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www.us-tech.com Production
Extended-Length LED Light Engines Speed Production and Cut Costs
By Ed Sullivan
FROM YOUR PERSPECTIVE, THIS IS MUCH BIGGER THAN IT LOOKS.
in light engine design allows for quicker, easier, and therefore cheaper assembly of linear light fixtures. Instead of two, four or even more light engines wired to- gether to create linear or other larger LED fixtures, a lighting manufacturer can simply connect the LED lamps to a single circuit board thereby providing signif- icant savings on labor, components and assembly time. Acra Phenolic, based in Traverse City, Michigan, and a supplier of new
L
and retrofit interior LED lighting for the office space and manufacturing sec- tors, has seen significant savings by becoming an early adopter of this tech- nology. “On the average four-foot linear LED fixture we’re saving at least $3.50 on each unit,” says Tom Kearney, COO. Kearney saw the need for interior lighting that was not only brighter, but
also more efficient, in the typical manufacturing plant and office space. His solu- tion was to replace T5HO lighting with more efficient LED lamps that have a life expectancy of 100,000 hours. “I thought there was considerable room for improve- ment through upgrading to LED lighting, especially in business and industrial fa- cilities where the high-pressure sodium or fluorescent lighting is often horrible,” he says. “The longer LED circuit board has added to that opportunity.” The conventional light engine — the circuit board used to power more ef-
ficient and longer-lasting LED lamps — was in the past limited to approxi- mately two feet (0.61m) in length. This meant that the assembly of linear LED fixtures, such as the four- or eight-foot (1.22, 2.44m) models that are typical- ly used to replace fluorescent lights, would require two or four boards attached in series or parallel end-to-end. As Kearney explains, with the introduction of the extended-length light
engines, it takes only one board to power a typical four-foot linear LED fix- ture, and just two boards for an eight footer. “Since each board contains con- nectors at each end, by using a single, extended-length board for a typical four-foot fixture I’m saving six to eight connectors on each one. Also, I’m prob- ably seeing a 20 to 25 percent savings on labor, and there is considerable sav- ing of production time.” The extended-length circuit boards, or light engines, are manufactured
by MADE (Manufacturing And Design Electronics), located in Auburn Hills, Michigan. Kearney selected this supplier not only because it was an innova- tor of the extended-length board, but also because the company performs 100 percent comprehensive testing, control and data reporting and recording. “MADE does this automated inspection of each LED circuit board, ensur-
ing that it lights properly, the color temperature, power output, brightness, and color rendering index are correct,” Kearney explains. “As a result, all of these things that I would have to do myself are already done when the prod- ucts arrive at my facility. And that provides an important quality assurance as well as added savings.”
Enabling Accurate Replacement In addition, in conjunction with the 100 percent inspection process, this
It’s just one small connection. Often smaller than a millimeter wide. But done right, it can save you millions. At Alpha, we place even the smallest electronic assembly challenge in a bigger light. As part of an assembly process that turns particles of material
into products and innovations that
change the world. So when we think of that one connection and how to do it better, we think of where it fits into your business. Because while it may be hard to see, your future success is connected there too.
AlphaAssembly.com
new test system stores all pertinent LED light engine lighting characteristics in a database that can be made accessible to lighting manufacturers. This database could prove valuable to manufacturers for use in handling
warranty claims and as an extended service to enable them to match the color and brightness of an LED lamp from a given production lot years later when the lamp eventually requires replacement. “Having the ability to match an LED light with one produced years ago
can be an important capability,” notes Don Bernier, president of MADE. “The end user might know exactly what model the LED chip is, and that same chip might not be available, so with the data we have we can provide the closest replacement.”
High-Performance Lighting Tom Kearney is an advocate of the long LED boards to replace standard
T5HO lamps as the standard for his linear fixtures, as LEDs provide 25 per- cent better lumens per watt than the next closest type of light source as well as better lumen maintenance. “The manufacturer of the LED chips estimates mathematically that they
will maintain over 90 percent of their output after 60,000 hours of operation, and over 70 percent after 200,000 hours of operation,” Kearney says. Kearney explains that, on the other hand, standard metal halide or high-
pressure sodium lamps provide only 50 percent of their initial light output in as little as eight to ten thousand hours or 36 months of service, and then re- quire replacement. He also says that when the type of light he recommends has operated for a year, they maintain a higher level of lumens per watt than any other current light source available. “Ironically, with traditional light sources you use the same amount of en-
ergy while getting less light output,” Kearney adds. “Fixtures using LEDs see a much smaller reduction of light output over the same period of time, and
that provides additional energy savings as the years go by.” Contact: MADE, 1124 Centre Road, Auburn Hills, MI 48326 % 248-997-4418 E-mail:
em@made-usa.net Web:
www.made-usa.net r
ight engines up to 48 in. (122.91 cm) long and 15 in. (38.1 cm) wide are lighting up the bottom line of LED light fixture manufacturers that create products such as replacements for fluorescent lighting. This advancement
August, 2016
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