A VIRTUAL APPROACH TO RAPID LIGHTING FIXTURE DEVELOPMENT

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Anthony York
5 years ago
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1 A VIRTUAL APPROACH TO RAPID LIGHTING FIXTURE DEVELOPMENT FROM DESIGNER S CONCEPT TO IES PHOTOMETRICS IN DAYS. FUNCTIONAL PROTOTYPES ON DESIGNERS DESK IN DAYS REDUCED LEAD TIME TO CLOSE ORDERS. REMOVES UNCERTAINTY FROM PROJECTS SOLID MODELING, DIGITAL OPTICAL MODELING AND ANALYSIS, RAPID PROTOTYPING 3D PRINTING FAST COMPUTING TECHNOLOGY HAS CHANGED THE FACE OF LIGHTING FIXTURE DESIGN. Pg. 1

2 A VIRTUAL APPROACH TO RAPID LIGHTING FIXTURE DEVELOPMENT DESIGNERS CONCEPT / SCOPE OF WORK BUDGET / CONTRACT FOR SERVICES 1 st meeting SOLID MODELS RENDERINGS FOR APPROVAL exchange of ideas and images 1 to 5 days OPTICAL DESIGN, IES FILES, PHOTOMETRIC REPORTS Photometric files can be used in AGI 32 etc 5 to 10 days RAPID PROTOTYPE 3D PARTS FOR APPROVAL Plastic parts on designers desk in 5 days 5 to 10 days APPROVAL AND ORDER Lead time to order is compressed drastically No questions manufacture with confidence Pg. 2

3 1 ST MEETING LAMP TYPE DEVELOP BASELINE CONCEPTS AND SPECIFICATIONS WITH CLIENT / DESIGNER WATTAGE DIMENSIONS DISTRIBUTION MAXIMUM / MINIMUM 3D FOOTPRINT STYLE INTENT INSTALLATION CONDITION POWER CONDITION CONTROL REQUIREMENTS OTHER CRITERIA Pg. 4

4 2ND MEETING DIGITAL EXCHANGE OF IDEAS SOLIDWORKS 3D SOLID MODELING SOFTWARE IS USED TO CREATE MULTIPLE SIMPLE DESIGNS SUBMITTAL OF SIMPLE RENDERINGS TO DETERMINE CLIENT S STYLE AND CONSTRUCTION PREFERENCE COMMUNICATION VIA AND INTERNET for SPEED AND COSTS CONTROL Pg. 5

Lamp holders are selected and lamps are roughly positioned in the 3d space available in the conceptual design.

5 STYLE SELECTED OPTICAL DESIGN STARTS With the base line style and construction selected, appropriate reflecting areas can be created allowing for higher efficiency and greater control in both up and down axes of the fixture. Lamp holders are selected and lamps are roughly positioned in the 3d space available in the conceptual design. Cutoff and efficiency are considered and a simple sketch of a possible reflector solution for each is created. Pg. 6

Photopia optical design and photometric modeling - Lamps ACAD and

Photopia has a library of standard lamp and LED models which are placed

happens in architectural lighting, we make a digital model of the lamp

6 Photopia optical design and photometric modeling - Lamps ACAD and SolidWorks 2d And 3d CAD files are imported into Photopia. Photopia has a library of standard lamp and LED models which are placed into the lamp holders in the fixture initially one lamp at a time up then down components. If the particular lamp is not available in the library, which rarely happens in architectural lighting, we make a digital model of the lamp which is combined with the IES file for the lamp. However, most commercial lamps and LEDs are available from the lamp library supplied with Photopia. Pg. 7

Photopia optical design and photometric modeling - reflectors Photopia will accurately determine filament and lamp image

$It is possible to model reflector facets, refractor forms and diffuser types to aid removal of filament image in$ Accurately measured reflector surfaces are available from multiple manufacturers and also as standard painted surfaces.

Accurately measured reflector surfaces are available from multiple manufacturers and also as standard painted surfaces.

7 Photopia optical design and photometric modeling - reflectors Photopia will accurately determine filament and lamp image resulting from each filament type and construction. It is possible to model reflector facets, refractor forms and diffuser types to aid removal of filament image in distributions. Accurately measured reflector surfaces are available from multiple manufacturers and also as standard painted surfaces. Peens and facets can be modeled within the program or created externally and imported. The software accurately predicts performance of standard and special reflector materials. One of our proprietary high reflectivity specular anodic coatings is shown here alongside a digitally modeled peen pattern. Pg. 8

$Photopia optical design and photometric modeling - refractors In this Refractor$ $Light rays can be seen being turned by the refractor.$ Numeric and shaded representations of output can be generated.

