Modular Luminaire Assembly with Information Key System
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Solution Overview
Problem
The manufacturing process of luminaires with different lighting effects is complex due to the need for precise assembly of light emitting members at specific mounting locations to achieve desired lighting patterns, which affects manufacturing speed and accuracy.
Innovation Solution
A method and apparatus that utilize modular components, including light guides, light emitting members, and base members with distinct mounting locations and labels, along with an information key to facilitate easy configuration and assembly, allowing for multiple lighting patterns by varying the combination and placement of these components based on predetermined information.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If precise assembly of light emitting members at specific mounting locations is performed to achieve desired lighting patterns, then manufacturing precision is improved, but manufacturing speed decreases
Solution Approach 1:
The luminaire is divided into modular components: a base member with multiple mounting locations, interchangeable light emitting members, and an information key system. This segmentation allows for standardized assembly procedures where light emitting members can be quickly swapped between predefined locations without requiring complex alignment or measurement processes, thus improving both precision and speed.
Solution Approach 2:
The base member is pre-configured with multiple mounting locations and associated information key indicators before assembly. The information key system pre-identifies which light emitting members correspond to which mounting locations for desired lighting patterns. This preliminary preparation eliminates the need for real-time decision-making during assembly, allowing workers to simply follow pre-determined configurations and significantly increase manufacturing speed while maintaining precision.
2Adaptability or versatility
If multiple lighting patterns are produced by varying combinations of components, then adaptability is improved, but device complexity increases
Solution Approach 1:
The base member serves multiple functions: it provides structural support, defines multiple mounting locations, and incorporates information key indicators that guide the selection of light emitting members for different lighting patterns. The information key system acts as a universal guide that simplifies the selection process regardless of which lighting pattern is desired, allowing a single base member design to support multiple lighting configurations without increasing overall system complexity.
Solution Approach 2:
Instead of creating custom assembly procedures for each lighting pattern, the patent uses an information key system that copies and communicates the correct light emitting member selections for each pattern. The information key indicators on the base member serve as templates or copies of the desired configuration, allowing workers to replicate the correct assembly without needing to understand or memorize the complexity of each lighting pattern's component arrangement.
3Ease of manufacture
If standardized modular components are used to facilitate easy configuration, then ease of manufacture is improved, but manufacturing precision may be compromised
Solution Approach 1:
The mounting locations on the base member are designed with asymmetric features or distinct identifiers corresponding to specific light emitting members. The information key indicators provide asymmetric guidance that distinguishes between different mounting positions. This asymmetry ensures that even though the components are modular and easy to handle, the precision of mounting location accuracy is maintained through distinctive, non-interchangeable positioning features that guide correct placement.
Data Source
AI summary
Example embodiments include modular lighting fixtures and methods for forming the same. Some include light emitters and base members with mounting locations for the light emitters, the light emitters and base members being combinable in varying combinations with each combination producing a different lighting effect. Some embodiments include a light guide, such as a planar light guide, that receives and redirects light from the light emitters. Additional embodiments include a reflector with portions that are positioned near a mounting location where no light emitter is mounted when the reflector is mounted to a base member. Further embodiments include a reflector with portions that are positioned near the mounting locations when mounted to a base member, the portions being easily removed, such as with an unpowered hand tool, to avoid interference with a light emitting member mounted adjacent to where the removable portion would be if not removed from the reflector.