Method 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 application patent application entitled "Apparatus, Method, and System for Retrofitting a Lighting System with LED Lamps" having application number 202480008925.2, filed on January 23, 2024.

[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 relates generally to a system for replacing an HID (high intensity discharge) lamp in a lighting system with an LED (light emitting diode). More specifically, the present disclosure enables such a system to be installed economically and efficiently, can use existing components of a previously installed lighting system, can save energy costs in use, provide comparable or better lighting, and can provide uplighting. BACKGROUND

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

[0006] For example, if a failed 60W incandescent bulb in the same table lamp is replaced with a 15W LED bulb (which has a light output comparable to the 100W incandescent bulb), this would be a typical retrofit situation. 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 noted that the above example is a simple retrofit situation compared to other more complex lighting retrofit situations that lack such a widely accepted, simple solution in the marketplace—different power requirements are addressed without any other modifications to the rest of the lighting system.

[0007] On the other hand, professional lighting systems, such as sports or large area lighting systems, require more consideration for replacement. Unlike the example of a desk lamp, there is no standard bulb shape or size, no standard bulb base, and no standard input power. Rather, all of these features can vary from site to site and manufacturer to manufacturer. For example, the input voltage of a site can be 480V or 240V, or the input power can be three-phase or single-phase, or the existing lighting system can 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 non-lighting technology portions of the existing lighting system, such as the light poles, housings, wiring, and cross arms, can also vary. As one example, the existing lighting system can include solid wood light poles with exposed wiring or hollow steel light poles with internal wiring. As another example, the light poles can 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] Accordingly, the one-for-one replacement approach in the residential lighting retrofit market, such as removing an old light source and installing a new light source without making other changes, is not practical for the professional lighting retrofit market.

[0009] Nonetheless, to date, some manufacturers have attempted to employ the one-for-one replacement approach in professional lighting system retrofits. These attempts have largely met with serious problems. For example, even though the one-for-one retrofit luminaire cannot match the existing cross arm footprint, some manufacturers have attempted to retain the existing cross arm. Doing so limits the achievable horizontal and vertical aiming range of the retrofit luminaire and often results in dark spots in the target area. This can affect the lighting uniformity. Some manufacturers have drilled new holes in the existing cross arm to accommodate the footprint of the one-for-one retrofit luminaire. Doing so often results in weakening the cross arm and introducing additional locations for moisture infiltration, which can damage the wiring and potentially exacerbate corrosion.

[0010] Accordingly, there is a need in the art for a system for properly retrofitting a specialized lighting system, such as a lighting system covering a large outdoor area, such as a sports field, a port, an airport, a railway, etc. SUMMARY

[0011] A method of retrofitting a HID lighting system with an LED lighting system according to an embodiment of the present disclosure can include decoupling a motor of the cam from a power source.

[0012] Another embodiment of a method of retrofitting a HID lighting system with an LED lighting system according to another embodiment of the present disclosure can include decoupling one or more ballasts from a power line and connecting the one or more ballasts to a circuit including a surge protection subcircuit.

[0013] A method for producing uplight according to another embodiment of the present disclosure can include attaching a lens, optic, or diffuser to a light source and redirecting light in an upward trajectory relative to the light source.

[0014] The details of one or more examples of the present disclosure are set forth in the accompanying drawings and the description below. Other features, objects, and advantages of the disclosure will be apparent from the description, drawings, and claims. BRIEF DESCRIPTION OF DRAWINGS

[0015] 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 to scale, but the examples can include the scale shown and are intended to be used in conjunction with the description in the following detailed description, where like reference numbers refer to like elements. Examples of the present disclosure will be described below with reference to the accompanying drawings.

[0016] FIG. 1 shows a prior art system of an external lighting system including a light pole with a HID (high intensity discharge) lamp attached thereto for illuminating 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.

[0017] FIG. 2 depicts the light pole and its cross arm with the HID lamp used in the prior art system of FIG. 1. In addition, the electrical component enclosure and grounding equipment are also clearly shown in the figure.

[0018] FIG. 3 is a side sectional view of the top portion of FIG. 2 showing the wiring within the light pole and to the cross arm of the lamp.

[0019] FIG. 4 is a top sectional view of the top portion of FIG. 3 showing the wiring within the top cross arm more clearly. FIGS. 3 and 4 also show the physical or photometric interference that can exist between fixtures on the same light pole (indicated by lines A and B), which can be avoided during retrofit design to allow for full horizontal and vertical pivoting and to avoid creating useless light, etc.

[0020] FIG. 5 is a schematic diagram of the components in the electrical component enclosure of FIG. 2. These components form the electrical circuit that runs the single HID lamp shown in FIGS. 2-4.

[0021] FIG. 6 is a schematic diagram of the prior power supply circuit of FIG. 5 for powering the single HID lamp.

[0022] Figure 7 The interior of the electrical component enclosure (ECE) according to an embodiment of the present disclosure is shown, with the ballast removed and one or more standalone ballast driver assemblies installed in the ECE for powering one or more LEDs. The front cover of the ECE has been removed to show these internal components and assemblies.

[0023] Figure 8is shown separately Figure 7 perspective view of the stand-alone ballast driver assembly of

[0024] Figure 9 is shown Figure 8 the stand-alone ballast driver assembly of

[0025] Figure 10 is Figure 9 bottom-oriented perspective view of the stand-alone ballast driver assembly of

[0026] Figure 11 is shown separately Figure 9 bottom-oriented perspective view of the cover of the stand-alone ballast driver assembly of

[0027] Figure 12 is shown separately Figure 8 front-oriented perspective view of the mounting bracket of the stand-alone ballast driver assembly of

[0028] Figure 13 is a perspective view of the circuit board assembly with a heat sink that is part of the stand-alone ballast driver assembly of Figure 8

[0029] Figure 14 is a top view of the circuit board assembly and heat sink of Figure 13

[0030] Figure 15 is an alternative to the ECE disclosed in Figure 7 with dual stand-alone ballast driver assemblies.

[0031] Figure 16 is a perspective view of the stand-alone ballast driver assembly similar to Figure 8 except with two PCBs and associated circuitry for driving more lighting fixtures than the driver of Figure 8 which can be used in the ECE of Figure 15

[0032] shows the stand-alone ballast driver assembly of Figure 17 with the cover removed, showing two PCBs (printed circuit boards) facing each other. Figure 16

[0033] Figure 18 is an alternative perspective view of the stand-alone ballast driver of Figure 17 showing more clearly the clamps that hold some components attached to the PCBs against the thermally conductive and electrically insulating plate. ​​​

[0034] Figure 19 is Figure 18 a rear perspective view of the independent ballast driver assembly of

[0035] Figure 20 contains a single instance of the Figures 17 to 19 PCB shown separately.

[0036] Figure 21 is an alternative perspective view of the PCB of Figure 20

[0037] Figure 22 is a schematic diagram of a rectification and power supply circuit configured to supply direct current (DC) to an LED lighting fixture, in accordance with an embodiment of the present disclosure.

[0038] Figure 23 shows some sub-circuits of the rectification and power supply circuit of Figure 22

[0039] Fig. 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 brightness loss that the HID lamp experiences over time.

[0040] Figure 25 is a perspective view of the wire end holder in the open configuration.

[0041] Figure 26 is a perspective view of the wire end holder in the closed configuration.

[0042] Figure 27 is a perspective view of an LED lighting fixture with a louvre that has a top surface that forms a top angle of about 12 degrees with the horizontal, in accordance with an embodiment of the present disclosure. An optional uplighting lens is shown attached to the front of the louvre.

[0043] Figure 28 is a side view of the LED lighting fixture of Figure 27

[0044] Figure 29 is a cross-sectional side view of the LED lighting fixture of Figure 28

[0045] Figure 30 is a front view of the LED lighting fixture of Figure 27

[0046] Figure 31 shows​​​​​is an LED lighting fixture of the type Figure 30 wherein the louvers and the upward lighting transmissive lens have been removed to more clearly show the square perimeter of the fixture.

[0047] Figure 32 is a perspective view of an LED lighting fixture according to another embodiment of the disclosure, which is similar or identical in construction to Figure 27 except that the bottom side of the louvers is straight as shown in Figure 26 .

[0048] Figure 33 is a side cross-sectional view of the LED lighting fixture of Figure 32 .

[0049] Figure 34 is a perspective view of an LED lighting fixture according to yet another embodiment of the disclosure, which is similar or identical in construction to Figure 32 except that the top surface of the louvers forms a top angle of about 18 degrees with the horizontal.

[0050] Figure 35 is a side view of the LED lighting fixture of Figure 34 .

[0051] Figure 36 is a side cross-sectional view of the LED lighting fixture of Figure 35 , showing the optics, LEDs, internal lenses, etc.

[0052] Figure 37 is a front view of the LED lighting fixture of Figure 34 .

[0053] Figure 38 depicts the LED lighting fixture of Figure 37 , showing the fixture, knuckle, and heat sink, etc. for Figures 27 to 34 all three embodiments shown are the same.

[0054] Figure 39 is a perspective view of an LED lighting fixture according to yet another embodiment, which is similar or identical in construction to Figure 34 except that the bottom surface of the louvers Figure 40 is contoured as shown.

