc. sold by Musco Sports Lighting, LLC can be used) and a heat sink 642 are attached to the lamp back plate 638.

[0184] See also Figure 31 、 41 42, the front fixture frame 616 defines a window (see window opening perimeter 618) that is configured to receive an external lens 644. Additionally, an LED board 644 having a plurality of LEDs 646 can be attached to the fixture back panel 638. An optics holder 648 having a plurality of apertures or recesses can be provided that, after assembly, is disposed around the LEDs and sandwiched between the front fixture frame 616 and the LED board 644. Additionally, after assembly, an optics board 650 can be disposed in the optics holder 648 adjacent to the LED board 644.

[0185] Figure 43An alternative design of LED board 644a is shown. A four-LED optical device for a wide beam is shown, which includes 4 horizontally extending rows and 15 vertically extending columns. In other embodiments of the present disclosure, other arrangements, layouts and configurations are also possible.

[0186] Uplighting lens

[0187] exist Figure 44 and 45 , the uplighting lens 700 will be discussed in more detail. The uplighting lens 700 may include an attachment portion 704 including a first elongated aperture 706, and a light directing portion 708 that is elongated in a direction (e.g., along the X-axis or horizontal direction) that is non-parallel to the first elongated aperture 706 (which extends along the Z-axis or vertical direction).

[0188] exist Figure 46 , it can be seen that the attachment portion 704 and the light guiding portion 708 are thinnest along a direction perpendicular to the horizontal and vertical directions (eg, along the Y-axis). This may not be the case with other embodiments of the present disclosure.

[0189] Reference again Figure 44 and 45 , the attachment portion 704 includes a second elongated aperture 706a that is elongated in a vertical direction (e.g., along the Z-axis), and the second elongated aperture 706a is spaced apart from the first elongated aperture 706 in a horizontal direction (e.g., along the X-axis). In addition, the attachment portion 704 may further define a first rounded-shaped aperture 710 that is horizontally disposed adjacent to the first elongated aperture 706. More specifically, the first rounded-shaped aperture 710 may be horizontally disposed between the first elongated aperture 706 and the second elongated aperture 706a.

[0190] Likewise, the attachment portion 704 may further define a second rounded-shaped aperture 710a disposed horizontally between the first rounded-shaped aperture 710 and the second elongated aperture 706a. Furthermore, the attachment portion 704 may further include a first vertically extending protrusion 712 defining the first elongated aperture 706 and a second protrusion 712a defining the second elongated aperture 706a. In other embodiments of the present disclosure, these protrusions may be omitted.

[0191] In addition, the wall or rib 714 can extend around the first elongated aperture 706 and the first rounded shape aperture 710, as well as the second elongated aperture 706a and the second rounded shape aperture 710a. Other embodiments of the present disclosure may not be like this. For example, the wall or rib may not extend across the top of the lens but from one lateral side of the lens to the other.

[0192] like Figure 46As shown, the light-directing portion 708 may define a sawtooth pattern 716 or barbed-tooth pattern in a plane perpendicular to the horizontal direction (e.g., the YZ plane). A double-sided sawtooth pattern is shown on both the front and back sides of the lens, but this may not be the case in other embodiments of the present disclosure. The sawtooth pattern may include a first curved portion 718, a second curved portion 718a, and a straight portion 720 connecting the first curved portion to the second curved portion. The first and second curved portions may be constructed similarly or identically as shown, but this is not required. For example, within a manufacturing tolerance of + / - 0.005 inches.

[0193] In some embodiments, the first arcuate portion 718 is defined by a spline curve 722 (or polynomial) extending primarily in a vertical direction (along the Z axis), while the straight portion 720 extends primarily in a direction perpendicular to the horizontal and vertical directions (e.g., along the Y axis). Figure 45 and 46 In the embodiment of the present invention, the first symmetry plane (e.g., the YZ plane) is perpendicular to the horizontal direction, and the second symmetry plane (e.g., the XZ plane, which can also be the mold parting line during molding) is perpendicular to the direction perpendicular to the horizontal direction and the vertical direction. In other embodiments of the present disclosure, one or more of these symmetry planes can be omitted.

[0194] Figures 48 to 50 Another embodiment of lens 700a is shown, which is Figures 44 to 46 The lenses shown in FIG8 are similarly or identically constructed, except for the following differences.

[0195] The one or more elongated apertures 706b, 706c and the one or more ribs 714a surrounding them extend further downward into the light-directing portion 708a. This allows for greater adjustment of the vertical position of the lens relative to the LED or other light source, providing the user with greater flexibility in adjusting how much upward illumination is generated when attached to a lighting fixture. For example, this embodiment allows for 1 inch of travel, while previous embodiments of the lens may only allow for 0.5 inches of travel. When in the fully upward position, little or no upward illumination is generated.

[0196] Furthermore, the number of construction holes 724, 724a has been increased compared to the first embodiment. These construction holes allow the lens to be created into multiple subsections as desired and attached to each other using spline curves, etc. Of course, these construction holes can be omitted if a sufficiently large mold or 3D printer is used to manufacture the lens.

[0197] Now go to Figure 51 The light guiding portion 708a includes a direction perpendicular to the direction in which the light guiding portion 708 extends (i.e. Figure 50 and 51 The polynomial curve is defined in the plane of the plane). It is necessary to understand that Figure 50Compared to the curve shown in Figure 51 The curve in the figure turns sideways.

