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Book of services


HEAD OFFICE iLumTech OMS, spol. s r. o. 906 02 Dojč 419 Slovakia Tel.: +421(0)34/694 0847 e-mail: info@ilumtech.eu www.ilumtech.eu

Book of services


The establishment of iLumTech Almost two decades ago, OMS entered the lighting market as a small luminaire manufacturer. It was never their intention to be a merely average company. Over the years, OMS’ portfolio expanded, which in turn allowed them to focus more on the development of lighting technologies and not only their manufacture. As OMS delved into the intricacies of light and implemented their findings into innovative products, they grew to become an influential player on the international lighting scene. In-house development advanced, and they came to realise that the R&D department had at their disposal a huge untapped potential, a potential that could truly move the lighting world forward. In response to this, OMS expanded their operations and founded iLumTech, housed within the OMS Lighting Innovation Centre. Within this state-of-theart building, you can find an international team of academic and technical lighting specialists spread across several design, technical and service divisions. These field-leading specialists have access to the most refined, precise and powerful development technologies, meaning that the products and services we at iLumTech provide to our customers are of unrivalled quality. Thanks to the continued success and innovation of the OMS R&D department, iLumTech now plays a key role in the development of lighting and control technologies as we continue to feed our desire for knowledge and understanding by undertaking research into all areas of light and lighting. Our knowledge is limited only by inherent boundaries, boundaries we push and expand every day as pioneers in the innovation of ground breaking electronic, optical and thermal management technologies in addition to consistently moving back the limits of conceptual design and production processes.

The level of technology, expertise and skill we have at our fingertips is truly remarkable and allows us to play a key role in defining the future of lighting.

iLumTech now wishes to offer the technologies, expertise and skill found within our various engineering departments to you, to help you design, develop and refine your ideas into a high quality product ready for release to the market. Furthermore, our services are not limited to full projects and lighting and control systems; our capacity enables us to satisfy the needs of customers across a wide range of industries, from the automotive, aeronautic and transportation industries, to the consumer electronic and medical industries. In fact, we can provide support for any manufacturer during the product design phase, and the services of our optical, thermal and electronic departments are of use in almost any industry. We can also impart our know-how through our licensing programme, meaning that we can provide you with a solution no matter what your needs iLumTech backs up its expertise by collaboration with several leading universities, institutions and companies. This high-level cooperation with some of the greatest minds in the industry means we can provide you with the very best solutions and services. Take a look through the following pages and find out what happens within a state-of-the-art scientific facility, and see how we can you help you reach your business goal.

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I The establishment of iLumTech

The establishment of iLumTech

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Product development & engineering services CONCEPT & DESIGN SERVICES

OPTICAL DESIGN services

THERMAL CHARACTERISATION & SERVICES

ELECTRONIC SOLUTIONS & SERVICES

MECHANICAL ENGINEERING SERVICES

Full luminaire development PRODUCT development request

TECHNICAL & COMMERCIAL NEGOTIATION & AGREEMENT

Development stages

PROTOTYPING

TESTING

PRODUCT COMPLETION, UPDATES & AFTER SALES SERVICES


Product development & engineering services CONCEPT & DESIGN SERVICES

OPTICAL DESIGN services

THERMAL CHARACTERISATION & SERVICES

ELECTRONIC SOLUTIONS & SERVICES

MECHANICAL ENGINEERING SERVICES

Design research Product design Mock-ups and prototypes Product promotion

Optical parts Reflector and parabolic louvre design Refractor, diffuser and lens design Spectral and luminance analysis Laboratory

Temperature cycling Power cycling Steady state operation lifetime High / low temperature storage lifetime Thermal simulation Thermo–mechanical simulation Fluid dynamics Building heating and ventilation Force prediction Thermography Glow wire testing

Hardware design Firmware design Software design Labware design Electronic design review Rapid prototyping Electrical safety tests Functional tests Long-term tests DALI compatibility tests

Sheet metal design Alumnium die cast and extrusion design Alumnium forging Mechanical analysis Rapid prototyping


Concept & design services DESIGN RESEARCH

PRODUCT design

MOCK-UPS & PROTOTYPES

PRODUCT PROMOTION

Style definition Branding and communication Design strategy Competitor research Customer research Product review Product optimisation Sustainability review Design management

Project definition Concept innovation Product design Product optimisation and enhancement Virtual model construction

Low-fidelity mock-ups Rapid prototyping High-fidelity prototypes

Product visualisations Product presentations Packaging design


Design research

Product design

Mock-ups & prototypes

Concept & design services The iLumTech product design department is a unique creative body. Here you will find an international team of experienced designers who focus on the conceptual designs and creative concepts that transform innovative ideas into successful products. The design team provides visionary concepts, new product development and product upgrades and redesigns. However, there is more; the team can also perform competitor research and create tailored design strategies for your product as well as producing rapid prototypes and mock-ups for aesthetic evaluation to support the decision making process. Our designers work in partnership with customers at the highest professional level to deliver ingenious ideas, innovative solutions and design concepts according to project specifications. Furthermore, the design team will cover the entire product design process within our own facilities, making use of advanced 3D computer modelling programmes, 3D laser scanning, our own 3D printing machine and a fully equipped prototyping workshop to delivered prototypes and mock-ups in a fast and economical manner. Our aim is to create excellent designs based on your ideas that will fit, enhance and develop your product portfolio.

Product promotion

Our international, awardwinning team of product designers is at hand to help you design the perfect product.


Design research

Product design

Mock-ups & prototypes

Product promotion

Design research Design research Product design Mock-ups & prototypes Product promotion

When it comes to design, knowing comes before doing. Based on a full understanding of your needs we are able to precisely define targets, provide fresh ideas and go on to transform them into viable industrial products that meet the highest international standards.

Our research team includes trend scouts, researchers, designers, material and process engineers, and product and account managers, all of whom will give their best to help turn your idea into an innovative and commercially successful product.

The first step of the design process is knowing in which direction to go.

Outcomes: Style definition Branding and communication Design strategy Competitor research Customer research Product review Product optimisation Sustainability review Design management

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I Product development & engineering services / Concept and design / Design research

Design research / Concept and design / Product development & engineering services

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Design research

Product design

Mock-ups & prototypes

Product promotion

Design research Design research Product design Mock-ups & prototypes Product promotion

Style definition We will accurately assess your current company and product visual style, which acts as the base for future product definition, brand development, redesign or portfolio expansion. This service is provided by our team of designers with the support of product managers and brand strategists. Branding and communication We will analyse your brand and perform corporate identity and competitor research specifically with a focus on branding. Based upon this we will propose suggestions for future brand redesign, style updates and definitions of new or revised corporate identities. This service is provided by a dedicated team of brand managers, graphic designers, product designers and account managers. Design strategy In order for a product to succeed it must have a market focus. We will help you define specific targets and guidelines for future products. This will help you create achievable goals as well as to choose a suitable approach and marketing strategy, which will in turn enable you to calculate the costs of manufacturing and tooling and set release dates. This service is provided by a specific multi-disciplinary team with the aim of providing measurable and target-trackable strategies.

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Competitor research This service acts as a base for any new project. Specific competitors are selected for approach comparison to aid in product definition, key features definition and product market placement. It provides the customer with a review of current relevant competitor strategies for selected products. This service is provided by a team of designers supported by product managers and marketing strategists. Customer research This service acts as a base for any new project definition and product market placement. It provides the customer with a review of key customers with varying demands. This service is provided by a team of designers, product managers and marketing strategists. Product review A service designed to provide a review of existing product design proposals from a design point of view. This means the selection of key features or capabilities and their review (for example engineering, manufacturing, thermal simulation, sales strategy, promotion strategy, etc.). This service is provided by a team of specialists within selected reviewing parameters.

I Product development & engineering services / Concept and design / Design research services

Product optimalisation / redesign / customisation A service designed to review a product, suggest ways to optimise it and select redesign options to fit specific customer needs. This can lead to future design updates, new materials, colours or textures, manufacturing process upgrades and the redesign of specific features. This service is provided by an interdisciplinary team of product designers, product managers and engineers from various fields of expertise. Sustainability review A service designed to calculate product lifetime and cost / investment return. This service is provided by a team of product managers and product designers. Design management We will create a relevant product strategy by setting key achievable goals using selected measurable processes and provide management leading up to successful product release. This service acts as a communication and management body overseeing all production processes, provided by designers and product managers.

Design research services / Concept and design / Product development & engineering services

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Product design

Design research

Mock-ups & prototypes

Product promotion

Product design Design research Product design Mock-ups & prototypes Product promotion

Product design is a vast area that covers all the pre-production processes that lead to a fully functional prototype. The iLumTech design team understands that success depends on the close cooperation of all involved in the process. As a result of this, we stay close to our customers and want to get you involved in every step.

By combining the design team’s creative cross-industry expertise with innovative ideas, software analysis, CAD virtual reality simulation and effective manufacturing processes, we can ensure lean production and the reliability and quality of the developed product. Our design team works in close partnership with engineers and managers to ensure that we find the very best solution for every project.

Product design is where an idea takes form and starts to become reality.

Outcomes: Project definition Concept innovation Product design  Product optimisation and enhancement Virtual model construction

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I Product development & engineering services / Concept and design / Product design

Product design / Concept and design / Product development & engineering services

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Design research

Product design

Mock-ups & prototypes

Product promotion

Product design Design research Product design Mock-ups & prototypes Product promotion

Project definition A service designed to assess and define the future product. We select the product style and relevant features to be incorporated into design proposals for the final product. This acts as a base for any product or brand style development, redesign and portfolio expansion. The service is provided by a team of strategists, designers and engineers. Concept innovation A process including discussions and brain storming sessions that enable us to combine ideas and share critical thinking for the purpose of better understanding the future product and identifying ways to provide meaningful results. This service focuses on new, creative and unconventional approaches to problem solving, and is provided by designers, strategists, trend scouts and engineers.

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Product design A service designed to provide product shape definition as well as material, colour, pattern and graphic scheme proposals for various design applications according to the specific needs of the customer. This service is the most critical part of the product design process, producing first hand results that can be evaluated by key indicators. Usually, design proposals are delivered using a variety of different approaches according to the varying product strategies applied by different groups of designers. Shape creation is provided using various mediums such as sketch renders, clay models, CAD shapes, 3D laser scans and others. The results of the design process can be presented in various forms as renders or 3D animations. This part of the product design process is essential for product definition and the selection of optimal manufacturing processes. This service is provided by groups of industrial designers and material, colour or trim designers within the design team.

I Product development & engineering services / Concept and design / Product design services

Product optimisation and enhancement This service optimises mechanical engineering and manufacturing processes according to any key indicators that need to be added or modified. Optimisation can be used to minimise the number of processes involved in production, cost reduction and alternative material selection. All processes are supervised by the design team, ensuring a high level of design quality throughout. This service is provided by a multidisciplinary team of designers, mechanical engineers, material engineers and project managers. Virtual model construction This service provides 3D models in selected qualities and formats according to need and timeframe. The 3D virtual model is provided for shape definition, construction evaluation, measurements of key indicators, rapid prototyping processes, and presentation purpose renders and animations. The 3D virtual model can be used for real time conference evaluation in various locations to ensure better understanding of selected issues. This service is provided by designers and mechanical engineers using specialised CAD programmes.

Product design services / Concept and design / Product development & engineering services

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Design research

Mock-ups & prototypes

Product design

Product promotion

Mock-ups & prototypes Design research Product design Mock-ups & prototypes Product promotion

To effectively assess and evaluate the design, manufacturing optimisation and aesthetic features of a product it is necessary to see a tangible and realistic version of it. In this case, nothing can replace the experience of seeing and touching a physical model. With mock-ups, we simulate the physical appearance of a product. Prototypes take this experience to the next level by adding the real, simulated or similar functionality of selected features.

We can create both low-fidelity mock-ups and high-fidelity prototypes using various manufacturing processes. For example, we can provide you with clay models for shape evaluation or 3D scanning, full models for exhibition presentation and promotion, and mock-ups of interior spaces and complex objects, for which we use rapid prototyping that utilises CNC milling and vacuum forming technologies as well as certain hand-modelling processes.

Nothing can provide you with such a clear idea of your product as a prototype.

Outcomes: Low-fidelity mock-ups Rapid prototyping High-fidelity prototypes

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Product development & engineering services / Concept and design / Mock-ups & prototypes Mock-ups & prototypes / Concept and design / Product development & engineering services

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Design research

Mock-ups & prototypes

Product design

Product promotion

Mock-ups & prototypes Design research Product design Mock-ups & prototypes Product promotion

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Low-fidelity mock-ups With this service we simulate the physical appearance of a product with focus on specific features that need to be tested, such as the simulation of a dimensioned outer shape for component selection, material and surface texture, and colour schemes or other selected features that require physical appearance testing. With mock-ups we simulate the first hand product experience with critical focus on ergonomics in daily use. This process quickly leads to product optimisation and design enhancements, and is provided by designers, engineers, shape modellers and workshop staff.