Numeric and shaded representations of output can be generated.

8 Photopia optical design and photometric modeling - refractors In this Refractor design an extruded Fresnel lens converts the LED light distribution from 120 degrees to a narrow 30 degree distribution. Light rays can be seen being turned by the refractor. Numeric and shaded representations of output can be generated. In particular filament and lamp image are detected and designed out of the system. The element was subsequently prototyped in a clear rapid prototype plastic before tooling was undertaken. Pg. 9

Photopia optical design and photometric modeling real world results The

This pendant fixture line was optimized to eliminate lamp image from the

9 Photopia optical design and photometric modeling real world results The results obtained from Photopia are a very good indicator of real world performance. Frequently within 10% or better of the physically measured output values. This pendant fixture line was optimized to eliminate lamp image from the surface of the diffuse bowl. Multiple lamp placements and bowl diameters were evaluated. Photopia will also takes into account ceiling reflectivity Pg. 12

developed it is relatively simple to adjust to lamp

Sometimes Photopia will lead you in a new direction to

10 Photopia optical design and photometric modeling diffusion and control Once the initial design is developed it is relatively simple to adjust to lamp positions and scale reflectors to create IES files for a whole line of product. As here in a line voltage track line. Sometimes Photopia will lead you in a new direction to discover something that you never expected existed like this unusually shaped and patent applied for HID wall wash fixture. Pg. 13

After joining, the combined part is brought back into Photopia and a full photometric test is run with lamps in

11 OPTICAL DESIGN COMPLETED Reflector profiles were developed, then exported back into the 3D model to be joined together with the rest of the fixture model. After joining, the combined part is brought back into Photopia and a full photometric test is run with lamps in place and in a real room with a ceiling in place. In the images below you can see light rays exiting an invisible lamp and reflector system, the up component then bouncing back from the ceiling. Pg. 14

12 OPTICAL DESIGN OUTPUT The accuracy of results generated depends upon how long you let the computer run the test for. The longer, the more accurate and the more likely it is that you will be able to see problems in distribution. Candela and footcandle plots are generated. Pg. 15

13 OPTICAL DESIGN PHOTOMETRIC FILE OUTPUT The photometric file for the fixture follows this page. In the page following that you will see the content of a typical IES format file for use in AGI32 etc. Pg. 16

14 OPTICAL DESIGN PHOTOMETRIC FILE OUTPUT.IES IESNA:LM [TEST] Photopia PHOTOMETRIC REPORT [MANUFAC] productswithpassion [LUMINAIRE] dwave [LUMCAT] second_combined_forcandela [_FIXTURE] Extruded plastic housing [DATE] FEB-02 [MORE] 2 LAMPS - HO [LAMPCAT] F54T5HO [_LAMPLUM] 5000 [BALLAST] ELECTRONIC [_ALIGN] SYMMETRIC--0 degree plane parallel to lamps TILT=NONE [_WATT] 100 NUBER OF LAMPS = Pg. 17

15 OPTICAL DESIGN PHOTOMETRIC FILE OUTPUT.IES Zonal Lumens Cone Between Lumens IESNA:LM [TEST] Photopia PHOTOMETRIC REPORT Pg. 18

Multiple technologies now exist which can produce plastic, high temperature plastic and even sintered metal parts directly from our

16 DESIGN COMPLETED / RAPID PROTOTYPING AND RELEASE TO PRODUCTION Once the design is completed, the individual parts of the fixture are sent for rapid prototyping. The process of rapid prototyping, or stereo lithography, is well known in the lighting industry. Multiple technologies now exist which can produce plastic, high temperature plastic and even sintered metal parts directly from our solid model files. We have been using this technique with great success. It works, and we have the depth of experience to make it work for you. Pg. 19

IES FLOOD REPORT PHOTOMETRIC FILENAME : IN.IES. DESCRIPTIVE INFORMATION (From Photometric File)

IES FLOOD REPORT PHOTOMETRIC FILENAME : IN.IES. DESCRIPTIVE INFORMATION (From Photometric File) DESCRIPTIVE INFORMATION (From Photometric File) IESNA:LM-63-1995 IESNA:LM-63-1995 [TEST] Photopia 2.0.0.14 PHOTOMETRIC REPORT [MANUFAC] TMS LIGHTING [LUMINAIRE] SIGN 12 FLOODLIGHT [MORE] ASYMMETRICAL ANGLED