Intelligent Outlets Ensure Safer Skies

At Norlux, our goal is to innovate and update current product generations to ensure the best customized solution for your needs- both now and into the future. So when we partnered with an aviation company to make an intelligent outlet for aircrafts, utilizing GFI and over-current detection was simply not good enough. Our customer wanted us to add more protection to create the safest product in the air.

An FAA memorandum on power systems in airplanes, PS-ANM-01-111-165, requires that “…the design does not introduce a source of injury due to electrical shock…” While electrical shock can be guarded against with the use of a plug cover and still meet the requirements, it can be easily circumvented in real world applications. We wanted added protection for when the cover is removed and the outlet is exposed. The memorandum offers an optional example of such protection, suggesting “a design where output power is present at the PSS [power supply system] socket only when the PED [portable electronic device] connector is correctly mated with the socket.” Our design does just that; only a proper insertion of a plug activates power to the socket.

This extra level of protection was accomplished by adding plug presence detection (PPD) to the outlet. With PPD, the intelligent outlet does not supply power to the receptacle unless a plug is detected in the outlet. This prevents an individual from an electrical shocked caused by inserting a foreign object- a paperclip, a child’s toy, a piece of food- into the outlet. The PPD detection uses infrared emitters/receivers embedded into the side of the outlet to detect when a plug is in the outlet. Unlike some designs that only have one sensor in the outlet, our design uses two separate emitters/receivers as a redundancy check. With one sensor for each prong, the dual sensor design ensures that it is in fact a plug that is inserted into the outlet, and not a conductive object inserted into only one side. The sensor system can also be calibrated once the outlet is installed so that any ambient inferred light will be compensated for, preventing any false detections. The PPD also correctly detects all plugs styles that can fit into the universal outlet faceplate.

On top of the strict guidelines required to make the outlet safe for aviation use, we have gone above and beyond to ensure a high-quality product for our customer and the safest device for the end user. Contact Norlux today for a consultation on your LED lighting project.

Reference:
http://rgl.faa.gov/Regulatory_and_Guidance_Library/rgPolicy.nsf/0/6283af43db9a694486256fd30077ca7d/$FILE/PSSforPED.pdf

Combining Surface Mount Technology (SMT) & Microelectronics Assembly

Throughout the history of electronics manufacturing, there have been distinct boundaries between those that assemble SMT components and those that assemble microelectronics. In today’s market, it is difficult to identify a U.S. source for low-volume prototype services that offers both disciplines.

SMT and microelectronics die and wire bond services are not usually found in one contract assembly location. In the past, organizations had to deal with two different companies to fulfill build requirements. For example, hybrids or chip on board (COB) integrate wire bonding directly on the board.


The specific application, process requirements, thermal considerations and printed circuit board characteristics all must be accounted for when determining how and when to involve the precise sequence of SMT and microelectronics assembly.  With proper planning, manufacturers can take a product from design to volume-production at a lower cost, in a shorter time and with less risk than a company not specialized in these technologies trying to do the prototyping, manufacturing and test on its own.

Although these SMT and microelectronics assembly have been--traditionally--separate, more manufacturers are faced with both SMT and microelectronics build requests since many boards and assemblies are requiring mixed technologies.  Microelectronics assemblies require a class 100,000 cleanroom for most operations with some of the sub-processes requiring class 10,000. Expertise is expected in process engineering, die attach, wire bonding, and custom deliverable parts. Most companies looking to outsource these processes want someone with 15-to-20 years of experience in building microelectronics parts.

Taking into account and planning of SMT and microelectronics assembly simultaneously has many advantages. Simultaneous production planning enables process engineers to look at the total product rather than at one board or view it in isolation. Temperature plays a large part in determining the order of assembly; maximum temperature requirements for wire bonding can be different than for other components. Working together enables an evaluation of which part needs which processes and at what temperature profile so as not to destroy other elements of the component or adjacent wire bonds.

Norlux's team of engineers understand SMT and micreoelectronic assembly like no other manufacturer in the world today. Contact us today to discuss your LED based lighting projects.

Blog re-published with permission.  Authored originally by Jessica Sylvester on Oct 09, 2012
http://www.palomartechnologies.com/blog/bid/109934/Combining-Surface-Mount-Technology-SMT-Microelectronics-Assembly

Prototype Fabrication: Bringing Vision to Fruition

With great advances in LED (Light Emitting Diode) technology over the years, the opportunities are increasing for companies to design and implement LED-based lighting products. These products utilize the inherent energy savings and environmentally friendly characteristics of LEDs. The common business goal is to develop LED lighting products that fit specific market applications and can compete favorably with the competition in appearance, efficacy (lumen per watt,) as well as price. Product design and development begins with the collective input of Marketing, R&D and Engineering, with the eventual aim of creating a fully functional and testable prototype.
 

