Photocell Module Assembly With Solderless Fixture Contacts
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Solution Overview
Problem
Current light sensor assemblies for outdoor lighting, such as street and parking lot lights, are time-consuming and labor-intensive to assemble due to the use of solder technology for connecting photocontrol printed circuit boards to light fixtures, which hinders automation.
Innovation Solution
A light sensor assembly featuring a base assembly with receptacle contacts that are removably connected to fixture contacts, using a photocell module with a control circuit board and a cover for environmental protection, allowing for easy assembly and automation by eliminating the need for soldering, with twist-lock power contacts for secure electrical connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If solder technology is used to connect fixture contacts to photocontrol printed circuit boards, then reliable electrical connections are achieved, but assembly time and labor intensity increase significantly
Solution Approach 1:
The patent replaces the soldering process (thermal/chemical joining) with a mechanical push-in connection system. The receptacle contacts are inserted into contact openings in the control circuit board and secured through mechanical engagement, eliminating the need for heat, solder material, and complex soldering equipment. This mechanical substitution maintains electrical connection reliability while dramatically reducing assembly time and enabling automation.
Solution Approach 2:
The patent divides the electrical connection system into separate modular components: fixture contacts, receptacle contacts, and control circuit boards with contact openings. Each component can be manufactured independently and assembled through simple insertion, replacing the monolithic soldered connection. This segmentation enables parallel manufacturing and automated assembly, improving productivity while maintaining connection integrity.
2Reliability
If soldering process is used for assembling photocontrol printed circuit boards, then secure electrical connections are achieved, but labor intensity and complexity increase
Solution Approach 1:
The patent replaces the complex soldering process (requiring soldering irons, flux, heating control, and skill training) with a simple mechanical push-in system. The receptacle contacts are designed with engagement features that securely mate with corresponding features in the control circuit board, achieving reliable connections through straightforward mechanical insertion without thermal processes or specialized equipment.
Solution Approach 2:
The receptacle contacts are designed with self-aligning and self-securing features that automatically ensure proper engagement with the control circuit board contact openings. The mechanical design includes built-in alignment guides and retention mechanisms that guide the connection process, eliminating the need for operator skill or complex positioning procedures, thereby reducing assembly complexity.
3Productivity
If automated assembly is desired for light sensor assemblies, then productivity increases, but traditional solder-based connections are incompatible with automation
Solution Approach 1:
The patent segments the electrical connection into separate insertable components (receptacle contacts and fixture contacts) that can be independently manufactured and precisely positioned. This modular design allows automated pick-and-place machines or insertion tools to easily handle and assemble the components without requiring complex soldering equipment, thereby enabling automated assembly while maintaining manufacturing simplicity.
Solution Approach 2:
The patent replaces the soldering process with a mechanical insertion system that is inherently more suitable for automation. The receptacle contacts are designed with standardized engagement features that can be reliably engaged by automated insertion devices, eliminating the need for thermal control, solder material handling, and post-solder inspection, thus enabling seamless integration with automated assembly lines.
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 solution enables a cost-effective and reliable assembly process, reducing labor and time while ensuring secure electrical connections, facilitating easier automation and efficient operation of light sensor assemblies.
Implementation Method 1
photocontrol components... based upon the ambient light from the sun
Data Source
Figure 1
Figure 2
Figure 3A~3B
AI summary
A light sensor assembly is provided including a base assembly configured to be fixedly mounted to a housing of a light fixture. The base assembly holds fixture contacts configured to be electrically connected to the light fixture. A photocell module is provided on the base assembly. The photocell module includes a control circuit board having upper and lower surfaces. The control board includes contact openings and conductors associated with corresponding openings. The photocell module has a photocell electrically connected to the control circuit board. Receptacle contacts are received in corresponding contact openings in the control board. Each receptacle contact has a socket removably receiving the corresponding fixture contact. Each receptacle contact has a mating interface electrically connected to the corresponding fixture contact. Each receptacle contact has a mounting beam terminated to the corresponding conductor of the control board. A cover is coupled to the base assembly over the photocell module.