Waterproof LED Whip Light Assembly with Modular Base
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Solution Overview
Problem
The existing 1156 light fixtures for warning whips are prone to connection failures under severe vibration and impact forces, leading to reliability issues despite additional connection features like sleeves and set screws.
Innovation Solution
A waterproof LED whip light assembly with a base and LED light assembly, featuring a programmable controller, ambient light sensor, and a lens with a liquid-tight connection, which includes a plurality of LED lights with optics providing a limited light angle, and a plug power connector for improved reliability and ease of replacement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If 1156 light fixture with bulb and socket is used, then the light can be provided, but the connection is susceptible to failure under severe vibration and impact forces
Solution Approach 1:
The light assembly is divided into modular components: a base that mounts to the whip rod, an LED circuit board with mounted LEDs, and a lens assembly. This segmentation allows each component to be optimized independently and facilitates replacement if damage occurs during vibration or impact events.
Solution Approach 2:
The base, LED circuit board, and lens are combined into a single integrated assembly that mounts as one unit to the whip rod. This merging provides structural stability and ensures all light-emitting components remain properly positioned and connected during severe vibration and impact forces.
2Reliability
If additional connection features like sleeves and set screws are added, then the connection security is improved, but the device complexity increases
Solution Approach 1:
The base integrates multiple functions into a single component: it provides structural mounting to the whip rod, electrical connections to the LED circuit board, and mechanical support for the lens assembly. This eliminates the need for separate sleeves and set screws while maintaining connection security.
Solution Approach 2:
The base serves multiple purposes simultaneously: it is the mounting structure for the entire assembly, the electrical connection point for power and ground wires, and the support structure for both the LED circuit board and lens. This multi-functionality reduces overall device complexity.
3Ease of repair
If the LED light assembly is made replaceable, then the ease of repair is improved, but the connection complexity increases
Solution Approach 1:
The LED light assembly is designed as a distinct, separable module that can be removed and replaced independently from the base and lens. This segmentation enables easy repair by allowing users to swap out the entire LED assembly as a single unit without disassembling other components.
Solution Approach 2:
The base provides a standardized mounting interface with uniform electrical and mechanical connection points. This standardized interface simplifies the replacement process by ensuring that any compatible LED assembly will connect in the same way, reducing the complexity of the connection mechanism.
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
The solution enhances the reliability of the warning whip light connection by providing a secure, waterproof, and adjustable LED light system that can withstand vibrations and impacts, with controlled light intensity and on/off functionality based on ambient conditions.
Implementation Method 1
The LED light assembly is mounted to the base and includes a plurality of LED lights
Implementation Method 2
The plurality of LED lights may include optics providing a limited light angle in at least the vertical direction
Data Source
AI summary
A light emitting diode (LED) whip light assembly includes a base and an LED light assembly. The base is configured to mount to an elongate whip rod. The LED light assembly is mounted to the base and includes a plurality of LED lights, an LED circuit, and a lens. The LED circuit includes a circuit board to which the plurality of LED lights are mounted. The lens is mounted to the base with a releasable, liquid-tight connection and covers the plurality of LED lights.