Prototyping is always a critical phase in product development. It amounts to taking your best theoretical concepts and engineering them into existence, with the help of a quality manufacturer. A company that excels at providing timely and accurate LED light engine prototypes must shine in the following areas:

• Understand the customer requirements and needs, even before they do
• Create multiple, innovative solutions to achieve the desired results
• Master capabilities in all aspects of LED lighting
• Thermal management
• Optics
• Controls
• Drivers
• Chip-on-Board (COB)
• Gold wire bonding
• Surface-mount technology (SMT)
• Printed circuit board (PCB) layout
• Screen/stencil printing
• Exhibit flexibility with design changes
• Demonstrate quick-turn capabilities
• Produce high-quality, accurate first yield assemblies
• Maintain close communications between the customer and the prototyping engineering group
• Facilitate seamless transitions between manual and automated processes
• Sustain electrostatic discharge (ESD) control

The ultimate goal is to get the prototype back to the customer quickly for evaluation. Customers take this opportunity to align initial calculations/expectations with real-world results. This is the time to verify form, fit and function of the finished product, or suggest a possible change moving forward.
 

With an ever-evolving technology like LEDs, it is business critical that companies get their LED lighting designs developed, built, tested, refined and launched in a timely manner. Product lifecycles are short with LED-based lighting fixtures, and the competition will take your share of the market if you’re not nimble. Fast and accurate prototyping is a critical phase your company needs to master to beat your competition to the punch.

 

Contact Norlux today for a consultation on your next LED lighting project, and we’ll start bringing your unique vision to fruition today.

Industrial Applications Embrace LED Technology

The usage of energy efficient LEDs in large-scale industrial lighting applications is becoming more critical than ever. Factories, warehouses, manufacturing plants and workshops all require a very large volume of light to properly illuminate operations, and as a result have created huge costs for businesses utilizing outdated lighting technologies of the past. Commercial grade LED industrial lighting is designed to replace existing mercury, sodium and metal halide lamp fixtures of much higher wattages, and therefore save money, energy and by extension: the environment. Thanks to advancements in semiconductors, optics and materials, LED lighting has excellent applications in industrial environments.

Below, Steve Henry (greenmanufacturer.net; 11/2011) gives us an overview of features that illustrate why LED technology is suitable for nearly any industrial lighting application. 

• Energy-efficient. The main driver for LED adoption is energy efficiency. Achieving the lighting levels required for a particular application at the lowest possible energy input becomes critical as energy costs rise and as government regulations clamp down on wasteful energy sources.
• Long-living. Correctly designed, LED fixtures offer up to 60,000 hours of illumination, with no "droop," or color shifts, and no penalty for frequent on/off cycles.  LEDs' longer lifespan than most other lighting sources' means less material is disposed over time.
• Low-maintenance. Because it is rugged and long-running, LED lighting requires very little maintenance. When LED lighting is used in a fixture with an intelligent modular design, even end-of-life replacement of components becomes quick and simple.
• Resistant to Shock, Vibration, Corrosion. LEDs can be used in environments where other technologies fail—prematurely or catastrophically.
• Cold Start-Capable. LEDs provide instant on and instant restrike capabilities to -40 degrees C, with no warm-up time required to achieve full brightness.
• Non-damaging. LEDs do not produce ultraviolet or infrared radiation often emitted by other lighting sources. This lowers cooling costs, simplifies maintenance, prolongs product life, protects eyes and sensitive equipment, and provides a margin of safety in hazardous environments.
• Safe for Hazardous Locations. Available LED luminaires are rated for use in areas where flammable gases and vapors are present under conditions defined by NEC Class I, Division 2 and IEC Zone 2.
• Easily Positionable. LED lighting often is the best choice for areas with low clearance, severe weather conditions, excessive moisture or dust, corrosive atmospheres, and high ambient temperatures.
• Nontoxic. LED lighting is also the only non-incandescent lighting source that contains no mercury. This eliminates any chance for mercury to escape into the environment either in operation or after disposal, therefore special handling is not required. Lights with lead-free solder ensure no toxins leak out when components finally reach end-of-life.
• White and Bright. Today's industrial LED luminaires provide high-quality white light that eases eye strain.
• Highly Directional. LED luminaires can be configured to produce nearly any horizontal and vertical distribution of light—from illuminating a tall, narrow fence line for security purposes to area lighting that allows production crews to work efficiently and safely.