[0055] Figure 40 is a side cross-sectional view of the LED lighting fixture of Figure 39 .

[0056] Figure 41 shows the LED lighting fixture of Figure 39LED luminaire, with the upward illumination lens removed, showing mounting holes in the front panel of the visor. It is to be understood that the upward illumination lens, optic, or diffuser can be used with each of the embodiments of the visors disclosed herein, such that each of the visors' front panels have the same mounting holes.

[0057] Figure 42 is a partially exploded assembly view of the luminaire of the LED luminaire disclosed herein.

[0058] Figure 43 is a perspective view of an optic having a four LED array to produce a wide beam of light, which can be used with the luminaire of Figure 42 .

[0059] Figure 44 is a perspective view of a lens constructed in accordance with an embodiment of the disclosure, shown separately.

[0060] Figure 45 is a front view of the lens of Figure 44 .

[0061] Figure 46 is a side view of the lens of Figure 44 .

[0062] Figure 47 is a rear view perspective view of the wire end holder shown attached to the side of the circuit board and heat sink subassembly.

[0063] Figure 48 is a perspective view of a lens constructed in accordance with another embodiment of the disclosure, shown separately.

[0064] Figure 49 is a front view of the lens of Figure 48 .

[0065] Figure 50 is a side view of the lens of Figure 48 .

[0066] Figure 51 is a chart showing the curves of the side surfaces forming the light redirecting portion of the lens of Figure 50 .

[0067] Figure 52 shows the incident light to the lens of Figure 50 , the refraction of the light in the lens, and the redirection of the light as it exits the lens.

[0068] Figure 53 shows the incident light to the lens having a different profile, the different refraction in the lens resulting therefrom, and the different redirection of the light as it exits the lens, with the same incident light shown as in Figure 52 .

[0069] Figure 54 A front perspective view of yet another embodiment of a lens of the present disclosure is depicted.

[0070] Figure 55 A rear perspective view of a lens of the present disclosure, showing one or more mounting pads of the lens. Figure 54

[0071] Figure 56 A right side view of a lens of the present disclosure. Figure 54

[0072] Figure 57 shows a horizontal aiming bracket employed on certain HID lighting systems, as well as some LED lighting systems found in the field.

[0073] Figure 58 A perspective view of a main crossbar according to an embodiment of the present disclosure, as well as auxiliary crossbars attached to the main crossbar by aiming brackets and aiming plates (also referred to as aiming spacers). One aiming bracket and aiming plate are each attached proximate to each end of the main crossbar, while one aiming bracket and aiming plate are also each attached proximate to an end of the auxiliary crossbars.

[0074] Figure 59 A top cross-sectional view of a main crossbar and auxiliary crossbars of the present disclosure, showing mounting holes and mounting hardware used to secure aiming brackets to the crossbars. The middle aiming bracket is angled at about 10 degrees relative to a direction normal to the main crossbar, the right aiming bracket is angled at about 30 degrees relative to a direction normal to the main crossbar, and the left aiming bracket is angled at about 40 degrees relative to a direction normal to the main crossbar. Figure 58

[0075] A perspective view of an aiming bracket, knuckle, aiming plate, and mounting hardware of the present disclosure, with the crossbar removed. Figure 60 Figure 58 A perspective view of the middle aiming bracket, knuckle, mounting hardware, and middle aiming plate, shown separately.

[0076] Figure 61 A perspective view of the right aiming bracket, knuckle, mounting hardware, and right aiming plate, shown separately.

[0077] Figure 62 A perspective view of the left aiming bracket and left aiming plate, shown separately.

[0078] Figure 63 A perspective view of the middle aiming bracket and middle aiming plate of the present disclosure, shown separately.

[0079] Figure 64 Figure 61 A perspective view of the right aiming bracket and right aiming plate of the present disclosure, shown separately.

[0080] Figure 65 A perspective view of the left aiming bracket and left aiming plate of the present disclosure, shown separately. Figure 61 ​​​​bottom-oriented perspective view of the aiming bracket.

[0081] Figure 66 is a top-oriented perspective view of a top portion of the knuckle. Figure 61

[0082] Figure 67 is a top view of an aiming plate, such as the one shown by itself Figure 61 used with the intermediate aiming bracket of

[0083] Figure 68 is a top view of an aiming plate, such as the one shown by itself Figure 62 and 63 used with the right and left aiming brackets of

[0084] Figure 69 is a top view of an aiming plate according to another embodiment of the disclosure, which is configured similarly or identically to the aiming plate of Figure 67 except that the angle indicators have been removed.

[0085] Figure 70 is a top view of an aiming plate according to another embodiment of the disclosure, which is configured similarly or identically to the aiming plate of Figure 68 except that the angle indicators have been removed.

[0086] Figure 71 is yet another embodiment of an aiming plate lacking angle indicators, which can be used with other old-style A-arms or in other locations in the A-arm not explicitly disclosed herein.

[0087] Figure 72 is a perspective view of an aiming bracket used in conjunction with an aiming plate according to yet another embodiment of the disclosure, which has an extended angle indicator portion so that smaller angles can be more easily read along the front flat portion of the aiming bracket.

[0088] Figure 73 is a top view of the aiming plate of Figure 72 shown by itself.

[0089] Figure 74 is a flowchart describing a method for determining whether some of the HID lighting system and its components are suitable or ready for retrofitting with an LED lighting system.

[0090] Figure 75 contains a method for adjusting the capacitance supplied to the power line and the resulting power supplied to the LED lighting fixture using Smart technology or similar technology according to embodiments of the disclosure.

[0091] Figure 76 ​A method of retrofitting an HID lighting system using an LED lighting system is shown in accordance with embodiments of the present disclosure.

[0092] Figure 77 A method for assembling a housing around a circuit board having a heat sink in accordance with another embodiment of the present disclosure is included.

[0093] Figure 78 A method of producing uplight using a lens, optic, or diffuser in accordance with embodiments of the present disclosure is shown.

[0094] Figure 79 A method of aiming a horizontal direction of a knuckle that can be attached to a lighting fixture, such as an LED lighting fixture, an HID lighting fixture, or the like is depicted. DETAILED DESCRIPTION

[0095] The following detailed description is exemplary in nature and is not intended to limit the scope or applicability of the technology or system described herein in any way. Rather, the following description provides some practical examples for implementing exemplary aspects of the technology or system described herein. One skilled in the art will appreciate that many of the examples provided above have a wide applicability beyond the specific examples described.

[0096] For further understanding of the present disclosure, specific exemplary embodiments in accordance with the present disclosure will be described in detail. Reference will be frequently made to the drawings. Reference numerals will be used to indicate particular components in the drawings. Unless otherwise noted, like reference numerals will be used to indicate like components in all of the drawings. Further, like reference numerals (e.g., 702, 802, 902, 1002, 1102) will be used to indicate similar components or functionality between embodiments. Reference numerals with letters (e.g., 100, 100a) can indicate the same or similar features that can be symmetrical to each other, etc.

[0097] With respect to terminology, terms such as "device," "apparatus," "element," "component," "part," "structure," "assembly," and "member" and the like can be used interchangeably, as is convenient for ease of reference, and are not intended to limit the aspects of the present disclosure, unless otherwise specifically stated.

[0098] Further, the terms "have," "include," "contain," and the like, or forms thereof, are to be construed as open-ended, not limiting, and are to be understood to mean that additional components can be added to the structure. The terms "substantially linear," "linear array," and the like, or forms thereof, are to be construed as including an array of items, such as LEDs, that follow at least a partially straight or slightly curved scan path such that a tangent line at one end of the array forms an angle of less than 40 degrees with a tangent line at the other end of the array.

[0099] Also, for convenience or ease of explanation, some terminology is used herein, but such terminology should not be deemed limiting of the scope of what is described herein. For example, the terms "luminaire" and "light fixture" are used interchangeably herein, as they are commonly used in the lighting industry. Neither of these terms is intended to be limited to any particular lighting fixture beyond what is described herein.

[0100] As another example, reference is made herein to "ballasts" and "drivers"; while both are power conditioning devices for 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 is noted that the corresponding terminology for power conditioning devices can vary where aspects of the present disclosure are applied to other types of light sources, such as laser diodes. It is generally understood that various embodiments of the present disclosure are directed to lighting system retrofitting and therefore any specific reference to light source type or power conditioning device should be given the broadest interpretation.

[0101] For example, ballasts can include inductive ballasts, electronic ballasts, and generally any AC power conditioning device; while drivers can include general purpose drivers (i.e., simple DC power conditioning devices), so-called intelligent drivers (i.e., complex DC power conditioning devices that can include programmable features, self-healing components, active feedback loops, etc.), or something in between. All of the above possibilities are considered to be within the scope of the present disclosure.

[0102] Finally, with respect to terminology, reference can be made herein to terms such as "ray", "light beam", "light beam pattern", "light beam shape", "composite light beam", "light beam design", etc. All of these terms refer to light rays projected from a lighting fixture. It is understood that the nature of light rays is complex and that the terms herein can generally describe the shape of the light rays projected from a lighting fixture to a target area, or the intensity of the space above the target area, or the general direction of the light rays as they exit the lighting fixture, etc. While specific descriptions and illustrations are provided herein, it is understood that none of these terms, descriptions, or illustrations should be considered as fully encompassing the lighting issues that can be encountered during retrofit situations; however, it is also noted that all of these terms, descriptions, or illustrations are well-known and readily understood terms in the lighting industry.