Rapid prototyping This service provides rapid development of full models based on 3D virtual models provided by the design team. It is an enhanced mock-up manufacturing process that allows us to create complex parametric structures with inside cavities that are impossible to manufacture in any other way. We can work together regardless of location by sending and receiving the data required and communicating about manufacturing issues over long distances. This service is provided by product designers supported by mechanical engineers.

I Product development & engineering services / Concept and design / Mock-ups & prototype services

High-fidelity prototypes A service dedicated to high quality full scale working mock-up production for product promotion and usability testing. With this service we simulate the physical appearance of a product with a focus on specific features that need to be tested in physical appearance, for example, the simulation of shape, incorporation of selected components, material applications and tests, surface finish tests and more. Highfidelity prototypes can be manufactured in a selected quality and scale according to the needs of usability testing. This service is provided by product designers, mechanical engineers and workshop staff.

Mock-ups & prototype services / Concept and design / Product development & engineering services

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Design research

Product design

Mock-ups & prototypes

Product promotion

Product promotion Design research Product design Mock-ups & prototypes Product promotion

We can use a variety of approaches to promote your final product. Sometimes it is ideal to use a full-scale model that it is possible to interact with, which is especially beneficial when installed or used in a location suitable for photoshoots. We can produce animated presentations and even entire retail solutions and strategies according to specific customer needs.

Whatever your ideas, we can provide you with everything required to promote your product on a global scale. By using the potential of our marketing and product management departments, we are able to deliver a tailored solution for global, local or targeting marketing campaigns.

Put your product in context and let the world know about it!

Outcomes: Product visualisations Product presentations Packaging design

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I Product development & engineering services / Concept and design / Product promotion

Product promotion / Concept and design / Product development & engineering services

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Design research

Product design

Mock-ups & prototypes

Product promotion

Product promotion Design research Product design Mock-ups & prototypes Product promotion

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Product visualisations We can create high-quality product visualisations for different purposes, from advertising applications to catalogues and web applications. For this, we use specialised CAD rendering programmes and post-production processes to achieve a realistic outcome. This service is provided by product designers.

Product presentations We can provide product presentations based on specific needs or audience, ranging from tailored presentations of your product for exhibition to detailed manual product externals and internals, incorporated components or product ergonomic documentation. We can provide visualisations, line drawings, prototype photos and construction schemes as well as assembly and other technical or artistic documentation. This service involves the interaction of designers, advertising and marketing specialists and contracted advertising consultants such as directors and marketing experts.

I Product development & engineering services / Concept and design / Product promotion services

Packaging design This service provides a retail suitable packaging design for any product. For this purpose we use specialised graphic software to provide many possibilities and variants. This service incorporates interaction between packaging designers, product designers and product managers to fit your needs.

Product promotion services / Concept and design / Product development & engineering services

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Optical design services OPTICAL PARTS Optical part selection Optical system optimisation

REFLECTOR & PARABOLIC LOUVRE DESIGN

REFRACTOR, DIFFUSER & LENS DESIGN

SPECTRAL & LUMINANCE ANALYSIS

Reflector selection Reflector optimisation Reflector design

Refractor and diffuser selection Refractor optimisation Refractor design Lens optimisation Lens design

Luminaire optimisation

LABORATORY Goniophotometer Luminance meter Luminance analyser Luxmeter Scatterometer Spectrometer Integration sphere 3D scanner


Optical parts

Reflector & parabolic louvre design

Refractor, diffuser & lens design

Optical design services The optical system of a luminaire is one of its most vital parts. Together with LED performance, it is responsible for luminaire efficacy and the suitability of the product for its target application. An example of this is a street luminaire, it may have the most efficient LEDs but without an appropriate optical system it cannot meet the requirements demanded of it. Another factor to mention is that inadequate or unsuitable optical parameters result in losses that ultimately negate the effectiveness of other aspects of the design. Based on this, it becomes clear that optics is not only about creating the suitable light distribution for a purpose, but can also significantly affect energy saving potential, giving your luminaire great advantages over the competition. iLumTech places the necessary focus on this area of research and development, and has built a strong team of highly educated and experienced specialists who are able to design any kind of optical system. Furthermore, we have at our disposal a wide range of state-of-theart equipment that enables us to measure optical parameters in-house, helping to keep development times to a minimum and removing the need to outsource any part of the design process.

Spectral & luminance analysis

Laboratory

Optics act as the interface between light as science and light as part of life.


Optical parts

Reflector & parabolic louvre design

Refractor, diffuser & lens design

Spectral & luminance analysis

Laboratory

Optical parts Optical parts Reflector & parabolic louvre design Refractor, diffuser & lens design Spectral & luminance analysis Laboratory

Optics is the branch of physics concerned with the behaviour and properties of light, including its interactions with matter and the construction of equipment that uses or detects it. A luminaire is a device that modifies the light emitted by a light source by changing its Light Intensity Distribution Curve (LIDC), diffusing it, reducing its brightness at angles of observation or changing its spectral composition. These changes are achieved using optical parts – reflectors, refractors, diffuser and lenses – used in addition to auxiliary parts like sockets, starters and ballasts.

Optimal luminaire performance can only be achieved if effective and appropriate optical parts are used and are further refined to meet the specific needs of each product. We understand that customers need fully optimised solutions that perform, meet standards and are cost effective. Our dedicated optical design team have access to the latest development technologies as well as having vast practical experience and theoretical knowledge, all of which are applied to every product that passes through our hands.

To harness light, you first have to understand its properties and behaviour.

Outcomes: Optical part selection Optical system optimisation

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I Product development & engineering services / Optical design / Optical parts

Optical parts / Optical design / Product development & engineering services

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Optical parts

Reflector & parabolic louvre design

Refractor, diffuser & lens design

Spectral & luminance analysis

Laboratory

Optical parts Optical parts Reflector & parabolic louvre design Refractor, diffuser & lens design Spectral & luminance analysis Laboratory

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Optical part selection There are several types of optical part to choose from, each with its own strengths and suitable for different uses. Reflectors and parabolic louvres change the light emitted from the light source by reflection and are made from materials with high reflectance, with parabolic louvres also serving to shield light sources from view at key angles. Refractors and lenses change the light distribution of a light source by refraction and are made of materials with direct transmission. Diffusers change the light distribution mostly by diffusion and are made from materials with light diffusing properties. The choice of the most suitable optical parts for each product is the first step in the design of a tailored optical system.

Optical system optimisation We use LightToolsÂŽ, one of the bestknown software applications used for optical analysis. It is a unique optical engineering and design software tool that features virtual prototyping, simulation, optimisation and photorealistic renderings of precision illumination applications. The software has adapted solid modelling technology to accommodate the inherent accuracy required to simulate the ray paths of light as they traverse through and within optical elements and mechanical structures. The software is straightforward to use, accurate, has the most advanced capabilities commercially available and supports the tasks of design and engineering iterations in addition to analysis. It provides us with unlimited possibilities in terms of optical design and analysis, meaning that we can achieve the best results for every product solution.

I Product development & engineering services / Optical design / Optical parts services

Optical parts services / Optical design / Product development & engineering services

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Optical parts

Reflector & parabolic louvre design

Refractor, diffuser & lens design

Spectral & luminance analysis

Laboratory

Reflector & parabolic louvre design Optical parts Reflector & parabolic louvre design Refractor, diffuser & lens design Spectral & luminance analysis Laboratory

Reflectors modify the LIDC of a light source by reflecting the light emitted from a reflective material using mirror, diffuse or mixed reflections. The luminance of the reflection on the optical axis is directly proportional to the luminance of the light source yet insignificantly small at arbitrarily different angles. Reflectors can be classified into three basic groups: the first includes conical reflectors of elliptical, zonal, hyperbolic or parabolic geometries, while the second group includes non-conical reflectors such as linear, square or asymmetric ones and the third group includes free form reflectors. Furthermore, the reflective surface often has additional surface treatments that minimise degradation and can be of a simple shape or have planar or 3D facets.

A very common yet specific application of reflector technology is for parabolic louvres, used mainly in office settings to ensure that lighting systems meet the ‘EN 12464-1 Light and lighting of interior workplaces’ standard. Parabolic louvres consist of side blades that create the desired LIDC, generally of an elliptical shape, as well as lamellas, which are the parts of the louvre that are placed perpendicular to the light source to hide it from view and minimise glare.

Reflectors and louvres are highly flexible optical and can be precisely tailored to need.

Outcomes: Reflector selection Reflector optimisation Reflector design

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I Product development & engineering services / Optical design / Reflector & parabolic louvre design

Reflector & parabolic louvre dsign / Optical design / Product development & engineering services

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Optical parts

Reflector & parabolic louvre design

Refractor, diffuser & lens design

Spectral & luminance analysis

Laboratory

Reflector & parabolic louvre design Optical parts Reflector & parabolic louvre design Refractor, diffuser & lens design Spectral & luminance analysis Laboratory

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Reflector selection Which type of reflector is most suitable depends on the type of luminaire and where it will be used. For example, spotlight luminaires are generally equipped with faceted conical reflectors whereas linear luminaires used in an industrial hall will tend to be equipped with a simply shaped reflector with a metallic or white surface finish. Whatever the area of application, there is an ideal type of reflector. We have an extensive library of materials from which to choose to make sure that the reflector used will perform as needed.

Reflector optimisation In order to provide the exact LIDC needed, we will need to know various things about the space the luminaire will be used in. Based on this we can determine the necessary optical parameters and modify the reflector accordingly. For this purpose we use LightToolsÂŽ as well as our own LIDC Optimiser software.

I Product development & engineering services / Optical design / Reflector & parabolic louvre design services

Reflector design Reflective optics are a standard tool in optical design, and use reflection to capture the light emitted by a light source. In most cases we use parabolic, hyperbolic or eliptical reflectors to control the light output according to need. It is most difficult to create freeform reflectors, which are able to preciselt deliver light to the right place and with right intensity. This will be a key point in our future reflector designs: that there be no limitation to the optical design of reflecitve optical parts.

Reflector & parabolic louvre design services / Optical design / Product development & engineering services

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Optical parts

Refractor, diffuser & lens design

Reflector & parabolic louvre design

Spectral &luminance analysis

Laboratory

Refractor, diffuser & lens design Optical parts Reflector & parabolic louvre design Refractor, diffuser & lens design Spectral & luminance analysis Laboratory

Refraction is the modification of a light ray’s movement through a material in order to create uniform light distribution with a desired LIDC. The 3D shape of a refractor is calculated and optimised based on geometric optics, a very complex and time-consuming process. The most commonly used refractive materials are in fact referred to as diffusers as their refractive properties cause diffusion of the transmitted light. Prismatic and microprismatic diffusers have a surface made up from many small-scale refracting geometric structures that create the desired LIDC and reduce glare.

There are also diffusers that do not use refraction but are rather made of materials with light diffusing properties. Opal diffusers are made of a material containing light scattering micro-particles, whereas Gaussian diffusers have a fine surface structure resembling sandblasted glass that scatters the light. Lenses are often categorised separately, although they are, in fact, a kind of refractor. A simple lens is made from a transparent material that transmits and refracts light and converges or diverges the beam. It is also possible to use lenses that have geometrically shaped surfaces such as Fresnel lenses.

We developed the LIDC Optimiser to help us find the ideal light distribution for any application.

Outcomes: Refractor and diffuser selection Refractor optimisation Refractor design Lens optimisation Lens design

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I Product development & engineering services / Optical design / Refractor, diffuser & lens design

Refractor, diffuser & lens design / Optical design / Product development & engineering services

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Optical parts

Reflector & parabolic louvre design

Refractor, diffuser & lens design

Spectral & luminance analysis

Laboratory

Refractor, diffuser & lens design Optical parts Reflector & parabolic louvre design Refractor, diffuser & lens design Spectral & luminance analysis Laboratory

Refractor and diffuser selection It is difficult to understand the advantages and disadvantages of each type of refractive or non-refractive diffuser, especially in terms of its application in a specific setting. Our optical engineers are experienced in making these choices and can help customer understand which best suits their needs. Refractor optimisation It is possible to modify a refractive material in order to achieve a desired LIDC; however, this is an incredibly difficult task that requires a high level of expertise. To help us with this process we have developed our own LIDC Optimiser software, which helps us determine the precise LIDC needed for each application and provides calculations we can use as a base for optical optimisation.

Lens optimisation Lenses are used in LED luminaires and are commonly positioned directly on the LED. There are many lens shapes to choose from. Only experienced and knowledgeable optical engineers know how to determine the best lens for each product, with the possibility of combining various lenses within one optical system in order to achieve the desired result. For highly demanding street lighting luminaires we have developed our own optimisation software, the Street Light Configurator, which allows us to combine up to four different lenses at various angles in order to provide the needed LIDC.

