Illumination assembly and illumination system having an illumination assembly - Patents.com

Abstract

To provide an illumination system for a surgical room that conforms to obstacles. The lighting assembly includes an upper mount having a pan gear and a plurality of indicator flanges. A lower mount is operably coupled to the lower mount and includes a pan motor and a tilt motor. A printed circuit board is operably coupled to the upper mount and includes a plurality of sensors. At least one sensor is selectively and operably coupled to the plurality of indicator flanges of the upper mount. A light module is operably coupled to the lower mount and includes a tilt gear operably coupled to the lower mount. A controller is operably coupled to the printed circuit board, the pan motor, and the tilt motor and configured to rotate the lower mount and the light module via the pan motor and tilt the light module via the tilt motor.

Description

[Technical Field]

[0001] The present disclosure relates generally to lighting assemblies, and more particularly to lighting assemblies that may include surgical and medical rooms where dynamic lighting solutions may be advantageous. [Background technology]

[0002] Artificial lighting provided in surgical and medical rooms can present several challenges with regard to positioning, shadows, luminosity, glare, and cleaning. Medical professionals are often not stationary, transferring personnel and equipment throughout surgical procedures, requiring that lighting be dynamic. Lights may be suspended from the ceiling in the presence of other medical equipment, such as hoses, monitor stands, booms, imaging equipment, air handlers, etc. Therefore, an illumination system for surgical rooms that accommodates these obstacles would be advantageous. Summary of the Invention

[0003] According to one aspect of the present disclosure, a lighting assembly includes an upper mount having a pan gear and a plurality of indicator flanges. A lower mount is operably coupled to the upper mount and includes a pan motor and a tilt motor. A printed circuit board is operably coupled to the lower mount and includes a plurality of sensors. At least one sensor is selectively and operably coupled to the plurality of indicator flanges of the upper mount. A light module is operably coupled to the lower mount and includes a tilt gear operably coupled to the lower mount. A controller is operably coupled to the printed circuit board, the pan motor, and the tilt motor and configured to rotate the lower mount and the light module via the pan motor and tilt the light module via the tilt motor.

[0004] According to another aspect of the present disclosure, a lighting assembly includes an upper mount, a lower mount coupled to the upper mount, and a gear assembly between the upper mount and the lower mount configured to rotate the lower mount relative to the upper mount. A printed circuit board is operably coupled to the lower mount and defines an opening. The gear assembly extends through the opening. A first actuation device is disposed within the lower mount and coupled to the gear arrangement to drive the gear arrangement.

[0005] According to another aspect of the present disclosure, an illumination system includes at least one air handler unit. The illumination system further includes a housing operably coupled to the at least one air handler unit. The housing defines a cavity and includes a transparent panel selectively removable from the housing. The transparent panel is configured to provide access to the cavity. The illumination system also includes a lighting assembly. The lighting assembly includes an upper mount, a lower mount coupled to the upper mount, and a gear assembly between the upper mount and the lower mount configured to rotate the lower mount relative to the upper mount. A printed circuit board is operably coupled to the lower mount and defines an opening. The gear assembly extends through the opening. A first actuation device is disposed within the lower mount and is coupled to the gear arrangement to drive the gear arrangement. The illumination system further includes a controller in communication with the lighting assembly. The controller is configured to communicate instructions to control the first actuation device to adjust the lighting assembly.

[0006] According to another aspect of the present disclosure, there is provided an illumination system including at least one air handler unit and a housing operably coupled to the at least one air handler unit. The housing includes a transparent panel defining a cavity and selectively removable from the housing. The transparent panel is configured to provide access to the cavity, and a lighting assembly is disposed within the cavity of the housing. A light module is proximate to the transparent panel.

[0007] According to another aspect of the present disclosure, an advanced lighting system provides better lighting for medical staff when treating a patient. The advanced lighting system can rotate and tilt to maximize the lighting angle to the patient. Each lighting assembly can be individually adjusted via rotation and tilt to provide personalized, fine-tuned directional lighting.

[0008] These and other features, advantages, and objects of the present disclosure will be further understood and appreciated by those skilled in the art with reference to the following specification, claims, and accompanying drawings.

[0009] The drawings are as follows: [Brief explanation of the drawings]

