3D Printer Brings Concepts to Life at Norlux

From the first minute our Stratays uPrint SE Plus 3D printer arrived in early June, the Norlux team of engineers immediately put it to good use. Having the ability to quickly fabricate and validate various product designs while trimming down prototype lead times from weeks to hours was critical for our business as well as our customers. The 3D printer works seamlessly with popular CAD software, translating complex designs into being before your very eyes. Adding this technology to our engineering capabilities was not only important to offer customers but it also has served internal customers as well. We’re very excited to have this new tool in our arsenal and below we'll illustrate some examples of how we’ve employed our 3D printing capabilities thus far.

Delighting the customer:
3D printing allows us to quickly produce product designs for validation or to identify potential design issues, otherwise known as “rapid prototyping”. By authenticating concepts early in the development process, customers can get product to market faster and at a lower cost. Below are two examples of 3D printed parts used by the engineering department to verify concepts and improvements for our customers.

Use in manufacturing:
Manufacturing has accounted for the largest use of our 3D printer to date. 3D printing technology has enabled Norlux engineers to model and print fixtures in the same day. The shortened conceptualization to actualization window allows for improved product quality and shorter lead times. Rapid fixture creation also improves employee morale by reducing fatigue and stress. Below is an example of fixture that went from concept to production in mere days.

 

 

 

Use internally:
When Norlux acquired our 3D printer, engineers immediately began thinking of ways to fully utilize the technology. In only a month we’ve collectively imagined many creative ways of using 3D printed parts here internally. One example involved fabricating a replacement part for one of our solder screen printers. These parts routinely fail and cost Norlux $50 to replace. Now, rather than purchasing a replacement when a failure occurred, we found that 3D printing the part at a fraction of the cost worked just as well.

Another example of internal usage involved the initial setup of Norlux’s new 2 meter integrating sphere. We needed a way to route wires and sensors into the sphere. Openings were available, but there was no elegant way to house the necessary wires and sensors. We decided to 3D print the adapters that were needed to house the sensors and route the wires into the sphere.

 

 

With our new 3D printing capabilities, the sky is the limit. This is just another tool we offer our customers to help create the finest LED based products in the market today. Please contact us today to learn how our 3D printing capabilities can help with your product's design.

LEDs Helping to Advance Medical Research

When it comes to surgical, examination and dental lighting, most manufacturers turn to LED technology as a means to reduce heat and eye strain while producing accurate color rendering of live tissue. Couple that with the environmentally friendly and energy efficient aspects of LED technology and it becomes clear why LEDs are king in to medical illumination applications. But where do LEDs fit of in terms of the advancement of medical science? Can LED technology actually help address and alleviate common mental conditions?

An article in Science Daily's April 2013 edition titled “Tiny Wireless Device Shines Light On Mouse Brain, Generating Reward” describes how implanting a miniature electronic device in the brain, scientists can manipulate the internal reward system of mice by illuminating specific areas and “prodding neurons to release dopamine, a chemical associated with pleasure” (Science Daily, 4/13). The lighting technology described in the article that was small but effective enough to elicit promising results were in fact LEDs. "This strategy should allow us to identify and map brain circuits involved in complex behaviors related to sleep, depression, addiction and anxiety," says co-principal investigator Michael R. Bruchas, PhD, assistant professor of anesthesiology at Washington University (Science Daily, 4/13).

To work in such a sensitive and fragile location such as the brain, engineers needed to devise a way to affect precise areas safely and accurately. “Washington University neuroscientists teamed with engineers at the University of Illinois to design microscale (LED) devices thinner than a human hair. This was the first application such devices in optogenetics, an area of neuroscience that uses light to stimulate targeted pathways in the brain” (Science Daily, 4/13). Now engineers invented a less invasive way to conduct very sensitive experiments where fiber optics and lasers were used in the past. “With the new devices, the mice freely moved about and were able to explore a maze or scamper on a wheel. The electronic LEDs are housed in a tiny fiber implanted deep in the brain. That's important to the device's ability to activate the proper neurons”, according to John A. Rogers, PhD, professor of materials science and engineering at the University of Illinois. "You want to be able to deliver the light down into the depth of the brain," Rogers says. "We think we've come up with some powerful strategies that involve ultra-miniaturized devices that can deliver light signals deep into the brain and into other organs in the future” (Science Daily, 4/13).