[0198] More specifically, the polynomial curve may take the form of a parametrically defined degree=(n-1) Bezier curve 726, which is controlled by a set of (n) discrete control points and is governed by the following equation: P(t)=(1-t) 2 Pr+2t(1-t)P q +t2P p , where P r and P p is the predetermined endpoint, and P q is the center point that changes to change the divergence angle from the incident light to the desired target

[0199] For example, Figure 52 and 53 As shown, change P q The position of the lens results in different profiles, light refraction in the lens and the resulting light emission direction.

[0200] In various embodiments of the present disclosure, a point on a Bezier curve may be defined by the following equation: y(t)=(1-t) 2 y r +2t(1-t)y q +t 2 y p , and the z coordinate of a point on the Bezier curve can be defined by the following equation: z(t) = (1-t) 2 z r +2t(1-t)z q +t 2 z p .

[0201] For use Figure 44 The coordinate system shown Figure 51 The specific example shown, P r The Y coordinate is 0 and P r The Z coordinate is 0, P p The Y coordinate is .046 inches and P p The Z coordinate is .259 inches, and P q The Y coordinate is 0.582 inches and P q The Z coordinate is 0.184 inches.

[0202] Other types of curves may be used in other embodiments of the present disclosure.

[0203] It is noted that the lens can be used for other applications besides uplighting and can be made of a variety of materials, including glass, acrylic, polystyrene, polycarbonate, silicone, etc. Furthermore, other devices for directing or redirecting one or more light beams, such as diffusers and optical devices, can also be employed. For example, the inventors have tested a 60x1 holographic light-shaping diffuser, a 40x0.2 holographic light-shaping diffuser, a 30x30 holographic light-shaping diffuser, and an approximately 30-degree ribbed asymmetric glass lens.

[0204] See also Figures 54 to 56 , shows another embodiment of lens 700b, which is the same as the lens shown in the previous reference Figure 44 and 48 The lenses discussed above (eg, see lenses 700, 700a) are similar or identical, except that lens 700b has at least some of the following differences.

[0205] Figure 44 The projections 712, 712a shown in FIG are incorporated by providing walls 728 extending tangentially from the projections. Figures 54 to 56 , making the attachment portion 704a larger (taller) and more robust.

[0206] In addition, the front of the lens no longer has Figure 44 and 48 The ribs 714, 714a surrounding each set of elongated apertures 706, 706a, 706b and 706c and / or rounded apertures 710, 710a for mounting are shown. Instead, these mounting apertures are all provided in a single front receptacle 730 (see FIG. Figure 54 ), the front receiving portion is surrounded by a continuous side wall 732. In other embodiments of the present disclosure, it is conceivable that the receiving portion can be split. The receiving portion 730 can allow the head of the fastener to be seated therein and provide a certain degree of protection.

[0207] In addition, if Figure 55 As can be seen, the rear of lens 700b now has a mounting pad 734 that can be used as a platform to contact the front of the visor of the lighting fixture (see, for example, FIG. Figure 41 634 in the front panel of the lighting fixture). The mounting pad 734 can have a substantially flat surface 736 (i.e., within an appropriate manufacturing tolerance of + / - .010") so that stress is not induced when the lens is secured to the front panel of the lighting fixture. Similar to the receptacle 730, the mounting pad 734 can also be split. A mounting aperture (or at least one mounting aperture) can extend through the rear mounting pad to the front receptacle to allow fasteners to pass through.

[0208] In any case, whether split or not, the mounting pad 734 can be sized to be comparable or coextensive with the receptacle, providing support and a consistent nominal wall thickness (which can also limit buckling). This can also help ensure that the lens is robust enough to withstand any stresses applied or induced when fastened to the front panel of the lighting fixture. In fact, the surface area of ​​the pad can be slightly larger than the bottom surface 738 of the receptacle 730.

[0209] For example, in some embodiments, the substantially flat surface 736 may define at least a 3.75 in. 2 surface area, while in other embodiments of the present disclosure it is defined as at least 7.5 in 2 In certain embodiments of the present disclosure, the surface area of ​​the substantially flat surface 736 may be 15.0 in. 2 (+ / - 10%). These ranges may vary in other embodiments of the present disclosure, for example, when the design is scaled up or down, split into several separate mounting pads, etc. In any embodiment, the surface area can be large enough so that the head of the fastener is properly supported to prevent buckling or bending stress.

[0210] Additionally, the substantially flat surface 736 may project in another direction 750 that is non-parallel to the first elongated aperture 706d (see Figure 56 ) The light directing portion 708b protrudes by an appropriate amount 752, which in some embodiments of the present disclosure is at least 0.002 inches or at least 0.005 inches. In practice, it may protrude by about 0.007 inches. Other amounts are possible in other embodiments of the present disclosure.

[0211] More specifically, the front receiving portion 730 (see Figure 54 ) may include an elongated portion 740 extending in a direction 742 non-parallel to the first elongated aperture 706d, and a pair of downwardly extending slot portions 744, 744a communicating with the elongated portion 740. Furthermore, the rear mounting pad 734 may include an elongated pad portion 746 coextensive with at least the elongated portion 740 of the front receptacle 730, and downwardly extending leg portions 748, 748a coextensive with at least the pair of downwardly extending slot portions 744, 744a. In other embodiments of the present disclosure, this may not be the case.

[0212] Due to this configuration, the lens 700b may not be flipped over, unlike the lenses 700 and 700a which can be flipped over. In addition, it is also contemplated that in many industrial applications, a movable or slidable cover or panel may be used, such as that in U.S. Patent No. 10,344,948 owned by the applicant of the present disclosure. Figure 17 and 30 , to replace the lenses discussed herein (those typically used for golf applications).

