Aircraft Light Optics Support Board for Multi-Height LED Alignment
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Solution Overview
Problem
Aircraft lights face challenges due to light source obsolescence, requiring time-consuming redesigns and re-certifications when LED types change, as optical elements need realignment with new light sources, prolonging production cycles.
Innovation Solution
An optics support system with a multi-layer support board and dual sets of leg stands at different heights allows flexible adjustment of optical elements to accommodate various LED types without redesign, ensuring optimal light output.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the optical element is fixed at a specific height for a particular LED type, then the light output is optimized for that LED, but the aircraft light cannot accommodate different LED types without redesign
Solution Approach 1:
The support board is segmented into multiple height levels with distinct sets of leg stands (first set at first height, second set at second height). Each height level corresponds to specific LED types, allowing the optical element to be positioned at the appropriate height for each LED variant without requiring a complete redesign of the support structure.
Solution Approach 2:
The optics support system is designed with multi-functionality to accommodate multiple LED types (first LED type, second LED type, third LED type) using the same support board structure. By providing multiple height levels with corresponding leg stands, a single support board serves universal purposes across different LED generations, eliminating the need for separate support boards for each LED type.
2Productivity
If the aircraft light design is adapted for each new LED type, then optimal light output is achieved, but production time and certification processes are prolonged
Solution Approach 1:
Multiple sets of leg stands at different heights are pre-configured on the support board during manufacturing. This preliminary arrangement of support structures at various height levels ensures that when different LED types are installed, the optical element can be immediately positioned at the correct height without requiring additional alignment adjustments or redesign, thus maintaining manufacturing precision while accelerating production.
Solution Approach 2:
The support board provides dynamic adaptability through its multi-level leg stand configuration, allowing the system to adjust to different LED types without physical modification. The optical element can be dynamically repositioned between different height levels by selecting the appropriate leg stand set, enabling rapid adaptation to new LED technologies while maintaining precise alignment.
3Adaptability or versatility
If a single height level is used for the optical element, then the structure is simple, but LEDs of different types cannot be accommodated
Solution Approach 1:
Different regions of the support board are assigned different height levels with corresponding leg stands (first height for first LED type, second height for second LED type). This local differentiation of height levels allows the support board to provide customized support for each LED type in its appropriate region, achieving high adaptability while keeping each local section relatively simple and manageable.
Data Source
AI summary
An optics support system for an aircraft light comprises: a multi-layer support board, having a main plane of extension; an LED arranged on the multi-layer support board; a first set of leg stands, positioned around the LED, wherein the first set of leg stands provides first abutment surfaces for arranging an optical element, having a corresponding set of legs, over the LED in a first orientation; and a second set of leg stands, positioned around the LED. The second set of leg stands provides second abutment surfaces for arranging the optical element over the LED in a second orientation; and the first abutment surfaces and the second abutment surfaces are at different heights in a z-dimension of the multi-layer support board, orthogonal to the main plane of extension.