You might be asking yourself how exactly did LED light affect the mice’s decision making process. The article describes how “using light from the cellular-scale LEDs to stimulate dopamine-producing cells in the brain, the investigators taught the mice to poke their noses through a specific hole in a maze. Each time a mouse would poke its nose through the hole, that would trigger the system to wirelessly activate the LEDs in the implanted device, which then would emit light, causing neurons to release dopamine, a chemical related to the brain's natural reward system. When the brain cells were activated to release dopamine, the mice quickly learned to poke their noses through the hole even though they didn't receive any food as a reward. They also developed an associated preference for the area near the hole, and they tended to hang around that part of the maze" (Science Daily, 4/13).

So where will this research lead us into the future? “Researchers believe the LED implants may be useful in other types of neuroscience studies or may even be applied to different organs. Related devices already are being used to stimulate peripheral nerves for pain management” (Science Daily, 4/13). Testing of this nature could “help scientists better understand what goes on in the brain in disorders such as depression and anxiety. We believe these devices will allow us to study complex stress and social interaction behaviors," Bruchas explains. "This technology enables us to map neural circuits with respect to things like stress and pain much more effectively” (Science Daily, 4/13).

By mapping brain circuits involved in specific behaviors, we may be on the road to finding ways to alleviate and prevent common ailments in humans. "Understanding which populations of neurons are involved in these complex behaviors may allow us to target specific brain cells that malfunction in depression, pain, addiction and other disorders" (Science Daily, 4/13). LEDs and their specific form and function proved ideal for these experiments which are going a long way to advancing medicine and the understanding of our own brain functionality.

Reference:
Washington University in St. Louis (2013, April 11). Tiny wireless device shines light on mouse brain, generating reward. ScienceDaily. Retrieved June 25, 2013, from http://www.sciencedaily.com/releases/2013/04/130411142708.htm

LEDs Illuminate Famous Austrian Museum

After a decade of closure to the general public, the Kunstkammer Wien Museum (Vienna, Austria) reopened for legions of admirers of fine art. As described in a March, 2013 LED Professional article titled “Contemporary Lighting Art by Zumtobel at the New Re-Opened Kunstkammer Wien”, the museum embarked anew with the “highest conservation requirements, content-related didactic criteria, but also emotional factors played an equally essential role for the new presentation of the Kunstkammer” (staff author). A modern solution for lighting diverse art pieces within the museum was provided by well-respected Austrian lighting company, Zumtobel. Now, contemporary LED lighting solutions bring energy efficiency as well as elegance to the historical pieces from days long past.

The article describes beautifully how Zumtobel “developed a customized LED lighting solution in order to obtain a highly differentiated, gentle and effective illumination of the various objects on display. ‘The point was literally to present the objects in the best possible light. All exhibits are originals, and each of them has its very special aura that we want visitors to be able to feel and experience,’ says Sabine Haag, General Director of the Kunsthistorisches Museum. At the heart of the lighting solution is the Starbrick, a Zumtobel Masterpiece developed in collaboration with Danish-Icelandic artist Olafur Eliasson. Boasting unpretentious elegance and multi-functionality, the Starbrick is the only representative of contemporary art and cutting-edge technology in these rooms of the museum that were opened for the first time in 1891. The installation includes a total of 51 Starbrick assemblies consisting of four modules each, especially designed for illuminating the unique and sensitive works of art. Additional direct light is ensured by integrated Supersystem spotlights and indirect light is provided by a Panos Infinity module, while one of the Starbrick's surfaces that is directed downwards doubles as emergency lighting. ‘Due to the height of the ceiling, we had to increase the levels of light intensity, but the original shape of the Starbrick remained unchanged. Taking the historical rooms into particular consideration, a highly specific Starbrick assembly was created, so that the modules work like a picture, like stars in the sky,’ explains Olafur Eliasson” (Contemporary Lighting, 2013).

Zumtobel’s masterful use of LEDs with the museum walls goes beyond the Starbrick. “In addition to LED Supersystem spotlights mounted on the walls, single Supersystem spotlights were also installed in the showcases. Especially in the showcases, each of them a highly sensitive closed system, the benefits of LED technology can be fully exploited. Thus, light-emitting diodes not only boast a long service life and high energy efficiency, combined with reduced maintenance cost, but also ensure an effective and at the same time gentle presentation of the exhibits. More-over, the light colors can be individually matched to the colors and materials of the exhibits, so that they can unfurl their full charm and allow visitors to experience them authentically” (Contemporary Lighting, 2013).

At Norlux, we're developing cutting edge LED lighting solutions for OEMs, lighting designers and manufacturers. Contact us today and let's work together to design and manufacture a custom LED solution for your company.