Lens design Lenses are standard parts in optical design. Illumination designs use internal reflection and the law of refraction to capture the light emitted by a light source. In Refractor design most cases we use free form lenses. This There are a variety of refractive optics will be an area of focus in ourfuture deused in illumination systems. In this group signs, as such lenses are incredibly flexible we can find lenses, arrays, prisms, pillow and can be used in variety of applications. optics and also protective covers. The ability of these opitcal parts to directly control the light is due to the law of refraction. Based on this great flexibility, we are able to creat any refractor design according to customer needs.

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I Product development & engineering services / Optical design / Refractor, diffuser & lens design services

Refractor, diffuser & lens design services / Optical design / Product development & engineering services

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Optical parts

Reflector & parabolic louvre design

Refractor, diffuser & lens design

Spectral & luminance analysis

Laboratory

Spectral & luminance analysis Optical parts Reflector & parabolic louvre design Refractor, diffuser & lens design Spectral & luminance analysis Laboratory

One advantage of our using sophisticated optical analysis software is that it enables us to perform the spectral and luminance analysis of light sources. When designing an optical system it is vital to know what light parameters are required and to ensure that the product under development meets those needs. This includes knowledge of the luminance, LIDC, Colour Rendering Index (CRI) and Correlated Colour Temperature (CCT) of the light source. This means we can save both time and money by creating and analysing mathematical models rather than needing to produce expensive working prototypes.

We can precisely define your light and help you to optimise its use.

Outcomes: Luminaire optimisation

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I Product development & engineering services / Optical design / Spectral & luminance analysis

Spectral & luminance analysis / Optical design / Product development & engineering services

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Optical parts

Reflector & parabolic louvre design

Refractor, diffuser & lens design

Spectral & luminance analysis

Laboratory

Spectral & luminance analysis Optical parts Reflector & parabolic louvre design Refractor, diffuser & lens

Luminaire optimisation We can optimise any part of an optical system so that the luminaire meets international standards based on in-depth analysis of the light emitted by a chosen light source.

design Spectral & luminance analysis Laboratory

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I Product development & engineering services / Optical design / Spectral & luminance analysis services

Spectral & luminance analysis services / Optical design / Product development & engineering services

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Optical parts

Reflector & parabolic louvre design

Refractor, diffuser & lens design

Spectral & luminance analysis

Laboratory

Laboratory Optical parts Reflector & parabolic louvre design Refractor, diffuser & lens design Spectral & luminance analysis Laboratory

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We have one of the best-equipped laboratories in Europe. Within our state-ofthe- art facilities, we can make the measurement that act as vital building blocks of a product’s development. We have all the necessary devices in-house and our engineers are skilled and experienced in their use, saving time and money as measurements and procedures don’t need to be outsourced. Available tests: • Luminous intensity distribution curves (LIDC) • Ray data available in various formats (e.g. ASAP, SPEOS, LucidShape, LighTTools, Zemax, SimuLux) • Processing and archiving of the LVK data in a photometric database (LumCAT) • Measurement of the luminance of CRTs, LED, and ELs • Measurement of road and tunnel brightness • Measurement of rail-system signals • Measurement of road and airport signals • Measurement of illumination and out door signs • Measurement of illumination equipment and devices • Research and measurement testing • Measurement of device brightness, brightness and brightness uniformity • RGB colour values of the CMOS matrix • Luminous flux
 • Spectral measurements
 • CCT and CRI measurements • Measurements of x,y,z coordinates • Scattering measurements – BRDF/ 
BSDF • 3D scanning of objects

I Product development & engineering services / Optical design / Laboratory services

Our well-equipped laboratories mean we can provide you with all the measurements you need.

Equipment: Goniophotometer Luminance meter 3D scanner Luxmeter Luminance analyser Scatterometer Spectrometer Integration sphere

Laboratory services / Optial design / Product development & engineering services

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Optical parts

Reflector & parabolic louvre design

Refractor, diffuser & lens design

Spectral & luminance analysis

Laboratory

Laboratory Optical parts Reflector & parabolic louvre design Refractor, diffuser & lens design Spectral & luminance analysis Laboratory

Goniophotometer The RiGO 801 is a near-field goniophotometer described in the EN 13032-1 standard and uses a luxmeter and luminance camera, i.e. a photo detector array with imaging optical system, which allows for the splitting of the luminous surface into smaller segments. It is able to measure LIDCs, luminous flux and the luminance of light-emitting surfaces. It enables us to create photometric files (eulumdat or IES) and measurement reports. It provides all necessary values for use in the DIALux plug-in.

Luminance analyser The complex evaluation of illuminated areas requires knowledge of the luminance distribution within the whole field of view or at least in many selected parts of it. Doing this by making many parallel measurements is both time consuming and requires the use of a coarse raster grid, if it possible at all. The luminance analyser is a resolved radiation receiver, in particular a CCD matrix camera, and allows for measurement of these complex areas for glare evaluation, assessment of road visibility conditions at night, emission evaluations of glare sources Luminance meter and the determination of contrast ratios in We use the best handheld spot lumi- illuminated situations, such as workplaces, nance meters on the market. The single lens or directly of light sources like luminaires, reflex (SLR) optical system allows for precise computer monitors, indicator lights, etc. targeting and enables the viewfinder to show the exact area to be measured even Scatterometer at close range, making focusing very easy The Mini-Diff is an ‘optical mouse’ for and therefore accurate. The viewfinder also optical designers and enables the capture shows the measured luminance value. Spe- of scattering properties of a surface to be cial attention has also been paid to the mini- exported to the appropriate software. misation of flare to give precise V(λ) correlation (CIE relative photopic luminosity curve).

Spectrometer A spectrometer (or spectrograph or spectroscope) is an instrument that measures the properties of light across a specific part of the electromagnetic spectrum. It is typically used in the spectroscopic analysis and identification of materials. The most measured parameter is light intensity but other measurement possibilities include polarisation states. Integrating sphere An integration sphere allows for the evaluation of the luminous flux of a light source based on the measurement of indirect luminance within the sphere. Different measurement positions can be used, for example, omnidirectional measurements of light sources places in the centre of the sphere and unidirectional measurements of light sources placed on the wall of the sphere.

3D scanner The ATOS Compact Scan takes 3D scanning to a new level as it is incredibly easy to use thanks to its low weight and adaptability. Luxmeter The RadioLux 111 is a precision handheld instrument used for photometric and radiometric measurements. It is as useful in the laboratory as it is in the field and can be equipped with various photometric heads depending on the type of illumination being measured, according to the EN 124641 standard. We have heads for spherical, semi-cylindrical and horizontal illuminance measurements.

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Laboratory equipment / Optical design / Product development & engineering services

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Thermal characterisation & services TEMPERATURE CYCLING POWER CYCLING Product reliability Failure rate Lifetime prediction

FLUID DYNAMICS Optimised solution

Product reliability Failure mode

BUILDING HEATING & VENTILATION Airflow optimisation Temperature control Air quality and contaminant control

STEADY STATE OPERATION LIFETIME

HIGH/LOW TEMPERATURE STORAGE LIFETIME

THERMAL SIMULATION

THERMO-MECHANICAL SIMULATION Optimised solution Lifetime prediction

Intrinsic reliability of integrated circuits

The effects of storage conditions Material degradation Shelf life prediction

Optimised solution

FORCE PREDICTION

THERMOGRAPHY

GLOW WIRE TESTING

Dangerous conditions prediction

Real time capture of infrared images

Evaluation of flammability and fire resistance


c

Temperature cycling

Power cycling

Steady state operation lifetime

High/low temperature storage lifetime

Thermal simulation

Fluid dynamics

Building heating & ventilation

Force prediction

Thermography

Glow wire testing

Thermal characterisation and services As technology becomes smaller, faster and more powerful, thermal management is becoming and increasingly crucial part of any product’s design. Afterall, higher device performance often comes at the price of reliability and lifetime if thermal factors are not given due consideration. This trend for all things small continues to the boards that devices are mounted on, with units being placed closer and closer together into smaller spaces to decrease system size and cost and improve electrical performance. Yet, from a thermal management perspective, increased power and smaller sizes are a bad combination. This increased ‘power density’ is the driving force behind a heightened focus on thermal management across many industries. To assist board and system level designers in their quest to create more intricate products, iLumTech can provide a wide range of thermal characterisation services to customers.

Thermo-mechanical simulation

Thermal management is key to making possible the utilisation of intricate modern technologies in everyday devices.


Temperature cycling

Power cycling

Steady state operation lifetime

High/low temperature storage lifetime

Thermal simulation

Fluid dynamics

Building heating & ventilation

Force prediction

Thermography

Glow wire testing

Thermo-mechanical simulation

Temperature cycling Temperature cycling Power cycling Steady state operation lifetime High/low temperature storage lifetime Thermal simulation Thermo-mechanical simulation Fluid dynamics Building heating & ventilation Force prediction

Temperature cycling is used to determine the resistance of components to sudden exposure to extreme changes of temperature. The test procedure consists of subjecting the device under test to a specified low temperature and then to a specified high temperature, a cycle that is repeated a set number of times using a piece of equipment called a Temperature Cycle Chamber. The alternating high and low temperature extremes induce mechanical stress such as solder joint cracking, warpage of materials and damage to electronic components.

The reliability of components and solder joints are crucial for a successful product.

Temperature cycling conditions, including high and low temperature values, the number of cycles, soak times, transfer times and ramp rates, vary based on the item to be tested and can be specifically determined. Test method: JEDEC standard JESD22

Thermography Glow wire testing Outcomes: Product reliability Failure rate Lifetime prediction

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I Product development & engineering services / Thermal design / Temperature cycling

Temperature cycling / Thermal design / Product development & engineering services

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Temperature cycling

Power cycling

Steady state operation lifetime

High/low temperature storage lifetime

Thermal simulation

Fluid dynamics

Building heating & ventilation

Force prediction

Thermography

Glow wire testing

Thermo-mechanical simulation

Temperature cycling Temperature cycling Power cycling Steady state operation lifetime High/low temperature storage lifetime Thermal simulation

Product reliability Mechanical stress caused by temperature fluctuations can have a profound effect on a product’s reliability and lifetime, and although the operation of a product will not normally undergo extreme changes in temperature, it is always a possibility. It is important to understand the effects of that mechanical stress in order to verify and, if necessary, improve the design of the final product.

Failure rate Any product can fail due to unforeseen circumstances or simply due to minor or hidden faults in components or even operation. However, even though failure rates are an inevitable parameter, we try to keep them to a minimum. By measuring the failure rate of a product, standardly expressed as a percentage, it is possible to assess its robustness and maybe find faults in the design at earlier stages, making the resolution easier, faster and more cost effective.

Lifetime prediction We all want quality products, and a mark of their quality is their predicted lifetime. Lifetimes are also important when it comes to designing a device, or using a device in a larger system, as it affects the final outcome. A product’s lifetime is calculated based on the determination of material deterioration and durability, literally, how long the product can last before it is worn out or deemed no longer effective.

Thermo-mechanical simulation Fluid dynamics Building heating & ventilation Force prediction Thermography Glow wire testing

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I Product development & engineering services / Thermal design / Temperature cycling services

Temperature cycling services / Thermal design / Product development & engineering services

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Temperature cycling

Power cycling

Steady state operation lifetime

High/low temperature storage lifetime

Thermal simulation

Fluid dynamics

Building heating & ventilation

Force prediction

Thermography

Glow wire testing

Thermo-mechanical simulation

Power cycling Temperature cycling Power cycling Steady state operation lifetime High/low temperature storage lifetime Thermal simulation Thermo-mechanical simulation Fluid dynamics Building heating & ventilation Force prediction

Under standard operational conditions, devices are switched on and off many times throughout their lifetime. Power cycling is used to predict the fatigue lifecycle of a device, and can be used in combination with electrical, heat and stress analysis to predict the lifetime of a product. The power cycling test procedure consists of turning the power to the device under test on and off repeatedly under a specified and constant ambient temperature.

To achieve industrial qualification, we must test a product using operating biases.

Power cycling is also important in the determining of electronic device reliability. The repeated active heating of the device under test by the load current in combination with the subsequent cooling phase subjects the assembly and packaging of the device to thermo-mechanical stress and aging. The number of cycles passed by the item before it fulfills failure criteria is a critical qualifier of its reliability. Test method: JESD22

Thermography Glow wire testing Outcomes: Product reliability Failure mode

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I Product development & engineering services / Thermal design / Power cycling

Power cycling / Thermal design / Product development & engineering services

IÂ 65


Temperature cycling

Power cycling

Steady state operation lifetime

High/low temperature storage lifetime

Thermal simulation

Fluid dynamics

Building heating & ventilation

Force prediction

Thermography

Glow wire testing

Thermo-mechanical simulation

Power cycling Temperature cycling Power cycling Steady state operation lifetime High/low temperature storage lifetime Thermal simulation Thermo-mechanical simulation Fluid dynamics

Product reliability The operation of a device influences its temperature in addition to the external temperature fluctuations most devices will be exposed to repeatedly throughout their life. A key determiner of a product’s quality is its ability to withstand high and low temperatures under normal operating conditions, something that we can both calculate and assess. Failure mode One of the best ways to understand product failures is to use cyclic loading to identify and assess the types of failure. This enables any weaknesses to be resolved during the early stages of product development, saving time and investment.

