Lighting fixtures and methods for manufacturing lighting fixtures

Abstract

The lighting fixture includes an outer housing, a main circuit board mounted inside the outer housing, a lighting fixture driver mounted on the main circuit board, and a light source mounted to the outer housing from outside the outer housing, the light source including a first push-fit connector portion extending into the main housing, and the main circuit board including a second push-fit connector portion that engages with the first push-fit connector portion when the main circuit board, outer housing, and light source are assembled to provide an electrical connection between the main circuit board and the light source.

Description

Technical Field

[0001] The present invention relates to an assembly of lighting fixtures. In particular, the present invention relates to an automatic assembly of road lighting fixtures.

Background Art

[0002] The Fourth Industrial Revolution (Industry 4.0) is a concept that encompasses the rapid technological changes in recent years. One such change is the increasing trend towards automating the manufacturing and assembly of components.

[0003] For example, automated robots are used in the manufacture of products. However, in many cases, these products must be designed taking into account the manufacturing capabilities of the robots in order for the robots to be able to manufacture the products accurately and consistently.

[0004] Road lighting fixtures are recognized as products that can benefit from automated manufacturing. However, the problem with this is that road lighting fixtures have many components (such as light sources, lighting drivers, sensors, etc.), all of which need to be interconnected using wires. It can be difficult to use automated robots in the wiring process because it is difficult to predict the precise positioning of the wires when the robots move the wires during manufacturing.

Summary of the Invention

Problems to be Solved by the Invention

[0005] Thus, it is necessary to improve the design of lighting fixtures in order to facilitate automated manufacturing.

Means for Solving the Problems

[0006] The present invention is defined by the claims.

[0007] According to an example according to one aspect of the present invention, Outer housing and, The main circuit board is mounted inside the outer housing, A lighting fixture driver that is mounted on the main circuit board, A light source attached to the outer housing from the outside of the outer housing, A pluggable connector is used to connect the lighting fixture driver and the main circuit board to provide an electrical connection between them. Lighting fixtures including, A lighting fixture is provided, in which the light source includes a first push-fit connector portion extending into the main housing, and the main circuit board includes a second push-fit connector portion that engages with the first push-fit connector portion when the main circuit board, outer housing, and light source are assembled, providing an electrical connection between the main circuit board and the light source.

[0008] The pluggable connector is a push-fit component, and thus can be mounted by a robotic arm (in the same direction as the light source and main circuit board assembly), eliminating the need to run and connect wires between the luminaire driver and the main circuit board.

[0009] Product manufacturing / assembly using robotic arms and the like offers faster and more efficient product assembly. However, in the case of road lighting fixtures, the components used and the way they are connected make it difficult for robotic arms to assemble the product. The wiring process for road lighting fixtures has been found to be particularly challenging for robotic assembly. In particular, while it is relatively easy to achieve product placement along one axis on the circuit board (i.e., the z-axis direction if the circuit board is in the xy-plane), more complex robotic movements are required, for example, to thread wires through openings that do not coincide with the z-axis direction.

[0010] Thus, it is proposed to use a main circuit board to connect all components instead of wires. The connection between the light source and the main circuit board is achieved by push-fit connections, such as male and female push-fit pin connections. This can be more easily achieved using a robotic arm that handles wires. Similarly, other components within the outer housing can be connected to the main circuit board by push-fit connectors that can be mounted by a robotic arrangement.

[0011] The only wires that need to be routed are the external power lines that supply power to the main circuit board.

[0012] Thus, the use of a main circuit board enables a robotic arm to assemble road lighting fixtures quickly and efficiently, and the mechanical assembly automatically creates the electrical connection between the light source and the main circuit board.

[0013] By mounting the light source from the outside of the outer housing, without requiring the light source to be pre-assembled on the main circuit board, the housing assembly itself provides the electrical connection between the main circuit board and the light source.

[0014] Furthermore, the use of a main circuit board also makes it easier to maintain lighting fixtures, as there is no longer a mix of wires connecting all the different components, thus avoiding confusion during maintenance.

[0015] For example, the first push-fit connector portion includes one or more pins, and the second push-fit connector portion includes a socket.