[0010] [Figure 1] FIG. 1 is a side perspective view of an illumination system of the present disclosure within a surgical operating room. [Figure 2] FIG. 2 is an enlarged partial perspective view of the illumination system of FIG. 1 including an air handler unit and a lighting array. [Figure 3] FIG. 1 is a bottom perspective view of a lighting array of the present disclosure. [Figure 4] FIG. 1 is a side perspective view of a single lighting assembly of the present disclosure having an upper mount, a lower mount, and a light module. [Figure 5] FIG. 1 is an exploded top perspective view of a lighting assembly of the present disclosure. [Figure 6] (A) A bottom perspective view of an upper mount having a pan gear and indicator flange of the present disclosure, (B) a top perspective view of a printed circuit board of the present disclosure, and (C) a top perspective view of an actuator ring of the present disclosure. [Figure 7] FIG. 1 is a side perspective view of an illumination assembly of the present disclosure with an upper mount illustrated partially in phantom. [Figure 8] 8 is an enlarged partial cross-sectional view of the lighting assembly of FIG. 7 having a magnet and Hall sensor of the present disclosure, and a printed circuit board having a sensor of the present disclosure. [Figure 9]FIG. 1 is a side view of a lighting assembly of the present disclosure having a ramp gear defined along the light module of the present disclosure. [Figure 10] FIG. 1 is a side perspective view of a light module of the present disclosure in a first position. [Figure 11] FIG. 11 is a side perspective view of the light module of FIG. 10 in a second tilted position. [Figure 12] FIG. 1 is a bottom perspective view of a lighting array of the present disclosure coupled to a controller having a detection storage system. [Figure 13] FIG. 1 is a flow diagram of a method of making a lighting assembly of the present disclosure. [Figure 14] FIG. 1 is a bottom perspective view of a lighting array of the present disclosure. DETAILED DESCRIPTION OF THE INVENTION

[0011] The illustrated embodiments herein primarily pertain to combinations of method steps and apparatus components related to lighting assemblies. Accordingly, the apparatus components and method steps are described, and, where necessary, conventional numerals in the drawings indicate only those specific details relevant to an understanding of the embodiments of the present disclosure so as not to obscure the detailed disclosure that those skilled in the art will readily understand and have the benefit of the description herein. Furthermore, like numerals in the description and drawings represent like elements.

[0012] For purposes of this description, terms such as "top," "bottom," "right," "left," "rear," "front," "vertical," and "horizontal," and variations thereof, refer to the disclosure as oriented in FIG. 1. Unless otherwise specified, the term "front" shall refer to the side of the device that is closer to the intended observer of the device, and the term "rear" shall refer to the side of the device that is further from the intended observer of the device. It is to be understood, however, that the disclosure can assume various alternate orientations, unless expressly specified to the contrary. It is also to be understood that the specific devices and processes illustrated in the accompanying drawings and described in the following specification are merely exemplary embodiments of the inventive concepts defined in the appended claims. Hence, specific dimensions and other physical characteristics relating to the embodiments disclosed herein are not to be considered limiting, unless the claims expressly state otherwise.

[0013] The terms "comprise," "include," "comprise," "including," or other variations thereof are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises listed elements does not include only those elements, but may include other elements that are not expressly listed or that are inherent to such process, method, article, or apparatus. An element preceded by "comprises..." does not, without further constraints, exclude the existence of additional identical elements in the process, method, article, or apparatus that comprises the element.

[0014] 1-14, reference numeral 10 generally designates a lighting assembly. The lighting assembly 10 includes an upper mount 12 having a pan gear 14 and a plurality of indicator flanges 16. A lower mount 20 is operably coupled to the upper mount 12 and includes a pan motor 22 and a tilt motor 24. A printed circuit board 28 is operably coupled to the lower mount 20 and includes a plurality of sensors 30. At least one sensor 30 is selectively and operably coupled to the plurality of indicator flanges 16 of the upper mount 12. A light module 32 is operably coupled to the lower mount 20, and the light module 32 includes a tilt gear 34 operably coupled to the lower mount 20. A controller 36 is operably coupled to the printed circuit board 28, the pan motor 22, and the tilt motor 24. The controller 36 is configured to rotate the lower mount 20 and the light module 32 via the pan motor 22 and tilt the light module 32 via the tilt motor 24.

[0015] 1-4 , lighting assembly 10 is illustrated as being coupled to an air handler unit 50 in a surgical operating room 52 above a surgical table 54. It is generally contemplated that lighting assembly 10 may be utilized in other environmental settings, including, but not limited to, surgical operating rooms, hospital rooms, examination rooms, and other settings in which lighting assembly 10 may be advantageously utilized. It is generally contemplated that air handler unit 50 may be one of multiple air handler units 50 that may define at least a portion of a ceiling 56 in surgical operating room 52. Stated another way, lighting assembly 10 is operably coupled to at least one air handler unit 50 in surgical operating room 52. Air handler unit 50 is configured to provide ambient lighting within surgical operating room 52 and to filter airflow within surgical operating room 52 to define a positive pressure environment around surgical table 54. Air handler unit 50 defines the positive pressure environment by pushing air toward and away from surgical table 54. Air handler units 50 may at least partially define a grid pattern along ceiling 56 of surgical suite 52 .

[0016] As illustrated in FIG. 2 , gaps 58 in which lighting assemblies 10 can be disposed can be defined between each air handler unit 50. By way of example and not limitation, three linear gaps 58 are illustrated as being defined between air handler units 50. A lighting assembly 10 can be disposed within each of the three linear gaps 58 to provide illumination above the surgical table 54. It is generally contemplated that at least one of the lighting assemblies 10 positioned within the central gap 58 a includes at least one imaging device 60, such as a camera or other vision-based device, configured to record or otherwise document activity within the surgical room 52 relative to the surgical table 54. It is also contemplated that the imaging device 60 can be directed toward the surgical table 54 and communicatively coupled to the controller 36 ( FIG. 12 ) to define a three-dimensional map of the surgical room 52. The controller 36 can adjust the position of the lighting assembly 10 based on the three-dimensional map generated by the imaging device 60. For example, it is contemplated that the imaging device 60 and the controller 36 may cooperate to minimize shadows and potential illumination blockages proximate the surgical table 54. In some embodiments, the controller 36 is configured to communicate instructions for adjusting the illumination assembly 10 based on images captured by the imaging device 60.

