Extended Knuckle and Snout Retrofit for LED Fixture Aiming
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Solution Overview
Problem
Specialized lighting systems, such as those used for sports fields, airports, and railroads, face challenges in retrofitting with LED lights due to disparate power requirements, non-standard bulb shapes and sizes, and structural incompatibilities, leading to issues like photometric and physical interference, glare control loss, and structural weakening.
Innovation Solution
The system employs an extended knuckle and snout to space lighting fixtures away from structures, an aiming device for precise positioning, and self-contained ballast driver assemblies to adapt power, allowing LED fixtures to be installed without modifying the existing crossarms, thus preserving the lighting system's integrity and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If one-for-one replacement approach is used with existing crossarms, then installation cost is reduced, but lighting uniformity deteriorates due to restricted aiming range and dark spots
Solution Approach 1:
The patent introduces a new spatial dimension by extending the knuckle length to position the LED fixture away from the crossarm structure. This dimensional change allows the fixture to be located in a position where it does not create dark spots or restrict aiming, while still being mounted on the existing crossarm without requiring structural modifications.
2Ease of operation
If existing crossarms are drilled to accommodate retrofit fixtures, then fixture installation is enabled, but crossarm strength deteriorates and corrosion risk increases
Solution Approach 1:
The patent uses pre-drilled holes that were originally created during crossarm manufacturing for structural purposes (such as for guy wires or other mounting). By utilizing these existing holes, the retrofit process avoids creating new holes that would compromise crossarm strength, while still enabling secure fixture installation through the extended knuckle mechanism.
3Area of stationary object
If LED fixtures are positioned close to existing structures, then installation space is minimized, but photometric interference and glare control are compromised
Solution Approach 1:
The extended knuckle acts as an intermediary element between the crossarm structure and the LED fixture. It provides the necessary spacing to eliminate photometric interference and glare issues while maintaining a compact overall installation footprint. The knuckle's extension creates optimal distance without requiring additional support structures or occupying excessive space.
4Device complexity
If standard knuckle length is used, then device complexity is minimized, but aiming precision and fixture positioning are insufficient
Solution Approach 1:
The patent modifies the knuckle length parameter from a standard fixed length to an extended custom length. This parameter change enables precise positioning of the LED fixture to achieve optimal aiming angles and eliminate dark spots, while the overall device complexity remains low because it simply extends an existing component rather than introducing a completely new aiming mechanism.
Data Source
AI summary
An apparatus for retrofitting a HID lighting system with LED fixtures includes an aiming device for aiming the retrofit LED fixtures, a snout for spacing the retrofit LED fixtures away from a possibly interfering structure, and an extended knuckle for spacing the retrofit LED fixtures away from a possibly interfering structure.