[0016] A pin and socket arrangement allows a light source to be precisely aligned with the main circuit board when the pins are aligned with the sockets. The pins may extend through holes that penetrate the housing, thereby allowing the pins to pass through the housing and connect to the main circuit board.

[0017] For example, the main circuit board is mounted on a first surface inside the outer housing, and the light source is mounted on a second surface outside the outer housing. The main circuit board and the light source are mounted, for example, in opposing directions, and the robot assembly system allows for component placement in these two opposing directions (for example, the positive and negative z-axis directions if the main circuit board is in the xy-plane).

[0018] The lighting fixture may further include a motion sensor within the outer housing, which is connected to a main circuit board and configured to detect motion outside the outer housing.

[0019] A motion sensor can be used to detect nearby activity and turn on a light when such activity is detected. The motion sensor is located inside the housing and connected to the main circuit board, while sensing motion outside the housing.

[0020] The motion sensor and luminaire may be mounted on the first surface of the outer housing when assembled. Furthermore, the motion sensor may be connected to the main circuit with a push-fit coupling. The luminaire may further include a pluggable connector that plugs into the motion sensor and the main circuit board to provide an electrical connection between the motion sensor and the main circuit board.

[0021] For example, the main circuit board further includes a wireless signal receiver. The wireless signal receiver is, for example, for receiving coded optical signals.

[0022] The radio signal receiver may be mounted on the first surface of the outer housing when the lighting fixture is assembled. In this way, the radio signal receiver can be positioned in a window of the outer housing or project through the outer housing.

[0023] For example, the lighting fixture further includes a pluggable connector that is plug-connected to the wireless signal receiver and the main circuit board in order to make an electrical connection between the wireless signal receiver and the main circuit board.

[0024] For example, the outer housing includes a housing body and a housing cover, and the main circuit board is attached to the housing body. The housing body may be regarded as a base portion.

[0025] For example, an O-ring is provided between the housing body and the housing cover to waterproof the housing.

[0026] The lighting fixture may be a road lighting fixture.

[0027] The present invention also relates to a method for manufacturing a lighting fixture, the method comprising: placing a main circuit board inside an outer housing; positioning a lighting fixture driver on the main circuit board before or after placing the main circuit board inside the outer housing; attaching a light source to the outer housing from the outside of the outer housing; controlling a robotic arm to follow a manufacturing instruction including the above; A method is provided in which the attachment of the light source provides an electrical connection between the light source and the main circuit board by a push-fit connection between a first push-fit connector portion of the light source extending into the outer housing and a second push-fit connector portion of the main circuit board.

[0028] The use of the push-fit connection eliminates the need to route a wire between the light source and the lighting fixture driver because the main circuit board functions as an intermediate portion where the push-fit connection can be made. All of these push-fit connections can be made using a robotic arm movement along a single axis.

[0029] For example, the main circuit board is mounted on a first surface inside the outer housing, and the light source is mounted on a second surface outside the outer housing.

[0030] Mounting the main circuit board and light source to opposing surfaces of the outer housing means they can be consistently aligned vertically by a robotic arm. Furthermore, this allows the push-fit connector portion of the main circuit board to be precisely aligned with the push-fit connector portion of the light source.

[0031] For example, manufacturing instructions are: After placing the main circuit board inside the outer housing, the lighting fixture driver is attached to the main circuit board. To electrically connect the lighting fixture driver to the main circuit board, a pluggable connector is used, Includes.

[0032] Thus, the main circuit board is first positioned within the outer housing, and then other components are mechanically attached to the main circuit board or to the housing, and pluggable electrical connectors may be used to make electrical connections.

[0033] For example, the manufacturing instructions may further include aligning the first and second push-fit connector portions before mounting the light source. For example, the manufacturing instructions may include aligning one or more pins of the first push-fit connector portion with the socket of the second push-fit connector portion. After these alignments, the connection can be made in single-axis movement.

[0034] For example, the manufacturing instructions further include: The motion sensor is placed inside the outer housing, and the motion sensor is configured to sense motion outside the outer housing. To electrically connect the motion sensor to the main circuit board, a pluggable connector is used, Includes.