Building heating & ventilation Force prediction Thermography Glow wire testing

One power cycle Power on

Power off

5

10

15

20

25

30

35

40

45

50

55

60

65

70

Time (minutes) Source: JEDEC standard 22A105C

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I Product development & engineering services / Thermal design / Power cycling services

Power cycling services / Thermal design / Product development & engineering services

IÂ 67


Temperature cycling

Power cycling

Steady state operation lifetime

High/low temperature storage lifetime

Thermal simulation

Fluid dynamics

Building heating & ventilation

Force prediction

Thermography

Glow wire testing

Thermo-mechanical simulation

Steady state operation lifetime Temperature cycling Power cycling Steady state operation lifetime High/low temperature storage lifetime

In most areas of the world, the average ambient temperature varies between a maximum of +45 °C and a minimum of -30 °C. Steady state operation lifetime testing is used to precisely assess and verify a product’s performance under such high and low temperature conditions by subjecting the device under test to electrical stress at a specified high and low temperature over a defined extended period of time.

There are two tests: the High Temperature Operating Life (HTOL) and Low Temperature Operating Life (LTOL) used to test devices that start up at low temperatures. Test method: JESD22-A108D

We can assure our customers that every product we develop will have a long life.

Thermal simulation Thermo-mechanical simulation Fluid dynamics Building heating & ventilation Force prediction Thermography Glow wire testing Outcomes: Intrinsic reliability of integrated circuits

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I Product development & engineering services / Thermal design / Steady state operation lifetime

Steady state operation lifetime / Thermal design / Product development & engineering services

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Temperature cycling

Power cycling

Steady state operation lifetime

High/low temperature storage lifetime

Thermal simulation

Fluid dynamics

Building heating & ventilation

Force prediction

Thermography

Glow wire testing

Thermo-mechanical simulation

Steady state operation lifetime Temperature cycling Power cycling Steady state operation lifetime High/low temperature

Intrinsic reliability of integrated circuits There are many tests that a product must undergo to quantify and evaluate its quality and robustness. One of the most basic tests is that which determines the inherent resistance of the device under test to prolonged operational stress, including both electrical and thermal stress.

storage lifetime Thermal simulation Thermo-mechanical simulation Fluid dynamics Building heating & ventilation Force prediction Thermography Glow wire testing

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I Product development & engineering services / Thermal design / Steady state operation lifetime services

Steady state operation lifetime services / Thermal design / Product development & engineering services

IÂ 71


Temperature cycling

Power cycling

Steady state operation lifetime

High/low temperature storage lifetime

Thermal simulation

Fluid dynamics

Building heating & ventilation

Force prediction

Thermography

Glow wire testing

Thermo-mechanical simulation

High/low temperature storage lifetime Temperature cycling Power cycling Steady state operation lifetime High/low temperature storage lifetime

Temperature storage tests are used to determine the effects of long-term storage at high or low temperatures on devices. The test procedure involves measuring the resistance of the device under test to storage in a simulated storage environment with no electrical stress applied.

Find the best shelf life temperature for a product to optimise its long-term storage.

Test methods: JESD22-A119 and JESD22-A103D.

Thermal simulation Thermo-mechanical simulation Fluid dynamics Building heating & ventilation Force prediction Thermography Glow wire testing Outcomes: The effects of storage conditions Material degradation Shelf life prediction

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I Product development & engineering services / Thermal design / High/low temperature storage lifetime

High/low temperature storage lifetime / Thermal design / Product development & engineering services

IÂ 73


Temperature cycling

Power cycling

Steady state operation lifetime

High/low temperature storage lifetime

Thermal simulation

Fluid dynamics

Building heating & ventilation

Force prediction

Thermography

Glow wire testing

Thermo-mechanical simulation

High/low temperature storage lifetime Temperature cycling Power cycling Steady state operation lifetime High/low temperature storage lifetime Thermal simulation Thermo-mechanical simulation Fluid dynamics Building heating & ventilation Force prediction Thermography Glow wire testing

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The effect of storage conditions Every product needs to be stored at some point, and it is inevitable that storage and the conditions of that storage affect the product. It is important to understand the effects of various storage conditions on products, specifically on the materials used, which will degrade over time. This test helps us to know how best to protect the items from unnecessary damage and degradation during storage and to define ideal storage conditions. Material degradation All materials degrade over time due to a myriad of external factors. It is therefore important to assess the stability of the materials used to construct a product and their resistance to environmental conditions. This test goes on to act as the base for shelf life predictions. Shelf life prediction It is important to know how long a product can be stored before it becomes unsuitable for use. In the case of food, this is an obvious and vitally important parameter. However, it is no less important for any other kind of product as it impacts on all stages of a product’s life, from production to its ability to be stored.

I Product development & engineering services / Thermal design / High/low temperature storage lifetime services

High/low temperature storage lifetime services / Thermal design / Product development & engineering services

IÂ 75


Temperature cycling

Power cycling

Steady state operation lifetime

High/low temperature storage lifetime

Thermal simulation

Fluid dynamics

Building heating & ventilation

Force prediction

Thermography

Glow wire testing

Thermo-mechanical simulation

Thermal simulation Temperature cycling Power cycling Steady state operation lifetime High/low temperature storage lifetime Thermal simulation Thermo-mechanical simulation Fluid dynamics Building heating & ventilation

The cost effective design of an electronic system requires careful consideration of thermal management. The over-design of an electronic system adds unnecessary cost and weight, whereas the under-design of a system may result in overheating and even system failure. Finding an optimised solution requires in-depth understanding of how to predict the operating temperature of a device and how the heat generated by the given components affects neighbouring components and devices. Thermal assessment requires a combination of analytical calculations using thermal specifications, empirical analysis and thermal modelling. CADembedded thermal simulation enables the performance of thermal analysis at various stages of a product’s design process to ensure that all components and their assembly perform properly within the expected temperature ranges and highlights safety issues before they arise.

Finding an optimised solution in the early stages of development can prevent the under- or over-designing of a system and unnecessary costs and failures.

Force prediction Thermography Glow wire testing Outcomes: Optimised solution

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I Product development & engineering services / Thermal design / Thermal simulation

Thermal simulation / Thermal design / Product development & engineering services

IÂ 77


Temperature cycling

Power cycling

Steady state operation lifetime

High/low temperature storage lifetime

Thermal simulation

Fluid dynamics

Building heating & ventilation

Force prediction

Thermography

Glow wire testing

Thermo-mechanical simulation

Thermal simulation Temperature cycling Power cycling Steady state operation lifetime High/low temperature storage lifetime

Optimised solution Nothing is perfect, yet optimisation is the process by which we can get as close as possible. It is the act of trading off various potential solutions in order to arrive at the one that best meets the given product design objectives. This ensures that products have the greatest performance possible while remaining lean and cost effective.

Thermal simulation Thermo-mechanical simulation Fluid dynamics Building heating & ventilation Force prediction Thermography Glow wire testing

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I Product development & engineering services / Thermal design / Thermal simulation services

Thermal simulation services / Thermal design / Product development & engineering services

IÂ 79


Temperature cycling

Power cycling

Steady state operation lifetime

High/low temperature storage lifetime

Thermal simulation

Fluid dynamics

Building heating & ventilation

Force prediction

Thermography

Glow wire testing

Thermo-mechanical simulation

Thermo-mechanical simulation Temperature cycling Power cycling Steady state operation lifetime High/low temperature storage lifetime Thermal simulation

Many materials experience changes in their thermo-mechanical properties during heating and cooling, changes that affect the reliability of products. Thermomechanical simulation allows engineers to understand how the structure of a device behaves under both mechanical and thermal loading, enabling the prediction of its structural reliability. The test procedure measures deformations and stresses in solids based on the combined effect of mechanical and thermal stress, including coupling due to thermal expansion.

Understanding the effects of mechanical and thermal loading enables engineers to understand how a structure behaves and performs.

Thermo-mechanical simulation Fluid dynamics Building heating & ventilation Force prediction Thermography Glow wire testing Outcomes: Optimised solution Lifetime prediction

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I Product development & engineering services / Thermal design / Thermo-mechanical simulation

Thermo-mechanical simulation / Thermal design / Product development & engineering services

IÂ 81


Temperature cycling

Power cycling

Steady state operation lifetime

High/low temperature storage lifetime

Thermal simulation

Fluid dynamics

Building heating & ventilation

Force prediction

Thermography

Glow wire testing

Thermo-mechanical simulation

Thermo-mechanical simulation Temperature cycling Power cycling Steady state operation lifetime High/low temperature storage lifetime

Optimised solution Advanced computer simulations allow us to analyse and understand the performance of structures and systems so that we can improve them. This requires the cooperation of engineers and designers throughout product development with the aim of providing useful and constructive feedback and ideas.

Lifetime prediction The basic steps involved in the thermomechanical lifetime assessment of components are fluid dynamic studies, transient thermal calculations and mechanical computations that identify loading conditions. Estimating the lifetime of thermomechanically loaded components is both time-consuming and expensive, therefore, the simulation of fatigue is a vital design step that minimises timescales and costs.

Thermal simulation Thermo-mechanical simulation Fluid dynamics Building heating & ventilation Force prediction Thermography Glow wire testing

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I Product development & engineering services / Thermal design / Thermo-mechanical simulation services

Thermo-mechanical simulation services / Thermal design / Product development & engineering services

IÂ 83


Temperature cycling

Power cycling

Steady state operation lifetime

High/low temperature storage lifetime

Thermal simulation

Fluid dynamics

Building heating & ventilation

Force prediction

Thermography

Glow wire testing

Thermo-mechanical simulation

Fluid dynamics Temperature cycling Power cycling Steady state operation lifetime High/low temperature storage lifetime Thermal simulation

The analysis of a fluid (a liquid or gas) within a device is very complex as it is based on heat transfer, mixing and unsteady and compressible flows. To predict the impact of fluid flow on a product can be both time consuming and very costly without appropriate simulation tools. Computational Fluid Dynamics (CFD) analysis enables the quick and efficient simulation of both fluid flow and heat transfer in order to calculate fluid forces and understand the impact of a liquid or gas on product performance.

The analysis of fluid flow assures innovative design and greater product efficiency.

Thermo-mechanical simulation Fluid dynamics Building heating & ventilation Force prediction Thermography Glow wire testing Outcomes: Optimised solution

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I Product development & engineering services / Thermal design / Fluid dynamics

Fluid dynamics / Thermal design / Product development & engineering services

IÂ 85


Temperature cycling

Power cycling

Steady state operation lifetime

High/low temperature storage lifetime

Thermal simulation

Fluid dynamics

Building heating & ventilation

Force prediction

Thermography

Glow wire testing

Thermo-mechanical simulation

Fluid dynamics Temperature cycling Power cycling Steady state operation lifetime High/low temperature

Optimised solution By performing robustness predictions for an untested idea, fluid dynamics helps us to place true design innovation within reach. Fluid dynamics and building physics, for instance, work together to enable the creation of the highest performance and sustainable designs that are both affordable and buildable.

storage lifetime Thermal simulation Thermo-mechanical simulation Fluid dynamics Building heating & ventilation Force prediction Thermography Glow wire testing

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I Product development & engineering services / Thermal design / Fluid dynamics services

Fluid dynamics services / Thermal design / Product development & engineering services

IÂ 87


Temperature cycling

Power cycling

Steady state operation lifetime

High/low temperature storage lifetime

Thermal simulation

Fluid dynamics

Building heating & ventilation

Force prediction

Thermography

Glow wire testing

Thermo-mechanical simulation

Building heating & ventilation Temperature cycling Power cycling Steady state operation lifetime High/low temperature

Ventilation flow rate is an important parameter in the measurement of indoor air quality. It can affect respiratory diseases, Sick Building Syndrome symptoms, productivity and perceived air quality. The determination of ventilation flow rate is very complex as it is based on various difficult to quantify factors including

outdoor air quality, airflow rate, indoor generation of pollutants, air moisture content, thermal environment and air supply. Only by including all these parameters in a simulation can an optimal indoor design be provided that ensures the thermal comfort of building users.

