Linear Rail Node Lighting System for Warehouse Aisle Illumination
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Solution Overview
Problem
Current lighting solutions for warehouse storage racks, such as linear fluorescent lamps and high-intensity discharge (HID) light sources, face inefficiencies in light delivery and uniformity, leading to brighter tops and dimmer bottoms, as well as glare and shadow issues due to their size and spacing.
Innovation Solution
A linear rail and node lighting system with discreet light sources and elongated optical elements tailored for aisle and shelf applications, incorporating control, sensing, and communication circuitry, allowing for localized control and power sharing between nodes to optimize photometric distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If linear fluorescent lamps are mounted end to end, then uniform illumination along the aisle is achieved, but light delivery efficiency decreases and top to bottom uniformity on racks deteriorates
Solution Approach 1:
The linear fluorescent lamp is divided into multiple discrete LED modules arranged in a line. Each module contains one or more LEDs with associated optics, allowing the light source to be segmented into controllable units that can be individually optimized for directionality and efficiency while maintaining continuous linear illumination coverage.
Solution Approach 2:
The patent replaces the linear fluorescent lamp system with an LED-based linear light fixture. LEDs provide more directional light output and higher efficiency compared to fluorescent lamps, while the linear arrangement of multiple LED modules maintains the uniform illumination along the aisle that fluorescent lamps provided.
2Power
If HID light sources are used, then high lumen output is achieved with fewer lamps, but glare increases and shadow formation becomes stronger
Solution Approach 1:
The single HID lamp is replaced by multiple discrete LED modules distributed along a linear fixture. This segmentation allows the total lumen output to be achieved through distributed sources rather than a single intense point source, reducing glare while maintaining overall illumination levels.
Solution Approach 2:
Each LED module is equipped with specific optics (lenses or reflectors) tailored to its position in the linear array. This allows local optimization of light distribution patterns, directing light appropriately to achieve uniform rack illumination while minimizing glare in specific viewing directions, unlike the uniform omnidirectional output of HID lamps.
3Ease of manufacture
If HID fixtures are spaced distant apart, then material use and installation cost decrease, but illuminance uniformity along racks deteriorates
Solution Approach 1:
The linear light fixture consists of multiple discrete LED modules that can be independently optimized. This segmentation allows each module to contribute to uniform illumination along the rack, enabling greater spacing between fixtures while maintaining uniformity, as each module acts as a distributed light source along the linear path.
4Reliability
If fluorescent lamps are used in highbay fixtures, then lumen maintenance and color quality improve, but optical control capability decreases leading to poor illuminance uniformity
Solution Approach 1:
The fluorescent lamp is replaced by multiple discrete LED modules, each capable of having its own optics. This segmentation restores optical control capability by allowing individual modules to be equipped with lenses or reflectors that direct light precisely, overcoming the inherent lack of optical control in fluorescent highbay fixtures.
Solution Approach 2:
Each LED module can be equipped with position-specific optics tailored to its location in the linear array. This allows local optimization of light distribution to achieve uniform rack illumination, providing the adaptability and optical control that fluorescent lamps lacked while maintaining the reliability benefits of modern LED technology.
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 system provides improved light uniformity and reduced glare by tailoring the photometric distribution along racks, enhancing energy efficiency and reducing maintenance through localized control and intelligent node communication.
Implementation Method 1
Each module may include one or more light emitting diodes (LEDs) and an optical element
Implementation Method 2
The optical element can be any suitable type including, but not limited to, a lens, reflector, or diffuser
Data Source
AI summary
Embodiments of the invention provide for a lighting system for illuminating aisles with shelving. A rail can include a plurality of LEDs that extend along the length of the rail. The rail can be coupled with a node that includes various components along with an egress light source. The LEDs can be used to primarily illuminate the shelving on both or one side of the aisle. The egress light can be used to illuminate the aisle during times of emergency, at night, or when egress may be required.