Field Replaceable LED Assembly with Quick-Release Cooling
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Solution Overview
Problem
Conventional LED-based light systems lack field replaceable components, making maintenance and repair complex for operators, often requiring the entire system to be returned for service, which is costly and inefficient.
Innovation Solution
A field replaceable assembly design for light systems, featuring a lamp head assembly with driver circuits and a separable replaceable assembly that includes light producing elements, a cooling structure, and a reflector, connected using quick-release fasteners and a gasket for easy disconnection of the cooling fluid supply, allowing for quick replacement without exposing sensitive components to operators.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the entire light system is designed as a non-replaceable integrated unit, then the system structure is simpler and more reliable, but the maintenance cost increases and system downtime increases when failure occurs
Solution Approach 1:
The light system is divided into two main segments: a lamp head assembly containing driver circuits and control electronics, and a replaceable assembly containing light producing elements (LEDs), cooling structure, and reflector. This segmentation allows the replaceable assembly to be quickly swapped out when LEDs fail, minimizing system downtime while keeping the expensive lamp head assembly reusable.
Solution Approach 2:
The light producing elements along with their cooling structure and reflector are extracted as a separate replaceable assembly from the main lamp head assembly. This extraction enables field replacement of the consumable light-producing components without returning the entire system for service, directly reducing maintenance time and cost.
2Ease of operation
If the entire light system is treated as a consumable unit, then replacement is simple, but the cost to the user increases significantly
Solution Approach 1:
By segmenting the system into a permanent lamp head assembly and a consumable replaceable assembly, the expensive driver circuits and control electronics are preserved and reused. Only the lighter, less expensive replaceable assembly containing LEDs needs to be replaced periodically, significantly reducing maintenance costs compared to replacing the entire system.
Solution Approach 2:
The replaceable assembly containing light producing elements is designed as a consumable component that gets discarded after failure, while the expensive lamp head assembly is recovered and reused. This approach eliminates the need to discard or return the entire system for service, reducing maintenance costs while maintaining ease of replacement.
3Ease of repair
If operators are trained to troubleshoot and repair complicated light systems, then repair capability improves, but training time and complexity increase
Solution Approach 1:
The system is segmented so that the complex electronic components (driver circuits) remain with the lamp head assembly, while the replaceable assembly contains only the light producing elements, cooling structure, and reflector. This segmentation allows operators to perform simple field replacements without needing to understand or troubleshoot the complicated electronic control systems, reducing training requirements.
Solution Approach 2:
The replaceable assembly is designed to be easily replaceable by operators without requiring specialized troubleshooting or repair skills. The quick-connect cooling fluid connections and simple mechanical attachment allow operators to perform maintenance themselves through straightforward replacement rather than complex repair procedures.
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
Enables customers to perform maintenance and replacements quickly, reducing downtime and costs by allowing field replacement of faulty assemblies, improving operational efficiency and accessibility for maintenance personnel.
Implementation Method 1
a cooling structure for receiving a cooling fluid from the cooling system, the plurality of light producing elements being supported by the cooling structure
Data Source
AI summary
A light system is provided. The light system includes: (a) a lamp head assembly, the lamp head assembly including (i) driver circuits, and (ii) a cooling system; and (b) a replaceable assembly connected to the lamp head assembly, the replaceable assembly including (i) a plurality of light producing elements, (ii) a cooling structure for receiving a cooling fluid from the cooling system, the plurality of light producing elements being supported by the cooling structure, and (iii) a reflector for receiving light from the plurality of light producing elements. The replaceable assembly is separable, as a single assembly, from the lamp head assembly.