[0213] Sight Plate

[0214] Turning now to FIG. 57 , a horizontal aiming plate is disclosed for use in a factory aiming method, such as that disclosed in U.S. Patent No. 8,717,552 owned by the assignee of the present application. The horizontal aiming plate includes angle markings to indicate to the user the angle at which the lamp or lighting device should be pointed relative to the cross arm. By using the method disclosed in the '552 patent, the lamp or lighting device can be pre-aligned relative to the horizontal and vertical planes so that when the pole and cross arm are installed at the site, the lamp is pointed in the proper direction. If the lamp or lighting device is removed at the site, the angle markings can be used to reliably re-determine the angular orientation in the horizontal and vertical planes.

[0215] However, this does not include Sports All field lighting systems sold under the trademark HID lighting system utilize this horizontal aiming plate with angle markings. Consequently, once the lamp or luminaire is removed from the cross arm, the knuckle also becomes loose, causing the horizontal aiming direction to be lost. However, many of these systems have the proper horizontal aiming direction or orientation documented on the floor plan, or the proper horizontal aiming direction of the lamp or luminaire can be measured using a laser or other device and determined before the lamp or luminaire is removed.

[0216] This can allow the following equipment to be used to re-establish proper aiming or orientation at the factory before the LED luminaire or LED lamp holder is sent to the site to replace the HID luminaire or HID lamp. In some applications, this can be done before the new lighting system is sent to the site. Figure 47 and 48 In the embodiment of the present invention, a lighting system 800 that allows for proper horizontal aiming of a lighting fixture and / or its steering knuckle may include a first cross arm member 802, a first aiming bracket 804, and a first aiming plate 900 disposed between the first cross arm member 802 and the first aiming bracket 804. The first cross arm member 802 may be an auxiliary cross arm 802a (so called because it is shorter and extends from a longer main cross arm 802b), but may also be a main cross arm 802b, etc. Although Figure 58 、 59 Not shown in and following, but understood to be, the fasteners shown in FIG. 57 may be used to attach portions of the steering knuckle together and to attach the steering knuckle to the aiming plate, and to attach the aiming plate to the wishbone, etc.

[0217] like Figures 60 to 63As best shown, a first knuckle 640 can be attached to the first aiming bracket 802 and includes a lower electrical receptacle portion 806 and an upper knuckle portion 808 rotatably attached to the lower electrical receptacle portion 806 about a first axis 810. This can set a vertical orientation or aiming direction and can be secured by tightening fasteners, etc. Additionally, once the upper knuckle portion is inserted into and connected to the aiming bracket, the upper knuckle portion 808 of the first knuckle 640 can be fixed in relation to the first aiming bracket 804 about a second axis 812 that is perpendicular to the first axis 810.

[0218] Even so, the upper knuckle portion 808 of the first knuckle and the aiming bracket 804 can still rotate relative to the first cross arm member 802 about the second axis 812. To facilitate horizontal aiming, the first aiming bracket 804 includes a peripheral edge 814 having angle markings 815 disposed at least partially around the peripheral edge 814. In this case, the first aiming plate 900 can include a first angle indicator 902 extending to the peripheral edge 814 of the first aiming bracket 804, allowing a user to read the relative angular orientation of the first aiming bracket and the first aiming plate. Alternatively, the angle markings can extend from the peripheral edge to the angle indicator.

[0219] In other embodiments of the present disclosure, the angle indicator and angle mark may be omitted, or the angle mark and angle indicator may be switched between the aiming plate and the aiming bracket, etc. Figure 72 As shown, perimeter 814 of first sight bracket 804 may include a front flat portion 816, and first angle indicator 902a may extend to the front flat portion of the first sight bracket. In other embodiments of the present disclosure, this may not be the case. For example, first angle indicator 902 may not extend as far, as will be discussed in further detail later herein. In such cases, the angle may be read using a straight edge, a magnetic compass, or the like, or the angle markings may extend to the top surface of the sight bracket or thereon to the angle indicator.

[0220] review Figure 59, the first cross arm member (e.g., see 802a) can define a rounded rotation aperture 818 that defines an axis of rotation (which can be the same as the second axis 812 when the steering knuckle is attached to the cross arm member), and a first mounting aperture 820 that is disposed about the axis of rotation away from the rounded rotation aperture 818. More specifically, the second mounting aperture 820a can be disposed about the axis of rotation, forming a circular array with the first mounting aperture 820 about the axis of rotation (e.g., the first mounting aperture 820a and the second mounting aperture 820c can be disposed 180 degrees apart). Similarly, the third mounting aperture 820b and the fourth mounting aperture 820c can, together with the first mounting aperture 820 and the second mounting aperture 820a, define a rectangular pattern 822 centered about the axis of rotation (see the center example of the mounting apertures). The side examples of the mounting apertures have a square pattern 824. Other patterns and arrays are possible. As shown, typically only two diagonally oriented mounting apertures are used, but more or fewer mounting apertures may be used depending on the fasteners used to secure the aiming bracket and aiming plate to a structural member such as a cross arm member.

[0221] As seen by Figure 59 and Figure 60 As will be appreciated, the first aiming plate 900 may define a pair of parallel side surfaces 904 that are flush or recessed relative to the pair of side surfaces 826 of the first cross arm member.

[0222] Now refer to Figures 60 to 73 The description provides for sight bracket and sight plate assemblies 828, 828a, 828b to be retrofitted in the field. Figures 61 to 63 As best shown, the assembly 828, 828a, 828b may include an aiming bracket 804 including an outer circular portion 830 defining a circular axis (which may coincide with the second axis 812) and a radial direction 832. The outer circular portion 830 may include a circular periphery 814a spaced a first radial distance 834 from the circular axis (see also FIG. Figure 64 ).

