Bus PCB Spring Contact Driver Mounting for Lighting Assembly
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Solution Overview
Problem
Traditional light fixture manufacturing is time-consuming and error-prone due to the manual routing and interconnection of individual wires, especially with the addition of digital controls and sensors, which require multiple electrical connections.
Innovation Solution
A lighting fixture system utilizing a bus printed circuit board with mechanical features and spring contacts for efficient power routing and driver mounting, along with a method for programming programmable drivers using configuration information to simplify assembly and reduce errors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If individual wires are routed and interconnected by hand, then the light fixture can be assembled with traditional methods, but the manufacturing process becomes time-consuming and error-prone
Solution Approach 1:
The invention segments the wiring system into modular components: a bus structure with multiple contact points and separate driver modules with corresponding connection elements. This segmentation allows parallel assembly of multiple drivers simultaneously rather than sequential wire routing, dramatically reducing manufacturing time while maintaining ease of assembly through standardized connection interfaces
Solution Approach 2:
The bus structure serves as an intermediary component that consolidates multiple electrical connections into a single modular interface. Instead of routing individual wires from power sources to each driver, the bus acts as a centralized distribution network that drivers connect to en masse, eliminating time-consuming individual wire routing while preserving assembly simplicity
2Ease of manufacture
If individual wires are routed and interconnected by hand, then the light fixture can be assembled with traditional methods, but the process becomes error-prone
Solution Approach 1:
By segmenting the connection system into standardized bus contacts and driver connection elements with precise geometric matching, the invention eliminates the variability and human error inherent in manual wire routing. Each driver connects to predetermined contacts through rigid mechanical interfaces, ensuring consistent and reliable electrical connections without the errors associated with hand-wiring
Solution Approach 2:
The invention replaces the flexible, error-prone mechanical process of manual wire routing and connection with rigid, precision-machined mechanical interfaces between the bus and drivers. These fixed geometric connections eliminate the variability of hand-wiring while maintaining ease of assembly through straightforward mechanical attachment
3Adaptability or versatility
If digital controls and sensors are added to light fixtures, then the functionality is enhanced, but the number of electrical connections increases and manufacturing difficulty increases
Solution Approach 1:
The bus structure is designed as a universal platform with multiple standardized contact points that can accommodate various driver types, control modules, and sensors through the same connection interface. This multi-functionality allows digital controls and sensors to be integrated without increasing connection complexity, as all components connect to the bus using the same modular approach
Solution Approach 2:
The invention segments the increasing number of electrical connections into standardized bus contacts and modular driver/connection elements. This segmentation allows multiple digital controls and sensors to be added by simply connecting additional modular units to the bus rather than creating complex individual wiring paths, thereby enhancing functionality without proportionally increasing manufacturing difficulty
Data Source
AI summary
A lighting fixture, including a bus printed circuit board that receives power from an external source, may be configured with programmable drivers. The bus printed circuit board has mechanical features for receiving the programmable drivers to mechanically mount the programmable driver to the bus printed circuit board. Each programmable driver may have a set of spring contacts positioned to engage exposed pads of the bus printed circuit board when the programmable driver is mounted to the bus printed circuit board, to supply power to the programmable driver. The lighting fixture further includes one or more light sources driven by the programmable drivers.