Co-op #3 |
Digital Lumens is a small (100 employee) company based in Boston MA who specializes in highly efficient and intelligent LED lighting solutions for industrial spaces. Because of its size, I had the opportunity to work on multiple product lines in support and R&D roles. Testing high bay lights in an office downtown presents its own set of unique challenges which is highlighted in the work sample below.
Work Sample 1 |
Daylight Harvesting Functional Testing
•Problem
– There is an ambient light sensor within the systems which reduces light output when the room is lit naturally. - Depending on the sensor placement, some systems will self-trigger the light reduction and render the feature useless - There are no spaces with 30' of clear space for testing. •Goal – Develop and validate a test chamber to simulate a dark room with 30' ceilings •Solution – A collapsible system of walls was built out of insulation foam and coated with light absorbing paper to reduce reflection back to sensor – Lights were hung in the center of the room, and a script varied the light level and recorded the light sensor measurement – Through a series of fixtures and measurements, the results were comparable when compared to functioning fixtures in the field. A threshold was determined and SOP created for fixture validation moving forward. - Non-functional systems were modified to restore full functionality to the full model range |
A 5th gen prototype undergoing preliminary testing (above) and configurable test stand to chose location (below)
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Work Sample 2 |
IP65, NSF Rated Housing Design
•Problem
– Current water resistant fixture is expensive and not able to be NSF certified (food safety and preparation areas). •Goal – Modify an OTS housing to include sensors and electronics which is IP65 and NSF rated and low cost - Utilize electronics common to all fixtures (no modifications) - Ensure daylight harvesting functionality through lens placement and shielding. •Solution – A two part, injection molded housing was designed to fit the fixture, electronics, and utilize custom designed compression molded gaskets - Prototypes were 3D printed and assembled using hand cut gaskets to confirm fit, compression, and water resistance - Shielding was added inside of the OTS enclosure to prevent excessive light from entering the sensor |
Prototype housing attached to OTS fixture (above) and split view of housing showing compression molded seals (red) and electronics boards (below)
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