The Molex Helieon module with Bridgelux array won the “Most Innovative Product” award, the highest honor one can achieve at Lightfair!
As a consultant to Molex on their entry into the SSL arena, specifically on the Transcend and Helieon projects, I can offer that the effort put into understanding the lighting market, and how SSL can be applied within it, has been impressive. Seeing them take the prize was a thrill for me personally, and certainly for the groups at both Molex and Bridgelux. Playing the role of “Lighting Guy” in this group of exceptional electronics and mechanical engineers, who tackle connector problems in everything from cars and consumer products to computers and spaceships, I’ve experienced a development pace unprecedented. The combination of optics, tactile feel, simplicity in application, and potential for further expansion of capabilities, the Helieon is just one more example of what a market leading connector manufacture can do for the lighting market.
In Architectural SSL we’ve continually pressed for modularity as an important and necessary component in the furthering of SSL deployment. In 2010, this appears to be the year for just such development. The Xicato, Cree’s introduction, Philips Fortimo, and GE, along with Sharp, and the GX53 socket for SSL by BJB, and the Helieon, all offer significant improvements in the way LEDs will be incorporated into products. On top of this, manufacturers, such as Solid State Luminaires, have incorporated modularity into the construction of their latest downlights and other products. Modules have finally arrived – with the Helieon taking top honors as the leader of the pack.
The snapshots below are from the show display, where Lumenique fixtures were used incorporating 45 Helieon modules used to illuminate the display.
01/07/10 – And now for something completely different. Ever heard of Steam Punk? It’s a design vocabulary founded on Victorian styling blended with technology as it might have been had we not moved into micro-electronics. Time machine movies are excellent examples of the aesthetic. Applying this to an SSL product just seems too ironic not to do, so this will be the week two project. This one is going to use Bridgelux 400lm LED arrays as uplight and downlight, within a pivoting head. Driver will be from Luxdrive, and operated at 1A. Control is going to be via placing a plumb bob in one of three sockets, which will control the driver dim level. Finishes will be powder coat red, powder coat black, polished aluminum and polished brass. This one is mostly lathe turnings, my favorite tool.
01/11/10 – Got a lot of parts made and some details figured out. Had a bit of an issue with the ball turner, which decided to grab a part and bend it over on me. Really a pain since the ball is the last thing you turn after cutting the rest of the part. Had to re-invent the tool a little before I trashed another blank, then started all over to replace the bent part. Been making a few adjustments in detail as I go through each part – some to fit materials I have in stock and to improve detailing, since there is nothing quite like having the metail in hand to fine tune detail. Working the light heads now – a lot of stuff packed into a somewhat small space. Last bit to work out is the swivel so it will hold the head in place and not sag, but will be easy to adjust. So far so good. The Bridgelux LEDs put out so much soft light, this one should make a nice general space illuminator, with back/uplight and down/tasklight.
01/15/10 – Been a tough week, but the project is progressing. Just finished the base plates, have the vertical conductor towers ready to finish, have figured out how to make the controls work properly, and have the head 90% complete, just need a couple of holes drilled and everything is ready to finish. While the target is to finish each of these on Thursday or Friday of each week, projects like this one are abit more complex, so will take a day or two longer. By the end of the day today, everything on this will be in finishing, with assembly tommorrow (Saurday), just in time to startweek 3, which has already beed designed. This is going to be tough to keep up with, and requires I think clearly and not make any serious mistakes that eat time.
So… the first week went well enough. Even with taking time off for the holidays, working in a deep freeze workshop, and managing to mess up several blocks of metal, I managed to get this one done. I’m also breaking in a new powder coat oven and learning to use a couple of new tools, like a virbatory deburring machine that works away at the sharp corners and file marks while I get on with other work. Generally this one worked out about as I had invisioned, except for shortening the arm a little. I’m also thinkin that the next iteration of this will use finishes a little differently. I’ve created a matte white powder finish I really like the look and feel of, will need to find more places to use it. In any case, with this in the done file, its time for a couple days to regroup and get into the next one.
I’ve got an idea in mind for use of Bridgelux 400lm LEDs in a steam-punk looking design that will light up and down, providing good ambient as well as accent downlighting. Something a bit less edgy, maybe use a lot of lathe turned parts and do a little polishing. Might even use some brass I have on hand for just such a purpose.
52 in 52 Design One Specification Brief
24″ wide x 20″ tall Lynk Labs 12W Snapbrite strip (12VAC) on SnapDriver power supply Custom switch design and fabrication Tumble finish aluminum with clear gloss topcoat, wrinkle black and matte white finishes
12/30/09 – This is the first of 52 designs for the year. I thought about posting a drawing or rendering of the complete design at the start, but what is the fun in that? Instead, I’m including a few sneek preview details that will be included in the final design. To see what the finished product, both in-process and completed, you’ll just have to follow along, or wait a week. Design One is a fixed head architecturally styled task lamp for a desk or side table. It’s going to be around 20″ tall and extend 28″ horizontally. It will use a Lynklabs 12″ SnapBrite LED strip with 12 Tesla LEDs, powered by the companies BriteDriver 12VAC power supply, provided as samples to me by the company. This will deliver roughly 200fc onto the task surface. The finish will be black textured and matte white high reflectance powder coat (my own formulation), with satin and polished aluminum accents. I plan to get most of the rough cut parts machined this weekend, so stay tuned!
