Copyright 01 July 2008 CROWNLITE MFG. CORP., Bohemia, NY 11720 Pg. 1 A VIRTUAL APPROACH TO RAPID LIGHTING FIXTURE DEVELOPMENT FROM DESIGNERS

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

www.crownlite.com Pg. 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.



A VIRTUAL APPROACH TO RAPID LIGHTING FIXTURE DEVELOPMENT

DESIGNERS CONCEPT / SCOPE OF WORKBUDGET / CONTRACT FOR SERVICES

1st meeting

SOLID MODELS – RENDERINGS FOR APPROVALEmail exchange of ideas and images

OPTICAL DESIGN, IES FILES , PHOTOMETRIC REPORTSPhotometric files – can be used in AGI 32 etc

RAPID PROTOTYPE 3D PARTS FOR APPROVALPlastic parts on designers desk in 5 days

APPROVAL AND ORDERLead time to order is compressed drasticallyNo questions – manufacture with confidence

5 to 10 days

5 to 10 days

1 to 5 days



1ST MEETING

• DEVELOP BASELINE CONCEPTS AND SPECIFICATIONS WITH CLIENT / DESIGNER

• LAMP TYPE

• WATTAGE

• DIMENSIONS

• DISTRIBUTION

• MAXIMUM / MINIMUM 3D FOOTPRINT

• STYLE INTENT

• INSTALLATION CONDITION

• POWER CONDITION

• CONTROL REQUIREMENTS

• OTHER CRITERIA



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 EMAIL AND INTERNET for SPEED AND COSTS CONTROL



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.



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.



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.



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.



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



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.



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.



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.



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.



OPTICAL DESIGN PHOTOMETRIC FILE OUTPUT – .IES • IESNA:LM-63-1995

• [TEST] Photopia 1.5.0.22 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 = 2

• 0.00 22.50 45.00 67.50 90.00 112.50 135.00 157.50 180.00 202.50

• 0.00 1196 1196 1196 1196 1196 1196 1196 1196 1196 1196• 5.00 1180 1183 1195 1169 1190 1195 1184 1166 1239 1203• 10.00 1199 1231 1188 1175 1142 1171 1186 1205 1208 1211• 15.00 1232 1226 1202 1143 1155 1133 1190 1243 1244 1251• 20.00 1261 1253 1190 1145 1113 1129 1212 1264 1276 1250• 25.00 1250 1237 1183 1111 1076 1127 1225 1252 1266 1252• 30.00 1209 1188 1153 1059 1021 1082 1168 1206 1211 1198• 35.00 1166 1138 1091 1001 934 1010 1100 1159 1196 1176• 40.00 1091 1083 1019 921 852 943 1049 1125 1152 1123• 45.00 1002 992 945 852 769 868 990 1051 1078 1048• 50.00 918 903 856 776 692 802 928 971 975 970• 55.00 848 814 774 696 613 736 843 880 891 880• 60.00 722 718 688 618 520 664 756 779 775 769• 65.00 575 580 577 518 437 578 637 561 497 563• 70.00 311 363 451 430 344 479 454 280 218 286• 75.00 126 134 242 321 266 364 211 118 138 120• 80.00 110 114 112 197 171 204 152 329 402 331• 85.00 38.2 52.3 72.9 93.1 75.5 143 352 523 573 513• 90.00 0.760 4.72 24.2 48.7 35.7 179 375 528 576 527• 95.00 0.100 8.68 59.2 129 72.4 206 430 582 622 582• 100.00 225 282 365 268 171 294 492 644 682 635• 105.00 546 538 451 397 302 416 542 671 725 680• 110.00 618 603 520 455 337 469 594 730 769 731• 115.00 707 694 619 515 379 509 674 792 834 788• 120.00 764 762 736 602 430 593 798 837 872 837• 125.00 865 845 826 725 596 714 880 926 944 937• 130.00 974 976 914 754 679 744 950 1059 1075 1054• 135.00 1129 1096 985 772 725 755 1003 1185 1208 1172• 140.00 1231 1210 1064 807 763 820 1037 1244 1299 1234• 145.00 1293 1221 1087 913 861 923 1072 1230 1293 1234• 150.00 1221 1188 1044 1002 967 989 1045 1149 1214 1148• 155.00 1158 1101 1032 1004 991 1008 1024 1082 1144 1121• 160.00 1114 1078 1039 1003 995 1020 1023 1077 1116 1085• 165.00 1108 1045 1036 1009 1012 1009 1023 1064 1089 1064• 170.00 1077 1085 1062 1066 1041 1063 1021 1065 1078 1077• 175.00 1094 1089 1089 1021 1104 1046 1075 1059 1094 1102• 180.00 1060 1060 1060 1060 1060 1060 1060 1060 1060 1060