Humans need fresh air, and its provision is of vital importance in all indoor environments.

storage lifetime Thermal simulation Thermo-mechanical simulation Fluid dynamics Building heating & ventilation Force prediction Thermography Glow wire testing Outcomes: Airflow optimisation Temperature control Air quality and contaminant control

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I Product development & engineering services / Thermal design / Building heating & ventilation

Building heating & ventilation / Thermal design / Product development & engineering services

IÂ 89


Temperature cycling

Power cycling

Steady state operation lifetime

High/low temperature storage lifetime

Thermal simulation

Fluid dynamics

Building heating & ventilation

Force prediction

Thermography

Glow wire testing

Thermo-mechanical simulation

Building heating & ventilation Temperature cycling Power cycling Steady state operation lifetime High/low temperature storage lifetime

Airflow optimisation It is vital that living and working environments receive suitable ventilation for both health and wellbeing. We use advanced computer simulations of airflow through buildings, allowing us to determine the most effective outcomes.

Temperature control Interior environments must be kept at comfortable temperatures in order that occupants are both at ease, healthy, perform well and not detrimentally affected by excessive heat or cold. To achieve optimal temperature control it is necessary to take into account all heat sources, not only the obvious ones. This includes everything from the heating system itself, through lighting to appliances and technical devices.

Air quality and contaminant control In some environments, the safeguarding of air quality is of crucial importance. This involves both the prediction and optimisation of contaminant removal and circulation of air supplies.

Thermal simulation Thermo-mechanical simulation Fluid dynamics Building heating & ventilation Force prediction Thermography Glow wire testing

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I Product development & engineering services / Thermal design / Building heating & ventilation services

Building heating & ventilation services / Thermal design / Product development & engineering services

IÂ 91


Temperature cycling

Power cycling

Steady state operation lifetime

High/low temperature storage lifetime

Thermal simulation

Fluid dynamics

Building heating & ventilation

Force prediction

Thermography

Glow wire testing

Thermo-mechanical simulation

Force prediction Temperature cycling Power cycling Steady state operation lifetime High/low temperature

Strong winds such as experienced during heavy storms and hurricanes induce forces and pressured distributions on objects that can lead to safety issues and potentially dangerous conditions. To avoid disaster, force predictions for a product need to be incorporated into its design from a very early stage.

A product’s reliability depends on its ability to withstand the forces of nature.

storage lifetime Thermal simulation Thermo-mechanical simulation Fluid dynamics Building heating & ventilation Force prediction Thermography Glow wire testing Outcomes: Dangerous conditions prediction

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I Product development & engineering services / Thermal design / Force prediction

Force prediction / Thermal design / Product development & engineering services

IÂ 93


Temperature cycling

Power cycling

Steady state operation lifetime

High/low temperature storage lifetime

Thermal simulation

Fluid dynamics

Building heating & ventilation

Force prediction

Thermography

Glow wire testing

Thermo-mechanical simulation

Force prediction Temperature cycling Power cycling Steady state operation lifetime

Dangerous conditions prediction To minimise and control the risk of dangerous conditions from exceptional air velocities, forces, pressures and accelerations, it is important to assess and understand the effects of such forces on all components and the assembly of a product.

High/low temperature storage lifetime Thermal simulation Thermo-mechanical simulation Fluid dynamics Building heating & ventilation Force prediction Thermography Glow wire testing

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I Product development & engineering services / Thermal design / Force prediction services

Force prediction services / Thermal design / Product development & engineering services

IÂ 95


Temperature cycling

Power cycling

Steady state operation lifetime

High/low temperature storage lifetime

Thermal simulation

Fluid dynamics

Building heating & ventilation

Force prediction

Thermography

Glow wire testing

Thermo-mechanical simulation

Thermography Temperature cycling Power cycling Steady state operation lifetime High/low temperature storage lifetime

Radiation is one of the heat transfer mechanisms in which electromagnetic radiation is emitted by a heated surface. Heat transferred by radiation does not depend on contact and can be transmitted through empty space. Examples of radiation are heat from the sun or the heat emitted by the filament of a light bulb. Thermography, or thermal imaging, measures the thermal radiation of an object and produces easy

to understand visualisations of radiated heat energy: the higher the temperature, the higher the radiated energy. Advantages of using thermography include its ability to capture real time temperature states, produce a picture of temperature over a large area and measure inaccessible areas, as well as the fact that it is a nondestructive procedure.

Bring the invisible world of heat to life and see how it influences everything around us.

Thermal simulation Thermo-mechanical simulation Fluid dynamics Building heating & ventilation Force prediction Thermography Glow wire testing Outcomes: Real time capture of infrared images

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I Product development & engineering services / Thermal design / Thermography

Thermography / Thermal design / Product development & engineering services

IÂ 97


Temperature cycling

Power cycling

Steady state operation lifetime

High/low temperature storage lifetime

Thermal simulation

Fluid dynamics

Building heating & ventilation

Force prediction

Thermography

Glow wire testing

Thermo-mechanical simulation

Thermography Temperature cycling Power cycling Steady state operation lifetime High/low temperature

Real time capture of infrared images Thermography enables us to measure temperatures in applications where conventional sensors cannot be used. This is especially the case when dealing with the measurement of moving objects or where contact-free measurement is required due to the risk of contamination or hazardous occurrences.

storage lifetime Thermal simulation Thermo-mechanical simulation Fluid dynamics Building heating & ventilation Force prediction Thermography Glow wire testing

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I Product development & engineering services / Thermal design / Thermography services

Thermography services / Thermal design / Product development & engineering services

IÂ 99


Temperature cycling

Power cycling

Steady state operation lifetime

High/low temperature storage lifetime

Thermal simulation

Thermo-mechanical simulation

Fluid dynamics

Building heating & ventilation

Force prediction

Thermography

Glow wire testing

Glow wire testing Temperature cycling Power cycling Steady state operation lifetime High/low temperature

Due to human misapplication, overcurrent or short circuit, components may reach a temperature that can unduly affect or even ignite items nearby. Glow wire testing is used to evaluate the fire hazard components pose and the fire protection and flammability of materials used within a device.

A vital part of ensuring the safety of domestic appliances.

storage lifetime Thermal simulation Thermo-mechanical simulation Fluid dynamics Building heating & ventilation Force prediction Thermography Glow wire testing Outcomes: Evaluation of flammability and fire resistance

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I Product development & engineering services / Thermal design / Glow wire testing

Glow wire testing / Thermal design / Product development & engineering services

IÂ 101


Temperature cycling

Power cycling

Steady state operation lifetime

High/low temperature storage lifetime

Thermal simulation

Fluid dynamics

Building heating &ventilation

Force prediction

Thermography

Glow wire testing

Thermo-mechanical simulation

Glow wire testing Temperature cycling Power cycling Steady state operation lifetime High/low temperature

Evaluation of flammability and fire resistance For reasons of safety it is essential to understand the behaviour of components and materials when exposed to open fire or conditions that can cause ignition, such as unexpected heat from surrounding components or even from operation at high temperatures.

storage lifetime Thermal simulation Thermo-mechanical simulation Fluid dynamics Building heating & ventilation Force prediction Thermography Glow wire testing

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Glow wire testing services / Thermal design / Product development & engineering services

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Electronic solutions & services HARDWARE DESIGN Analysis of customer requirements Key component selection Schematic design PCB design Prototype Documentation and validation Final product

ELECTRICAL SAFETY TESTS High voltage test (dielectric voltage withstand test) Insulation resistance test Earth bond test Leakage current test Functionality test

FIRMWARE DESIGN

SOFTWARE DESIGN

Firmware solution analysis Customised solution Complete firmware design for prototype device Full support and maintenance of firmware for serial production

FUNCTIONAL TESTS

LONG-TERM TESTS

Quality analysis

Functionality test Frequent switching test Under-voltage test Over-voltage test Endurance test (IEC60598-1-12) Dimming test (DALI, 0–10 V, 1–10 V) Lifetime test

LABWARE DESIGN Data acquisition systems Automatic measuring systems Instrument control and device driver development Data processing, mathematical analysis and storage Machine control and vision Complete turnkey solutions (fully automated customer defined measurement and process units)

DALI COMPATIBILITY TESTS Conformity report

ELECTRONIC DESIGN REVIEW

RAPID PROTOTYPING

Consultancy and product optimisation

Bare prototype PCBs Assembled PCBs Functional prototypes Enclosed functional prototypes / engineering samples


Hardware design

Firmware design

Software design

Labware design

Electrical safety tests

Functional tests

Long-term tests

DALI compatibility tests

Electronic solutions & services Many well know concepts and technologies have great hidden potential. In the field of electronics, boundaries are being broken not only by new technologies but also by the intelligent use of familiar ideas in new and extraordinarily innovative ways. Nevertheless, we also believe that the success of an idea greatly depends on the time it takes to reach the market. There is no room for a slow and expensive trial and error approach during the transition of an idea into a working product, and neither for semi-finished ‘engineering’ samples when competing with qualified rivals. The iLumTech electronic design team can offer you a comprehensive range of electronic design solutions and services along with our full and continued support. Starting with advanced hardware design and the design of various types of software, to the final combining of them together with a pinch of synergy added in, we are able to provide the system level design of a vast array of customer defined electronic products and solutions. All stages are checked and verified during various in-house tests, which we can also offer as independent services. Furthermore, we can assist you with our professional review of your own designs at any stage of their development. Our personal approach and high level of expertise throughout the whole process of transforming your idea to a professionally formed functional prototype, or any derivative of it, ensures you and your product will be first on the market.

Electronic design review

Rapid prototyping

The field of electronics is moving forward so rapidly that it is almost impossible to keep up, but we will help you do just that.


Hardware design

Firmware design

Software design

Labware design

Electrical safety tests

Functional tests

Long-term tests

DALI compatibility tests

Electronic design review

Rapid prototyping

Hardware design Hardware design Firmware design Software design Labware design Electronic design review Rapid prototyping Electrical safety tests Functional tests Long-term tests DALI compatibility tests

Since hardware is the basis of each electronic device, creating a functional part of its physical body, there is vital need for good hardware design. Only well-designed hardware will ensure the quality, reliability, and long-term stability of a solution. Our hardware design engineers are responsible for the complete development process from idea to final product, and are keen to develop tailored solutions utilising the Altium Designer development environment, all within unbeatable timescales.

Only the best hardware can ensure the reliability and stability of a solution.

We have extensive experience in both lowspeed digital and analogue designs, and the routing of printed circuit boards (PCB) with multiple layers. We are especially experienced in hardware designs tailored for the lighting industry. The hardware design process is a complex combination of tasks, decisions, and repetitions. With this in mind we follow well– defined internal processes together with ISO9001 documentation so that we can provide a fast and almost flawless hardware design process. And once the design is complete, we deliver a final product made using the very best components thanks to our wide network of cooperating partners and suppliers. They periodically provide us with the latest news from semiconductor industry and with important notifications, e.g. EOL, based upon which we have available to us state-of-the-art components along with full supplier support. Furthermore, our fully equipped R&D laboratories allow us to minimise the time taken to manufacture a prototype.

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I Product development & engineering services / Electronic design / Hardware design

Outcomes: Analysis of customer requirements Key component selection Schematic design PCB design Prototype Documentation and validation Final product

Hardware design / Electronic design / Product development & engineering services

IÂ 109


Hardware design

Firmware design

Software design

Labware design

Electrical safety tests

Functional tests

Long-term tests

DALI compatibility tests

Electronic design review

Rapid prototyping

Hardware design Hardware design Firmware design Software design Labware design Electronic design review Rapid prototyping Electrical safety tests Functional tests Long-term tests DALI compatibility tests

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Analysis of customer requirements The identification and analysis of customer requests act as the primary input for the development process. Precise request definition from the customer is of vital importance both at the beginning and throughout the entire project.

PCB design PCBs are designed based on the functional schematic, but consideration also needs to be given to the mechanical aspects of the device. The design itself is strongly influenced by forecasted production quantities, based upon which the appropriate PCB manufacturing technologies Key component selection will be chosen. Electrical safety require The overall cost and complexity of a ments also have an impact on the design device depends predominantly on key rule check. component selection. The ratio between those parts needed for the hardware, Prototype firmware and software of the product are A prototype is an integral part of the put in place during this phase of develop- development process as it is the first real ment. substantiation of a customers’ vision. It also acts as the base for demonstration Schematic design of functionality, corrections to functional The functional schematic of the solu- ity and price adjustment of the product. tion is based on the chosen key compo- Depending on customer needs, several nents, supporting blocks and the analysis prototypes can be prepared during develof customer needs. This schematic defines opment. the complexity as well as the final cost of the developed solution.

I Product development & engineering services / Electronic design / Hardware design services

Documentation and validation One of the primary outcomes of the development process is the technical documentation of the product. This enables customers to run serial production as well as being a requirement for product certification. Final product Finalisation of the development process is marked by the product entering serial production. This is based on the aforementioned technical documentation and requires that the product first receive appropriate certification.