LED industrial lighting is here today, and it's here to stay. The benefits it provides simply cannot be ignored. Even local and national governments are taking notice of LEDs as they focus on the problems of energy consumption, greenhouse gases, pollutants, and toxic waste.  LEDs are Green, and most important green feature of LEDs are their energy efficiency. LEDs have the smallest environmental footprint of any manufactured source. Because a large percentage of electricity in the U.S. is produced by burning fossil fuels, switching to LED lighting also is likely to cut emissions of greenhouse gases and toxic pollutants. In addition, LEDs are mercury-free.

 

For all of the advantages of LED based illumination, it's easy to see why the industrial market space is embracing LED technology now and will continue to switch-over well into the future.  Contact Norlux today for a consultation on your LED lighting project.

Reference: 

"Shedding light on LED for industry: LED primed to replace metal halide, mercury vapor".By Steve Henry; October 12, 2011; Green Manufacturer http://www.greenmanufacturer.net/article/facilities/shedding-light-on-led-for-industry

Norlux: Perfecting LED Logistics

In the world of LEDs, you’re going to find a lot of logistical details. These can range from choosing among a variety of LED package types, to managing lead times on shipments from overseas, choosing the right correlated color temperature (CCT) variation for your application, dealing with revision changes on LEDs as your product matures, and many more.

At Norlux, we are experts in all of these areas. We can help you manage all of these details so that you can keep your focus on your own business needs and trust the logistics to us.

Norlux has a build-to-order manufacturing model. This philosophy combined with our high capacity gives us the ability to be very nimble in meeting our customer’s demand. Norlux works with our trading partners to find the optimal balance between shipment and replenishment cycles, which, in turn, will reduce transportation expenses. Also, our central location in the suburban Chicago area makes us an optimal distribution point for North American customers.

Our volume and scale bring value to you. Norlux purchases millions of LEDs per year, so we have gained significant buying power and strong supplier relationships with all major LED manufacturers. This ultimately gives our customers access to more competitive pricing and in many cases, shorter lead times than would be otherwise achievable. Norlux also has a world class material tracking system, complete with lot number traceability.

Product lifecycle management is another area we excel in. With rapid improvements in performance and falling prices seen in the LED industry, you need an expert in managing your product lifecycle. At Norlux, we have a system in place for dealing with this. We coordinate the changes for you every step of the way. If the market price of your LED platform falls, you will benefit from the positive impact shortly thereafter. By minimizing inventory on hand and knowing precisely what exists in the supply chain, we can help you make an optimal business decision on how and when to evolve your design.

You should be free to keep your attention on your own business’ growth rather than managing these kinds of details. At Norlux, we want to partner with you and allow our expertise to fill this role, so that you can move forward with confidence and assurance in the LED lighting world. Contact us today to discuss your LED logistical needs!

Rating Systems for Outdoor Lighting Applications

Outdoor lighting applications are subject to two very important rating systems that serve to define the fixture's level of protection from the elements (IP Rating) and the projection of stray and unwanted lighting from a luminaire (BUG Rating).

IP Rating:
IP or “Ingress Protection” ratings are crucial to outdoor lighting applications because they represent a more accurate means of classifying a fixtures ability to stop the ingress of solid particles (dust and dirt) and water in the form of rain, a hose (cleaning or watering foliage) or total submersion.  The first digit in an IP rating refers to how dust proof a fixture is and the second digit refers to how waterproof a fixture is. The two numbers combined will depict the likelihood of foreign objects getting into the light fitting and possibly damaging the sensitive electronics inside. The higher the protection numbers in the chart (see example below), the greater the protection from ingress. Lower numbered fixtures are typically better suited for inside, carpeted areas like offices, waiting rooms or schools.

 

BUG Rating:
BUG stands for “Backlight”, “Uplight” and “Glare.” The acronym describes the types of stray light escaping from an outdoor lighting luminaire. Backlight is the light directed in back of the mounting pole, uplight is the light directed above the horizontal plane of the luminaire, and glare is the amount of light emitted from the luminaire at angles known to cause glare. It is expected that BUG values will be published by luminaire manufacturers so lighting specifiers, designers or purchasers can tell at a glance how well a certain luminaire controls stray light or compares with other luminaires under consideration for an installation. The BUG system was developed by the Illuminating Engineering Society (IES) to make comparing and evaluating outdoor luminaires fast, easy and more comprehensive, than older systems.

For more detailed information on the BUG rating, please visit this guide from the International Dark-Sky Association.  See also the chart below that defines the various light angles of acceptable and stray light.

 

Our team of engineers at Norlux are experts in LED lighting for outdoor applications.  Please contact us to discuss your LED based outdoor projects today.