[0017] For example, multiple lighting assemblies 10 may include an imaging device 60, which may provide a comprehensive view of the position of each respective lighting assembly 10 relative to the surgical table 54. It is generally contemplated that the imaging device 60 may be disposed within a housing 62 along with the lighting assembly 10. The imaging device 60 may be operable via a controller 36 ( FIG. 12 ) to which the imaging device 60 is communicatively coupled as well as the surrounding lighting assemblies 10. Stated another way, the imaging device 60 may be communicatively coupled to the controller 36 ( FIG. 12 ).

[0018] 1-4 , lighting assembly 10 is disposed within housing 62 operably coupled to and positioned between air handler unit 50. It is generally contemplated that air handler unit 50, housing 62, and lighting assembly 10 may collectively be defined as an illumination system 64, as described further herein. Housing 62 may be formed from a metal material and includes side panels 66 and a top panel 68, defining a cavity 70 therein. Housing 62 also includes a mounting perimeter 72 defining an opening 74 that may be selectively closed via a transparent panel 76 that is selectively removable from housing 62. Transparent panel 76 may be formed from glass, laminated glass, tempered glass, Plexiglas®, plastic, and / or other practical materials. It is generally contemplated that the transparent panel 76 may be threadably coupled to the housing 62 such that during maintenance of the illumination system 64, the transparent panel 76 may be threadably removed from the mounting perimeter 72 of the housing 62 to generally provide access to the cavity 70 of the housing 62.

[0019] Illumination system 64 is generally contemplated to include a plurality of lighting assemblies 10 positioned within housing 62 to form a lighting array 80. Stated another way, lighting array 80 is comprised of a plurality of lighting assemblies 10. Lighting array 80 may be powered and operated independently of air handler unit 50, and each lighting assembly 10 of lighting array 80 may be powered independently of adjacent lighting assemblies 10. Additionally or alternatively, lighting assemblies 10 may be collectively powered and operated individually. Other operating configurations of lighting assemblies 10 and lighting array 80 are also contemplated, such that all lighting assemblies 10 are operated uniformly as lighting array 80.

[0020] 1-4 , each lighting assembly 10 of the lighting array 80 may be selectively removed from the housing 62 to facilitate servicing of the lighting system 64 and / or servicing a single lighting assembly 10. For example, one of the lighting assemblies 10 may be removed from the lighting array 80 for servicing any one of the components. Additionally or alternatively, a lighting assembly 10 may be removed for servicing the entire lighting array 80 and / or lighting system 64. It is generally contemplated that the housing 62 may contain electrical components 82 that may provide power and / or communications within the lighting system 64.

[0021] 2-5 and 12, a single light assembly 10 will now be described in more detail. It is generally contemplated that details described in connection with a single lighting assembly 10 may be incorporated into or otherwise applied to each lighting assembly 10 within the illumination system 64. As described above, the lighting assembly 10 includes an upper mount 12, a lower mount 20, and a light module 32. A central shaft 100 is rotatably coupled to the upper mount 12 and operably coupled to the lower mount 20. The central mount 100 may assist in aligning the lower mount 20 and the upper mount 12, as described herein, and is configured to rotate within the upper mount 12.

[0022] An actuator ring 102 is disposed around the central shaft 100 proximate the upper mount 12 and the printed circuit board 28. The actuator ring 102 is configured to selectively engage at least one of the sensors 30 on the printed circuit board 28, as described in more detail herein. A first actuating device (e.g., pan motor 22) is illustrated as including a first drive gear 104 extending through an opening 106 defined in the printed circuit board 28. The first drive gear 104 and the pan gear 14 form a first gear assembly 109 ( FIG. 7 ) between the upper mount 12 and the lower mount 20 that is configured to rotate the lower mount 20 relative to the upper mount 12. A second actuating device (e.g., tilt motor 24) includes a second drive gear 108 as described herein. The first drive gear 104 and the second drive gear 108 selectively engage or interface with the pan gear 14 and the tilt gear 34, respectively. 5, second actuation device 24 also includes a magnet 110 coupled to second actuation device 24 proximate printed circuit board 28. Printed circuit board 28 includes a Hall sensor 112 (FIG. 8), described further herein, configured to detect magnet 110 during operation of second actuation device 24. It is also contemplated that other sensors may be utilized to detect magnet 110, including, but not limited to, a reed switch sensor.

