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.
copyright 01 July 2008
CROWNLITE MFG. CORP., Bohemia, NY 11720

2. A VIRTUAL APPROACH TO RAPID LIGHTING FIXTURE DEVELOPMENT
1 to 5 days
copyright 01 July 2008
CROWNLITE MFG. CORP., Bohemia, NY 11720

3. CROWNLITE MFG. CORP., Bohemia, NY 11720
TYPICAL PROJECT
The development strategy is applicable to all source types. We have applied it in architectural, film and video, entertainment and scientific / industrial fixtures.
One typical project is illustrated – just one of hundreds successfully completed by us.
US DOE contacts lighting fixture manufacturers with request for fixture submittals for a new energy initiative.
Initiative is to encourage the Peoples Republic of China to adopt energy efficient building design.
Federally purchased fixtures to be donated to a Beijing US designed office building, incorporating the best of US “Green” technology.
Fixture specification is unique.
T5 and T8 lamping.
Novel reflector design required to accommodate both lamps.
Fixture must significantly outperform competing fixtures photometrically in order to successfully land the order.
Fixture to be pendant – cable or other suspension. 4’ T5/T8 cable pendant illustrated.
Single and continuous run capable.
Up / down light for office space lighting.
Independent control of up / down light component capable. Mixed lamp type on a single fixture capable.
Local individual user control of up / down components via hand held remote – overrides central control.
Central building management with talkback – monitors and predict lamp-life / ballast condition monitoring capable. Passive and active occupancy sensing capable.
THE IMAGES AND INFORMATION CONTAINED HEREIN ARE OF A PROPRIETARY AND CONFIDENTIAL NATURE AND MAY NOT BE USED OR DISTRIBUTED WITHOUT THE EXPRESS PERMISSION OF JON CONNELL AND / OR THE REPRESENTATIVES AND OFFICERS OF PRODUCTS WITH PASSION INC. COPYRIGHT PRODUCTS WITH PASSION INC & THINGS THAT SWING INC. 2001
THIS IS AN INCOMPLETE PROJECT DEVELOPED AS PART OF A US DOE FEDERAL ENERGY INITIATIVE IN COOPERATION WITH THE GOVERNMENT OF THE PEOPLE’S REPUBLIC OF CHINA. SUBSEQUENTLY ABONDONED BY PRESIDENT BUSH FOLLOWING POLITICAL DISAGREEMENTS WITH THE PRC OVER TAIWAN IN SPRING 2002 IT REMAINS UNDER DEVELOPMENT BY PRODUCTS WITH PASSION AND IS AVAILABLE FOR LICENSE.
copyright 01 July 2008
CROWNLITE MFG. CORP., Bohemia, NY 11720

4. CROWNLITE MFG. CORP., Bohemia, NY 11720
1ST MEETING
LAMP TYPE
WATTAGE
DIMENSIONS
DISTRIBUTION
MAXIMUM / MINIMUM 3D FOOTPRINT
STYLE INTENT
INSTALLATION CONDITION
POWER CONDITION
CONTROL REQUIREMENTS
OTHER CRITERIA
DEVELOP BASELINE CONCEPTS AND SPECIFICATIONS WITH CLIENT / DESIGNER
copyright 01 July 2008
CROWNLITE MFG. CORP., Bohemia, NY 11720

5. 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
copyright 01 July 2008
CROWNLITE MFG. CORP., Bohemia, NY 11720

6. 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.
copyright 01 July 2008
CROWNLITE MFG. CORP., Bohemia, NY 11720

7. 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.
copyright 01 July 2008
CROWNLITE MFG. CORP., Bohemia, NY 11720

8. 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.
copyright 01 July 2008
CROWNLITE MFG. CORP., Bohemia, NY 11720

9. 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.
copyright 01 July 2008
CROWNLITE MFG. CORP., Bohemia, NY 11720

10. Photopia optical design and photometric modeling - integration
600 Watt Theatrical image projection system developed for Leviton Inc.
Molded dichroic glass reflector delivers high intensity light through an optically ray traced multi-element aspheric lens system.
copyright 01 July 2008
CROWNLITE MFG. CORP., Bohemia, NY 11720

11. CROWNLITE MFG. CORP., Bohemia, NY 11720
Photopia optical design and photometric modeling – diffusion and control
Series of light control accessories developed for Zumtobel Staff Lighting Inc. for a museum grade track lighting system.
Photopia has a library of standard diffuse materials. Custom materials can be tested and imported into the library for analysis.
Alternate materials can be applied to designs to determine the best light control solution – in this example alternate diffusion mediums, refractive spread lenses, light control louvers with specular and matte finish were evaluated. This enables accessories to be catalogued without test / manufacture – the light output from each option being reflected in the digitally generated IES files and photometric charts.
A similar process was useed on the Altman Stage Lighting MR16 fixture at bottom right.
copyright 01 July 2008
CROWNLITE MFG. CORP., Bohemia, NY 11720

12. 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
copyright 01 July 2008
CROWNLITE MFG. CORP., Bohemia, NY 11720

13. CROWNLITE MFG. CORP., Bohemia, NY 11720
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.
copyright 01 July 2008
CROWNLITE MFG. CORP., Bohemia, NY 11720

14. 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.
copyright 01 July 2008
CROWNLITE MFG. CORP., Bohemia, NY 11720

15. CROWNLITE MFG. CORP., Bohemia, NY 11720
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.
copyright 01 July 2008
CROWNLITE MFG. CORP., Bohemia, NY 11720

16. 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.
copyright 01 July 2008
CROWNLITE MFG. CORP., Bohemia, NY 11720

17. 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]
NUBER OF LAMPS = 2
copyright 01 July 2008
CROWNLITE MFG. CORP., Bohemia, NY 11720

18. OPTICAL DESIGN PHOTOMETRIC FILE OUTPUT – .IES
Zonal Lumens
Cone Between Lumens
IESNA:LM
[TEST] Photopia PHOTOMETRIC REPORT
copyright 01 July 2008
CROWNLITE MFG. CORP., Bohemia, NY 11720

19. 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.
copyright 01 July 2008
CROWNLITE MFG. CORP., Bohemia, NY 11720