[0035] The manufacturing instructions further state: The wireless receiver is placed inside the outer housing, To electrically connect the wireless receiver to the main circuit board, a pluggable connector is used, It may include.

[0036] For example, the outer housing includes a housing body and a housing cover, and the manufacturing instructions further include securing the housing cover to the housing body and closing the housing by waterproofing it.

[0037] The positioning of the lighting fixture driver on the main circuit board, the positioning of the main circuit board within the outer housing, and the mounting of the light source to the outer housing may each include the arrangement of components perpendicular to the main circuit board. Different components may be arranged in opposing directions, for example, in the +z axis direction and the -z axis direction.

[0038] Pluggable connectors may also be applied in the same z-axis direction.

[0039] The present invention also provides a computer program including computer program code means, wherein the computer program code means is adapted to carry out the above method when the computer program is executed on the computer of a robot arm controller.

[0040] These and other aspects of the present invention will become apparent and clarified by reference to the embodiments described below. [Brief explanation of the drawing]

[0041] For a better understanding of the present invention and to more clearly illustrate how the present invention may be carried out, the accompanying drawings are referred to only as examples. [Figure 1] This shows the first step in manufacturing a lighting fixture. [Figure 2] This shows the second step in manufacturing lighting fixtures. [Figure 3] This shows the second step in manufacturing lighting fixtures. [Figure 4] This shows a cross-sectional view of a road lighting fixture during the second step of manufacturing. [Figure 5] This shows the third step in manufacturing lighting fixtures. [Figure 6] This shows the third step in manufacturing lighting fixtures. [Figure 7] This shows the fourth step in manufacturing lighting fixtures. [Figure 8] This shows the fourth step in manufacturing lighting fixtures. [Figure 9] This shows the fifth step in manufacturing lighting fixtures. [Figure 10] This shows an exploded view of a street lighting fixture. [Modes for carrying out the invention]

[0042] The present invention will be described with reference to the figures.

[0043] The detailed descriptions and specific examples illustrate exemplary embodiments of the apparatus, systems, and methods, but should be understood to be for illustrative purposes only and not intended to limit the scope of the invention. These and other features, aspects, and advantages of the apparatus, systems, and methods of the invention will be better understood from the following description, the appended claims, and the appended drawings. Please understand that the drawings are for illustrative purposes only and are not drawn to scale. Please also understand that the same reference numerals are used to indicate the same or similar parts throughout the drawings.

[0044] The present invention provides a lighting fixture comprising an outer housing, a main circuit board mounted inside the outer housing, a lighting fixture driver mounted on the main circuit board, and a light source mounted on the outer housing from the outside. The light source includes a first push-fit connector portion extending into the main housing, and the main circuit board includes a second push-fit connector portion that engages with the first push-fit connector portion when the main circuit board, outer housing, and light source are assembled, providing an electrical connection between the main circuit board and the light source.

[0045] Lighting fixtures can be advantageously manufactured / assembled using automated robots. The advantages of automated manufacturing are particularly evident in the production of road lighting fixtures. Therefore, the following examples will describe road lighting fixtures. However, the same steps and design features can be applied to any type of lighting fixture.

[0046] Figure 1 shows the first step in manufacturing a road lighting fixture. The first step includes mounting the main circuit board 102 to the outer housing, in particular to the housing body 104 which may be considered a housing base, and to which a cover is later applied.

[0047] The main circuit board is mounted on the first, internal surface 110 of the housing body 104 and is later covered by a housing cover so that it is mounted inside the outer housing. The housing body 104 includes a first through-hole 106 for mounting a sensor (not shown) and a second through-hole 108 for power wires (not shown).

[0048] The main circuit board is intended to replace most of the wires typically used in road lighting fixtures, thereby enabling a robotic arm to manufacture road lighting fixtures accurately and consistently. The robotic arm can easily attach the main circuit board 102 to the housing body 104 (for example, by screwing the main circuit board 102 to the housing).

[0049] Figures 2 and 3 illustrate the second step in manufacturing a road lighting fixture. The second step includes mounting a light source 202 to the housing body 104. The light source is, for example, one or more LED panels. In particular, the light source 202 is mounted on a second, external surface 206 of the housing body 104. The second surface 206 is opposite the first surface 110 shown in Figure 1. In this way, the light source 202 can be mounted on the outside of the housing body while being aligned with a main circuit board (not shown) located inside the outer housing.