01/04/10 – All design, machining, and mock up of rough components completed. Ran into a little snag finding a proper switch, so made my own from a proximity control and Delrin block. Had to remake the block at the top of the main column three times due to the length of the drilling horizontally for the support rod which went in straight and came out off center. Also fussed with the length of the arm – cut hree inches off it to balance the appearance of the assembly. Man, is it cold in the garage where my machining equipment is. Had to take a couple days off due to temps in the single digits, which makes the oil so stiff the machines struggle. The rest of the process can be done in the sheet metal and assembly area, which is heated. Going to have to get a better heater in the machining area.
In response to a growing sentiment that “playful” design is doomed due to the demand to cut energy use, that we must give up quality to cut watts quantity. I could not disagree with this more. In fact design plays a much larger role in cutting energy use than anyone is, giving it credit for. In fact, I contend that design of an application plays a larger role than reaching for some ultimate efficiency number. The two renderings shown here were created in AGI32 using photometric data from available LED products. The effect of design on the quality of a space and its energy use are clearly illustrated. The only factor changed between these two renderings is the lighting system applied. All other factors are identical.
Don’t buy into the baloney that energy conservation requires one must eschew design. Instead embrace the use of artful application of light to reduce the amount of light being thrown into a space from luminaires with poor control but high efficiency – use less light, with greater focus onto target surfaces. The art of lighting design is about design for vision, not meeting prescribed illuminance levels on some plane above the finished floor. The best designs create the most interesting and visually attractive space with the least amount of energy. We do not want to live in a world where the only qualifier of efficiency is the luminaire manufacturers data sheet above all else. Not only will this lead to greater energy consumption, it will reduce the quality of space we all live within for no reason. We need more design, more interest in the application of light, and less influence of purely empirical calculation.
Design has been devalued by those who believe lighting is something to be applied to meet minimum standards, that “effect” is a luxury that we can live without. This is why we live in offices with uniform illumination levels and flat surface rendering that gives us all headaches and eye strain. We know we don’t like it, ut live withit it. Why? Dynamic vision is created as much from the design of dark releif within a space, as it is from applying light onto horizontal planes within a calculation tool. The difference in these renderings are subtle in 2 dimensional presentation. In the 3D space we all live within, the effect is far greater and more readily felt and seen. With a greater degree of design expertise, we can realize greater energy savings AND an improvement in visual performance and quality.
LEDs bring a lot of creative potential to the lighting market. At this creative front will be artists who apply them in unique ways outside the mainstream general illumination marketplace. I’m one of them in fact. Gone are my days of fooling with halogen lamps and transformers – now its LEDs, drivers and power supplies… and heat sinks.
The first wall hit in application of LEDs is their output and thermal dynamic. In halogen lighting, the fixtures got hot, no big deal. As long as it wasn’t peeling flesh or raising a blister, its was fine. LEDs don’t work that way. Long before the lighting portion gets hot enough to raise a blister, the LED is fried, game over.
Ultimately, the goal of an artist in creating a new work of light is to generate as much light as possible in the smallest, most innocuous package. That makes LEDs at once attractive, and a problem. To illustrate, a 350mA 1W LED requires very little thermal management to survive. Glue or screw it to plate of aluminum or copper and its happy. Problem is, the amount of light is pretty weak, between 35 and 60 lumens if you want 3,000k color with good color rendering (yes, artists do care about color – a lot.) That’s a long way from the 600 to 800 lumens we were used to in halogen sources. Optimally, for a task light with a good optic (wide smooth beam), gettting to around 350 to 500 lumens is optimal. This means more energy. At 700mA, 100 lumens is attainable, and lands us in the 3 to 4 watt range. Three is always better than 10, so this sounds like the way to go. Problem is, a 3W LED is exponentially more demanding thermally than that 1W device. These higher energy devices demand heat sinks, real life thermal management, with airflow and everything.
This is my very first functional LED task light, completed at the end of 2005. Construction is welded steel. Originally, the main components of this fixture (2004) were designed for a 12V/20W Halogen bi-pin lamp that created an overheating of the lighting head and poor light output. This was changed to (12) 1/2W Nichia HB LEDs (2800k) mounted to PC board with through hole thermal connection to the heat sink, as an experiment and proof of concept for the application of LEDs to provide greater light output for the same or less energy. Light on the task surface was either 70FC or 150FC, with a very wide distribution, as there is no secondary optical control. An aluminum heat sink inside the lighting head maintains reasonable operating conditions for the LEDs (under 60C TJ), while remaining cool to the touch. The horizontal arm ratchets up and down, the red arches are fiberglass springs that tension the ratchet. The parallel link on the head and arm keep the head level when it is adjusted up and down.