[0103] SUMMARY

[0104] As previously mentioned, the present disclosure relates to lighting system retrofitting. More specifically, retrofitting of dedicated lighting systems is disclosed.

[0105] Figures 1-4 illustrate one such specialized lighting system. Here, a sports lighting system is described for illuminating a sports field 2 and portions of the airspace above the field. As can be seen in Figure 1, field power is delivered through a transformer 4 or other device. Delivery of the power along a power supply line 8 to HID fixtures 6 is regulated and / or controlled at multiple points in the circuit, here referring to a pole 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.

[0106] Additional control, if desired, can be made from an off-site control center 18, for example, by wireless communication to an antenna and control module located in the control cabinet 14, 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 a base 22, and routed as internally as possible to prevent theft and exposure to environmental influences.

[0107] In Figures 2-4, the wiring 8 is routed internally through the light pole 12, into a cross arm 24, through an adjustable armature 26, and to each HID fixture 6 arranged in an array 28. This is a sufficient description of a specialized 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.

[0108] As discussed earlier herein, a retrofit situation occurs when the replaced light source is different from the light source it replaces. Typically, LED lamps have different power requirements than HID lamps. In the context of retrofitting the sports lighting system in Figures 1-4 from HID to LED, this translates to some change in the power regulating device at the pole cabinet 10. While 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 regulated at the pole cabinet 10 for the particular load (i.e., one or more HID sources 6) by a ballast 30 and capacitor bank 32, and thus, this power, as shown in Figures 5 and 6, is an aspect of the present disclosure.

[0109] Another aspect of the present disclosure is at the top of the pole: the luminaire level. Ideally, the retrofitted luminaire will fit in the existing cross arm footprint so that it can pivot left and right (sometimes referred to as swing) or up and down (sometimes referred to as tilt) without creating photometric or physical interference. Photometric interference occurs when light from one luminaire (see light rays A and B in FIGS. 3 and 4) strikes another luminaire in the system and causes on-site glare or other undesirable lighting effects. This can occur, for example, if the top-most luminaire 6 in FIG. 3 is pivoted down so that light ray A strikes the top of the bottom-most luminaire 6a in FIG. 3 (i.e., the luminaire associated with light ray B).

[0110] Physical interference occurs when certain aiming angles are excluded due to the luminaire colliding with each other or colliding with some other part of the lighting system. This can occur, for example, if the left-most luminaire 6b in FIG. 4 (i.e., the luminaire associated with light ray A) is pivoted laterally into the next luminaire 6c (i.e., the luminaire associated with light ray B). Both photometric and physical interference reduce useful light: light that is useful for the particular application (here, lighting of the field 2 and the airspace above the field 2).

[0111] It can be argued that photometric and physical interference in a retrofit system is simply the result of poor aiming or lighting design, but it is important to note that extreme aiming is sometimes the only way to achieve the desired lighting design if the retrofit luminaire itself does not match well with the application in terms of required light levels, required glare control, and existing pole location / weight load restrictions. Other times, even if the luminaire design is excellent, the wiring quality is too low or the cross arm is bent or the existing light levels that are preserved are too low for the retrofit situation, and so the best approach is to retrofit full array LED luminaires on new cross arms with new wiring harnesses - which also has the added benefit of photometric and physical interference testing being done at the factory. All of these will be addressed in some embodiments set forth herein.

[0112] Further, retrofitting existing dedicated lighting systems, such as the one just described, in a one-for-one manner to include LED luminaires, which is the current industry practice, often results in a significant loss of glare control (on-site and / or off-site). To combat the increase in glare, LED retrofit luminaires of the prior art often have a shroud, are painted black, coupled with a glare shield, etc. - which, while effective at reducing glare - also reduce overall light output, which requires more luminaires to achieve a light level comparable to the previous HID lighting system. This can cause problems with the weight that the existing light pole or cross arm can bear and the available space on the cross arm (as discussed with respect to FIGS. 3 and 4). It can be argued that LEDs are always a better choice than traditional lighting technology - if operated properly, their useful life is indeed very long - but this can come at the expense of glare control (often, the poor quality of the retrofit system is not realized until it is installed). Some embodiments set forth herein also address this issue.

[0113] Exemplary embodiments envision devices and methods for designing a dedicated LED retrofit lighting system in a manner that addresses different power requirements, meets required lighting conditions, preserves much of the existing lighting system, and is more cost effective and customizable than the prior art. These exemplary embodiments will be described herein with respect to various aspects of the general examples already described.

[0114] Retrofit electronics housing

[0115] Turning now to Figures 7 to 26 and Figure 47 Various embodiments associated with adjusting the power provided by a previously installed lighting system utilizing HID lamps using some of the existing components of the system will now be discussed.

[0116] Beginning with Figure 7 and Figure 8 , an improved ECE is shown in which some of the ballasts previously used to power the HID lamps have been removed and replaced by 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 luminaires, but this is not a requirement. In some embodiments, three ballasts can be removed and replaced by three ballast drivers installed in the ECE. The three existing ballasts and the existing capacitor can still be used. In other embodiments, the number of ballasts, capacitors, and ballast drivers can be reduced due to the fact that LED lighting is inherently more efficient than HID lighting. Conversely, a dedicated or new ECE can be supplied with more ballasts and ballast drivers to increase the amount of lighting in terms of brightness levels or area covered on-site by the previously installed HID lighting system.

[0117] The ECE 100 includes one or more ballasts 30 as described previously and one or more standalone ballast driver assemblies 200 in electrical communication with the one or more ballasts 30 for providing direct current (DC) to the LEDs. More specifically, the standalone ballast driver assemblies 200 can include a circuit board 302 and a circuit board housing 204 (which can be made of sheet metal) that surrounds the circuit board 302 for protecting the circuit board and securely mounting it in the ECE 100.

[0118] Attention is directed Figure 7 to the ECE can be described hereinafter as a separate and vendable item. The ECE 100 can include a sidewall 102, a bottom wall 104, a first ballast 106 attached to the sidewall 102 or the bottom wall as shown, and a first ballast driver (e.g., standalone ballast driver assembly) attached to the sidewall 102 or the bottom wall adjacent the first ballast 106 as shown.

[0119] Similarly, a second ballast 106a and a third ballast 106b can be attached to the sidewall 102, while a second ballast driver 200a and a third ballast driver 200b can be attached to the sidewall 102 or to the bottom wall as shown. The first, second, and third ballasts can be disposed in a linear array, while the first, second, and third ballast drivers can form a linear array adjacent the array of ballasts.

[0120] In a retrofit application, the first ballast driver, the second ballast driver, and / or the third ballast driver can occupy space vacated by removal of a plurality of previously installed ballasts. This can not be the case when the ECE is supplied as a new component.

[0121] More specifically, the ECE can take the form of a polygonal sheet metal housing (e.g., can be rectangular) such that the sidewall 102 includes a plurality of panels 108, 108a forming a polygonal perimeter 110 and the bottom wall 104 is adjacent or even attached to the plurality of panels 108, e.g., when the ECE is folded into shape.

[0122] As Figure 7As shown, the plurality of panels can 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 can be attached to the first panel 108, while the first ballast driver (see, e.g., 200), the second ballast driver 200a, and the third ballast driver 200b can be attached to the second panel 108a. Moreover, the first ballast driver, the second ballast driver, and the third ballast driver can be identically configured (i.e., within + / - 0.020 inch manufacturing tolerance). In other embodiments of the present disclosure, other configurations and arrangements of the ECE and these components are possible.

[0123] As mentioned earlier herein, the first ballast can be in electrical communication with the first ballast driver, the second ballast can be in electrical communication with the second ballast driver, and the third ballast can be in electrical communication with the third ballast driver, e.g., through electrical wires (not shown).

[0124] The first and second panels 108, 108a can be parallel to each other, but need not be. The ballasts can be attached to the first panel, and the ballast drivers can be attached to the second panel. In other embodiments of the present disclosure, this can not be the case. For example, the ballasts and the ballast drivers can alternate along one of the panels, etc.

[0125] Still referring to Figure 7 The DIN (Deutsches Institut fur Normung) rail 112 can 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 can be attached to the DIN rail 112. Fuses or circuit breakers that are no longer used when ballasts are removed can also be removed, but need not be.

[0126] As will be discussed in further detail later herein, the cam motor assembly 34 or manual cam assembly associated with the Smart Technology can be disposed below the DIN rail 112 adjacent to the panel 108; the capacitor bank 116 can be disposed below the DIN rail 112 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 can include a lever configured to rotate one or more cams to connect selected different capacitors in the capacitor bank to a power supply line to one or more ballasts, etc. Electrical wire inlets and outlets (which can be implemented by a single aperture 118) can be formed in the bottom wall 104. In other embodiments of the present disclosure, the number and location of the capacitors, cam assemblies, electrical wire inlets, and electrical wire outlets can vary.

[0127] One or more standalone ballast driver assemblies 200 can be attached by the fastener and bracket assembly 120 and the toe 124 that mates with the flange 122 that was used in the previous ECE to attach the ballast to the sidewall. In other embodiments of the disclosure, other attachment methods are possible.