[0023] The pan motor 22 and the tilt motor 24 are disposed within the lower mount 20. The lower mount 20 includes a first arm 118 and a second arm 120. The first and second arms 118, 120 are configured to couple the light module 32 to the lower mount 20. Each of the arms 118, 120 includes a retention opening 122 into which a mounting feature 124 of the light module 32 is disposed. It is generally contemplated that the pan motor 22 is disposed within the first arm 118 and the tilt motor 24 is disposed within the second arm 120. The operation of the pan and tilt motors 22, 24, along with the pan and tilt gears 14, 34, respectively, will be described in more detail herein.

[0024] 5-8 , the upper mount 12 includes an outer surface 130 and an inner surface 132 and defines a central opening 134 through which the central shaft 100 extends. The inner surface 132 includes a peripheral recess 136 adjacent the peripheral rim 18 and a central ring 138 from which a plurality of indicator flanges 16 extend. The pan gear 14 is defined adjacent the peripheral recess 136 along the peripheral rim 18 such that the pan gear 14 is circumferentially disposed around the central ring 138 of the upper mount 12. In some embodiments, the pan gear 14 is provided separately from the upper mount 12 and is fixedly or otherwise non-rotatably coupled to the upper mount 12 via one or more fasteners (e.g., screws, adhesives, bolts, etc.) or mating connections (e.g., flanges, keyways). In some embodiments, it is contemplated that the pan gear 14 is integrally formed with the upper mount 12 such that the upper mount 12 and pan gear 14 may be formed via an injection molding process. The upper mount 12 also includes a central housing 140 that defines a central opening 134 through which the central shaft 100 extends. The central housing 140 includes a first mechanical stop 142. A second mechanical stop 143 extends upwardly from the lower mount 20. Together, the mechanical stops 142, 143 are configured to limit rotation of the lower mount 20 relative to the upper mount 12 via engagement with the actuator ring 102, as described in more detail herein.

[0025] The upper mount 12 is rotatably coupled to the lower mount 20 via a first drive gear 104 and a pan motor 22. The pan gear 14 engages the first drive gear 104, which extends from the pan motor 22 within the lower mount 20. It is generally contemplated that the upper mount 12 is fixed relative to the lower mount 20 such that engagement between the first drive gear 104 and the pan gear 14 results in circumferential rotation of the lower mount 20 relative to the upper mount 12. As mentioned above, the first drive gear 104 aligns with and extends through an opening 106 defined by the printed circuit board 28 to selectively engage or cooperate with the pan gear 14 of the upper mount 12 to rotate the lower mount 20. Stated another way, the pan motor 22 may communicate with the pan gear 14 through the opening 106. The printed circuit board 28 includes a plurality of sensors 30, and a plurality of indicator flanges 16 extend centrally and circumferentially from the upper mount 12 toward the plurality of sensors 30. The plurality of indicator flanges 16 selectively engage the sensors 30 disposed along the printed circuit board 28. The indicator flanges 16 selectively pass the sensors 30 to indicate the position of the lower mount 20 relative to the upper mount 12.

[0026] 5-8 , the indicator flange 16 includes a plurality of outer flanges 149 and a home indicator flange 150 spaced radially inward from the outer flange 149. The sensors 30 on the printed circuit board 28 include at least one home sensor 152 configured to detect the home indicator flange 150. It is contemplated that the at least one home sensor 152 on the printed circuit board 28 may include a first home sensor 154 and a second home sensor 156. The plurality of sensors 30, including the at least one home sensor 152, rotate relative to the indicator flange 16 and detect the indicator flange 16 as each passes a respective sensor 30. The home sensors 152 are configured to detect when the lower mount 20 has completed a full rotation relative to the upper mount 12 by detecting the home indicator flange 150.

[0027] As illustrated in FIG. 7 , the printed circuit board 28 is configured with a first home sensor 154 and a second home sensor 156, as described above. The home indicator flange 150 can be detected by both the first home sensor 154 and the second home sensor 156. It is generally contemplated that the second home sensor 156 can detect the home indicator flange 150 when the lower mount 20 has rotated an additional 180 degrees relative to the upper mount 12. Additionally or alternatively, the second home sensor 156 can be configured as part of a detection memory system 158 ( FIG. 12 ) configured within the controller 36 ( FIG. 12 ) to verify with the controller 36 ( FIG. 12 ) that the lower mount 20 has completed a full rotation. For example, it is contemplated that the detection memory system 158 ( FIG. 12 ) can memorize the position of the lower mount 20 in the event of a power outage so that the controller 36 ( FIG. 12 ) can accurately resume rotation of the lower mount 20 when power is restored.

[0028] 5-8 and 12, the actuator ring 102 is disposed around the central shaft 100 adjacent the printed circuit board 28. The actuator ring 102 includes a circumferential body 160 and an engagement feature 162 extending outward from the circumferential body 160. The engagement feature 162 includes a pair of side surfaces 163 configured to engage with the first mechanical stop 142 and the second mechanical stop 143. For example, at a hard-stop position for rotation of the lower mount 20, the mechanical stops 142, 143 may engage the opposing side surfaces 163, with a first of the side surfaces 163 engaging the first mechanical stop 142 and a second of the side surfaces 163 engaging the second mechanical stop 143. In this manner, the mechanical stops 142, 143 may sandwich the actuator ring 102 to limit rotation of the lower mount 20. A proximity tab 164 extends from the engagement feature 162 on the actuator ring 102. The plurality of sensors 30 on the printed circuit board 28 also includes a proximity sensor 166 that detects the proximity tab 164 on the actuator ring 102. The proximity sensor 166 is configured to detect the proximity tab 164 at a first point and a second point.