References:
LED Professional.com, “Contemporary Lighting Art by Zumtobel at the New Re-Opened Kunstkammer Wien”. 3/1/13, Author Unknown.http://www.led-professional.com/project_news/art-museum-lighting/contemporary-lighting-art-by-zumtobel-at-the-new-re-opened-kunstkammer-wien

Visit the Kunstkammer Wien web site:
http://www.khm.at/en/?cHash=dfb045333efd096a1ea1afd262c4a608

It's Halftime for Solid-State Lighting

In the world of lighting, it's hard to dispute that in just a decade solid-state lighting (SSL) has "progressed beyond the limited world of traffic signals, exit signs and Christmas lights to become a player to be reckoned with in a growing number of general illumination applications".  We must however keep in mind that "the technology is still at a relatively early stage of its development" (Brodrick, 2013).

Through our collective efforts to determine where solid-state lighting resides on the technology life cycle, the Norlux team found an interesting perspective from a March 2013 Department of Energy article titled "It's Halftime for Solid-State Lighting". Author James Brodrick (Lighting Program Manager for the U.S. Dept. of Energy) offers a succinct view of where LEDs exist presently in commercial applications and what pitfalls must be negotiated for the technology to thrive well into the future.

Brodrick believes the forward momentum of SSL hasn't quite reached the level of persistence that sharks embody, but users of the technology must keep making consistent progress. "'Move forward or die' might be an overstatement, but as SSL reaches the mid-point of its potential, it must continue to make steady strides or risk becoming a novelty" (Brodrick, 3/13). James continues: "As tempting as it might be for SSL manufacturers to ease up a bit on the throttle that would be a big mistake, because the technology is at a turning point. Despite the dizzying acceleration in the sales of LED lighting products, they still only represent a drop in the bucket compared with the total universe of lighting installations—and, what’s more, increasingly find themselves in competition not only with CFLs and linear fluorescents, but also with earlier generations of LED products. So in order to turn the corner and achieve the widespread adoption necessary to make a significant dent in our energy consumption, SSL has to continue to improve" (Brodrick, 3/13).

To state it in sporting vernacular, James believes SSL technology has reached "half-time". James states "according to the best estimates, it’s roughly at the halfway point in terms of its potential. For example, checking the U.S. Department of Energy’s (DOE) LED Lighting Facts database of SSL products on the market, we find some good ones that have efficacies in the 90-100 lumens per watt range and are used in a number of different applications. While this represents a huge leap from even the best efficacies a few years back, DOE’s ultimate goal—which most people in the industry consider achievable—is to surpass luminaire efficacies of 200 lumens per watt" (Brodrick 3/2013).

One advantage of a maturing technology is the declining cost associated with that technology; and SSL is no different. "While efficacies are on the rise, prices are heading in the opposite direction. For many SSL luminaires, the LED package still comprises a significant portion of the cost, but those prices are dropping quickly, to as low as $5-$7/klm, which is on track with the projections in DOE’s SSL R&D Manufacturing Roadmap. In order to meet the needs of an increasing number of applications, LED packages are also becoming more and more diverse—though, fortunately, not at the expense of efficacy" (Brodrick, 3/13).

On the flip side, James explains some of the challenges facing SSL moving forward, stating "there’s a need for better greens and reds, and also for multichip monochromatic sources. It’s also essential to address such performance issues as dimming, flicker and reliability. The widespread claims that LED lighting products are fully dimmable often get contradicted by what happens in real-world installations—particularly with phase-cut dimmers, which are designed to work with incandescent lamps and thus can have compatibility problems with LED drivers. Those drivers are also the key to SSL flicker, with some drivers producing no visible flicker regardless of the light output, others causing noticeable flicker at all output levels, and others flickering only when dimmed" (Brodrick, 3/13).

We at Norlux agree with James that LEDs offer endless innovative possibilities in lighting because of the unique qualities of the technology. These attributes, if fine-tuned and constantly re-immagined will keep SSL on the fast-track to even greater adoption. "The keys to SSL’s market penetration are its unique attributes, which will function as value-added differentiators. One such attribute is SSL’s controllability, which makes it especially suited for use in smart lighting applications, where sensors can give a significant boost to energy savings. There’s also the potential to control SSL’s visible spectrum, which makes it possible to change chromaticity—not just for aesthetic reasons, but also to optimize our mood, productivity and health" (Brodrick, 3/13).

Norlux is the North American leader in high-brightness LED applications and complimentary technologies; contact us today!