Hardware design services / Electronic design / Product development & engineering services

IÂ 111


Hardware design

Firmware design

Software design

Labware design

Electrical safety tests

Functional tests

Long-term tests

DALI compatibility tests

Electronic design review

Rapid prototyping

Firmware design Hardware design Firmware design Software design Labware design Electronic design review Rapid prototyping Electrical safety tests Functional tests Long-term tests DALI compatibility tests

Programmable components are used in almost every electronic product found on today’s market. Even if only a trivial logic function is requested, a microcontroller unit (MCU) is usually chosen to be used instead of discrete components such as diodes, transistors or operational amplifiers. Firmware development requires close cooperation with the customer, especially when dealing with user interfaces, in order to design the device functions according to customer wishes. We have been dealing with firmware design for several years, and we have expertise mainly in ST Microelectronics architecture (both 8 and 32 bit cores). However, if required, we are able to work with manufacturers such as Microchip, Atmel, NXP, or any other. We have tight partnership with all the big MCU players on the market and their vendors, which gives us direct access to the latest technology available.

Firmware design is closely connected with hardware design. Therefore, the two processes often start parallel to each other, which considerably shortens development time. The timeline that is required for professionally done and thoroughly tested firmware design depends on the complexity of the desired product. For instance, a simple switching function that depends on user input can be done in weeks, while the development of a network with tens of nodes communicating with each other will take months. In order to optimise development time we have at our disposal a library of various ready-to-use solutions such as PWM control, analogue measurements, buck/boost regulation, communication interfaces (UART, I2C, SPI, etc.), communication protocols (DC-PLC, USB, DALI, TCP/IP, DMX, etc.) and others. To achieve the creation of efficient and safe firmware we are using the standard MISRA C:2012 during the design process.

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The meeting place between hardware and user software.

Outcomes: Firmware solution analysis Complete firmware design for prototype device Full support and maintenance of firmware for serial production

I Product development & engineering services / Electronic design / Firmware design

Firmware design / Electronic design / Product development & engineering services

IÂ 113


Hardware design

Firmware design

Software design

Labware design

Electrical safety tests

Functional tests

Long-term tests

DALI compatibility tests

Electronic design review

Rapid prototyping

Firmware design Hardware design Firmware design Software design Labware design Electronic design review Rapid prototyping Electrical safety tests Functional tests Long-term tests DALI compatibility tests

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Firmware solution analysis The analysis of a firmware solution is a fundamental step in the final design. It results in the estimation of hardware requirements, MCU selection and a flow chart.

Complete firmware design for prototype device Once the firmware solution has been analysed and all subsequent output prepared, the next phase is to design the firmware itself. This will result in a functional prototype that can be tested and all correCustomers are required to provide a list sponding documentation. of features they expect the firmware to incorporate, based upon which the firm- Firmware design can be compared to PCB ware designer will decide if it is suitable routing in hardware design. The firmware to use an MCU. If so, the designer will go designer uses ready-to-use functional on to provide an analysis of the solution blocks or creates completely new ones including an estimated memory size and and then defines the relationships bedetails of any peripheral units that may tween the blocks. The outcome of this be needed, such as communication in- stage is functional firmware tested on a terfaces, pulse width modulators, timers, real prototype. Full documentation is now analogue measurements, etc., as well as prepared, which includes source code, any the size of the required MCU (the number necessary software tools and a compreof pins). The next step is to select a suit- hensive description of the design. able MCU. At this point, the customer may request that a particular manufacturer be chosen. The final step is to prepare the firmware flow chart, which simply outlines the firmware solution, similar to the schematics of a hardware design.

I Product development & engineering services / Electronic design / Firmware design services

Full support and maintenance of firmware for serial production There is a world of difference between firmware designed for a prototype device and that needed for serial production. For production, it is necessary to also take into consideration the workflow needed for the programming of devices. We can either provide device programming within our own facilities or prepare for you a programming tool that you can use in your own production facilities. It is common that, during the first months of use, some ‘bugs’ will appear, and you may also have ideas about how to improve the product. For this reason, we are also happy to correct and update firmware according to your needs and desires.

Firmware design services / Electronic design / Product development & engineering services

IÂ 115


Hardware design

Firmware design

Software design

Labware design

Electrical safety tests

Functional tests

Long-term tests

DALI compatibility tests

Electronic design review

Rapid prototyping

Software design Hardware design Firmware design Software design Labware design Electronic design review Rapid prototyping Electrical safety tests Functional tests Long-term tests DALI compatibility tests

Software is the most important part of an overall system design as this is the only part the customer really sees. There are hundreds of thousands of software programs on the market that can do almost anything you could desire, yet, these programs are so diversified and specified that it is near impossible to find one that does everything you need in one package, necessitating the creation of something precisely tailored to your needs.

Using smart programming approaches, we are able to develop qualitative software solutions within very short timeframes. Furthermore, we use proven design patterns to ensure best practice and rapid development. Alongside this, we use the Unified Modelling Language (UML) to allow us to combine techniques from data, object and component modelling. We also use refactoring to make future modifications updates easier and faster to implement.

If hardware is the heart of an electronic system, software is its soul.

Our software design engineers have extensive and wide-ranging experience in the design of all types of software. We are able to design software for any PC or portable device platform and can provide truly tailored solutions for any kind of control software in cooperation with our hardware and firmware designers. Our quality outputs are characterised by their usability, portability, maintainability, reliability and security.

Outcomes: Customised solution

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Software design / Electronic design / Product development & engineering services

IÂ 117


Hardware design

Firmware design

Software design

Labware design

Electrical safety tests

Functional tests

Long-term tests

DALI compatibility tests

Electronic design review

Rapid prototyping

Software design Hardware design Firmware design Software design Labware design

Customised solution Software brings added value to a product when it precisely meets customer needs, and can, if appropriate, be controlled and set-up remotely. Its effective design and operation will minimise hardware requirements and maximise performance.

Electronic design review Rapid prototyping Electrical safety tests Functional tests Long-term tests DALI compatibility tests

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I Product development & engineering services / Electronic design / Software design services

Software design services / Electronic design / Product development & engineering services

IÂ 119


Hardware design

Firmware design

Software design

Labware design

Electrical safety tests

Functional tests

Long-term tests

DALI compatibility tests

Electronic design review

Rapid prototyping

Labware design Hardware design Firmware design Software design Labware design Electronic design review Rapid prototyping Electrical safety tests Functional tests Long-term tests DALI compatibility tests

Labware is a specific kind of software that automates operations in laboratories or in industry applications, controls machines and measuring instruments, and acquires data and process it. Our solutions are based on the LabVIEW development environment, which enables short development cycles, user-friendly GUI design and a large number of libraries for data acquisition, data processing, data generation, mathematics, statistics, etc.

A large number of various measurement devices from different manufacturers can be integrated into the data acquisition system very effectively, making data processing a particular strongpoint of LabVIEW. A large set of functions for data processing and mathematical analyses enables fast implementation of the application. After acquisition and processing, data can be easily exported to reports. A very interesting option is connectivity with databases.

LabVIEW (Laboratory Virtual Instrument Engineering Workbench) is a development environment for a visual programming language from National Instruments. It is widely used for instrument control, data acquisition or industry automation. Another advantage is that all hardware provided by National Instruments is supported by LabVIEW and using this hardware, the development cycle is even shorter.

To control fast processes, FPGA-based devices from National Instruments can be programmed by LabVIEW with outstanding performance. For industrial automation, LabVIEW offers machine control and machine vision. Another noteworthy possibility is the development of LabVIEW device drivers. With all these features, we are offering complete turnkey solutions for fully automated customer defined measLabVIEW-based applications are very use- urement and process units. ful in data acquisition, where data acquisition systems can be controlled via PC or can run as stand-alone applications.

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Complex electronic solutions for complex environments.

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Outcomes: Data acquisition systems Automatic measuring systems Instrument control and device driver development Data processing, mathematical analysis and storage Machine control and vision Complete turnkey solutions (fully automated customer defined measurement and process units)

Labware design / Electronic design / Product development & engineering services

IÂ 121


Hardware design

Firmware design

Software design

Labware design

Electrical safety tests

Functional tests

Long-term tests

DALI compatibility tests

Electronic design review

Rapid prototyping

Labware design Hardware design Firmware design Software design Labware design Electronic design review Rapid prototyping Electrical safety tests Functional tests Long-term tests DALI compatibility tests

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Data acquisition systems Data acquisition systems are responsible for measuring and sampling electrical or physical quantities and their consecutive processing. A complete data acquisition system is composed of sensors, measurement hardware and a computer with programmable software. Such a solution is powerful, flexible and cost effective.

Instrument control and device driver development Device drivers act as the software interface with the hardware device and should contain all the functions implemented within the device. The main purpose of the driver is to create a higher-level application without requiring that users have detailed knowledge of the device hardware.

Machine control and vision Machine vision is a technology used for automated inspection of and within industrial processes to achieve higher product quality. Other uses include the control of production processes and industrial robots. Machine control and vision ensures high industrial process throughput and reduced production costs.

Automatic measuring systems Automatic measuring systems are useful when large numbers of electrical or physical quantities need to measured, necessitating the use of many different data acquisition devices. It is possible to synchronise the functions of all devices using a programming environment. The basic steps involved in this synchronisation are the setting of hardware parameters, acquisition of data, evaluation of that data and the creation of a measurement report.

Data processing, mathematical analysis and storage Data acquisition is the term used for the process of manipulating data in various ways in order to obtain meaningful results. These manipulations include mathematical calculations, signal processing and report generation.

Complete turnkey solutions (fully automated customer defined measurement and process units) Complete turnkey solutions can be realised in one project. The project includes the hardware, firmware programming of the designed hardware, development of a device driver to act as the interface between the hardware and higher-level application and development of the control application.

I Product development & engineering services / Electronic design / Labware design services

Labware design services / Electronic design / Product development & engineering services

IÂ 123


Hardware design

Firmware design

Software design

Labware design

Electrical safety tests

Functional tests

Long-term tests

DALI compatibility tests

Electronic design review

Rapid prototyping

Electronic design review Hardware design Firmware design Software design Labware design Electronic design review Rapid prototyping Electrical safety tests Functional tests Long-term tests DALI compatibility tests

Electronic design is not always a simple task. The performance of an electrical device is influenced by many factors such as the selection of components, their combination and placement on the PCB, routing on the PCB, interference from the environment, ambient temperature, and many other factors. There are some basic principles that you can learn but the real master of electronic design firstly needs to be experience. Problems connected with electronic design are likely to repeat; therefore, you do not have to ‘reinvent the wheel’ because we can solve the problem with you and save your time.

Integration support is aimed to provide customers with direct access to our engineers who can provide immediate assistance during the integration phase of a product. Typical problems faced are configuration, connection, system performance and general system behaviour issues, although we are here to help with any problems that may arise.

Thorough analysis guarantees that your electronic device will have no ‘bugs’.

Thanks to our well equipped, ESD protected laboratory we are able to quickly test and diagnose the source of a problem. Our long-term partnership with component manufacturers allows us to consult your difficulties directly with their applicaOur team consists of highly-experienced tion engineers, thus rapidly shortening the hardware design engineers who are avail- time needed to find a solution. able to help customers build high-performance and reliable systems. We can help Our engineers have a great amount of you to create custom designs based on ex- practical and real world experience that perience and knowledge. Such support in- they are open to share with customers. cludes the provision of reference designs, We can also provide support via an email detailed device and system design rules, hotline, the phone or face-to-face consuldesign reviews and general advice. tation.

Outcomes: Consultancy and product optimisation

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Electronic design review / Electronic design / Product development & engineering services

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Hardware design

Firmware design

Software design

Labware design

Electrical safety tests

Functional tests

Long-term tests

DALI compatibility tests

Electronic design review

Rapid prototyping

Electronic design review Hardware design Firmware design Software design Labware design Electronic design review Rapid prototyping Electrical safety tests Functional tests Long-term tests

Consultancy and product optimisation Inspection of electronic designs during the development process can uncover potential weak points and risk areas, which should be treated carefully by a responsible and experienced developer. During the electronic design review, we provide the results of our extensive knowledge and expertise. This will considerably shorten the development process as well as help designers avoid problematic or clumsy solutions. Based on the advice we offer during consultation, the development of electronic devices will proceed in an optimal way thanks to the use of already proven and tested design blocks.

DALI compatibility tests

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I Product development & engineering services / Electronic design / Electronic design review services

Electronic design review services / Electronic design / Product development & engineering services

IÂ 127


Hardware design

Firmware design

Software design

Labware design

Electrical safety tests

Functional tests

Long-term tests

DALI compatibility tests

Electronic design review

Rapid prototyping

Rapid prototyping Hardware design Firmware design Software design Labware design Electronic design review Rapid prototyping Electrical safety tests Functional tests Long-term tests DALI compatibility tests

Prototyping is an integral part of the system level design process. Customers can take advantage of our in-house rapid prototyping services to verify the functionality of their projects. Functional prototypes help to identify problems during early design stages and thus minimise risks, development costs and accelerate development cycles.