[0029] The proximity tab 164 passes over a proximity sensor 166 to communicate the position of the lower mount 20 relative to the upper mount 12 to the controller 36 as the lower mount 20 rotates. In other words, the proximity tab 164 and the proximity sensor 166 cooperate to inform the controller 36 of the rotational position of the lower mount 20. By way of example, and not limitation, the lower mount 20 may rotate approximately 540 degrees relative to the upper mount 12, and the proximity tab 164 and the proximity sensor 166 cooperate to inform the controller 36 of the rotational position of the lower mount 20.

[0030] It is generally contemplated that the lower mount 20 is configured to rotate approximately 540 degrees relative to the upper mount 12. The home indicator flange 150 may pass through the home sensor 152 twice during a single rotation. The proximity tab 164 remains on the proximity sensor 166 during the first 270 degrees of rotation of the lower mount 20 relative to the upper mount 12. The first mechanical stop 142 engages the engagement feature 162 after the first 270 degrees of rotation, thereby displacing the proximity tab 164 from the proximity sensor 166. The displacement of the proximity tab 164 indicates to the controller 36 that the lower mount 20 has displaced from the home position relative to the upper mount 12. In other words, the home indicator flange 150 may be disposed on either the first or second home sensor 154, 156 while displaced from the home position when the proximity tab 164 displaces from the proximity sensor 166.

[0031] 5-8 and 12, the engagement feature 162 can also be configured as a fail-safe stop mechanism to prevent additional rotation of the lower mount 20 beyond a predetermined 540-degree rotation limit. If the pan motor 22 rotates the lower mount 20 beyond the 540-degree rotation mark, the engagement feature 162 engages with the first mechanical stop 142 defined by the upper mount 12, preventing any additional rotation of the lower mount 20 in that direction. It is also contemplated that the first mechanical stop 142 of the actuator ring 102 and the engagement feature 162 are configured to minimize strain on the electrical wiring 168 during rotation of the lower mount 20. In other words, the electrical wiring 168 between the printed circuit board 28, the controller 36, and each of the pan and tilt motors 22, 24 may be configured within a wire harness 170, and engagement of the first mechanical stop 142 with the engagement feature 162 helps to minimize potential strain and / or tension on the wire harness 170 to extend the useful life of the wire harness 170.

[0032] 5 and 9-12, the lower mount 20 includes a body 180 from which arms 118, 120 extend. Each of the arms 118, 120 defines a space 182 in which at least one of the pan motor 22 and the tilt motor 24 is disposed. The spaces 182 of the arms 118, 120 may accommodate the motors 22, 24 facing each other (e.g., 180 degrees from each other) as depicted. The pan motor 22 may be disposed within the first arm 118, and the tilt motor 24 may be disposed within the second arm 120. As described above, the pan motor 22 is operably coupled to the first drive gear 104 and configured to rotate the lower mount 20 relative to the upper mount 12. The pan motor 22 rotates the lower mount 20 between a first position 190 (FIG. 10) and a plurality of second positions 192. At least one of the plurality of second rotational positions 192 is illustrated in Figure 11. Pan motor 22 is configured to face or be aligned with a first direction (e.g., toward upper mount 12) such that the shaft of pan motor 22 extends along the first direction.

[0033] The tilt motor 24 is configured to tilt or otherwise angle the light module 32 relative to the lower mount 20. The tilt motor 24 is configured to face or be aligned with a second direction opposite the first direction (e.g., away from the upper mount 12) such that the shaft of the tilt motor 24 extends along the second direction. The tilt motor 24 tilts the light module 32 between a first position 194 ( FIG. 10 ) and a plurality of second tilt positions 196. At least one of the plurality of second tilt positions 196 is illustrated in FIG. 11 . The tilt motor 24 includes a magnet 110 extending outward from the tilt motor 24 adjacent to the printed circuit board 28. Stated differently, the magnet 110 is positioned adjacent to a Hall sensor 112 disposed on the underside or opposite surface 184 of the printed circuit board 28 from the proximity sensor 166.

[0034] The Hall sensor 112 is configured to detect the magnetic field of the magnet 110 to detect the position of the light module 32 relative to the submount 20 and the printed circuit board 28. The Hall sensor 112 is communicatively coupled to the controller 36 and indicates the position of the light module 32 relative to the submount 20. The magnet 110, coupled to the tilt motor 24, is configured with dual hemispherical polarity such that the Hall sensor 112 can detect the position of the magnet 110 based on the pole position. The magnet 110 rotates about a shaft 186 coupled to the tilt motor 24 as the tilt motor 24 tilts or otherwise actuates the light module 32 relative to the submount 20. The rotation of the magnet 110 indicates to the Hall sensor 112 the position of the light module 32 relative to the submount 20.