[0128] Referring now to Figure 15 , an alternate ECE 100a is shown that is similarly or identically constructed as the ECE 100 except that a standalone ballast driver assembly 200c with dual PCBs is used to power more luminaires as will be described in further detail below. In addition, the driver assembly 200c is set lower in the ECE on either side (e.g., on the first sidewall or bottom wall and on the second sidewall or bottom wall opposite each other next to the DIN rail 112) to facilitate efficient cooling of the PCBs. For example, heat generated from one driver does not rise to the next driver by natural convection. In addition to or instead of this effect, the driver assemblies can be distanced from traditional ballasts that generate heat that rises away from the now lower set driver assemblies. The fact that the driver assembly 200c has two PCBs instead of just one allows for the elimination of the two higher placed driver assemblies 200, 200a in Figure 7 .

[0129] Circuit board housing

[0130] Referring now to Figures 8 to 12 , the circuit board housing 204 can include a five-sided cover 206 and a three-part mounting bracket 208. The five-sided cover 206 can include a front panel 210 that defines a plurality of connector receiving windows 212, a top panel 214 that defines a plurality of vent openings 216, and a bottom panel 218 that defines a plurality of vent holes 220. The five-sided cover 206 can also have a first side panel 222 and a second side panel 224. The first side panel 222 can define a plurality of first side apertures 226, while the second side panel 224 can define a plurality of second side apertures 228. These apertures can allow for the attachment of wire end retainers to the housing as will be described in greater detail later.

[0131] As shown in Figure 8 and Figure 11 , the top panel 214 can include a first pair of attachment flanges 230, 230a that extend downward from the top panel 214 and define a first pair of attachment apertures 232, 232a, and the bottom panel 218 can include a second pair of attachment flanges 230b, 230c that extend upward from the bottom panel 218 and define a second pair of attachment apertures 232b, 232c.

[0132] In addition, the top panel 214 can be connected to the front panel 210 by a plurality of top bends 234, 234a, 234b, each separated by a top cutout 236, 236a. Likewise, the bottom panel 218 can be connected to the front panel 210 by a plurality of bottom bends 234c, 234d, 234e, each separated by a bottom cutout 236b, 236c. These cutouts facilitate bending of the panels without tearing or using excessive force. In other embodiments of the disclosure, these cutouts can be omitted.

[0133] With reference to Figure 9 , 10 and 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 case 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 case attachment portion or handle portion 240 can include an elongated aperture 246 (racetrack-shaped or oval-shaped, etc., which can be used to mount to the ECE using the fastener and bracket assembly 120 previously mentioned herein). The handle and the 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 and electrically insulating material until the installation step is complete.

[0134] The handle portion 240 can be coupled to the first side circuit board mounting portion 238 by a first side bend 248, and the top case attachment portion or handle portion 240 can also be coupled to the second side circuit board mounting portion 238a by a second side bend 248a. The first side bend 248 can be separated by a first side cutout 250, and the second side bend 248a can be separated by a second side cutout 250a.

[0135] More particularly, the first side circuit board mounting portion 238 can include a first pair of cover mounting holes 242, 242a and a first pair of attachment flange receiving notches 244, 244a disposed proximate the first pair of cover mounting holes 242, 242a. Similarly, the second side circuit board mounting portion 238a can include a second pair of cover mounting holes 242b, 242c and a second pair of attachment flange receiving notches 244b, 244c disposed proximate the second pair of cover mounting holes 242b, 242c.

[0136] In addition, the first side circuit board mounting portion 238 can define a first circuit board receiving slot 252, and the second side circuit board mounting portion 238a can define a second circuit board receiving slot 252a. The first side circuit board mounting portion 238 can also define a first side heat sink receiving aperture 254, and the second side circuit board mounting portion 238a can also define a second side heat sink receiving aperture 254a.

[0137] Focusing 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.

[0138] 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.

[0139] 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.

[0140] 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.

[0141] Due to the absence of wire retainers, the side apertures 226a are configured differently (with rounded shapes rather than polygonal shapes). These apertures can also provide additional cooling, etc. In addition, transverse support portions 258 connecting the toes 214a are provided to provide rigidity to the housing after it has been assembled. The transverse support portions can also help prevent one or more PCBs from being crushed or damaged.

[0142] Circuit board and heat sink assembly

[0143] As shown in Figure 13 and 14 , a circuit board and heat sink assembly 300 can include such a circuit board 302 having a top circuit mounting surface 304 and a plurality of side mounting tabs 306 configured to fit within the slots of a housing, as previously described. In addition, a plurality of circuit components 308 can be attached to the top circuit mounting surface 304, as well as a heat sink 314 attached to the top circuit mounting surface 304 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 can be disposed between one or more of the plurality of circuit components 308 and the heat sink 314. In particular, the thermally conductive and electrically insulating material can include silicone and aluminum oxide, among others. For example, the aluminum oxide can be AL204 with a purity of 96%. Other types of thermally conductive and electrically insulating materials can be used in other embodiments of the present disclosure.

[0144] As previously described, 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 employed so long as an appropriate amount of heat is removed from the electrical components, etc.

[0145] Referring to Figure 8 and 13 , a plurality of connectors 316 can be disposed proximate the front of the top circuit mounting surface in communication with the plurality of circuit components. This allows for quick connection of wires from an existing ballast in an ECE, etc. to the circuit board and heat sink assembly, and at the same time also allows for easy connection of wires leading from the assembly to an LED luminaire or vice versa.

[0146] Turning now to Figures 17 to 21 , a circuit board and heat sink assembly 300a will now be discussed which is configured similarly or identically to Figures 8 to 13 , except for at least the following differences.

[0147] Attention is drawn to 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.

[0148] 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.

[0149] Circuit

[0150] 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.

[0151] However, if Figure 23 As 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.

[0152] 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.

[0153] The open circuit protection sub-circuit 404 can 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 sub-circuit will be sent to ground. In some embodiments of the disclosure, the voltage values of D3, D4, and D5 can range from 100 volts to 600 volts.

[0154] Turning now to the output regulation sub-circuit 406, which includes capacitor regulation set C1, C2, which are designed to reduce the electrical ripple (or light flicker resulting therefrom) of the AC component provided by the rectifier D1. In some embodiments of the disclosure, the values of these capacitors C1, C2 range from 100 μF to 4000 μF. In some embodiments, zero or near zero capacitance can be desired, while in other embodiments, even capacitance values greater than 4000 μF can be desired to reduce light flicker to a desired level, etc. Resistors R6 and R7 are supplied to discharge the capacitors C1, C2 when the power is 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 need not be. Further, a MOFSET (not shown) can be interposed between the open circuit protection sub-circuit and the output regulation sub-circuit to provide another level of protection.

[0155] Depending on the application, availability of components, design requirements, cost, etc., any of the components can be "through-hole" components or "surface mount" components (e.g., see Figure 13 and 14 ) components.

[0156] In some embodiments, an HID ballast capacitor circuit that produces a constant wattage of about 1500 W with a capacitance of 32 μF can be replaced with a capacitor set having a capacitance of about 28 μF to produce a constant wattage of about 900 W, which is sufficient to drive 224 XM-L LEDs (available from Cree LED, Inc. of Durham, North Carolina) wired in two parallel strings of 112 LEDs each within an LED retrofit fixture, etc.

[0157] It is further contemplated that the power or wattage supplied to one or more light poles can be regulated using Smart technology (e.g., the technology disclosed in U.S. Patent Nos. 7,675,251, 7,956,551, and 8,098,024), which can already be installed in a prior HID lighting system. For example, as understood with reference to Figure 7 and FIG. 24, the light pole cabinet 10 can incorporate a cam timer assembly 34, 34a that includes various cams and contacts to vary the capacitance, and thus the power supplied to the HID lamp, over time to compensate for the lumen efficiency loss experienced by such lamps over time.

[0158] More specifically, the motor 36 is powered to rotate the cam so that certain contactors are contacted and then closed, so that different capacitors with different capacitances enter the circuit, thereby changing the wattage.

[0159] In creating a retrofit LED lighting system, the motor can be disconnected and the cam manually rotated by a reset wheel 38 (or a lever as shown, etc.) to change the capacitance and, in turn, the power applied to the light pole. This system or method can not be available in other embodiments of the present disclosure. Figure 7

[0160] Wire Retainer

[0161] As previously mentioned, after the ballast is removed, various ECEs can need to be rewired. The ballast that is still in use will plug into the connector 316 of the circuit board. However, those ballasts that are no longer in use or other electrical or electronic components that are no longer in use will have loose ends that need to be dealt with to avoid shorting, etc. In some cases, wire nuts or the like can be employed to cover the exposed ends of the wires. In other cases, a wire end holder can be provided that is attached to the ECE, the interior of other cabinet, or to the housing of the circuit board and heat sink as will be described later.

[0162] In some embodiments, the right angle connectors are unplugged from the unused ballast and secured in a wire retainer as will be described in greater detail later. The bare stranded wires can be disconnected from the timer motor and capped for insulation with a closed end fitting crimped over each wire as described earlier herein. The wire ends are then secured in a wire retainer (also referred to as a wire end holder) that is then secured to the DIN rail of the ECE.

