Modular LED Line Light Liquid Cooling and Auto-ID
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Solution Overview
Problem
Current machine vision systems face challenges with LED line lights in terms of modular design, harsh environment durability, unique module identification, space constraints, and uniform illumination, particularly in applications requiring variable lengths and harsh conditions.
Innovation Solution
A modular LED line light system featuring U-shaped modules with external LED driver boards, liquid cooling, and a controller board that automatically assigns unique IDs to modules, along with a bus bar for power distribution and micro/macro lens arrays for collimated and uniform light output.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If a modular LED line light system is designed to be easily serviceable with replaceable modules, then ease of repair is improved, but device complexity increases due to the need for module identification and automatic configuration systems
Solution Approach 1:
The system implements automatic module identification and configuration where the controller board automatically detects and assigns unique IDs to modules when they are connected to the bus bar, eliminating the need for manual configuration and reducing the complexity burden on users
Solution Approach 2:
The patent replaces manual mechanical identification methods with an electronic detection system where the controller board automatically detects modules through electrical connections on the bus bar, substituting mechanical configuration with electronic self-identification
2Adaptability or versatility
If the line light is designed to be configurable to varying lengths to meet different OEM requirements, then adaptability is improved, but device complexity increases due to modular assembly requirements
Solution Approach 1:
The line light system is divided into discrete modular segments that can be independently manufactured and then assembled in various configurations to meet different length requirements, with each module containing standardized components including LED arrays, driver boards, and connection interfaces
Solution Approach 2:
The patent creates universal module designs with standardized interfaces and mounting mechanisms that can be used across different applications and configurations, allowing the same basic module type to serve multiple purposes and reducing the need for application-specific customizations
3Reliability
If liquid cooling is implemented to remove heat from LED modules in harsh environments, then reliability is improved, but device complexity increases due to cooling system integration
Solution Approach 1:
The patent implements liquid cooling systems that circulate coolant through channels in the module housing and heat sinks to efficiently remove heat from LED arrays and driver electronics, enabling reliable operation in harsh thermal environments
Solution Approach 2:
The cooling system is integrated into the module structure itself, with cooling channels formed as part of the housing and heat dissipation features built into the mounting interfaces, combining thermal management functions with structural components rather than adding separate cooling apparatus
4Ease of repair
If external LED driver boards are used to simplify module replacement, then ease of repair is improved, but space requirements increase due to additional external components
Solution Approach 1:
The patent positions driver boards on external surfaces of modules rather than embedding them within the internal volume, allowing easy access for replacement while utilizing the external dimensional space efficiently
Solution Approach 2:
The module housing is designed as a thin-walled structure that provides mechanical protection while minimizing space consumption, allowing external driver boards to be mounted on the exterior surfaces without significantly increasing the overall module footprint
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
Enables easy serviceability, uniform illumination across varying lengths, and efficient operation in harsh environments with automatic module identification and reduced space requirements, ensuring reliable performance in machine vision applications.
Implementation Method 1
a cooling tube for receiving a cooling fluid for removing heat from the at least one line light module
Implementation Method 2
a cooling tube for receiving a cooling fluid for removing heat from the at least one line light module
Implementation Method 3
at least one micro lens array for receiving the optical output of the at least one LED array; and a macro lens for receiving the optical output of the at least one micro lens array
Data Source
AI summary
A modular LED line light, the modular LED line light comprising: at least one line light module, the at least one line light module comprising: a U-shaped body comprising a base and two opposing side walls extending from the base, the base comprising an interior surface and an exterior surface; at least one LED array disposed on the interior surface of the U-shaped body; a rail for receiving the at least one line light module, the rail comprising a first surface and a second surface, wherein the first surface is configured to receive the exterior surface of the base of the U-shaped body of the at least one light module; and a cooling tube for receiving a cooling fluid for removing heat from the at least one line light module, the cooling tube being disposed between the exterior surface of the base of the U-shaped body and the first surface of the rail.