Sacrificial Lens Assembly for Abrasive Blasting Illumination
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Solution Overview
Problem
Conventional abrasive blasting systems face challenges with reduced illumination due to lens pitting and heat dissipation issues with LED lighting, requiring frequent maintenance and tool-carrying for lens replacement.
Innovation Solution
A light assembly with a sacrificial lens system and improved heat dissipation through a vented design, allowing for easy replacement of layers and integration with a carrier assembly for enhanced visibility and cooling during abrasive blasting operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If a conventional lens is used in the light assembly, then illumination is provided, but the lens becomes pitted and obscured over time, reducing lighting quality
Solution Approach 1:
The lens is divided into a permanent lens and a removable sacrificial lens. The permanent lens maintains optical quality while the sacrificial lens absorbs the impact damage from abrasive particles, allowing it to be replaced without replacing the entire light assembly.
Solution Approach 2:
The sacrificial lens is designed as a disposable component that can be easily replaced. It absorbs the harmful effects of abrasive particle impact and is discarded when pitted, while the expensive permanent lens and light assembly remain intact and reusable.
2Illumination intensity
If the operator stops operation to replace the lens, then lighting quality is restored, but productivity is reduced due to downtime
Solution Approach 1:
The lens system is segmented into replaceable sacrificial lenses, allowing quick replacement without disassembling the entire light assembly. This reduces maintenance time and maintains productivity while restoring lighting quality.
Solution Approach 2:
Multiple sacrificial lenses can be prepared in advance and stored in the light assembly. When one lens becomes pitted, a replacement is already available, eliminating the need to stop operation for lens procurement and reducing downtime.
3Illumination intensity
If LED lighting is used to provide additional light, then illumination intensity is improved, but heat generation increases requiring dissipation
Solution Approach 1:
The heat dissipation function is extracted as a separate feature through dedicated heat sinks and ventilation channels in the light assembly housing. This allows the LED module to be cooled efficiently without affecting the optical performance or requiring complex thermal management in the lens system.
4Ease of repair
If the operator removes safety equipment to replace the lens, then lens replacement is possible, but operational safety is compromised
Solution Approach 1:
The lens replacement process is segmented into simple, tool-free steps that can be performed while wearing safety equipment. The sacrificial lens is designed with features like pull tabs that allow removal without compromising safety gear or requiring the operator to remove protective equipment.
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 provides improved illumination and rapid lens replacement, reducing downtime and heat-related constraints, while maintaining operational safety and efficiency in abrasive blasting processes.
Implementation Method 1
There may be a passageway between an outer surface and the at least one recessed inner surface. In aspects, during operation of the light assembly the passageway may facilitate cooling of the illumination module.
Data Source
AI summary
A light assembly that includes a main housing having an illumination module disposed within the main housing. There is an end cap coupled with the main housing in a manner to form a lens cavity proximate a forward end of the illumination module. There is a sacrificial lens disposed in the lens cavity. The sacrificial lens includes a removable layer.