 

Reference:

International Dark-Sky Association: volume 2: issue 1 : 2009: (BUG Illustration and Information)

http://www.aal.net/content/resources/files/BUG_rating.pdf

The Benefits of LED Based Surgical Lighting

LED lighting units are becoming more and more prominent in all segments of lighting, and surgical lighting is certainly no exception. LEDs are proving to be perfectly suited for examination and surgical illumination applications, and the switch in lighting technology from halogen to LEDs is widespread. Hospitals are always interested in finding more effective ways to run their operations at an optimum level and LEDs fit the bill not only economically, but also in terms of comfort for both surgeon (who endure hours under these lights) and patients alike.

Light emitting diode surgical lights, first introduced in the United States in July 2006, were initially met with a healthy mix of interest and skepticism. Why use LEDs in the operating room (OR)? Were the proposed benefits real? Did those benefits justify turning away from proven technologies, such as halogen, especially with lives on the line in the OR?  In the relatively short period since their introduction, these questions have been answered and the validity of LED surgical lights has been confirmed by a variety of factors. 

Low heat
Reducing heat, particularly in the area of the surgeon’s head, provides a more comfortable environment with the potential to improve surgical team performance, OR efficiency, which also would improve patient outcomes. While traditional surgical light manufacturers have made continual progress to reduce the heat produced by their lights, LED technology essentially ends this battle. In fact, the heat output of LEDs is better described as “no heat” rather than “low heat,” with temperature increases in the area of surgeon’s head measured at less than 1 degree Celsius by one manufacturer.

Extended Lifespan

LED based lights offer dramatically longer life cycles over conventional halogen based lights. The expected service life for the light source used in traditional lights is upwards of 2,000 hours. Various LED surgical light manufacturers talk about dramatically different numbers. The diodes used in LED lights are manufactured to last 50,000 hours on average. LED surgical light manufacturers will either use that 50,000-hour figure or a more conservative guarantee of 20,000 hours referring to the whole light and all its components.

Quality of Light

Beyond the benefits of long life and low/no heat, which seem to dominate most conversations on LED technology, it is important from a surgical team’s viewpoint to pose more basic questions regarding the quality of the light output. Some things to consider are:

• A homogeneous light field: The quality of light is a subjective issue, with surgeon preference coming into play to explain why some lights get approval over others. Among the factors that are at work here is whether the light field is homogeneous. Surgeons are looking for consistency of the light across its focused area with no hot spots or drop-offs.
  The quality of the field is certainly affected by the configuration of LEDs in the light head, with more LEDs providing greater coverage and a better pattern. The critical assessment of the quality of the light field is best left to the surgeon’s discerning eye during a light trial.
• Focusing ability: Another basic question is how the light is focused. Some LED lights offer a manual focus but a few can be focused electronically. What is the size of the spot and quality of the focus? Again, these functions are best judged by clinical staff during a light trial.
• Intensity: The maximum allowable intensity of a surgical light is 160,000 Lux. The best traditional lights provide this level of intensity. The best LED surgical lights also meet this standard and provide dimming capabilities so a surgical team can adjust to the demands of each procedure.

Advanced Features

Depending on the manufacturer, LED surgical lights also offer various advanced features that can contribute significantly to a surgical team’s ability to deal with common problems, as well as provide them with new capabilities.

• Shadow correction: Shadows during surgery are created by surgeon positioning, surgical team movement, equipment or the depth of a wound. The key is to minimize shadows so a surgeon always has the clearest possible view of the surgical site. In a typical LED surgical light, each LED generates the entire spot. These individual spots are then precisely overlapped, so no matter how many LEDs are blocked, the spot remains round and consistent. As obstructions move inside the light field, the pattern does not change.
• Adjustable color temperature: An option currently offered by two LED light manufacturers is the ability to adjust color temperature. Color temperature is measured in Kelvin (K) with a lower number indicating a warmer, more orange light and a higher number representing a cooler, neutral, white light. The ability to adjust color temperature, not possible prior to the introduction of LED lights, allows a surgical team to improve contrast and tissue differentiation, based on factors such as the type and depth of the surgery, blood flow and a surgeon’s preference.

It comes down to a better view for a surgeon, and that can only help to benefit the patient. OR managers benefit by having one light that can address varied surgeon preferences, so staff satisfaction is increased and room scheduling is easier. The hospital benefits by being better positioned to recruit and retain qualified surgical talent. Factor in the economic advantages of consuming less electricity to power LED lights, and it’s easy to see why LEDs are the driving force in surgical lighting.

The team at Norlux will help design and manufacture your LED based examination, procedure and surgical lighting systems; call Norlux today!

Reference:

"The future of LED lighting and why surgeons prefer it: Benefits start to push new technology ahead of traditional products"

By Dave Rector, Jan 2008

http://www.matmanmag.com/matmanmag_app/jsp/articledisplay.jsp?dcrpath=MATMANMAG/Article/data/01JAN2008/0801MMH_FEA_OR_Technology&domain=MATMANMAG