Modular Luminaire Assembly with Interchangeable Sections
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing light fixtures, particularly area lights, lack flexibility in adjusting light output and configuration to meet varying lighting needs, as they are often fixed in size and design, limiting their adaptability for different applications and environments.
Innovation Solution
A modular luminaire assembly method using interchangeable housing sections with removably connected rear, middle, and front sections, allowing for adjustable light output and configuration by selectively connecting these sections and aligning conduits for light emitter assemblies and control components, enabling customization of light output in increments of 5 k lumens.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If fixed-size housing sections are used in light fixtures, then manufacturing and installation are simplified, but adaptability to different lighting requirements is reduced
Solution Approach 1:
The housing is divided into multiple interchangeable sections (first housing section, second housing section, third housing section) that can be selectively assembled. Each section contains specific components (light emitters, controls, conduit connections), allowing the system to be configured in different combinations to meet varying lighting requirements while maintaining standardized manufacturing processes for each module.
Solution Approach 2:
The housing sections are designed with universal connection features including standardized conduit conduit alignments, mounting features, and interconnection mechanisms. This allows the same basic sections to serve multiple functions and be assembled in different configurations for various lighting applications, from simple to complex arrangements.
2Adaptability or versatility
If modular housing sections with removable connections are used, then adaptability and customization are improved, but assembly complexity and installation time increase
Solution Approach 1:
By pre-assembling complete functional modules (housing sections with integrated light emitters, controls, and conduit connections), the system enables rapid deployment. Each section is a self-contained unit that can be manufactured, tested, and certified independently, then quickly installed by simply connecting the sections together using the standardized interconnection mechanisms.
Solution Approach 2:
The housing sections are pre-configured with all necessary components (light emitters, control systems, conduit alignments) during manufacturing. This preliminary assembly and testing of modular units eliminates the need for complex on-site configuration and reduces installation time, as the sections arrive ready-to-install in their final configured state.
3Manufacturing precision
If standardized conduit alignments are used across housing sections, then manufacturing precision is improved, but flexibility in conductor routing is reduced
Solution Approach 1:
The conduit conduit is designed with a universal alignment system that maintains precise positioning across all housing sections while incorporating flexible routing capabilities. The conduit can be configured to accommodate different conductor arrangements and connection points within the standardized framework, allowing the same precision-machined interface to serve multiple routing configurations.
Data Source
AI summary
A method of assembling a luminaire includes providing a housing rear section, a first housing middle section, and a housing front section. The housing rear section includes a control component. The first housing middle section is configured to removably connect to the housing rear section. The first housing middle section has a first light emitter. The housing front section is configured to removably connect to the first housing middle section and removably connect to the housing rear section. The housing front section has a second light emitter. The method further includes selectively connecting the housing front section to the housing rear section or connecting the first housing middle section to the housing rear section and the housing front section to adjust the light output of the assembled luminaire.