Modular LED Lamp System with Interchangeable Driver Mounts
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Solution Overview
Problem
Traditional lighting systems, such as fluorescent lamps, face challenges in transitioning to LED technology, particularly in terms of modular and flexible manufacturing processes that allow for rapid customization and assembly of LED lamp systems with varying specifications like voltage and lighting color.
Innovation Solution
A modular LED lamp system featuring a cover with snap connections, a circuit board with slot-shaped driver mounts, and interchangeable electrical connectors, enabling rapid assembly and customization by allowing the driver to be mounted on either side, facilitating quick manufacturing and mixing of components to meet different customer requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional fluorescent lamp manufacturing methods are used, then manufacturing processes are established and reliable, but manufacturing flexibility and customization capability are limited
Solution Approach 1:
The LED lamp system is divided into modular components including a driver module, LED array module, and interchangeable end caps. Each module can be independently manufactured and then assembled through snap-fit connections, enabling flexible customization without complex manufacturing processes. The driver module can be mounted in different positions (left or right side) depending on customer requirements.
Solution Approach 2:
The end caps are designed with universal mounting features that allow them to be used with different driver module configurations. The snap-fit connection system provides a universal interface that works across various lamp specifications, allowing the same basic structure to accommodate different voltages, colors, and driver positions through simple component interchangeability.
2Adaptability or versatility
If custom LED lamp systems are manufactured for each customer requirement, then customer needs are met precisely, but manufacturing time increases
Solution Approach 1:
Different end cap variations and driver module configurations are pre-manufactured and stored as inventory items. When an order comes in, the appropriate pre-manufactured components are simply assembled together using snap-fit connections rather than manufacturing everything from scratch. This allows rapid fulfillment of custom orders while maintaining high production efficiency.
Solution Approach 2:
The lamp system is segmented into independently manufacturable modules that can be produced in advance and stored. The driver module, LED array, and end caps can each be manufactured separately and then quickly assembled, enabling both customization and rapid production without compromising either goal.
3Adaptability or versatility
If driver mounting locations are fixed, then manufacturing process is simple, but adaptability to different configurations is reduced
Solution Approach 1:
The end caps are designed with asymmetric mounting features that accommodate driver modules mounted on either the left or right side of the lamp. The snap-fit connection points are positioned to work with both left-sided and right-sided driver configurations, providing flexibility without requiring completely different end cap designs for each configuration.
Data Source
AI summary
A modular LED lamp system has a cover. A driver is mounted to either a first driver mount or a second driver mounting area. An LED array is mounted to a circuit board, and the circuit board includes a first driver mount. The system has a left electrical connector, and a right electrical connector. The second driver mount is formed on the left electrical connector or is formed on the right electrical connector. The driver can be mounted to either the first driver mount or the second driver mount. The cover can be either plastic or glass. The LED array mounted to a circuit board is elongated. The first driver mount and the second driver mount are slot shaped.