[0050] In this way, the housing body is sandwiched between the light source and the main circuit board, and the electrical connections between the light source and the main circuit board pass through the housing body, rather than all connections being fully internalized within the outer housing. This design facilitates robotic assembly of the lighting fixture.

[0051] The main circuit board and light source are positioned by movement in a direction perpendicular to the plane of the main circuit board. For example, the main circuit board may be considered to be in the xy plane, in which case the movement of the parts required for assembly is in the z-axis direction, and in particular, the movement of different parts is in one or the other of the opposing z-axis directions (i.e., the +z direction or the -z direction).

[0052] Furthermore, the first through-hole 106 allows the sensor to be mounted on the inside of the housing on the first surface, while the sensing portion of the sensor can extend beyond the second surface 206 to sense, for example, movement outside the housing body. Alternatively, the sensing portion may be positioned relative to a sensing window of the outer housing.

[0053] Figure 2 shows the road lighting fixture before the light source 202 is mounted on the housing body 104. The second surface 206 of the housing body includes two through-holes so that two push-fit connector portions 204 of the main circuit board are visible from the second surface 206. These two push-fit connector portions 204 are aligned with the push-fit connector portion (not shown) of the light source 202. This allows the light source 202 to be electrically connected to the main circuit board by a simple push-fit connection along the z-axis without the need for wires.

[0054] The robot arm aligns the light source 202 with the through-hole 204 and thus with the main circuit board before it is attached to the housing body 104 (for example, using screws). The robot arm can precisely attach the light source 202 to the housing body 104 using only z-axis direction placement (i.e., aligning the light source 202 and moving it toward the housing body 104).

[0055] Figure 3 shows the road lighting fixture after the light source 202 has been attached to the housing body 104. In this case, the push-fit connector portion of the light source 202 is connected to the push-fit connector portion 204 of the main circuit board shown in Figure 2.

[0056] Figure 4 shows a cross-sectional view of the road lighting fixture during the second step of manufacturing. The upper cross-sectional view shows the main circuit board 102 mounted on the first surface 110 of the housing body 104 and the light source 202 mounted on the second surface 206 of the housing body 104.

[0057] The lower cross-sectional view shows an enlarged view of a portion of the upper cross-sectional view. In particular, the lower cross-sectional view shows the push-fit connector portion 204 of the main circuit board 102 and the push-fit connector portion 402 of the light source 202. The push-fit connector portion 402 of the light source 202 is a pin, and the push-fit connector portion 204 of the main circuit board 102 is a female socket connector. The pin 402 can be pushed into the female connector 204 to provide an electrical connection between the light source 202 and the main circuit board 102. The pin 402 is provided through a through hole in the housing 104.

[0058] Figures 5 and 6 show the third step in manufacturing a road lighting fixture. In the third step, additional components are added to the road lighting fixture. In particular, these components are electrically connected to the main circuit board 102. These components include a lighting driver 502, a passive infrared (PIR) sensor 504, a wireless receiver 506, and a surge protection device 508. These components are connected to the main circuit board 102 using pluggable connectors (e.g., connector 510 for the PIR sensor 504). The wireless receiver is for receiving, for example, coded optical signals. However, the wireless receiver may instead be for receiving other wireless signals such as shortwave RF signals (e.g., Bluetooth® or Wi-Fi®) to enable wireless remote control of the lighting fixture functions.

[0059] Furthermore, the components are preferably mounted in the z-axis direction. They may be mounted on the main circuit board or on the housing body. The initial mounting is, for example, mechanical only. Once mechanically mounted, electrical connections may be provided as pluggable electrical connectors. These pluggable electrical connectors are also plugged in in the z-axis direction. This is shown in Figure 5 for pluggable connector 510. Thus, all or almost all components can be mechanically positioned and electrically connected using only z-axis (+z or -z) component movement. However, the mechanical positioning of some components also implements electrical connections using push-fit electrical connectors, such as those used between the light source and the main circuit board.