[0035] 5 and 9-12, the light module 32 includes a tilt gear 34 proximate the second arm 120 of the lower mount 20. The tilt gear 34 is coupled to a light housing 188 of the light module 32 to define an arcuate configuration. The tilt gear 34 may be separately formed and operably coupled to the light housing 188. For example, the tilt gear 34 may be provided separately from the light housing 188 and fixedly or otherwise non-rotatably coupled to the light housing 188 via one or more fasteners (e.g., screws, adhesive, bolts, etc.) or a mating connection. Additionally or alternatively, the title gear 34 may be integrally formed with the light housing 188. A second drive gear 108 extends from the tilt motor 24 and is operably coupled to the tilt gear 34. The second drive gear 108 and the tilt gear 34 form a second gear assembly 189 between the lower mount 20 and the lighting module 32, which is configured to rotate the lighting module 32 relative to the lower mount 20. The second drive gear 108 engages with the tilt gear 34 when the second drive gear 108 is actuated by the tilt motor 24. In other words, the second drive gear 108 engages with the tilt gear 34 to rotate and tilt the light module 32 relative to the lower mount 20. The tilt motor 24 rotates the magnet 110 and the second drive gear 108 simultaneously, such that the rotation of the magnet 110 corresponds to the tilt of the light module 32. The rotation of the second drive gear 108 along the tilt gear 34 ultimately rotates and / or tilts the light module 32 relative to the lower mount 20. Rotation of the second drive gear 108 along with the tilt gear 34 corresponds to rotation of the magnet 110 such that the Hall sensor 112 can detect the tilt of the light module 32 based on the rotational position of the magnet 110 .

[0036] 1-12 , the controller 36 is configured to detect the positions of both the lower mount 20 and the light module 32 based on the detection of the indicator flange 16, the proximity tab 164, and the magnet 110, respectively. The detection storage system 158 of the controller 36 is configured to at least temporarily store the rotational positions of both the lower mount 20 and the light module 32. For example, the detection storage system 158 receives updated rotational positions of the lower mount 20 from the sensors 30 and verifies whether the pan motor 32 and the tilt motor 34 are operating according to input commands. The controller 36 repeatedly receives signals from the sensors 30 that provide position data of the lower mount 20 and the light module 32. It is generally contemplated that the controller 36 may shut down one of the lighting assemblies 10 if the detection storage system 158 detects inconsistent rotational or tilt movement of either the lower mount 20 and / or the light module 32, respectively.

[0037] It is generally contemplated that the controller 36 may initiate a reverse motion to return the lower mount 20 to a starting position once the sensor 30 on the printed circuit board 28 detects a full rotation of the lower mount 20. The controller 36 operates the rotation function of the lower mount 20 via activation of the pan motor 22 and also the tilt function of the light module 32 via activation of the tilt motor 24. It is also contemplated that the controller 36 is configured to adjust and activate the brightness of the light module 32 during operation. The controller 36 may be selectively activated via a user interacting with the user interface 200 or other user controls. By way of example, and not limitation, the user interface 200 may be a wireless computing device connected to the controller 36 via a wireless network 202.

[0038] Additionally or alternatively, the network 202 and / or the user interface 200 may include wired connections. It is also contemplated that the user interface 200 may be communicatively coupled to the controller 36 in each of the lighting assemblies 10 of the lighting system 64 such that the user interface 200 may activate a single light assembly 10 and / or activate multiple lighting assemblies 10 in the lighting system 64. The user interface 200 may also be configured with indicia associated with various functions of the lighting assembly 10, including, but not limited to, rotation and / or tilt of the lower mount 20 and light module 32, respectively.

[0039] 13 , a method 1300 of fabricating or assembling a lighting assembly 10 includes coupling the pan gear 14 to the upper mount 12 in step 1302. In step 1304, the actuation devices 22, 24 are placed in a recess, such as the space 182, with the first actuation device (e.g., the pan motor 22) facing upward and the second actuation device (e.g., the tilt motor 24) facing downward. Generally, the orientation of the first actuation device 22 may be generally opposite to the orientation of the second actuation device 24. The second actuation device 24 may be aligned with the Hall sensor 112 coupled to the lower surface of the printed circuit board 28. The printed circuit board 28 is aligned with the lower mount 20 in step 1306. In step 1308, the opening 106 in the printed circuit board 28 aligns with the first actuation device 22 to allow the first drive gear 104 to extend from the lower mount 12 into the upper mount 12. The lower mount 20 couples to the upper mount 12 in step 1310 to engage the first drive gear 104 and the pan gear 14, thus providing communication between the first actuation device 22 and the pan gear 14. The lower mount 20 may couple to the upper mount 12 via a bolt (e.g., formed in the central shaft 100) and nut extending through the central opening 134. In some embodiments, the light module 32 is then coupled to the lower mount 20 in step 1312. These steps are not limited, and it is contemplated that other steps may be included in method 1300, such as connecting wiring to individual output devices of the lighting assembly 10 (e.g., motors 22, 24, light sources, etc.), as well as to the housing 62 and wiring to the controller 36 and / or electrical components 82.