[0223] Still refer to Figure 64 , the annular boss 836 can be centered about the circular axis, and the front flat portion 816 can be spaced a second radial distance 838 from the circular axis, the second radial distance being greater than the first radial distance 834. Figures 61 to 63 As shown, the aiming plate 900 , 900 a may define an annular boss receiving aperture 906 , and a first fastener receiving aperture 908 , 908 a radially spaced from the annular boss receiving aperture 906 .

[0224] Still refer to Figures 61 to 63, the circular rim 814a may include a plurality of angle markings 815 as previously described, and the aiming plate 900, 900a may include an angle indicator 902 extending to the circular rim 814a. In addition, the front flat portion 816 may include a plurality of angle markings 815. To facilitate the use of these angle markings, the angle indicator 902a of the aiming plate 900b may extend all the way to the Figure 72 815 , the outer circular portion 830 may be connected to the front flat portion 816, but this is not required. Additionally, the side surface 840 may couple the outer circular portion 830 to the front flat portion 816, which also includes a plurality of angle markings 815, so that a full range of angles from 0 to 90 degrees or from 0 to 180 degrees can be measured. In other embodiments of the present disclosure, this may not be the case. Furthermore, the angle markings may be located on the top surface of the sight bracket.

[0225] See together Figure 62 and Figure 64 , the aiming bracket 804 may define a first arcuate slot 842, and the first fastener receiving aperture 908 of the aiming plate 900a may be disposed above the first arcuate slot 842 to allow a fastener to pass therethrough. Similarly, the aiming bracket 804 defines a second arcuate slot 842a, and the aiming plate 900a further defines a second fastener receiving aperture 908a disposed above the second arcuate slot 842a.

[0226] exist Figure 64 , aiming bracket 804 may include a central hub 844 at least partially defined by a first arcuate slot 842 and a second arcuate slot 842a. An annular boss 836 may extend from central hub 844. Central hub 844 may be coupled to front flat portion 816 and outer circular portion 830 via a first web portion 846 and a second web portion 846a. Both first web portion 846 and second web portion 846a may at least partially define first arcuate slot 842 and second arcuate slot 842a. In other embodiments of the present disclosure, this may not be the case.

[0227] Now go to Figure 65 Aiming bracket 804 may also include a rear flat portion 848, which, together with front flat portion 816, may define a rectangular receptacle 850 configured to receive upper knuckle portion 808 of knuckle 640. More specifically, rear flat portion 848 of aiming bracket may define one or more undercuts 852 configured to receive and vertically capture upper knuckle portion 808 of knuckle 640. This undercut may not be present in other embodiments of the present disclosure. Furthermore, aiming bracket 804 may define a plurality of core-out recesses 854 radially disposed about first arcuate slot 842 and second arcuate slot 842a. This may allow the nominal wall thickness of the aiming bracket to be properly maintained to avoid porosity, voids, or other manufacturing issues associated with the casting process.

[0228] To secure the steering knuckle to the aiming bracket, the aiming bracket 804 may define a first fastener receiving hole 856 and a second fastener receiving hole 856a spaced 180 degrees from the first fastener receiving hole 856 about the circular axis (or second axis 812). Although these holes are shown as smooth and hollow, it will be understood that threaded inserts may be pressed into these holes to allow the steering knuckle to be secured to the aiming bracket. An annular cylindrical guide portion 858 may be provided that is configured to fit within a cavity 860 (see FIG. 1 ) of the upper knuckle portion 808 of the steering knuckle 640. Figure 66 An electrical connector receiving aperture 862 may be provided within the annular cylindrical guide portion 858 for receiving a female connector (not shown) that mates with a male steering knuckle connector (not shown), or vice versa, which allows for a quick electrical connection.

[0229] In some embodiments, the aiming plate 900, 900a is secured to the top surface 864 of the aiming bracket 804 by fastening, gluing (e.g., by a weak glue commonly sold for non-industrial use, such as white glue, wood glue, etc.) (see Figure 64 ). In this case, one or more angle indicators may be omitted, but this is not necessary.

[0230] Now refer to Figures 67 to 71 Various embodiments of the aiming plate are discussed in 73. The aiming plate can be made of sheet metal such as aluminum, stainless steel, etc. and can have a thickness ranging from .010 inches (similar to a shim) to .125 inches.

[0231] according to Figure 67 、 68 The aiming plates 900, 900a, 900b of the disclosed embodiments shown in Figures 73 and 74 may include a central hole 910 defining a central axis 912, and mounting holes (e.g., see first fastener receiving apertures 908) disposed about the central axis 912 and spaced a first minimum distance 914 from the central hole 910. A first straight surface 916, 916a is spaced a second minimum distance 918 from the central hole 910, the second minimum distance being greater than the first minimum distance 914. Furthermore, a second straight surface 920 may be disposed parallel to the first straight surface 916. The first straight surface 916 and the second straight surface 920 may define a first plane 922 and a second plane 924, respectively, that do not intersect the central axis 912.

[0232] As mentioned earlier, Figure 67 、 6872 shows an angle indicator 902, 902a extending from a first straight surface 916, 916a to a radial end 926, 926a of the aiming plate. In addition, the first angle indicator 902, 902a includes a third straight surface 928, 928a defining a plane 930 intersecting the central axis 912.

