Optic Carrier for Luminaire Alignment
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Solution Overview
Problem
The existing methods for attaching optics to LED lighting arrays are complex and time-consuming, requiring multiple steps and precise alignment, which can lead to errors and inefficiencies in the production of lighting panels with desired light distribution curves.
Innovation Solution
A carrier with a fastening structure and holding structure that allows for efficient and precise alignment and attachment of optics to a luminaire field, enabling temporary holding during transport and secure fastening during assembly, using a one-way barrier and clamping device for secure positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If optics are individually attached to ceiling elements or panels from the outside through openings, then precise alignment with LEDs can be achieved, but the manufacturing process becomes complex and time-consuming
Solution Approach 1:
The invention divides the attachment process into two independent stages: first, optics are attached to a carrier in a preliminary alignment step; second, the entire carrier-optics assembly is mounted to the ceiling panel in a final positioning step. This segmentation eliminates the need for complex real-time alignment during final installation, reducing manufacturing complexity while maintaining alignment precision.
Solution Approach 2:
The carrier serves as a preliminary mounting platform where optics are pre-attached and pre-aligned with LEDs before the final ceiling panel installation. This preliminary action allows alignment to be performed under controlled conditions, simplifying the final mounting process and reducing on-site adjustment requirements.
2Reliability
If optics are individually unpacked and attached through openings, then secure fastening can be achieved, but the number of manufacturing steps increases
Solution Approach 1:
The invention merges multiple individual attachment operations into a single integrated process. Instead of attaching each optic separately to the ceiling panel, all optics are first attached to the carrier as a group, and then the entire assembly is mounted in one operation. This merging reduces the number of manufacturing steps while maintaining secure fastening through the carrier's fastening structure.
Solution Approach 2:
The carrier acts as an intermediary component between the optics and the ceiling panel. It provides a standardized interface for attaching multiple optics and simplifies the connection to the ceiling panel, reducing the number of individual fastening operations required while ensuring reliable attachment.
3Manufacturing precision
If real-time alignment is performed during mounting, then precise light distribution can be achieved, but the process becomes error-prone and time-consuming
Solution Approach 1:
Alignment is performed in advance during the preliminary attachment of optics to the carrier, under controlled manufacturing conditions. This preliminary alignment eliminates the need for time-consuming real-time adjustment during ceiling panel installation, reducing both errors and mounting time while maintaining alignment accuracy.
Solution Approach 2:
The carrier design incorporates features that enable self-alignment or automatic positioning of optics relative to LEDs. The structured carrier provides reference surfaces and positioning mechanisms that guide correct alignment without requiring complex manual adjustment or real-time measurement during final installation.
Data Source
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AI summary
A carrier (1) for a set of optics, each intended to cover a point light source of a luminaire array, comprises a mounting structure (3) for attaching at least one optic adjacent to one of the point light sources of the luminaire array to a base element of the luminaire array. The carrier (1) further comprises a holding structure (4) for holding the at least one optic in a position oriented for mounting the at least one optic on the base element of the luminaire array. The carrier (1) according to the invention enables efficient and precise assembly of the set of optics in a relatively small number of steps and the use of a relatively small number of components and transport parts. This, in particular, enables efficient and precise manufacturing of the luminaire array.