[0040] 14 , an embodiment of the illumination system 64 includes an imaging device 60 disposed at an end of the lighting array 80. Each lighting assembly 10 may be received in a socket 204 defined by a support structure 206 disposed within the housing 62. Each wire harness 170 may pass through the socket 204 to couple with the electrical component 82. In some embodiments, a connection interface 208 is provided for each lighting assembly adjacent the backside of the support structure 206 and configured to align the wire harness 170. The connection interface 208 includes a bracket 210 and a mating clip 212 configured to receive the bracket 210 and attach the bracket 210 to the support structure 206. In some embodiments, the connection interface 208 is configured to rigidly secure the wire harness 170, limit tangling, and guide the wire harness 170 to the electrical component 82 and / or the controller 36. It is contemplated that the support structure 206 may be formed with more sockets 204 than lighting assemblies 10, allowing for rearrangement of the lighting array 80 and imaging devices 60 and customizing the illumination system 64 for a given application. For example, the support structure 206 illustrated in FIG. 14 may alternatively include a sixth lighting assembly 10 in place of the imaging device 60.

[0041] Generally, the placement of the actuation devices (e.g., first and second motors 22, 24) and / or printed circuit board 28 may provide for a reduced packaging size, further allowing for reduced costs. The modularity of the lighting assembly 10 may further allow for easy replacement of individual lighting assemblies of the lighting array 80. Furthermore, the non-rotating relationship between the pan gear 14 and upper mount 12 and the non-rotating relationship between the tilt gear 34 and light module 32 may maximize the overall useful life of the light assembly 10. The 540-degree rotation also provides maximum lighting options during surgical procedures and / or other situations in which rotation of the lighting assembly 10 may be advantageous. Additionally, the inclusion of multiple sensors 30 within the lighting assembly 10 advantageously provides position verification of the lower mount 20 and light module 32, respectively, to the controller 36.

[0042] The indicator flange 16 cooperates with multiple sensors 30 to detect rotation of the lower mount 20 relative to the upper mount 12. The controller 36 is in constant communication with the printed circuit board 28 regarding the position of the lower mount 20 relative to the upper mount 12. By way of example, and not limitation, the controller 36 may store rotational information detected by the multiple sensors 30 in a detection storage system 158 to minimize interruptions as a result of a potential power outage. Stated differently, the controller 36 may detect incremental positions of the lower mount 20 to detect whether the lower mount 20 has moved relative to a home position. If the lower mount 20 has moved, the controller 36 may reposition the lower mount 20 to the home position such that the home indicator flange 150 is detected by the home sensor 152. Additionally or alternatively, the controller 36 may detect whether the pan and / or tilt motors 32, 34 are properly executing commands from the controller 36, such that a significant deviation from the commands may cause the controller 36 to shut down the respective lighting assembly 10.

[0043] Those skilled in the art will appreciate that the disclosed and other component configurations are not limited to any particular materials, and other exemplary embodiments disclosed herein may be formed from a wide variety of materials unless otherwise stated herein.

[0044] In this disclosure, the term "coupled" (in all its forms, couple, coupling, coupled, etc.) generally refers to the joining of two components (electrical or mechanical) directly or indirectly to one another. Such a connection may be fixed in nature or movable in nature. Such a connection may be achieved when the two components (electrical or mechanical) and any additional intermediate members are integrally formed with each other or with the two components as one unitary body. Such a connection may be permanent in nature or may be removable or separable in nature, unless otherwise specified.

[0045] It is also important to note that the configuration and arrangement of elements of the present disclosure as shown in the exemplary embodiments are for illustrative purposes only. While this disclosure has described in detail only a few embodiments of the present innovation, those skilled in the art who review this disclosure will readily recognize that numerous modifications (e.g., changes in the size, dimensions, structure, shape, and proportions of various elements, parameter values, mounting arrangements, use of materials, color, orientation, etc.) are possible without significantly departing from the novel teachings and advantages of the detailed subject matter. For example, elements shown as integrally formed may be comprised of multiple pieces, or elements shown as multiple pieces may be integrally formed, interface operation may be reversed or otherwise changed, the structure and / or length or width of members, connectors, or other elements of the system may be changed, and the nature or number of adjustment positions provided between elements may be varied. It should be noted that the elements and / or assemblies of the system may be constructed from any of a wide variety of materials, in any of a wide variety of colors, textures, and combinations, that provide sufficient strength or durability. Accordingly, all such modifications are intended to be within the scope of the present innovation. Other substitutions, modifications, changes, and omissions may be made in the design, operating conditions, and arrangement of the desired and other exemplary embodiments without departing from the spirit of the innovation.

[0046] It will be understood that any described process or step within a described process may be combined with other disclosed processes or steps to form structures within the scope of the present disclosure. The example structures and processes disclosed herein are for illustrative purposes and are not to be construed as limiting.

[0047] It is also understood that variations and modifications can be made to the structures and methods described above without departing from the concepts of the present disclosure, and further that such concepts are intended to be covered by the following claims unless the language of those claims expressly states otherwise.