PCB DESIGN

Micro machining (2 hours)

Ultrasonic cleaning (1 hour)

Clean bare PCB

Solder paste dispensing (30 mins)

Components placing (1 hour)

Infrared soldering (30 mins)

3D printing (3 hours)

3D printed and micromachined parts

Assembled PCB

FUNCTIONAL PROTOTYPE WITHIN 8 HOURS

Bare PCB

We can provide a prototype of anything from a PCB to a full control system within a remarkably short timeframe.

We manufacture, assemble and test prototype PCBs and 3D printed or machined mechanical parts such as enclosures according to your input. All within very short timescales. Our ESD protected, well equipped laboratory is ready for assembling and testing. A comprehensively produced rapid prototype of any electronic device provides you, the customer, with a strong competitive advantage. The following workflow shows the rapid prototyping of a functional sample of an ambient light sensor based on previoisly prepared data. The overall time taken to produce the prototype is an amazing one working day.

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Outcomes: Bare prototype PCBs Assembled PCBs Functional prototypes Enclosed functional prototypes / engineering samples

I Product development & engineering services / Electronic design / Rapid prototyping

Rapid prototyping / Electronic design / Product development & engineering services

IÂ 129


Hardware design

Firmware design

Software design

Labware design

Electrical safety tests

Functional tests

Long-term tests

DALI compatibility tests

Electronic design review

Rapid prototyping

Rapid prototyping Hardware design Firmware design Software design Labware design Electronic design review Rapid prototyping

Bare prototype PCBs We manufacture prototype PCBs using a TECHNODRILL 2 CNC drilling and milling machine or conventional chemical processing. Whichever method suits customer needs best, the prototype will be provided within an unbeatable timescale.

Enclosed functional prototypes / engineering samples If desired, functional and tested prototypes can be provided in standardised or customised boxes. If a customised box is required, we will also manufacture this prototype from aluminium or 3D printed Functional prototypes Functional prototypes are required as plastic. the base for performance of a wide array of laboratory tests, a crucial part of the overall development process. Assembled PCBs We assemble both surface-mount devices (SMD) and through-hole devices. Reflow is carried out in a computer controlled infrared reflow oven.

Electrical safety tests Functional tests Long-term tests DALI compatibility tests

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I Product development & engineering services / Electronic design / Rapid prototyping services

Rapid prototyping services / Electronic design / Product development & engineering services

IÂ 131


Hardware design

Firmware design

Software design

Labware design

Electrical safety tests

Functional tests

Long-term tests

DALI compatibility tests

Electronic design review

Rapid prototyping

Electrical safety tests Hardware design Firmware design Software design Labware design Electronic design review Rapid prototyping Electrical safety tests Functional tests

Electrical safety testing is essential to ensure safe operating standards for any product that uses electricity. Various governments and agencies have developed stringent requirements for electrical products that are sold worldwide.

In general, IEC 60335 is the most widely applied standard for electrical safety testing, especially for domestic appliances. Many safety testing standards in the world have been based on it.

In most markets, it is mandatory for a product to conform to the safety standards of agencies such as UL, CE, VDE, CSA, BSI, and CCC. To conform to such standards, the product must pass various safety tests, all of which are described in IEC 60335, IEC 61010, and many other national and international standards.

A basic need for every electronic device, we can help you ensure the safety of your products.

Long-term tests DALI compatibility tests

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Outcomes: High voltage test (dielectric voltage withstand test) Insulation resistance test Earth bond test Leakage current test Functionality test

I Product development & engineering services / Electronic design / Electrical safety tests

Electrical safety tests / Electronic design / Product development & engineering services

IÂ 133


Hardware design

Firmware design

Software design

Labware design

Electrical safety tests

Functional tests

Long-term tests

DALI compatibility tests

Electronic design review

Rapid prototyping

Electrical safety tests Hardware design Firmware design Software design Labware design Electronic design review Rapid prototyping Electrical safety tests Functional tests Long-term tests DALI compatibility tests

Earth bond test This test is performed by measuring the resistance between the third pin (ground) and outside metal body of the product under test. The maximum acceptable value is generally 0.5 Ω. This test is usually carried out at a slightly higher current (e.g. 25–60 A) so that the ground bond circuit maintains safe voltages on the chassis of the product, even at a high current, before the circuit breaker. This test is essential so that the product does not cause an electric shock resulting from insulation failure. Leakage current Leakage current is the current that flows through the protective ground conductor to ground. In the absence of a grounding connection, it is the current that could flow from any conductive part or the surface of non-conductive parts to ground if a conductive path was available (such as a human body). There are always incidental currents flowing in the safety ground conductor.

High voltage test (dielectric voltage withstand test) A dielectric withstand test is an electrical test performed on a component or product to determine the effectiveness of its insulation. The test may be between mutually insulated sections of a part or energised parts and electrical ground. The test is a means to qualify a device’s ability to operate safely during rated electrical conditions. Insulation resistance test The insulation resistance (IR) test is a spot insulation test which uses an applied DC voltage to measure insulation resistance in either kΩ, MΩ or GΩ. The measured resistance is intended to indicate the condition of the insulation or dielectric between two conductive parts, where the higher the resistance, the better the condition of the insulation. Ideally, the insulation resistance would be infinite, but as no insulators are perfect, leakage currents through the dielectric will ensure that a finite (though high) resistance value is measured. Functionality test This test is performed by checking functionality of the electronic device under well defined standard operating conditions.

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Electrical safety test services / Electronic design / Product development & engineering services

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Hardware design

Firmware design

Software design

Labware design

Electrical safety tests

Functional tests

Long-term tests

DALI compatibility tests

Electronic design review

Rapid prototyping

Functional tests Hardware design Firmware design Software design Labware design Electronic analysis Rapid prototyping Electrical safety tests Functional tests Long-term tests DALI compatibility tests

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Each electronic device needs to pass through a testing stage in order to verify its functionality and to characterise its properties. Testing procedures are usually performed several times during device development as they provide the designer with feedback essential for correct electronic design.

Measurement of input voltage ranges is an example of the kind of test that can be performed using this equipment. Another test measures the output voltage range, the advantage of which is that an input voltage can be set at an arbitrary value. Also, time dependent device properties can be tested. These properties are turnon time, turn-off time, rise time, fall time, During the functional tests we first test voltage ripple, and current ripple. Another the device using the recommended condi- useful option is the ability to measure intions – temperature, input voltage, input rush current. signals. All the parameters necessary for the proper functioning of the device are All measured parameters are processed by measured. After passing this basic set of software and exported to reports. Graphs measurements, we can test the behaviour and tables can be exported to OriginLab of the device when working at the internal or MS Excel, and all results are then exedges of recommended conditions. ported to a Word document and can be saved also as a PDF. The overview clearly To reach fast and repeatable measure- shows the versatility of this automatic ments we have developed an automatic measurement system. testing instrument, originally designed for the characterisation of power supplies, but reconfigurable for the measuring of any kind of electronic device. This instrument is composed of a switching power supply, electronic load and four-channel digital oscilloscope. All these instruments are controlled and automated by a software application made in the LabVIEW development environment. Outcomes: Quality analysis

I Product development & engineering services / Electronic design / Functional tests

Every electronic device must pass functionality and characterisation tests to ensure it meets needs.

Functional tests / Electronic design / Product development & engineering services

IÂ 137


Hardware design

Firmware design

Software design

Labware design

Electrical safety tests

Functional tests

Long-term tests

DALI compatibility tests

Electronic design review

Rapid prototyping

Functional tests Hardware design Firmware design Software design Labware design Electronic analysis Rapid prototyping Electrical safety tests Functional tests

Quality analysis Electronic device functional tests are very useful when functional device characterisation is needed. Quality analysis can be performed on a large number of produced devices where failure rates can be determined using statistical methods. Another possibility is the determining of device reliability under abnormal conditions such as under-voltage, over-voltage and overheating. Also, useful are lifetime tests where the device is commonly exposed to relatively high temperatures and humidity to accelerate aging.

Long-term tests DALI compatibility tests

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Functional test services / Electronic design / Product development & engineering services

IÂ 139


Hardware design

Firmware design

Software design

Labware design

Electrical safety tests

Functional tests

Long-term tests

DALI compatibility tests

Electronic design review

Rapid prototyping

Long-term tests Hardware design Firmware design Software design Labware design Electronic analysis Rapid prototyping Electrical safety tests Functional tests Long-term tests DALI compatibility tests

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The use of Solid State Lighting (SSL) technology continues to grow rapidly, and LED-based luminaires bring new challenges in testing and characterisation. Modern SSL luminaries offer additional capabilities in the control of light properties in comparison with conventional light sources. Therefore, the complexity of electronic design is much higher, thus the demands on testing also. Our automatic long-term testing system was developed to test LED based luminaires. Our system was developed to measure in four measuring nodes, each with six channels (luminaries), which allows up to 24 luminaries to be measured simultaneously. Luminaries are powered from a regulated linear power source and measuring devices measure light output, electrical parameters such as input current, voltage, apparent power, active power, reactive power and power factor. Up to 10 thermocouples per channel are available to measure temperature on different parts of the luminaire. This large number of thermocouples fulfils also the highest requirements of the largest luminaries. Safety is also taken into consideration, with each luminaire powered through a circuit breaker with a temperature safety relay which turns the fixture off if overheated. This prevents serious damage to the luminaire as well as the fullyautomated laboratory.

At first, the system provides a basic functionality test followed by a frequest switching test. This system also enables the performance of endurance tests according to the EC 60598-1-12 standard. SSL luminaires often include dimming capability. The most frequently used protocols, DALI, 0–10 V and 1–10 V, can be tested both in exponential, as well as linear operation.

A new era in lighitng technology necessitates a new era in testing.

Another very important parameter, especially for SSL luminaires, is lifetime. This can be tested using the same principles as the functionality test, but over an extended period of time, for example, several thousand hours. All measurements are performed in a room with a stabilised temperature of +25 °C, varying not more than ±1 °C.

Outcomes: Functionality test Frequent switching test Under-voltage test Over-voltage test Endurance test (IEC60598-1-12) Dimming test (DALI, 0–10 V, 1–10 V) Lifetime test

I Product development & engineering services / Electronic design / Long-term tests

Long-term tests / Electronic design / Product development & engineering services

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Hardware design

Firmware design

Software design

Labware design

Electrical safety tests

Functional tests

Long-term tests

DALI compatibility tests

Electronic design review

Rapid prototyping

Long-term tests Hardware design Firmware design Software design Labware design Electronic analysis Rapid prototyping Electrical safety tests Functional tests Long-term tests DALI compatibility tests

Functionality test This basic functionality test determines if the device functions properly over a period of a few days under normal operating conditions. If the device fails this test, no further tests will be performed and the design must be reconsidered.

Endurance test (IEC60598-1-12) In this test, the device is supplied with s voltage 1.1 times higher than the nominal supply voltage. The test comprises ten cycles of 21 hours of operation and 3 hours of no operation. If the device still functions after this, it passes the test.

Frequent switching test This test determined the effects of frequent switching on and off of the power supply on the device under normal operating conditions. If the device turns on each time it passes the test.

Dimming test (DALI, 0–10 V, 1–10 V) It is important to understand the response of the device under test to various dimming protocols.

Under-voltage test Here, the device is tested under abnormal operating conditions. In this case, it is supplied with a lower than nominal supply voltage. The device passes the test when able to operate under these conditions for a defined period of time.

Lifetime test The determination of a device’s lifetime is paramount to its incorporation into a product or system. This test operates the device under normal conditions for an extended period of time to induce and measure the degradation of electrical and optical parameters, which are measured.

Over-voltage test Again, the device is tested under abnormal conditions. In this case, it is supplied with an above nominal supply voltage. The device passes the test if it can function under these conditions for a defined period of time.

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Hardware design

Firmware design

Software design

Labware design

Electrical safety tests

Functional tests

Long-term tests

DALI compatibility tests

Electronic design review

Rapid prototyping

DALI compatibility tests Hardware design Firmware design Software design Labware design Electronic analysis Rapid prototyping Electrical safety tests Functional tests Long-term tests DALI compatibility tests

DALI stands for Digital Addressable Lighting Interface, based on an internationally recognised IEC standard for the intelligent and easy management of lighting equipment. The standard incorporates several parts that provide control and monitoring functionality for ballasts, Emergency Gear and LED drivers; expanding to lighting controls in the near future. Its digital simplicity and flexibility enables customers to create solutions that are easy-to-use, robust, interoperable and above all affordable. DALI has proven its reliability for many years, and will continue to develop and support the growing demands for professional lighting.