OPTICAL DESIGN PHOTOMETRIC FILE OUTPUT – .IES • 225.00 247.50 270.00 292.50 315.00 337.50 360.00

• 0.00 1196 1196 1196 1196 1196 1196 1196• 5.00 1181 1206 1192 1206 1214 1200 1180• 10.00 1177 1146 1187 1154 1178 1203 1199• 15.00 1184 1132 1121 1153 1199 1215 1232• 20.00 1207 1116 1111 1148 1201 1261 1261• 25.00 1199 1110 1088 1113 1191 1239 1250• 30.00 1156 1078 1022 1075 1165 1193 1209• 35.00 1115 1009 941 1005 1083 1142 1166• 40.00 1049 944 843 915 1025 1083 1091• 45.00 988 867 768 851 933 996 1002• 50.00 928 813 684 771 867 902 918• 55.00 846 731 606 702 782 823 848• 60.00 759 657 520 614 682 724 722• 65.00 636 575 433 518 582 594 575• 70.00 452 478 350 423 461 371 311• 75.00 205 360 267 326 262 147 126• 80.00 154 204 173 203 107 99.9 110• 85.00 348 141 76.3 90.5 56.4 44.9 38.2• 90.00 370 177 34.0 46.1 23.4 3.86 0.760• 95.00 430 200 69.0 126 55.8 8.23 0.100• 100.00 497 292 172 269 357 280 225• 105.00 545 409 302 396 458 539 546• 110.00 589 468 339 449 525 598 618• 115.00 666 513 380 514 614 691 707• 120.00 798 590 425 603 729 748 764• 125.00 879 714 600 735 832 844 865• 130.00 937 739 692 750 909 976 974• 135.00 1007 759 715 768 996 1097 1129• 140.00 1050 808 753 803 1063 1194 1231• 145.00 1079 933 865 915 1079 1219 1293• 150.00 1041 1002 969 1002 1066 1166 1221• 155.00 1026 991 988 1005 1031 1103 1158• 160.00 1015 999 985 1013 1025 1064 1114• 165.00 1045 1036 1008 1015 1012 1087 1108• 170.00 1052 1043 1064 1041 1032 1091 1077• 175.00 1082 1058 1039 1021 1062 1082 1094• 180.00 1060 1060 1060 1060 1060 1060 1060• Zonal Lumens• Cone Between Lumens

• 0.0 0.0- 2.5 7.15•

• 0.0 0.0- 2.5 7.15• 5.0 2.5- 7.5 57.03• 10.0 7.5- 12.5 112.80• 15.0 12.5- 17.5 168.68• 20.0 17.5- 22.5 224.24• 25.0 22.5- 27.5 273.89• 30.0 27.5- 32.5 311.50• 35.0 32.5- 37.5 339.24• 40.0 37.5- 42.5 357.11• 45.0 42.5- 47.5 363.30• 50.0 47.5- 52.5 361.05• 55.0 52.5- 57.5 349.79• 60.0 57.5- 62.5 325.38• 65.0 62.5- 67.5 275.14• 70.0 67.5- 72.5 198.03• 75.0 72.5- 77.5 119.35• 80.0 77.5- 82.5 103.36• 85.0 82.5- 87.5 108.96• 90.0 87.5- 92.5 101.14• 95.0 92.5- 97.5 122.20• 100.0 97.5-102.5 199.97• 105.0 102.5-107.5 262.05• 110.0 107.5-112.5 283.15• 115.0 112.5-117.5 306.97• 120.0 117.5-122.5 330.01• 125.0 122.5-127.5 360.92• 130.0 127.5-132.5 372.13• 135.0 132.5-137.5 372.36• 140.0 137.5-142.5 360.71• 145.0 142.5-147.5 338.32• 150.0 147.5-152.5 294.82• 155.0 152.5-157.5 243.36• 160.0 157.5-162.5 195.09• 165.0 162.5-167.5 147.73• 170.0 167.5-172.5 100.88• 175.0 172.5-177.5 51.11• 180.0 177.5-180.0 6.34

• IESNA:LM-63-1995• [TEST] Photopia 1.5.0.22

PHOTOMETRIC REPORT



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.

Documents

Copyright 01 July 2008 CROWNLITE MFG. CORP., Bohemia, NY 11720 Pg. 1 A VIRTUAL APPROACH TO RAPID LIGHTING FIXTURE DEVELOPMENT FROM DESIGNERS