[0233] exist Figure 67 and 68 In the embodiment of the present invention, a second angle indicator 902b can be provided that extends from the second straight surface 920 to the radial end of the aiming plate 926. The second angle indicator can also include a fourth straight surface 928a that defines the same plane 930 that intersects the central axis 912 as the third straight surface 928 (but not necessarily). The first and second angle indicators can be arranged in a circular array around the central axis and have the same configuration, but not necessarily.

[0234] like Figure 67 、 68 As shown in FIG. 73 , an aiming plate 900 , 900 a , and 900 b constructed in accordance with another embodiment of the present disclosure may define a central aperture (e.g., see central aperture 910 ) defining a central axis 912 and a radial direction 932 ; a first mounting aperture (e.g., see first fastener receiving aperture 908 ) disposed about the central axis 912 and a first minimum distance 914 from the central aperture; and a second mounting aperture (e.g., see second fastener receiving aperture 908 a ) disposed about the central axis 912 and at the same first minimum distance 914 from the central aperture (i.e., within a manufacturing tolerance of 0.010 inches). The aiming plate 900 , 900 a , and 900 b may further define a radially varying outer periphery 934 including an angle indicator 902 , 902 a , and 902 b having a substantially radially extending surface 936 , 936 a . That is, in some embodiments of the present invention, the surfaces 936, 936a may form an angle less than 45 degrees with the radial direction, but may extend more or less close to pure radial direction (+ / - 5.0 degrees).

[0235] In many embodiments of the present disclosure, the third mounting holes (e.g., third fastener receiving apertures 908b) and the fourth mounting holes (e.g., fourth fastener receiving apertures 908c) form a rectangular array 938 centered about the central axis 912 (e.g., see Figure 67 、 69 In another embodiment, the rectangular array is actually as follows Figure 68 、 70 and square array 938a shown in FIG. 73 .

[0236] exist Figure 67 and 68, the radially varying outer perimeter 934 may include a first notch 940 defined by a first segment 942 defining a first segment length 944 and a second segment 946 defining a second segment length 948 less than the first segment length 944. Figure 67 , the rectangular array 938 can define a major axis 950 and a minor axis 952, wherein the minor axis 952 is parallel to the first segment 942. In other embodiments, the minor axis can be parallel to the second segment, etc.

[0237] exist Figure 73 , the radially varying outer periphery 934 can include a first angle indicator 902a defining a radial end 926a spaced a first minimum radial distance 954 from the central axis 912, and a first flat surface (e.g., see 916a) spaced a second minimum radial distance 956 from the central axis 912. The ratio of the first minimum radial distance 954 to the second minimum radial distance 956 ranges from 1.75 to 2.25 (e.g., approximately 2.0). Figure 67 and 68 In the embodiment, the ratio may range from 1.2 to 1.6 (eg, approximately 1.4).

[0238] The following will Figures 69 to 71 Initially, aiming plates 900c, 900d, and 900e constructed in accordance with another embodiment of the present disclosure are described. Such aiming plates 900c, 900d, and 900e may include a central circular hole 910a defining a central axis 912 and a radial direction 932. Furthermore, an array of mounting holes 958 (e.g., see FIG. 1 ) may be disposed about the central circular hole 910a. Figure 71 ). The outer periphery 960 of the aiming plate may include a pair of arcuate surfaces 962 and a pair of parallel surfaces 964. Figure 67 、 Figure 68 and Figure 73 A similar description can be made of the aiming plate in .

[0239] like Figure 71 As best shown, the pair of arcuate surfaces 962 can define a radius of curvature 966 measured from the central axis 912 to the pair of arcuate surfaces 962, and the pair of parallel surfaces 964 can be spaced apart from the central axis by a minimum radial dimension 968. In some embodiments of the present disclosure, the ratio of the radius of curvature to the minimum radial dimension ranges from 1.1 to 1.4 (e.g., approximately 1.25). In such instances, in some embodiments, the radius of curvature can range from 2.25 inches to 2.75 inches. Similarly, in certain embodiments of the present disclosure, for Figure 67 、 68 A similar description can be made of the sight plate in 73.

[0240] exist Figures 69 to 71In the embodiment, a pair of parallel surfaces 964 extend from one of the pair of arcuate surfaces 962 through the central circular hole 910 a to or toward the other of the pair of arcuate surfaces 962 .

[0241] Figure 67 、 68 This is not the case with the embodiments of FIG. 71. Instead, its outer periphery (e.g., see 934) includes a first L-shaped cutout 968 and / or a second L-shaped cutout 968a. These cutouts can form a circular array around the central axis 912, but this is not required.

[0242] exist Figure 73 , one of the pair of parallel surfaces 964 extends from one of the pair of arcuate surfaces 962 through the central circular hole 910 to or toward the other of the pair of arcuate surfaces 962, while the other of the pair of parallel surfaces (e.g., see 916a) extends to the angle indicator 902a. The angle indicator may include a flat surface (e.g., see 928a) that extends to a radial end 926a of the outer periphery, as previously described herein.

[0243] exist Figure 73 In the embodiment, radial end 926a is spaced from central axis 912 by a maximum radial distance greater than the radius of curvature of the pair of arcuate surfaces. Figure 67 and 68 This is not the case in .

[0244] Industrial Applicability

[0245] In practice, one or more of the following parts, assemblies or subassemblies may be initially offered at the first point of sale in an original equipment manufacturer (OEM) environment or as replacement or alternative parts in an aftermarket environment: a stand-alone ballast driver assembly, a circuit board and heat sink assembly, a loose wiring end bracket, an LED lighting fixture, a lens, an optic, a diffuser, a sunshade, an electrical / electronic component housing, an aiming plate, an aiming bracket and aiming plate assembly, and an aiming plate, among others.