[0060] In this particular example, the PIR sensor 504 is mounted on the housing body 104, with the sensing portion of the PIR sensor 504 extending beyond the first through-hole 106 of the housing body 104, while the wireless receiver and surge protection device are mounted on the main circuit board. However, the components may be mounted with different components fixed to the outer housing and different components fixed to the main circuit board.

[0061] In this example, the power wire 512 is shown as the only component that may need to be connected manually, because it may be difficult for the robot arm to pass the power wire 512 through the second through-hole 108.

[0062] Figure 5 shows the components before they are connected to the main circuit board 102. Figure 6 shows the components after they are connected to the main circuit board 102. As can be seen, all components except the power wire 512 can be connected to the main circuit board by the robot arm (i.e., by aligning each component, positioning the components on the housing body 104 or the main circuit board 102, and connecting the components to the main circuit board 102 using pluggable connectors such as the connector 510 for the PIR sensor 504).

[0063] Since relatively short cables are easier for the robot arm to handle, the connector may use a relatively short cable with male / female connectors at the ends. Alternatively, the component may include a single block connector having a male / female connector aligned with the corresponding female / male connector on the main circuit board 102.

[0064] Figures 7 and 8 show a fourth step in manufacturing a road lighting fixture. The fourth step includes adding a housing cover 702 with an O-ring (or gasket) 704 between the housing body 104 and the housing cover 104. The O-ring 704 ensures that the inside of the housing (formed by the housing body 104 and the housing cover 702) is sealed and waterproof. The inside of the housing has a main circuit board 102 mounted on the first surface of the housing body and components (i.e., a lighting driver 502, a PIR sensor 504, a coded receiver 506, a surge protection device 508, and power wires 512). In this way, the electrical components of the road lighting fixture are protected from the environment (e.g., rain, dust, etc.). The housing cover 702 can be attached to the housing body 104 with screws to form the housing of the road lighting fixture.

[0065] Of course, the robot arm can be easily assembled by aligning the O-ring 704 and the housing cover 702 with the housing body 104 and fixing them to the housing body, for example, with screws.

[0066] Figure 7 shows the housing cover 702 and O-ring 704 before they are assembled into the rest of the street lighting fixture. Figure 8 shows the street lighting fixture after the housing body 104, housing cover 702, and O-ring have been assembled.

[0067] Figure 9 shows the fifth step in manufacturing a road lighting fixture. The fifth step includes adding a mounting bracket 902 to the road lighting fixture so that it can be mounted, for example, on a pole near a road.

[0068] Figure 10 shows an exploded view of a street lighting fixture, illustrating all the components mentioned above.

[0069] The assembly method described above involves five steps. However, there is no reason why these steps must be performed in the exact order provided. For example, some of the components added in the third step may be attached to the main circuit board 102 before the main circuit board 102 is attached to the housing body 104.

[0070] The robotic arm manufactures / assembles the road lighting fixture according to manufacturing instructions. These instructions may be provided to a processor / controller configured to instruct the robotic arm to carry out the manufacturing instructions.

[0071] Those skilled in the art will be able to readily develop a controller to perform any of the methods described herein. The controller can be implemented in various ways using software and / or hardware to perform the various functions required. “Processor” is an example of a controller employing one or more microprocessors, which may be programmed using software (e.g., microcode) to perform the required functions. The controller may be implemented with or without a processor, or as a combination of dedicated hardware for performing some functions and a processor (e.g., one or more programmed microprocessors and associated circuitry) for performing other functions.

[0072] Examples of controller components that may be used in various embodiments of this disclosure include, but are not limited to, conventional microprocessors, application-specific integrated circuits (ASICs), and field-programmable gate arrays (FPGAs).

[0073] In various implementations, a processor or controller may be associated with one or more storage media, such as volatile and non-volatile computer memory, including RAM, PROM, EPROM, and EEPROM. The storage media may be encoded with one or more programs that, when executed on one or more processors and / or controllers, perform the required functions. These storage media may be fixed within the processor or controller, or they may be portable so that one or more programs stored on them can be loaded into the processor or controller.