[0163] As shown in FIG. 5, such a wire end holder 500 can include a first half 502 that defines a first wire connector receiving cavity 504 disposed within an outer wall 506. The cavity can be defined at least in part by a square or rectangular entry for receiving a crimped right angle wire connector (sometimes referred to as a faston). In addition, a first wire receiving slot 508 can extend through the outer wall 506 to allow the wire to enter the first half when the connector of the wire is placed into the first wire connector receiving cavity. As a result of 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 by the wire and connector when stored in the wire end holder. Figure 25

[0164] ​​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 these snap features of the first and second halves can be interchanged in other embodiments of the present disclosure.

[0165] Referring to Figure 25 and 26 , there are external snap features 520 that extend from the outer wall 506 of the first half 502. More specifically, the external snap features 520 can include a pair of male snaps 522 and 524. The male snap 522 can be configured to flex through a slot 526, while the male snap 524 can not be so configured. These snaps can include inwardly extending protrusions 528, 530 of different configurations. The protrusion 528 can be rounded, while the protrusion 530 can be more angular, such that the more flexible protrusion 528 more effectively grips the structural member than intended through the slot.

[0166] As a result of this configuration, the wire end holder can be attached through these snaps and inserted into the first and second side apertures 226, 228 of the standalone ballast drive assembly 200, as understood with reference to Figure 8 、 11 and 47.

[0167] As described herein with reference to Figure 25 and 26 , the second half 518 can include second half snap features 515 that are configured to engage the internal snap features 512 of the first half 502. Further, the second half 518 can be coupled to the first half 502 by a living hinge 532, but need not be.

[0168] As best shown in Figure 26 , the first half 502 can also define a second wire connector-receiving compartment 504a, as well as 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.

[0169] In Figure 25 and 26 , the first half 502 can define a first window 534 extending from the first wire connector-receiving cavity 504 through to the exterior of the first half 502, as well as a second window 534a extending from the second wire connector-receiving cavity 504a to the exterior of the second half 518. These windows can allow a user to see the connectors located within the holder and also allow these cavities and retention structures to be molded through a mold core exiting through the windows after the plastic is cured.

[0170] The wire end brackets may be molded from any suitable thermoplastic, such as nylon, polypropylene, ABS (acrylonitrile butadiene styrene), and the like.

[0171] 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.

[0172] 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.

[0173] LED lighting fixtures

[0174] 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.

[0175] Now refer to Figure 34 and 38The LED luminaire 600, 600a, 600b, 600c can 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 the horizontal width 606 to the vertical height 608 can range from 0.90 to 1.25. In more specific embodiments, the ratio of the horizontal width 606 to the vertical height 608 ranges from 0.97 to 1.17. A nominal value of this ratio can be about 1.07, such that the luminaire perimeter is nearly square or, more generally, rectangular. In embodiments of the disclosure, the horizontal width 606 can range from 14.0 inches to 15.5 inches (e.g., about 14.75 inches), and in some embodiments of the disclosure, the vertical height can range from 11.0 inches to 13.0 inches (e.g., about 12.0 inches). In other embodiments of the disclosure, the width can be about 14.25 inches to 15.25 inches (e.g., about 14.76 inches), and the height can be 11.5 inches to 12.5 inches (e.g., about 12.0 inches). In other embodiments in which the spatial footprint of the existing HID lamp is different, these ranges can be different if a larger downwardly extending knuckle or the like is used.

[0176] Focusing on Figure 38 The LED luminaire 600, 600a, 600b, 600c can 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 disclosure, the array can be rectangular or have other configurations. For example, in other embodiments of the disclosure, more or fewer LEDs can be used.

[0177] The LED luminaire 600, 600a, 600b, 600c can also include a front luminaire frame 616 defining a window opening perimeter 618, and a plurality of light sources (e.g., optics and / or LEDs) disposed within the window opening perimeter 618. The plurality of light sources is spaced a maximum vertical distance 620 from the luminaire perimeter 604.

[0178] In some embodiments of the disclosure, the ratio of the vertical height 608 of the luminaire perimeter 604 to the maximum vertical distance 620 ranges from 1.70 to 2.45. In more specific embodiments of the disclosure, the ratio of the vertical height 608 of the luminaire to the maximum vertical distance 620 ranges from 1.85 to 2.24. These ranges can allow the LED luminaire to fit within the "spatial footprint" of a prior HID lamp and place the LEDs low enough to cause little to no luminosity interference with nearby LED luminaires. In other embodiments of the disclosure, this can not be necessary.

[0179] Referring to Figure 28 and Figure 35 Different baffles 622, 622a that can be attached to the luminaire frame 616 can include top surfaces 624, 624a that form a top angle 626, 626a with a horizontal plane 628 (which can coincide or be parallel to the X-Y plane) that ranges from 10.0 degrees to 20.0 degrees. In particular, Figure 35 the top angle 626 of the baffle 622 in FIG. 32 is about 12.0 degrees, while Figure 35 the top angle 626a of the baffle 622a in FIG. 33 is about 18.0 degrees.

[0180] Similarly, the baffles 622, 622a can extend a horizontal projection distance 630, 630a that is measured perpendicular to the horizontal width 606 (e.g., along the Y-axis) and extends the vertical height 608 of the luminaire 602, as shown in Figure 31 In some embodiments of the disclosure, the ratio of the horizontal projection distance 630, 630a to the vertical height 608 ranges from 0.96 to 2.07. In more particular embodiments, the ratio ranges from 1.05 to 1.90. Moreover, the baffles 622, 622a can form a front included angle 632 (in the X-Z plane) that allows the baffle to extend far enough downward to prevent or limit side glare while also providing enough top clearance to avoid physical or photometric interference with neighboring luminaires / baffles.

[0181] In Figure 28 , the front included angle 632 (in the Y-Z plane) can range from 20.0 degrees to 28.0 degrees (e.g., can be about 24.0 degrees), while in Figure 35 , the front included angle 632a can range from 32.0 degrees to 40.0 degrees (e.g., about 36.0 degrees). In other embodiments of the disclosure, the top angle can be only 0 to 5.0 degrees such that the top of the baffle does not reach the top of the luminaire. Even so, the bottom angle of the baffle can be about 10.0 degrees to 20.0 degrees to limit side glare, etc.

[0182] As shown in Figures 27 to 30 , 32-37, 39, and 40, an upward lighting lens 700 can be attached to the free end of the baffle 622, 622a, 622b, 622c.

[0183] As shown in 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.

[0184] 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.

[0185] 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.

[0186] 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.

[0187] Figure 43 An 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.

[0188] Uplighting lens

[0189] In Figure 44 and 45 the uplighting lens 700 will be discussed in greater detail. The uplighting lens 700 can include an attachment portion 704 including a first elongated aperture 706 and a light directing portion 708 elongated in a direction non-parallel to the first elongated aperture 706 (e.g., along the X-axis or horizontal direction) that extends along the Z-axis or vertical direction.

[0190] In Figure 46 it can be seen that the attachment portion 704 and the light directing portion 708 are thinnest along a direction perpendicular to the horizontal and vertical directions (e.g., along the Y-axis). Other embodiments of the present disclosure can not be so.

[0191] Referring again to Figure 44 and 45 the attachment portion 704 includes a second elongated aperture 706a elongated along the vertical direction (e.g., along the Z-axis) and the second elongated aperture 706a is spaced apart from the first elongated aperture 706 along the horizontal direction (e.g., along the X-axis). In addition, the attachment portion 704 can also define a first rounded shape aperture 710 disposed horizontally adjacent to the first elongated aperture 706. More specifically, the first rounded shape aperture 710 can be disposed horizontally between the first elongated aperture 706 and the second elongated aperture 706a.

[0192] Likewise, the attachment portion 704 can also define a second rounded shape aperture 710a disposed horizontally between the first rounded shape aperture 710 and the second elongated aperture 706a. In addition, the attachment portion 704 can also include a first protrusion 712 defining the vertical extension of 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 can be omitted.

[0193] In addition, a 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 can not be so. For example, the wall or rib can extend from one lateral side of the lens to the other without traversing the top of the lens.

[0194] As Figure 46As shown, the light directing portion 708 can define a sawtooth pattern 716 or barb pattern in a plane perpendicular to the horizontal direction (e.g., the Y-Z plane). The double-sided sawtooth pattern is shown on both the front and back sides of the lens, but other embodiments of the present disclosure can not be so. The sawtooth pattern can include a first arcuate portion 718, a second arcuate portion 718a, and a straight portion 720 connecting the first arcuate portion to the second arcuate portion. The first and second arcuate portions can be similarly or identically configured as shown, but need not be. For example, within manufacturing tolerances + / - 0.005 inches.

[0195] In some embodiments, the first arcuate portion 718 is defined by a spline curve 722 (or polynomial) that extends primarily in the 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). In Figure 45 and 46 the first plane of symmetry (e.g., the Y-Z plane) is perpendicular to the horizontal direction, and the second plane of symmetry (e.g., the X-Z plane, which can also be the mold parting line when molded) is perpendicular to a direction that is perpendicular to the horizontal and vertical directions. In other embodiments of the present disclosure, one or more of these planes of symmetry can be omitted.