[0246] Before undertaking the rebuild process, it may be necessary to check whether the old component still functions properly or is within the desired operating parameters. Figure 74 A method 6000 is shown that may include the steps of testing one or more ballasts to see if they have an open circuit 6002, and / or one or more capacitors (e.g., Figure 7 The capacitor bank 116 in the luminaire can be tested to see if it has the expected capacitance 6004. Other vintage components can also be tested, the horizontal and / or vertical aiming direction of the lighting fixture determined and recorded, etc.

[0247] During a retrofit or initial installation, various approaches can be employed. For example, referring to Figures 5, 7, and 24, the power supplied to the LED lighting fixture can be regulated using equipment already installed to regulate the power of previous HID lighting fixtures to compensate for the brightness loss associated with such HIDs over time.

[0248] like Figure 75 As shown, the method 1000 for retrofitting an HID lighting system with an LED lighting system may include disconnecting the motor of the cam motor assembly from the power source 1002. For example, the motor may be disconnected from the input power line, battery, etc. Since the brightness of an LED lamp is not prone to significant decreases over time, the motor does not need to rotate a cam to adjust the capacitance and the resulting power supplied to the LED lamp. Instead, the user can rotate a wheel, slide a switch, rotate a lever as described above, switch a capacitor, etc. to change the capacitance supplied to the power line 1004. The user can do this manually depending on the wattage required by the LED lamp, etc. The LED lighting fixture may also be connected to the power line 1006, etc. Other embodiments of the present disclosure may not use or appear in this method and apparatus. In addition, the order of these steps may be different.

[0249] In various embodiments, the Figure 76 Method 2000 for retrofitting an HID lighting system with an LED lighting system is disclosed in [ 2000 ]. Method 2000 may include disconnecting one or more ballasts from a power cord 2002 (e.g., an existing power cord in an ECE). This may result in loose wires, so the ends of these wires may be capped 2012 using wire end brackets, wire nuts, etc., as previously described herein, to insulate or otherwise prevent short circuits. Unused ballasts 2003 may be removed.

[0250] Additionally, method 2000 may further include connecting one or more ballasts to a circuit 2004 that includes a surge protection subcircuit. In some embodiments, the surge protection subcircuit may be configured to withstand a 10 kV surge measured in common mode or a 5 kV surge measured in differential mode (or at least a 6 kV surge measured in differential mode, see 2005). This may protect the circuit from, for example, near lightning strikes. In other embodiments of the present disclosure, this may not be the case. In other embodiments, a 10 kV surge measured in differential mode may be withstandable. In other embodiments of the present disclosure, this may not be the case.

[0251] Similarly, the method 2000 can also include connecting one or more ballasts to a rectifier sub-circuit 2006 (to convert AC current to substantially DC current); connecting one or more ballasts to an open circuit protection sub-circuit 2008 (to protect various components in the circuit from overloading, burning out, etc.); and connecting one or more ballasts to an output regulation sub-circuit 2010 (to reduce ripple, which in turn reduces the flicker effect that some LED lighting systems experience when starting up). In other embodiments of the disclosure, one or more of these sub-circuits can be omitted.

[0252] In some embodiments, the surge protection sub-circuit, the rectifier sub-circuit, the open circuit protection sub-circuit, and the output regulation sub-circuit are connected in series 2014. This can not be the case in other embodiments of the disclosure.

[0253] Turning now to Figure 77 , a method for assembling a housing around a circuit board having a heat sink is disclosed. The method 3000 can include creating a first flat pattern of a first housing member, the first housing member including at least one aperture configured to receive a portion of the heat sink or the circuit board 3002; and folding the first flat pattern of the first housing member until the heat sink or the circuit board is received into the at least one aperture and / or sliding the circuit board and the heat sink until the circuit board and the heat sink are received into the at least one aperture 3004. In some embodiments, the first housing member is first folded and then the circuit board and heat sink are slid into the appropriate slot or aperture.

[0254] For example, the folding can first occur, thereby forming flexible ears (such as the first and second side circuit board mounting portions discussed previously), and then the circuit board is slid until the circuit board and heat sink having one or more mounting tabs are received into one or more apertures of the ears.

[0255] The second housing member can then be attached to the first housing member 3006. For example, the second housing member can be attached to the outside of the first housing member, thereby eliminating the flexibility of the ears so that the circuit board and / or heat sink are now securely confined in the first housing member.

[0256] To facilitate manufacturing, the second housing member can also be a folded member 3008. Further, the second housing member can first be manufactured as a second flat pattern, with a plurality of apertures punched out of the second flat pattern 3010. After the housing is assembled, the heat sink can protrude out of the housing so as to maximize heat transfer after installation to the ECE. That is, the contact between the heat sink and the housing (possibly with a thermally conductive but electrically insulating material disposed therebetween) leaves a small gap between the housing and the ECE. Other manufacturing methods can also be employed in addition to sheet metal forming.

[0257] When upward lighting is required, Figure 78 Another method described provides upward lighting so that sports balls, etc. can be seen at night.

[0258] This method 4000 may include attaching a lens, optic, or diffuser to a light source 4002 (eg, a laser, LED, but not necessarily) and redirecting the light in an upward trajectory relative to the light source 4004 .