[0074] By examining the drawings, this disclosure, and the appended claims, modifications to the disclosed embodiments can be understood by those skilled in the art and can be implemented in carrying out the claimed invention. In the claims, the word “comprising” does not exclude other components or steps, and the indefinite article “a” or “an” does not exclude plural.

[0075] The mere fact that certain means are enumerated in different dependent claims does not indicate that combinations of these means cannot be used advantageously.

[0076] Note that when the term "adapted to" is used in the claims or specification, it is intended to be equivalent to the term "configured to." Note that when the term "arrangement" is used in the claims or specification, it is intended to be equivalent to the term "system," and vice versa.

[0077] No reference numeral in the claims should be construed as limiting the scope.

Claims

1. Outer housing and The main circuit board is mounted inside the outer housing, A lighting fixture driver mounted on the main circuit board, A light source attached to the outer housing from the outside of the outer housing, To make an electrical connection between the lighting fixture driver and the main circuit board, a pluggable connector is provided which is plugged into the lighting fixture driver and the main circuit board, Lighting fixtures including, A lighting fixture comprising a light source including a first push-fit connector portion extending into the outer housing, and a main circuit board including a second push-fit connector portion that engages with the first push-fit connector portion and provides an electrical connection between the main circuit board and the light source when the main circuit board, the outer housing, and the light source are assembled.

2. The lighting fixture according to claim 1, wherein the first push-fit connector portion includes one or more pins, and the second push-fit connector portion includes a socket.

3. The lighting fixture according to claim 1 or 2, wherein the main circuit board is mounted on a first surface inside the outer housing, and the light source is mounted on a second surface outside the outer housing.

4. The lighting fixture according to claim 1 or 2, further comprising a motion sensor within the outer housing, the motion sensor being connected to the main circuit board, and the motion sensor being configured to sense motion outside the outer housing.

5. The lighting fixture according to claim 1 or 2, further comprising a wireless signal receiver mounted on the main circuit board, and a pluggable connector plugged into the wireless signal receiver and the main circuit board for making an electrical connection between the wireless signal receiver and the main circuit board.

6. The lighting fixture according to claim 1 or 2, wherein the outer housing includes a housing body and a housing cover, and the main circuit board is mounted on the housing body.

7. A lighting fixture according to claim 1 or 2, which is a road lighting fixture.

8. A method for manufacturing lighting fixtures, the method is The main circuit board is placed inside the outer housing, Positioning the lighting fixture driver on the main circuit board before or after placing the main circuit board inside the outer housing, The light source is attached to the outer housing from the outside of the outer housing, This includes controlling a robotic arm to follow manufacturing instructions, The method of mounting the light source involves providing an electrical connection between the light source and the main circuit board by a push-fit connection between a first push-fit connector portion of the light source extending into the outer housing and a second push-fit connector portion of the main circuit board.

9. The method according to claim 8, wherein the main circuit board is mounted on a first surface inside the outer housing, and the light source is mounted on a second surface outside the outer housing.

10. The aforementioned manufacturing instructions are: After placing the main circuit board inside the outer housing, the lighting fixture driver is attached to the main circuit board. A pluggable connector is applied to electrically connect the aforementioned lighting fixture driver to the main circuit board, The method according to claim 8 or 9, including the method described in claim 8 or 9.

11. The aforementioned manufacturing instructions further, The motion sensor is placed inside the outer housing, and the motion sensor is configured to sense motion outside the outer housing. A pluggable connector is applied to electrically connect the motion sensor to the main circuit board, The method according to claim 8 or 9, including the method described in claim 8 or 9.

12. The aforementioned manufacturing instructions further, The wireless receiver is placed inside the outer housing, A pluggable connector is applied to electrically connect the wireless receiver to the main circuit board, The method according to claim 8 or 9, including the method described in claim 8 or 9.

13. The method according to claim 8 or 9, wherein the positioning of the lighting fixture driver on the main circuit board, the positioning of the main circuit board within the outer housing, and the mounting of the light source to the outer housing each include the arrangement of components along two opposing directions perpendicular to the main circuit board.

14. A computer program including computer program code means, wherein the computer program code means is adapted to carry out the method described in claim 8 or 9 when the computer program is executed on the computer of a robot arm controller.

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