Claims

1. 1. A lighting assembly comprising: an upper mount having a pan gear and a plurality of indicator flanges including an outer flange and a home indicator flange spaced radially inward from the outer flange; a lower mount operably coupled to the upper mount and including a pan motor and a tilt motor; a printed circuit board operatively coupled to the lower mount, the printed circuit board including a plurality of sensors disposed on the printed circuit board for detecting the plurality of indicator flanges during rotation of the lower mount, the plurality of sensors including a home sensor configured to detect the home indicator flange; a light module operably coupled to the lower mount, the light module including a tilt gear operably coupled to the lower mount; a controller operably coupled to the printed circuit board, the pan motor, and the tilt motor, the controller configured to rotate the lower mount and the light module via the pan motor, and to tilt the light module via the tilt motor.

2. The lighting assembly of claim 1 , wherein the printed circuit board defines an opening aligned with the pan motor.

3. The lighting assembly of claim 2 , wherein the pan motor communicates with the pan gear through the opening.

4. The lighting assembly of any one of claims 1 to 3, further comprising an imaging device operatively coupled to the light module and communicatively coupled to the controller.

5. an actuator ring proximate the upper mount and the printed circuit board, the actuator ring including a proximate tab; and the plurality of sensors further comprising a proximity sensor configured to detect the proximity tab of the actuator ring during at least a portion of a range of rotation of the lower mount.

6. 1. A lighting assembly comprising: an upper mount, a lower mount coupled to the upper mount, and a gear assembly between the upper mount and the lower mount configured to rotate the lower mount relative to the upper mount; an actuator ring between the upper mount and the lower mount, the actuator ring including an engagement feature having a first surface, a second surface, and a proximal tab; a first mechanical stop extending from the upper mount to engage the first surface of the engagement feature to limit rotation of the actuator ring during rotation of the lower mount, and a second mechanical stop extending from the lower mount to engage the second surface of the engagement feature to clamp the actuator ring and limit the rotation of the lower mount; a printed circuit board operably coupled to the lower mount and defining an opening through which the gear assembly extends and including a proximity sensor configured to detect the proximity tab during at least a portion of the range of rotation; a first actuation device disposed within the lower mount and coupled to a gear arrangement to drive the gear arrangement.

7. 7. The lighting assembly of claim 6, wherein the gear arrangement includes a pan gear fixedly secured to the upper mount and a drive gear coupled to the first actuation device, the drive gear interlocking with the pan gear.

8. a plurality of indicator flanges extending from the upper mount; 8. The lighting assembly of claim 6 or 7, further comprising: a plurality of sensors in addition to the proximity sensor disposed on the printed circuit board for detecting the plurality of indicator flanges during rotation of the lower mount.

9. 9. The lighting assembly of claim 8, wherein the plurality of indicator flanges includes an outer flange and a home indicator flange spaced radially inward from the outer flange, and the plurality of sensors includes a home sensor configured to detect the home indicator flange.

10. 8. The lighting assembly of claim 6, further comprising a second actuation device disposed in the lower mount opposite the first actuation device and configured to drive tilt of the lighting assembly.

11. The lighting assembly of claim 10 , further comprising a lighting module pivotally coupled to the lower mount, the second actuation device configured to rotate the lighting module.

12. 11. The lighting assembly of claim 10, further comprising a Hall sensor coupled to the printed circuit board and aligned with the second actuation device, the Hall sensor configured to monitor the tilt.

13. A lighting assembly as described in claim 6 or 7, wherein the proximity tab extends from the engagement feature.

14. 1. An illumination system comprising: at least one air handler unit; a housing operatively coupled to the at least one air handler unit, the housing defining a cavity and including a transparent panel selectively removable from the housing, the transparent panel configured to provide access to the cavity; 1. A lighting assembly comprising: an upper mount, a lower mount coupled to the upper mount, and a gear assembly between the upper mount and the lower mount configured to rotate the lower mount relative to the upper mount; a printed circuit board operably coupled to the lower mount and defining an opening spaced from an outer periphery of the printed circuit board, the gear assembly extending through the opening; and a lighting assembly including a first actuation device disposed within the lower mount and coupled to a gear arrangement to drive the gear arrangement; a controller in communication with the lighting assembly and configured to communicate instructions to control the first actuation device to adjust the lighting assembly.

15. The illumination system of claim 14 , further comprising an imaging device disposed within the cavity and communicatively coupled to the controller.

16. 16. The lighting system of claim 15, wherein the imaging device is operably coupled to the lighting assembly, and the controller is configured to control the lighting assembly based on images captured by the imaging device.

17. a wire harness coupling the lighting assembly to the controller; 17. The lighting system of any one of claims 14 to 16, further comprising: a connection interface configured to align the wire harness between the lighting assembly and the controller.

18. a second actuation device disposed in the lower mount opposite the first actuation device and configured to drive tilt of the lighting assembly; and 17. The lighting system according to any one of claims 14 to 16, further comprising: a lighting module pivotally coupled to the lower mount, wherein the second actuation device is configured to rotate the lighting module.

Images