Source: "LED Watch: It's Halftime for Solid-State Lighting" by James Brodrick; March 2013.
http://apps1.eere.energy.gov/buildings/publications/pdfs/ssl/led_watch_03-04-13.pdf

Advantages of LED Streetlights

Eco-friendly LED lights for outdoor applications are becoming quite a trend in today’s society, and the reasons to choose this method of illumination are many. Speaking specifically of streetlights, large municipalities and small towns alike are constantly looking for ways to keep energy costs down while limiting potentially adverse effects on the surrounding environment. Listed below are some ways in which street lights that utilize LED technology come out ahead of the competition.

• Immediate switch-on: As soon as LED lights are turned on, they immediately begin to emit a high level of light. Contrarily, it takes time for the filaments inside of conventional types of streetlights to warm up before they begin to emit the correct level of light for viewing. 
• Requires less maintenance: The lifetime of LED streetlights is usually 10 to 15 years, many times the life of current technologies. LEDs are suitable for places where replacing light bulbs is expensive, inconvenient or otherwise difficult, such as roadways or around bridges and overpasses.
• Durable and efficient: As stated in the previous Norlux blog titled: "LEDs: Energy Efficiency Leaders", LEDs are leading the way in efficiency against other prevalent lighting technologies. LED-based streetlights are also very durable, with no fragile components, and are resistant to heat, cold, and shock and ingress protection.
• Environmentally friendly: LEDs are free from hazardous chemicals, such as mercury and lead. As a side note, LEDs don't produce ultraviolet light, which attracts bugs, so they can be left to their natural pursuits.
• Directional: Because they produce "directional" light (light emitted in one direction, rather than a diffused glow) LEDs can be used to direct light on specific areas. Utilizing LED streetlights reduces “light pollution” of our night skies, allowing for better stargazing opportunities.

Some cities have utilized motion sensor technology with their LED lights, so that the lights increase in brightness when a pedestrian walks by. They can also be made to alert officials to maintenance requirements or to blink rapidly to direct emergency responders to a specific location. By integrating solar panels, the LED street lights can become self-sufficient and virtually maintenance free for a decade.
 

As LED technology evolves even further, it will no doubt become the illumination technology of choice- and not only streetlights, but in all general lighting purposes in the future. For help in the design or manufacture of your LED-based lighting products, contact Norlux today!

 

References:

“Advantages of Having LED Street Lights”: 13 Nov. 2010, By Carol K L Oon http://EzineArticles.com/5375838
“How LED Streetlights Work” by Jacob Silverman

http://science.howstuffworks.com/environmental/green-tech/sustainable/led-streetlight1.htm/printable

LEDs: Energy Efficiency Leaders

When it comes to efficient lighting, LEDs are the solution. As Americans, we use from 10-15 kilowatt-hours of energy per day on lighting. How is this calculated? This is just another way of saying that we use the equivalent of twenty-five 60 watt incandescent lamps for an average of 6 hours throughout the day. Realistic estimates predict that introduction of LED lighting to replace incandescent lamps could cut this to one third of our current usage.

In order to understand how to reduce our consumption, we need to review some basic definitions:

• Lamp Life: The expected useful life of light source with end-of-life defined as failure or diminished light output (which is typically expressed in hours).
• Lumen (lm): The output (or relative “brightness”) of a light source normalized to correlate with human vision.
• Watt (W): Standard unit of energy.

With these definitions, we can now begin to evaluate logical buying choices. If we look at a standard 40 watt incandescent lamp, it typically delivers 450 Lumens of light. If we assume our energy cost is $.11 per kilowatt hour and the bulb is operated 3 hours a day for 365 days per year, the annual operating cost is: 3x365x40= 43,800 watt-hours per year. This is approximately 44 kilowatt-hours per year (we need to divide by 1000 to get kilowatts). At $.11 per kilowatt-hour, the bulb would cost us $4.82 per year just to operate.

Source: http://www.gelighting.com/LightingWeb/na/resources/tools/lighting-assistant-toolkit/simple-life-cycle-cost-estimator.jsp

Now let’s look at two other lamp sources LED (light emitting diode) and CFL (compact florescent lamp) that put out the same amount of light. Since they are more expensive, let’s look at the total cost of ownership over their respective lives using a cost calculator from General Electric.

Notice that the incandescent cost more not only from energy consumption, but due to the fact that you need 5 bulbs per year from short life! Even though the LED solution is the most expensive initially, it is the clear winner in the long run because of long life and low energy consumption.

LED’s have now become the leading choice for indoor lighting. Unlike fluorescent lamps, there is no Mercury content that can be harmful. Although our analysis is a residential example, Norlux stands ready to help you with an OEM solution for you architectural, medical or industrial products! Contact Norlux Today!