[0259] Attaching a lens, optic, or diffuser may involve mounting the lens, optic, or diffuser at the free end of the visor 4006, and the method may also include aiming a collimated light beam (e.g., a NEMA 3 standard beam) at a portion of the lens, optic, or diffuser 4008. In a specific embodiment of the present disclosure, the collimated light beam may be emitted or aimed from the third row of LEDs at the top of the LED array 4010. In other embodiments of the present disclosure, other rows or positions of the collimated light beam may be used. Furthermore, the method may include moving the lens, optic, or diffuser relative to the light source to adjust the redirected light 4012. For example, the lens, optic, or diffuser may be lowered to redirect more light upward; or, if less upward illumination is desired, the height of the lens, optic, or diffuser may be raised. The angle of the lens, optic, or diffuser relative to the light may also be adjusted to change the upward illumination, etc. If a lens or diffuser is used, there may not be a gap between the downward and upward illumination. Otherwise, there may be a gradual transition between the downward and upward illumination.

[0260] In some embodiments, there may be a combination of LED retrofit lighting fixtures and existing HID lighting systems. For example, in some cases, it may be easier or more economical to replace a failed HID lamp with an LED lighting fixture that is not easily replaced. This can be done in lieu of using screw-in LED lamps, as the light levels and distribution of the LED lighting fixtures are more easily matched to those of the HID lamps, whereas screw-in LED lamps cannot.

[0261] In other variations of the present disclosure, a reflector (such as disclosed in U.S. Patent No. 10,337,693) may be used instead of a lens, optical device, or diffuser. Furthermore, uplighting fixtures (such as disclosed in U.S. Patent No. 8,952,628 or U.S. Patent No. 10,337,680) (in which case one of the ballast drivers may be used to power the fixture) and sharp-cutoff LED lighting fixtures (such as disclosed in U.S. Patent No. 10,267,491 and U.S. Patent No. 10,378,732) may also be used.

[0262] In some applications, it is necessary or desirable to set the horizontal aiming angle of the steering knuckle and / or the lamp lighting fixture. It may be easier to aim the steering knuckle first and then attach the lamp, but this is not necessary.

[0263] This method is 5000 Figure 79 This is described and may include rotating the aiming plate having the mounting holes relative to the aiming bracket until the desired relative angular orientation between the aiming plate and the aiming bracket is established 5002. This may be done manually or automatically at the factory or in the field.

[0264] In some embodiments, method 5000 may further include securing the aiming plate to aiming bracket 5004. For example, the aiming plate may be fastened to the bracket. Alternatively, this may include adhering the aiming plate to aiming bracket 5006. These steps may omit the use of an angle indicator, but this is not required.

[0265] In some embodiments of the present disclosure, method 5000 may further include measuring relative angular orientation 5008 using an angle indicator to read an angular measurement on the sighting bracket.

[0266] At some point, the method 5000 may also include inserting 5010 a fastener through the mounting hole of the aiming plate and the slot of the aiming bracket, the fastener engaging the structural member. Figure 59 and 62 It will be appreciated that the fastener may have a knurled profile that engages a hole in the cross arm or other structural member, thereby preventing rotation thereof.

[0267] After the free end of the fastener passes through the aiming plate and the aiming bracket, Figure 79 The method may further include tightening the fasteners to secure the aiming bracket and the aiming plate to the structural member 5012. For example, a nut may be turned onto threads extending from a free end of the bolt until sufficient torque is applied.

[0268] Once the proper angle of the aiming bracket is set, method 5000 may also include attaching a steering knuckle and / or light fixture to the aiming bracket 5014. The steering knuckle and / or light fixture may or may not already be attached to the aiming bracket when the angle is set.

[0269] In some applications, the purpose of an aiming plate is to pre-align the luminaire at the factory. This can make installation easier and improve the accuracy of the lighting design intended by the application engineer.

[0270] Further variations or embodiments of the present disclosure may include providing or using LED Driver, Schiedewerks LED Driver or 880W LED driver for ECE.

[0271] In this case, a separate ballast driver and / or associated circuitry may not be required. In addition, additional features such as light shows, and / or light shows with audio, can be implemented using one or more of these commercially available drivers. Light dimming, etc.

[0272] It should be noted that, depending on the examples, certain actions or events of any of the techniques described herein may be performed in a different order, may be added, combined, or omitted entirely (e.g., not all described actions or events are necessary to practice these techniques). Furthermore, in some examples, actions or events may be performed in parallel, such as through multithreading, interrupt handling, or multiple processors, rather than sequentially.

[0273] The drivers or controllers can be programmed to provide various theatrical and lighting effects. In one or more examples, the functions described may be implemented in hardware, software, firmware, or any combination thereof. If implemented in software, the functions may be stored on or transmitted via a computer-readable medium as one or more instructions or codes and executed by a hardware-based processing unit. Computer-readable media may include computer-readable storage media, which corresponds to tangible media (e.g., data storage media) or communication media (including any media that facilitates the transfer of a computer program from one place to another (e.g., according to a communication protocol). In this manner, computer-readable media may generally correspond to (1) non-transitory tangible computer-readable storage media or (2) communication media such as signals or carrier waves. Data storage media may be any available media that can be accessed by one or more computers or one or more processors to retrieve instructions, codes, and / or data structures for implementing the techniques described in this disclosure. A computer program product may include computer-readable media.