[0196] Figures 48 to 50 Another embodiment of the lens 700a is shown that is similarly or identically configured as the lens shown in Figures 44 to 46 8, except for the following differences.

[0197] The one or more elongated apertures 706b, 706c and the one or more ribs 714a surrounding them extend much further downward to the light directing portion 708a. This allows for more adjustment of the vertical position of the lens relative to the LED or other light source, thereby providing more flexibility to the user in adjusting how much upward illumination is produced when attached to a lighting fixture. For example, this embodiment allows for a 1 inch travel, whereas previous embodiments of the lens can only allow for a 0.5 inch travel. When in the fully upward position, little or no upward illumination is produced.

[0198] In addition, the number of configuration holes 724, 724a is increased compared to the first embodiment. These configuration holes allow the lens to be created in multiple sub- portions and attached to each other using splines or the like as needed. Of course, these configuration holes can be omitted if the lens is made using a large enough mold or 3D printer or the like.

[0199] Turning now to Figure 51 , the light directing portion 708a includes a polynomial curve defined in a plane perpendicular to the plane in which the light directing portion 708 is elongated (i.e., the plane of the Figure 50 and 51 . It is to be understood that the polynomial curve is defined in a plane that is perpendicular to the plane in which the light directing portion 708 is elongated (i.e., the plane of the Figure 50Compared to the curve shown in Figure 51 The curve in the figure turns sideways.

[0200] 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

[0201] 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.

[0202] 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 .

[0203] 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.

[0204] Other types of curves may be used in other embodiments of the present disclosure.

[0205] Note that the lens can be used for other applications besides uplighting and can be made of a variety of materials, including glass, acrylate, polystyrene, polycarbonate, silicone, etc. Also, other devices for directing or redirecting one or more light beams can be employed, such as diffusers and optics. 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 a ~30 degree prismatic asymmetric glass lens, among others.

[0206] Referring to Figures 54 to 56 , another embodiment of a lens 700b is shown that is similar or identical to those lenses previously discussed with reference to Figure 44 and 48 (see, e.g., lenses 700, 700a), except that the lens 700b has at least some of the following differences.

[0207] Figure 44 The protrusions 712, 712a shown in Figures 54 to 56 are incorporated into by providing a wall 728 that extends tangentially from the protrusion, making the attachment portion 704a larger (taller) and more robust.

[0208] Figure 44 In addition, the front of the lens no longer has ribs 714, 714a around each set of elongated apertures 706, 706a, 706b and 706c and / or the rounded shaped aperture 710, 710a as shown in 48 . Instead, these mounting apertures are all disposed in a single front receptacle 730 (see Figure 54 ) that is surrounded by a continuous sidewall 732. In other embodiments of the disclosure, it is contemplated that this receptacle can be split. The receptacle 730 can allow the head of a fastener to seat therein and provide some protection.

[0209] In addition, as seen in Figure 55 , the back of the lens 700b now has a mounting pad 734 that can be used as a platform to contact the front of a visor of a lighting fixture (see, e.g., front panel 634 in Figure 41 ). The mounting pad 734 can have a substantially flat surface 736 (i.e., within + / -.010" of proper manufacturing tolerances) so that no stress is induced when the lens is fastened to the front panel of the lighting fixture. Like the receptacle 730, the mounting pad 734 can also be split. A mounting aperture (or at least one mounting aperture) can extend through the back mounting pad to the front receptacle to allow a fastener to pass therethrough.

[0210] 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.

[0211] 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.

[0212] 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.

[0213] 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.

[0214] 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).

[0215] Sight Plate

[0216] 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.

[0217] 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.

[0218] 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 it should be understood that the fasteners shown in Figure 57 can be used to attach parts of the steering knuckle together and to attach the steering knuckle to the aiming plate, and to attach the aiming plate to the cross arm, etc.

[0219] like Figures 60 to 63As best shown, the first knuckle 640 can be attached to the first sighting bracket 802, which includes a lower electrical receptacle portion 806 and an upper knuckle portion 808 that is rotatably attached to the lower electrical receptacle portion 806 about a first axis 810. This can set the vertical orientation or sighting direction, and can be fixed by tightening a fastener or the like. Further, once the upper knuckle portion is inserted into the sighting bracket and connected thereto, the upper knuckle portion 808 of the first knuckle 640 can be in fixed relation to the first sighting bracket 804 about a second axis 812 that is perpendicular to the first axis 810.

[0220] Even so, the upper knuckle portion 808 of the first knuckle and the sighting bracket 804 can still rotate about the second axis 812 relative to the first trailing arm member 802. To facilitate horizontal sighting, the first sighting bracket 804 includes a periphery 814 that has angle indicia 815 disposed at least partially about the periphery 814. In this case, the first sighting plate 900 can include a first angle indicator 902 that extends to the periphery 814 of the first sighting bracket 804, so that a user can read the relative angular orientation of the first sighting bracket to the first sighting plate. Alternatively, the angle indicia can extend from the periphery to the angle indicator.

[0221] In other embodiments of the disclosure, the angle indicator and angle indicia can be omitted, or the angle indicia and angle indicator can be switched between the sighting plate and the sighting bracket, or the like. As Figure 72 As best shown, the periphery 814 of the first sighting bracket 804 can include a front flat portion 816, and the first angle indicator 902a can extend to the front flat portion of the first sighting bracket. In other embodiments of the disclosure, this can not be the case. For example, the first angle indicator 902 can not extend so far, as will be discussed in further detail later herein. In this case, a straight edge, a magnetic compass, or the like can be used to read the angle, or the angle indicia can extend to the top surface of the sighting bracket or to the angle indicator thereon.

[0222] In review Figure 59, the first cross member (see, e.g., 802a) can define a rounded shape rotation aperture 818 that defines a rotation axis (which can be the same as the second axis 812 when the knuckle is attached to the cross member), and a first mounting aperture 820 disposed about the rotation axis away from the rounded shape rotation aperture 818. More particularly, a second mounting aperture 820a can be disposed about the rotation axis forming a circular array with the first mounting aperture 820 about the rotation axis (e.g., 180 degrees spacing between the first and second mounting apertures can be provided). Similarly, a third mounting aperture 820b and a fourth mounting aperture 820c can define a rectangular pattern 822 centered on the rotation axis (see center instances of mounting apertures). Side instances of the mounting apertures have a square pattern 824. Other patterns and arrays are possible. As shown, only two diagonally oriented mounting apertures are typically used, but more or fewer mounting apertures can be used depending on the fastener usage for securing the sighting bracket and sighting plate to a structural member such as a cross member.

[0223] As will be appreciated by reference to Figure 59 and Figure 60 , the first sighting plate 900 can define a pair of parallel sides 904 that are flush or recessed with respect to a pair of side surfaces 826 of the first cross member. Similar statements can be made with respect to the second sighting plate 900a and the main cross member 802b, etc.

[0224] A sighting bracket and sighting plate assembly 828, 828a, 828b that can be provided for retrofitting in a venue will now be described with reference to Figures 60 to 73 , as best shown in Figures 61 to 63 , the assembly 828, 828a, 828b can include a sighting bracket 804 that includes an outer circular portion 830 that defines a circular axis (which can coincide with the second axis 812) and a radial direction 832. The outer circular portion 830 can include a circular periphery 814a that is spaced a first radial distance 834 from the circular axis (see also Figure 64 ).

[0225] Still referring to Figure 64 , the annular ledge 836 can be centered on the circular axis, while the front flat portion 816 can be spaced a second radial distance 838 from the circular axis that is greater than the first radial distance 834. As shown in Figures 61 to 63 , the sighting plate 900, 900a can define an annular ledge receiving aperture 906, and a first fastener receiving aperture 908, 908a radially spaced apart from the annular ledge receiving aperture 906.

[0226] Still referring to Figures 61 to 63The circular perimeter 814a can include a plurality of angular markings 815 as previously described, and the aiming plate 900, 900a can include an angular indicator 902 that extends to the circular perimeter 814a. Further, the front flat portion 816 can include a plurality of angular markings 815. To facilitate use of these angular markings, the angular indicator 902a of the aiming plate 900b can extend all the way to the front flat portion 816 in Figure 72 , but need not. Further, the side surface 840 can couple the outer circular portion 830 to the front flat portion 816, which also includes a plurality of angular markings 815, such 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 disclosure, this can not be the case. Further, the angular markings can be located on the top surface of the aiming bracket.

[0227] Referring to Figure 62 and Figure 64 , the aiming bracket 804 can define a first arcuate slot 842 over which the first fastener receiving aperture 908 of the aiming plate 900a can be disposed to allow a fastener to pass therethrough. Likewise, the aiming bracket 804 defines a second arcuate slot 842a, and the aiming plate 900a also defines a second fastener receiving aperture 908a disposed over the second arcuate slot 842a.

[0228] In Figure 64 , the aiming bracket 804 can include a central hub 844 defined at least in part by the first arcuate slot 842 and the second arcuate slot 842a. The annular boss 836 can extend from the central hub 844. The central hub 844 can be coupled to the front flat portion 816 and the outer circular portion 830 by a first web portion 846 and a second web portion 846a. Both the first web portion 846 and the second web portion 846a can at least partially define the first arcuate slot 842 and the second arcuate slot 842a. In other embodiments of the disclosure, this can not be the case.