LED Lighting: At Home in the Hospitality Industry

Lighting is crucial to the hospitality industry, as it plays an important role in the overall customer experience.  Atmosphere, comfort and security all depend on properly lit banquet & conference rooms, lobbies, halls, restaurants and the guests’ quarters.  Hotel industry professionals considering alternative lighting sources from a cost and environmental impact standpoint are realizing more and more that LEDs are the answer.

On average, interior lighting accounts for 28% of a hotel’s energy bill. Switching to efficient lighting can help reduce the energy consumption and overall operating costs, while providing an opportunity to demonstrate tangible environmental responsibility to hotel guests. Compared with the general halogen lamps, fluorescent tubes and metal halide, LEDs have a long life (exceeding 5 years on average), resulting in lower overall maintenance costs.

High CRI (Color Rendering Index) LED lamps prove ideal for the hospitality industry.  CRI is defined as “a quantitative measure of the ability of a light source to reproduce the colors of various objects faithfully in comparison with an ideal or natural light source.”  By combining high CRI with warm or cool colors, interior designers are able to create a more natural, enticing atmosphere, or direct a customer's attention in a specific way.  In an industry where look, feel and comfort are vital, LEDs provide an ideal solution.

Changing over an entire hotel to LEDs is obviously a major investment, as the initial costs can be considerable.  To mitigate this, hotels often start retrofitting with LEDs or replacing outdated fixtures in areas where the lighting is in use 24/7 (lobbies, hallways and corridors). There, the impact on energy costs is greatest and the cost savings is felt almost immediately.  Energy savings can be one of the best ways to reduce cost while increasing guest satisfaction, which is ultimately the main industry goal.  Utilizing LED-based lights will substantially reduce electricity usage and costs, which is great for the environment and the bottom line. 

For help with the design and manufacture of your LED lighting products, contact Norlux today!

Reference:
http://ezinearticles.com/?LED-Lighting-For-Your-Hotel---Cut-Costs-And-Reduce-Your-Carbon-Footprint&id=6388655

How to Design Drivers for Long Life

In order to understand how to design LED drivers for long life, one first has to understand what factors can limit driver life span. The most basic potential cause for premature failure exists in the components that are used in the design of the driver. When do different components typically wear out and what is considered their “normal use”? 

Different types of components wear out in different ways. This concept seems simple, but it really needs to be understood. For example, semiconductors have a very long life when operated at a constant temperature within specifications. However, if the temperature is cycled, for example, by the driver being turned ON and OFF, then the thermal expansion and contraction of the semiconductor can cause mechanical failures in the connections between the semiconductor die and the outside world.  This failure mechanism can be mitigated by operating the semiconductors at temperatures significantly lower than their maximum rated temperature. For example, most MOSFET’s are rated to operate at a junction temperature of 150C. However, the maximum junction temperature is usually limited to 100-110C or lower at the maximum operating temperature, to limit the damaging effects of thermal cycling.

 Another “wear-out mechanism” for drivers is related to the limitations of electrolytic capacitors. These typically have a life rating of 5,000 to 10,000 hours for high grade capacitors at their rated maximum temperature. The life of an electrolytic capacitor increases by a factor of two for every ten degrees the operating temperature is lowered.  Since a year is about 8,000 hours, it is easy to see that the electrolytic capacitors must be operated at a lower temperature than their maximum rated temperature to achieve a “lifetime” that would exceed one year.  Other components such as film capacitors and magnetics also have maximum temperature ratings that must be observed to achieve long life.

One key life-span measurement addresses how long the driver will continue to function in a controlled laboratory environment with elevated temperature or with temperature cycling.  This type of test discounts other factors that can also limit the life or damage a driver in the field.  One such factor includes extreme voltages on the input, outside the normal specified input voltage operating range. Lightning strikes are very short, high voltage (several thousand volts) impulses applied to the input of the driver that can cause damage if input surge suppression components are not used in the design. The IEEE has recommended levels of lightning protection depending on the location that drivers are applied.  Europe has a general requirement for lightning immunity that is commonly met by U.S. products.  However, the levels and frequency of lightning that can happen in certain parts of the U.S. (such as the Southeast) are much higher than the European standards.  Moreover, normal power line voltage variations (due to load switching and power outages) can also produce voltages on the input that can damage components as well as limit the life of the driver. 

Designing drivers for long life can only be achieved by understanding the limitations of all the components that are used in creating them. Operating the components at levels well below their maximum ratings and understanding “real world” occurrences that could affect a driver’s longevity goes a long way in improving the long-term effectiveness of a driver design.

Norlux is the North American leader in high-brightness LED applications and complimentary technologies; contact us today!