Modular Power Track and Plug System for Adaptable Shelving Lighting
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Solution Overview
Problem
Current modular power and connector systems for LED lighting, particularly in shelving units, lack standardization and adaptability, leading to installation difficulties and inefficiencies due to varying shelving unit configurations and spacings.
Innovation Solution
A modular power and connector system featuring a power track with resilient side portions and a complementary power plug with vertically-offset prongs, allowing for flexible insertion and connection of light bars and power tracks, along with frangible portions for cable exit points, enabling adaptable and scalable power distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a standardized power connector system is implemented, then ease of installation and manufacturing are improved, but adaptability to various shelving unit configurations deteriorates
Solution Approach 1:
The power plug incorporates a resilient side portion that can deflect elastically to accommodate variations in opening spacing between different shelving unit uprights. This dynamic flexibility allows a standardized plug design to adapt to multiple configurations without requiring custom connectors for each shelving unit type.
Solution Approach 2:
The system allows for adjustment of the spacing between contact prongs on the power plug to match different opening spacings in shelving units. By changing this geometric parameter, the same basic connector design can be adapted to various shelving configurations while maintaining manufacturing standardization.
2Adaptability or versatility
If resilient side portions are added to the power track, then adaptability to different openings is improved, but device complexity increases
Solution Approach 1:
The power track incorporates resilient side portions made from elastic materials that can deflect and return to their original position. These flexible elements provide the necessary adaptability to different opening configurations without requiring complex mechanical adjustment mechanisms, thereby limiting the increase in device complexity.
3Ease of operation
If vertically-offset prongs with horizontal contact offset are used, then ease of operation and adaptability are improved, but manufacturing precision requirements increase
Solution Approach 1:
The resilient side portion acts as a compliance mechanism that absorbs positioning tolerances and variations in opening spacing. This dynamic element compensates for manufacturing variations in the horizontally offset contact points, allowing easier operation without requiring extremely tight manufacturing precision.
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 a modular, easy-to-install, and adaptable power solution for LED lighting in shelving units, accommodating various shelving configurations and spacings, ensuring robust and flexible power distribution to multiple light bars.
Implementation Method 1
Two side portions are connected to the central portion resiliently, such that they can deflect slightly inwardly
Data Source
AI summary
A modular lighting system for use with shelving and a variety of other applications. A power track is adapted to be disposed within an upright support of a shelving unit. A power plug with vertically-aligned prongs inserts through existing openings in the upright support to reach conductors within the power track. The power plug has connecting structure to connect to a cable, and frangible portions that allow the cable to exit in a number of positions. Light bars carry the same connecting structures, can connect to the cable and snap together to extend continuously across a shelf. A second power track and second plug may provide power to the power track within the upright. The second plug carries the same connecting structure as the other components.