[0229] Turning now to Figure 65 , the aiming bracket 804 can also include a rear flat portion 848 that can define, with the front flat portion 816, a rectangular receptacle 850 configured to receive the upper knuckle portion 808 of the knuckle 640. More specifically, the rear flat portion 848 of the aiming bracket can define one or more undercuts 852 configured to receive and vertically capture the upper knuckle portion 808 of the knuckle 640. This can not be present in other embodiments of the disclosure. Further, the aiming bracket 804 can define a plurality of core relief recesses 854 disposed radially about the first arcuate slot 842 and the second arcuate slot 842a. This can allow for proper retention of the nominal wall thickness of the aiming bracket to avoid porosity, voids, or other manufacturing issues related to the casting process.

[0230] To secure the knuckle to the sighting bracket, the sighting bracket 804 can define a first fastener receiving hole 856 and a second fastener receiving hole 856a spaced 180 degrees around a circular axis (or second axis 812) from the first fastener receiving hole 856. While these holes are illustrated as smooth and hollow, it is understood that threaded inserts can be pressed into these holes to allow the knuckle to be secured to the sighting bracket. An annular cylindrical guide portion 858 can be provided that is configured to fit within a cavity 860 (see Figure 66 ) of the upper knuckle portion 808 of the knuckle 640. An electrical connector receiving aperture 862 can be provided inside the annular cylindrical guide portion 858 for receiving a female connector (not shown) that mates with a male connector (not shown) of the knuckle, or vice versa, which allows for quick electrical connection.

[0231] In some embodiments, the sighting plate 900, 900a is secured to the top surface 864 (see Figure 64 ) of the sighting bracket 804 by fastening, adhesion (e.g., by a weak glue commonly sold for non-industrial use, such as white glue, wood glue, etc.). In this case, one or more angle indicators can be omitted, but need not be.

[0232] Various embodiments of sighting plates will now be discussed with reference to Figures 67 to 71 and 73. The sighting plate can be made of a sheet of metal, such as aluminum, stainless steel, etc., and have a thickness ranging from.010 inches (similar to a gasket) to.125 inches.

[0233] According to the embodiments of the present disclosure shown in Figure 67 , 68 and 73, the sighting plate 900, 900a, 900b can include a central hole 910 defining a central axis 912, and a mounting hole (e.g., see first fastener receiving aperture 908) disposed around the central axis 912 and at a first minimum distance 914 from the central hole 910. A first straight surface 916, 916a is at a second minimum distance 918 from the central hole 910, the second minimum distance being greater than the first minimum distance 914. In addition, a second straight surface 920 parallel to the first straight surface 916 can also be provided. The first and second straight surfaces 916, 920 can define first and second planes 922, 924, respectively, that do not intersect the central axis 912.

[0234] As previously mentioned, Figure 67 , 68and 72 show the angle indicators 902, 902a extending from the first straight surfaces 916, 916a to the radial extremity 926, 926a of the sighting board. In addition, the first angle indicators 902, 902a include third straight surfaces 928, 928a that define a plane 930 that intersects the central axis 912.

[0235] In Figure 67 and 68 , a second angle indicator 902b can be provided that extends from the second straight surfaces 920 to the radial extremity of the sighting board 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 (but need not do so) as the third straight surface 928. The first and second angle indicators can be provided in a circular array about the central axis, with the same configuration, but need not do so.

[0236] As shown in Figure 67 , 68 and 73, sighting boards 900, 900a and 900b constructed in accordance with another embodiment of the disclosure can define a central circular aperture (see, e.g., central aperture 910) that defines a central axis 912 and a radial direction 932; a first mounting aperture (see, e.g., first fastener receiving aperture 908) that is disposed about the central axis 912 and a first minimum distance 914 from the central circular aperture; and a second mounting aperture (see, e.g., second fastener receiving aperture 908a) that is disposed about the central axis 912 and the same first minimum distance 914 from the central circular aperture (i.e., within.010 inch manufacturing tolerance). The sighting boards 900, 900a, 900b can also define a radially varying outer periphery 934 that includes angle indicators 902, 902a, 902b having substantially radially extending surfaces 936, 936a. That is, in some embodiments of the invention, the surfaces 936, 936a can form an angle with the radial direction of less than 45 degrees, but can be more or less close to pure radial extension (+ / - 5.0 degrees).

[0237] In many embodiments of the disclosure, a third mounting aperture (see, e.g., third fastener receiving aperture 908b) and a fourth mounting aperture (see, e.g., fourth fastener receiving aperture 908c) form a rectangular array 938 (see, e.g., Figure 67 , 69 etc.) centered on the central axis 912. In another embodiment, the rectangular array is actually a square array 938a as shown in Figure 68 , 70 and 73.

[0238] In 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.

[0239] 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).

[0240] 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 .

[0241] 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.

[0242] exist Figures 69 to 71In some embodiments, one of the pair of parallel surfaces 964 extends from one of the pair of arcuate surfaces 962 through the central circular aperture 910a to or toward the other of the pair of arcuate surfaces 962.

[0243] Figure 67 、 68 This is not the case with embodiments of 70 and 71. Rather, the outer periphery (see, e.g., 934) includes a first L-shaped cutout 968 and / or a second L-shaped cutout 968a. These cutouts can form a circular array about the central axis 912, but need not do so.

[0244] In Figure 73 , one of the pair of parallel surfaces 964 extends from one of the pair of arcuate surfaces 962 through the central circular aperture 910 to or toward the other of the pair of arcuate surfaces 962, while the other of the pair of parallel surfaces (see, e.g., 916a) extends to the angle indicator 902a. The angle indicator can include a flat surface (see, e.g., 928a) that extends to a radial extremity 926a of the outer periphery, as described earlier herein.

[0245] In Figure 73 , the radial extremity 926a is spaced apart from the central axis 912 by a maximum radial distance that is greater than a radius of curvature of the pair of arcuate surfaces. But Figure 67 and 68 are not the case.

[0246] Industrial Applicability

[0247] Indeed, one or more of the following components, assemblies, or subassemblies can be provided at a first point of sale in an original equipment manufacturer (OEM) setting or as a replacement or replaceable component in an aftermarket setting: a standalone ballast drive assembly, a circuit board and heat sink assembly, a loose wiring end support, an LED lighting fixture, a lens, an optic, a diffuser, a louvre, an electrical / electronic component housing, a sighting board, a sighting support and sighting board assembly, and a sighting board, among others.

[0248] Prior to undertaking a retrofit process, it can be desirable to check whether old components are still functioning properly or whether they are within desired operating parameters. Figure 74 A method 6000 is shown that can include the following steps: testing one or more ballasts to see if they have an open circuit 6002, and / or one or more capacitors (e.g., the capacitor bank 116 in Figure 7 ) to see if they have a desired capacitance 6004. Other old components can also be tested, the horizontal and / or vertical sighting direction of the lighting fixture determined and recorded, and so on.

[0249] Various methods can be employed during a retrofit or initial installation of the device. For example, with reference to FIGS. 5, 7, and 24, a device that is already installed to adjust the power to a previous HID lighting fixture to compensate for the luminosity loss over time associated with such HID fixtures can be used to adjust the power supplied to the LED lighting fixture.

[0250] As Figure 75 shown, a method 1000 of retrofitting an HID lighting system with an LED lighting system can include disconnecting the motor of the cam motor assembly from the power source 1002. For example, the motor can be disconnected from the input power cord, battery, etc. Since the luminosity of the LED lamp does not tend to decrease significantly over time, the motor does not need to rotate the cam to adjust the capacitance and, in turn, the power supplied to the LED lamp. Instead, the user can rotate a wheel, slide a switch, rotate a lever as previously described, switch capacitors, etc. to change the capacitance supplied to the power cord 1004. The user can do so manually according to the wattage required by the LED lamp, etc. An LED lighting fixture can also be connected to the power cord 1006, etc. Other embodiments of the present disclosure can not use or have this method and device. Moreover, the order of these steps can vary.

[0251] In various embodiments, a method 2000 of retrofitting an HID lighting system with an LED lighting system can be used, such as that disclosed in Figure 76 Method 2000 can include disconnecting one or more ballasts from a power cord 2002, such as an existing power cord in the ECE, etc. This can result in loose wires, so the ends of these wires 2012 can be capped with a wire end holder, wire nut, etc. as previously described herein to insulate or otherwise prevent shorting, etc. The ballasts that are not used can be removed 2003.

[0252] Moreover, method 2000 can also include connecting one or more ballasts to a circuit that includes a surge protection subcircuit 2004. In certain embodiments, the surge protection subcircuit can be configured to withstand a 10 kV surge measured through a common mode or a 5 kV surge measured through a differential mode (or at least a 6 kV surge measured through a differential mode, see 2005). This can protect the circuit from a nearby lightning strike, etc. In other embodiments of the present disclosure, this can not be the case. In still other embodiments, a 10 kV surge measured through a differential mode can be withstood. In other embodiments of the present disclosure, this can not be the case.

[0253] 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.

[0254] 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.

[0255] 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 the heat sink are slid into the appropriate slot or aperture.