[0274] By way of example and not limitation, such computer-readable storage media may include RAM, ROM, EEPROM, CD-ROM or other optical disk storage, magnetic disk storage or other magnetic storage devices, flash memory, or any other medium that can be used to store the desired program code in the form of instructions or data structures and that can be accessed by a computer. In addition, any connection can be appropriately referred to as a computer-readable medium. For example, if instructions are transmitted from a website, server, or other remote source using a coaxial cable, fiber optic cable, twisted pair, digital subscriber line (DSL), or wireless technologies such as infrared, radio, and microwave, then the coaxial cable, fiber optic cable, twisted pair, DSL, or wireless technologies such as infrared, radio, and microwave are all included in the definition of medium. However, it should be understood that computer-readable storage media and data storage media do not include connections, carrier waves, signals, or other transient media, but rather refer to non-transient tangible storage media. As used herein, "disk" and "disc" include compact disks (CDs), laserdiscs, optical disks, digital versatile disks (DVDs), floppy disks, and Blu-ray discs. Disks typically reproduce data magnetically, while optical disks reproduce data optically using lasers. Combinations of the above two media should also be included within the scope of computer-readable media.

[0275] The instructions may be executed by one or more processors, such as one or more digital signal processors (DSPs), general-purpose microprocessors, application-specific integrated circuits (ASICs), field-programmable logic arrays (FPGAs), or other equivalent integrated or discrete logic circuits. Therefore, the term "processor" as used herein may refer to any of the aforementioned structures or any other structure suitable for implementing the techniques described herein. Furthermore, in some aspects, the functionality described herein may be provided in dedicated hardware and / or software modules configured for encoding and decoding, or incorporated into a combined codec. Furthermore, these techniques may also be implemented entirely in one or more circuits or logic elements.

[0276] The techniques of this disclosure can be implemented in a variety of devices or apparatuses, including wireless handheld devices, integrated circuits (ICs), or a set of ICs (e.g., a chipset). Various components, modules, or units are described in this disclosure to emphasize the functional aspects of devices configured to perform the disclosed techniques, but these components, modules, or units do not necessarily need to be implemented by different hardware units. Instead, as described above, the various units can be combined in a codec hardware unit, or provided by a set of interoperable hardware units (including one or more processors as described above) in combination with appropriate software and / or firmware.

[0277] This disclosure has described various examples. Any combination of the described systems, operations, or functions is within the contemplated scope. These and other examples are within the scope of the following claims.

Claims

1. An LED lighting fixture, comprising: a luminaire defining a luminaire perimeter having a horizontal width and a vertical height; The ratio of the horizontal width to the vertical height ranges from 0.90 to 1.

25.

2. The LED lighting fixture according to claim 1, wherein: A ratio of the horizontal width to the vertical height ranges from 0.97 to 1.

17.

3. The LED lighting fixture according to claim 1, wherein: The horizontal width ranges from 14.0 inches to 15.5 inches, and the vertical height ranges from 11.0 inches to 13.0 inches.

4. The LED lighting fixture according to claim 1, wherein: The periphery of the lamp is rectangular. 5 . The LED lighting fixture of claim 1 , further comprising a four-way wide-beam LED array, wherein the four-way wide-beam LED array comprises four horizontally extending rows and fifteen vertically extending rows.

6. The LED lighting fixture according to claim 1, further comprising a front lamp frame defining a perimeter of a window opening, and a plurality of light sources disposed within the perimeter of the window opening, wherein The plurality of light sources are spaced apart from the fixture perimeter by a maximum vertical distance, and a ratio of a vertical height of the fixture perimeter to the maximum vertical distance ranges from 1.70 to 2.

45.

7. The LED lighting fixture according to claim 6, wherein: A ratio of the vertical height of the lamp to the maximum vertical distance ranges from 1.85 to 2.

24.

8. The LED lighting fixture of claim 7, further comprising a visor attached to the front lamp frame, the visor comprising a top surface forming a top angle ranging from 10.0 degrees to 20.0 degrees with a horizontal plane.

9. The LED lighting fixture of claim 7, further comprising a sunshade attached to the front lamp frame with a horizontal projection distance perpendicular to the horizontal width and vertical height of the lamp, and a ratio of the horizontal projection distance to the vertical height ranges from 0.96 to 2.

07.

10. The LED lighting fixture according to claim 9, wherein: The ratio of the horizontal projection distance to the vertical height ranges from 1.05 to 1.

90.

11. The LED lighting fixture of claim 7, further comprising a lens, an optical device, or a diffuser attached to a free end of the visor.

12. The LED lighting fixture of claim 7, further comprising a rectangular array of LEDs comprising a series of top rows, and the lens, the optic, or the diffuser vertically covers 0% to 40% of the series of top rows of the rectangular array of LEDs.

13. The LED lighting fixture of claim 12, wherein the lens, the optic, or the diffuser vertically covers 30% to 40% of the series of top rows of the rectangular array of LEDs.

14. The LED lighting fixture according to claim 7, wherein: The sun visor includes a front panel having a plurality of mounting apertures. 15 . The LED lighting fixture of claim 14 , further comprising a lens, the lens comprising a plurality of mounting holes configured to align with the plurality of mounting apertures.

16. The LED lighting fixture of claim 1, further comprising a lamp back plate and a front lamp frame attached to the lamp back plate.

17. The LED lighting fixture of claim 16, further comprising a knuckle and a heat sink attached to the fixture back plate.

18. The LED lighting fixture according to claim 16, wherein: The headlamp frame defines a window configured to receive an outer lens.

19. The LED lighting fixture of claim 18, further comprising an LED board having a plurality of LEDs attached to the fixture back plate, an optical holder having a plurality of apertures disposed around the LEDs, and an optics board disposed in the optical holder adjacent to the LED board.

20. The LED lighting fixture according to claim 6, wherein: The maximum vertical distance is vertically arranged above the plurality of light sources and between the plurality of light sources and the light shielding plate.

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