Integrated LED Lighting Housing for Rig Masts
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current LED lighting systems for elevated structures, such as drilling and service rigs, face challenges due to high weight-to-lumen ratios, which can cause mast bending or breaking during lifting and require additional equipment for installation and removal, limiting their adoption due to increased costs and logistical barriers.
Innovation Solution
The development of an LED lighting system with a weight-to-lumen ratio of less than 0.55 g/lumen, achieved through a combination of air flow conduits for cooling and structural support, integrated heat transfer, and a control system to manage temperature and power, allowing for permanent or semi-permanent mounting on rigs and reducing the need for separate installation and removal processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If traditional LED lighting systems with separate heat sinks and mounting brackets are used, then adequate heat dissipation and structural support are achieved, but the weight-to-lumen ratio increases significantly
Solution Approach 1:
The patent combines the heat sink, mounting bracket, and support structure into a single integrated extruded aluminum housing. This merging of components eliminates the need for separate heat dissipation and support elements, reducing overall weight while maintaining both thermal management and structural functions. The extruded housing serves multiple purposes: it provides mechanical support, dissipates heat through integrated fins, and attaches directly to the mast structure.
2Illumination intensity
If heavy LED lighting systems are mounted on elevated structures, then adequate light output is achieved, but the structures require reinforcement and installation becomes complex
Solution Approach 1:
The lighting system is divided into modular LED lamp assemblies that can be independently configured and mounted on the extruded housing. Each module contains LEDs, reflectors, and integrated heat dissipation elements. This segmentation allows for flexible arrangement to achieve desired light output while simplifying installation and maintenance, as individual modules can be replaced without affecting the entire system.
Solution Approach 2:
The extruded aluminum housing serves multiple functions simultaneously: it acts as the structural mounting bracket, provides heat sinking through integrated fins, serves as the protective enclosure, and offers attachment points for multiple LED modules. This multi-functionality reduces the number of separate components needed, simplifying both the overall system design and installation process while maintaining high light output capability.
3Reliability
If LED lighting systems are designed for permanent mounting, then installation stability is improved, but removal and transport become problematic
Solution Approach 1:
The mounting system incorporates adjustable and removable connection mechanisms between the extruded housing and the mast structure. The design allows for secure permanent installation during operation through robust attachment points, while also enabling relatively easy removal and reconfiguration when needed. The modular nature of the system permits disassembly and transport without damaging components, bridging the gap between permanent stability and operational flexibility.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution significantly reduces the weight and installation costs of LED lighting systems while maintaining effective heat dissipation and light output, enabling safer and more efficient deployment on elevated structures with reduced logistical burdens.
Implementation Method 1
an air flow system having at least one air flow conduit (AFC) for directing air flow against each LED lamp assembly to effect cooling of the LED lamps
Implementation Method 2
a lamp assembly housing having a plurality of surfaces for effecting heat transfer of heat from the LED lamps away from the LED lamps
Data Source
AI summary
The invention relates to lightweight LED lighting systems for permanent and semi-permanent mounting on elevated structures, the lighting systems having integrated support and thermal transfer features. The systems are particularly suited for elevated mast systems and specifically for mast systems that are repeatedly lifted and lowered such as drilling and service rig masts. Specifically, the invention improves a) the weight/lumen ratios of LED lamp assemblies and LED lighting systems, b) the net added weight of LED lighting systems, c) the footprint of LED light systems and/or d) obviates the need for removing LED lighting systems or their sub-assemblies when transporting mast systems.