[0256] For example, the folding can first occur, thereby forming flexible ears (previously discussed, such as the first side circuit board mounting portion and the second side circuit board mounting portion), and then the circuit board is slid until the circuit board and the heat sink having one or more mounting tabs are received into one or more apertures of the ears.

[0257] 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 the heat sink are now securely confined in the first housing member.

[0258] 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.

[0259] When uplighting is desired, another method as described below can be employed to provide uplighting so that a sports ball or the like can be seen at night. Figure 78

[0260] This method 4000 can include attaching a lens, optic, or diffuser to a light source 4002 (e.g., a laser, LED, but not necessarily so) and redirecting light in an upward trajectory relative to the light source 4004.

[0261] Attaching a lens, optic, or diffuser can involve mounting the lens, optic, or diffuser at the free end of the visor 4006, and the method can further include aiming a collimated light beam (e.g., a NEMA 3 type standard light beam) at a portion of the lens, optic, or diffuser 4008. In particular embodiments of the disclosure, the collimated light beam can be emitted or aimed at a third row of LEDs from the top of the LED array 4010. In other embodiments of the disclosure, other rows or positions of the collimated light beam can be employed. Further, the method can further 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 can be lowered to redirect more light upward; or the height of the lens, optic, or diffuser can be raised if less uplighting is desired. The angle of the lens, optic, or diffuser relative to the light can also be adjusted to change the uplighting, etc. If a lens or diffuser is used, there can be no gap between the downlighting and the uplighting. Otherwise, a gradual transition between the downlighting and the uplighting can be presented.

[0262] In some embodiments, there can be a combination of LED retrofit lighting fixtures with existing HID lighting systems. For example, in some cases, it can be easier or more economical to replace a failed HID lamp with an LED lighting fixture that does not have a readily replaceable bulb. This can be in lieu of using a screw-in LED lamp, as the light level and distribution of the LED lighting fixture is more easily matched to the HID lamp, whereas the screw-in LED lamp is not.

[0263] In other variations of the disclosure, a reflector (e.g., as disclosed in U.S. Patent No. 10,337,693) can be used in lieu of a lens, optic, or diffuser. Further, an uplighting fixture (e.g., as disclosed in U.S. Patent No. 8,952,628 or U.S. Patent No. 10,337,680) can also be used (in which case one of the ballast drivers can be used to power the fixture), as well as a sharp cut-off LED lighting fixture (e.g., as disclosed in U.S. Patent No. 10,267,491 and U.S. Patent No. 10,378,732), etc.

[0264] ​In some applications, it is desirable or necessary to set the horizontal aiming angle of the knuckle and / or light fixture. It can be easier, but not necessarily so, to aim the knuckle first and then attach the fixture.

[0265] This method 5000 can be performed in a factory or in the field. Figure 79 Aiming the knuckle and / or light fixture can be performed in a factory or in the field. In some embodiments, the method 5000 can include rotating a knuckle to a desired angle orientation relative to a structure member 5000. For example, the knuckle can be rotated to a desired angle orientation relative to a structure member.

[0266] In some embodiments, the method 5000 can also include securing the aiming plate to the aiming bracket 5004. For example, the aiming plate can be fastened to the bracket. Alternatively, this can include adhering the aiming plate to the aiming bracket 5006. These steps can obviate the use of an angle indicator, but not necessarily so.

[0267] In some embodiments of the present disclosure, the method 5000 can also include using an angle indicator to measure the relative angle orientation 5008 using an angle measurement on the aiming bracket.

[0268] At some point, the method 5000 can also include inserting a fastener through the mounting hole of the aiming plate and the slot of the aiming bracket 5010, the fastener engaging the structural member. In conjunction Figure 59 and 62 It can be appreciated that the fastener can have a knurled profile that engages the hole of the cross arm or other structural member, thereby preventing its rotation.

[0269] Once the fastener is inserted through the aiming plate and the aiming bracket, Figure 79 The method can also include tightening the fastener, securing the aiming bracket and aiming plate to the structural member 5012. For example, a nut can be rotated onto the threads extending from the free end of the bolt until sufficient torque is applied.

[0270] Once the proper angle of the aiming bracket is set, the method 5000 can also include attaching a knuckle and / or light fixture to the aiming bracket 5014. The knuckle and / or light fixture can already be attached to the aiming bracket when the angle is set, or not.

[0271] In some applications, the purpose of the aiming plate is to pre-align the light fixture in the factory. This can make installation easier and improve the accuracy of the lighting design as intended by the application engineer.

[0272] Further variations or embodiments of the present disclosure can include providing or using an ECE employing an LED driver, a Schiedewerks LED driver, or an 880W LED driver.

[0273] In this case, a separate ballast driver and / or associated circuitry can not be required. Moreover, with one or more of these commercially available drivers, additional functionality can also be achieved, such as light shows, and / or audio light shows, light dimming, etc.

[0274] It is noted that, according to examples, certain acts or events of any of the methods described herein can be performed in a different sequence, can be added, merged, or omitted altogether (e.g., all described acts or events can not be necessary to practice the techniques). Moreover, in certain examples, acts or events can be performed in parallel, e.g., through multi-threaded processing, interrupt processing, or multiple processors, rather than sequentially.

[0275] The driver or controller can be programmed to provide a variety of theatrical and light effects. In one or more examples, the described functionality can be implemented in hardware, software, firmware, or any combination thereof. If implemented in software, the functions can be stored on or transmitted over as one or more instructions or code on a computer-readable medium and executed by a hardware-based processing unit. Computer-readable media can include computer-readable storage media, which corresponds to a tangible medium such as data storage media, or communication media including any medium that facilitates transfer of a computer program from one place to another, e.g., according to a communication protocol. In this manner, computer- readable media generally can correspond to (1) tangible computer-readable storage media which is non-transitory or (2) a communication medium such as a signal or carrier wave. Data storage media can be any available media that can be accessed by one or more computers or one or more processors to retrieve instructions, code, and / or data structures for implementation of the techniques described in this disclosure. A computer program product can include a computer-readable medium.

[0276] By way of example, and not limitation, such computer-readable storage media can include RAM, ROM, EEPROM, CD-ROM or other optical disk storage, magnetic disk storage, or other magnetic storage devices, flash memory, or any other storage medium that can be used to store desired program code in the form of instructions or data structures and that can be accessed by a computer. Also, any

[0277] Instructions can 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 circuitry. Accordingly, as used herein the term "processor" can refer to any of the foregoing structure or any other structure suitable for implementation of the techniques described herein. In addition, in some aspects, the functionality described herein can be provided within dedicated hardware and / or software modules configured for encoding and decoding, or incorporated in a combined codec. Also, the techniques could be fully implemented in one or more circuits or logic elements.

[0278] The techniques of this disclosure can be implemented in a wide variety of devices or apparatuses, including a wireless handset, an integrated circuit (IC) or a set of ICs (e.g., a chip set). Various components, modules, or units are described herein to emphasize potential functional aspects of devices configured to perform the disclosed techniques, but these need not necessarily correspond to physically segregated units. Rather, as will be appreciated by those skilled in the art, the various components, modules, or units can be combined in a codec hardware unit or provided by a combination of hardware and software components in one or more devices arranged to perform the disclosed techniques, e.g., a codec hardware unit and a corresponding software application or a set of software applications.

[0279] This disclosure has described various examples. Any combination of the described systems, operations, or functions is within contemplated ranges. These examples and other examples are within the scope of the following claims.

Claims

1. A method for transforming a HID lighting system using an LED lighting system, the method comprising: Disconnect the cam motor assembly's motor from the power source.

2. The method of claim 1 further comprising varying a capacitance supplied to the power line. 3 . The method of claim 2 , further comprising connecting an LED lighting fixture to the power line.

4. A method for transforming a HID lighting system using an LED lighting system, the method comprising: Disconnect one or more ballasts from the power line; as well as One or more ballasts are connected to a circuit that includes a surge protection subcircuit.

5. The method of claim 4, further comprising connecting one or more ballasts to the wire end bracket.

6. The method of claim 4, further comprising removing one or more ballasts from the housing.

7. The method of claim 4, further comprising connecting the one or more ballasts to a rectifier circuit.

8. The method of claim 7, further comprising connecting the one or more ballasts to an open circuit protection subcircuit.

9. The method of claim 8, further comprising connecting the one or more ballasts to an output regulation subcircuit.

10. The method according to claim 4, wherein: The surge protection subcircuit is configured to withstand at least a 10 kV surge measured via a common mode or at least a 5 kV surge measured via a differential mode.

11. The method according to claim 9, wherein The plurality of components of the surge protection sub-circuit, the rectifier sub-circuit, the open circuit protection sub-circuit, and the output regulation sub-circuit are connected in parallel with each other.

12. A method of generating uplighting, the method comprising: attaching a lens, optic, or diffuser to the light source; The light is redirected in an upward trajectory relative to the light source.

13. The method of claim 12, further comprising attaching the lens, the optic, or the diffuser at a free end of a sun visor.

14. The method of claim 12, further comprising aiming the collimated beam at a portion of a lens, an optic, or a diffuser.

15. The method of claim 14, further comprising aiming the collimated light beam from a top third row of LEDs of the LED array.

16. The method of claim 12, further comprising moving the lens, the optics, or the diffuser relative to a light source to adjust the redirected light.

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