In 2014, a new logo and licensing process will be agreed to define the conditions for proper usage of the DALI logo. Each new product must pass testing by an official DALI tester. In September 2013, we purchased a DALI tester, enabling us to perform DALI testing in-house. The basic DALI tester configuration can be extended for further testing, meaning we can provide even stricter testing than that required by the standards. We intend to become an official DALI testing house to simplify and shorten the DALI certification process for our customers. Furthermore, as an active member of the DALI WG, we have direct access to the newest version of test sequences and standards, thus ensuring the iLumTech has been a regular member of most up-to-date testing conditions. DALI since 2012 and actively participated in each DALI group meeting since the group’s establishment. This gives us the opportunity to influence the DALI standard itself and also certification conditions for new products.

Our ability to offer DALI compatibility tests makes product development even easier.

Outcomes: Conformity report

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DALI compatibility tests / Electronic design / Product development & engineering services

IÂ 145


Hardware design

Firmware design

Software design

Labware design

Electrical safety tests

Functional tests

Long-term tests

DALI compatibility tests

Electronic design review

Rapid prototyping

DALI compatibility tests Hardware design Firmware design Software design

Conformity report The results of testing, if positive, can be sent directly to DALI WG for the certification process in order to obtain the DALI logo for the product.

Labware design Electronic analysis Rapid prototyping Electrical safety tests Functional tests Long-term tests DALI compatibility tests

146

I Product development & engineering services / Electronic design / DALI compatibility test services

DALI compatibility test services / Electronic design / Product development & engineering services

IÂ 147


Mechanical engineering services SHEET METAL DESIGN Sheet metal design for different materials Production process selection Item drawings Compilation drawings Settlement sheet drawings BOM Sheet stress analysis Bend radius calculations

ALUMINIUM DIE CAST & EXTRUSION DESIGN

ALUMNIUM FORGING

Mechanical design of die casting parts Tooling 3D model review Tool production support Mechanical design of extruded parts Stress analysis Technology advisory service 3D modelling (STEP, IGES) Tooling support Tooling supplier recomendation

Mechanical design of cold, warm and hot forged parts Stress analysis Technology advisory service 3D modelling (STEP, IGES) Tooling support Tooling supplier recommendation Tooling 3D model review Tool production support

MECHANICAL ANALYSIS

RAPID PROTOTYPING

Stress analysis Structural analysis Mold flow analysis Static calculations Analysis report service

Increased visualisation capabilities Easy detection of design flaws at an early development stage Time and cost savings


Sheet metal design

Aluminium die cast & extrusion design

Aluminium forging

Mechanical engineering services Mechanical engineering is a discipline that applies the principles of engineering, physics and material sciences in the analysis, design, manufacture and maintenance of mechanical systems through the use of heat and mechanical power to produce and operate machines and tools. It is one of the oldest and broadest fields of engineering. We have almost two decades of experience in the mechanical design of luminaires for both indoor and outdoor application as well as the development of other mechanical appliances and precision tools such as optical measurement and electronic testing devices. Our mechanical design team is ready to provide you with the benefits of our experience and expertise, to help you prepare something as simple as an assembly jig or as complex as a complete mechanical solution that involves calculations, 2D production drawings and 3D modelling. Our highly skilled engineers use the latest 3D CAD software ‘CATIA’ from DASSAULT with several additional modules including sheet metal, structural analysis and mold flow among others. A precise document management system ensures that you receive a proper version of all documentation from which you can work in future. All data is available in 2D and 3D in various file formats (STEP, IGES, DXF or DWG).

Mechanical analysis

Rapid prototyping

Often underestimated, but crucial to the success of any product is its construction.


Sheet metal design

Aluminium die cast & extrusion design

Aluminium forging

Mechanical analysis

Rapid prototyping

Sheet metal design Sheet metal design Aluminium die cast & extrusion design Aluminium forging Mechanical analysis Rapid prototyping

Sheet metal is a very common material used in the construction of many products, from cars to aeroplanes. Products made from this material rely on its properties to support their functionality and robustness. Sheet metal is also incredibly versatile as it is made from a wide range of materials that make it suitable for an extensive array of uses. The iLumTech mechanical design team know all there is to know about sheet metal, how to shape, form and combine it with other materials.

It is important to fully understand the desired outcome so we can tailor the processes precisely to need.

It is important during the design phase of a project to know exactly what is required both from a product and manufacture point of view as each material provides different strengths and requires different processes such as stamping, hydroforming, thermoforming or simple bending.

Outcomes: Sheet metal design for different materials Production process selection Item drawings Compilation drawings BOM Sheet stress analysis Bend radius calculations

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I Product development & engineering services / Mechanical design / Sheet metal design

Sheet metal design / Mechanical design / Product development & engineering services

IÂ 153


Sheet metal design

Aluminium die cast & extrusion design

Aluminium forging

Mechanical analysis

Rapid prototyping

Sheet metal design Sheet metal design Aluminium die cast & extrusion design Aluminium forging Mechanical analysis Rapid prototyping

Sheet metal design for different materials Sheet metal design is not dependent on or limited by the forming process chosen, which is selected according to application and cost evaluations. However, it is important to bear in mind that each forming technology requires different tolerances and material properties. iLumTech’s mechanical engineers take all such parameters into account to ensure that you are supplied with the most suitable sheet metal design. Production process selection Depending on production quantities, product quality and usage, our engineers select the final sheet metal production process. This could be anything from bending and stamping to hydroforming, among many others.

BOM BOM, short for ‘BILL OF MATERIAL’, is the summary of all parts used within a project. We provide a BOM according to international standards. Also, as many companies create their own standards, we are also able to provide BOM´s accordingly. Sheet stress analysis This is a discipline of engineering focused on the determination of stresses placed on materials and structures under various forces and loads. In mechanical engineering, stress analysis is often a tool rather than the goal itself; the ultimate goal being the design of structures and artifacts that can withstand a specified load using a minimum amount of material, or to satisfy some other optimisation criterion.

Item drawings The whole is always the sum of its parts, therefore, we will always supply you with detailed drawings of every single part, including the parameters of their production.

Bend radius calculations The bend radius, measured at the inside curvature, is the minimum radius a pipe, tube, sheet, cable or hose can be bent without it kinking, as kinking damages the material and results in a shortened lifetime. The smaller the bend radius, the Compilation drawings greater the material’s flexibility. As the ra To make a full technical drawing, dius of the curve decreases the curvature the content of all the items drawings increases. are compiled and adjusted to the final versions.

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Sheet metal design services / Mechanical design / Product development & engineering services

I 155


Sheet metal design

Aluminium die cast & extrusion design

Aluminium forging

Mechanical analysis

Rapid prototyping

Aluminium die cast & extrusion design Sheet metal design Aluminium die cast & extrusion design Aluminium forging Mechanical analysis Rapid prototyping

The processes of die casting and extruding aluminum have been available for approximately 90 years. Beneficial, not only in terms of their ability to influence the feel of a product, these processes have been developed to allow for high speed production for many industries in order to meet demand.

Our mechanical engineers are experienced in the use of this technology and are ready to design anything from connecting parts to entire luminaires, or anything else you wish. This design includes all necessary calculations and mold flow simulations in order to guarantee precise tooling.

Today, this technology is a standard and is differentiated from sheet steel processing by its ability to provide a much higher quality and visually attractive surface finish.

Only the most precise designs and calculations can make full use of this versatile technology.

Outcomes: Mechanical design of die casting parts Tooling 3D model review Tool production support Mechanical design of extruded parts Stress analysis Technology advisory service 3D modelling (STEP, IGES) Tooling support Tooling supplier recomendation

156

I Product development & engineering services / Mechanical / Aluminium die cast & extrusion design

Aluminium die cast & extrusion design / mechanical design / Product development & engineering services

IÂ 157


Sheet metal design

Aluminium die cast & extrusion design

Aluminium forging

Mechanical analysis

Rapid prototyping

Aluminium die cast & extrusion design Sheet metal design Aluminium die cast & extrusion design Aluminium forging Mechanical analysis Rapid prototyping

158

Mechanical design of die casting parts Die casting is a metal casting process characterised by the forcing of molten metal into a mold cavity under high pressure. Mold cavities function similarly to injection molds, and are created using two hardened tool steel dies that have been machined into the desired shape. Most die castings are made from non-ferrous metals, specifically zinc, copper, aluminium, magnesium, lead, pewter and tin-based alloys. Depending on the metal to be cast, a hot- or coldchamber machine is used.

Mechanical design of extruded parts Extrusion is a process used to create objects of a fixed cross-sectional profile. A material is pushed or drawn through a die of the desired cross-section. The products of extrusion are generally called ‘extrudates’. The two main advantages of this process over other manufacturing processes are its ability to create very complex cross-sections, and to work materials that are brittle, because the material only encounters compressive and shear stresses. It also forms finished parts with an excellent surface finish. Extrusion may be continuous, theoretically producing inWithin the framework of this mechani- definitely long objects or semi-continuous cal design process, we provide tooling 3D for the production of many items. The exmodel reviews and tool production support. trusion process can be done with hot or cold materials. Most commonly, extruded materials are metals, polymers, ceramics, concrete, play dough, and foodstuffs.

Technology advisory service We can advise you as to the most suitable production technology for any chosen fabrication method, object shape and design.

Stress analysis As with sheet stress analysis, this process assesses the effects of various forces and loads on materials and structures to aid in the design of satisfactory items.

Tooling supplier recommendation Through the years of our operation as a manufacturer, we have built an extensive network of proven and trustworthy tooling suppliers that can provide a wide variety of tools. We are happy to point you in the direction of the most suitable and reliable suppliers for your projects.

I Product development & engineering services / Mechanical design / Aluminium die cast & extrusion design services

3D modeling (STEP, IGES) This is the process of developing a mathematical representation of any threedimensional surface or object using specialised software. The product is a 3D model, which can be displayed as a 2D render or as part of a computer simulation. The model can also be transformed into physical form using 3D printing. Tooling support Die casting and extrusion processes require precise preparation. We can review the drawings and 3D models of tooling suppliers in order to ensure proper design.

Aluminium die cast & extrusion design services / Mechanical design / Product development & engineering services

IÂ 159


Sheet metal design

Aluminium die cast & extrusion design

Aluminium forging

Mechanical analysis

Rapid prototyping

Aluminium forging Sheet metal design Aluminium die cast & extrusion design Aluminium forging Mechanical analysis Rapid prototyping

Forging is one of the oldest known metalworking processes. Traditionally performed by a blacksmith using a hammer and anvil, the process has developed greatly over the centuries into something that is highly viable even in modern industry. It requires the use of materials that are able to withstand extreme processes such as heat, pressure and mechanical stress, but the results are suitable for mass production and deliver some outstanding material properties. For example, the thermal conductivity of a forged heatsink is double that of an extruded one, resulting in a much smaller and lighter weight product.

A centuries-old process that, in the right hands, still provides remarkable results today.

Outcomes: Mechanical design of cold, warm and hot forged parts Stress analysis Technology advisory service 3D modelling (STEP, IGES) Tooling support Tooling supplier recommendation Tooling 3D model review Tool production support

Product development & engineering services / Mechanical design / Aluminium forging

Aluminium forging / Mechanical design / Product development & engineering services

IÂ 161


Sheet metal design

Aluminium die cast & extrusion design

Aluminium forging

Mechanical analysis

Rapid prototyping

Aluminium forging Sheet metal design Aluminium die cast & extrusion design Aluminium forging Mechanical analysis Rapid prototyping

Mechanical design of cold, warm and hot forged parts Forging is a manufacturing process that shapes metals using localised compressive force. The process is usually classified according to the temperature at it is performed: cold, warm or hot. To achieve the desired surface finish, it is necessary to further process the produced parts. Forged parts can weigh anything from grams to tons, with the process originally used for the creation of artistic and decorative objects from precious metals. Today, however, forging is a mainly industrial process. Stress analysis Stress analysis is required for forged products as for those made by any other process. By testing the effects of stress on the forged items it is possible to optimise the design to meet specified needs. Technology advisory service There are various forging technologies available. We have a lot of experience in the use of this metalworking process and can advise you as to which technology best suits your needs. 3D modeling (STEP, IGES) 3D models represent a 3D object using a collection of points in 3D space, connected by various geometric means. They can be created by hand or computer and are ideal as a base for 3D scanning.

162

Tooling support Various needs necessitate the use of various tools. For long-run production the tools must have a longer lifetime than those used for short-runs. We can advise you about the best tools to use depending on the predicted production quantity. Tooling 3D model review As the results of this metalworking process depend on the tools used, it is vital that they be precise and high quality. Before the production of your tools, we ensure their quality by checking the design and providing you with all necessary documentation. Tool production support Some tools cannot be produced in Europe due to size limitations. Therefore, we will audit the quality of produced tools, the first results of their use and make recommendations as to how improvements with regard to production technologies can be made. This ensures immediate reaction and resolution of issues and ultimately a perfect final output. Tooling supplier recommendation We are happy to recommend to you our trusted and time-proven tooling suppliers and help you choose those that best meet your specific needs.

I Product development & engineering services / Mechanical design / Aluminium forging services

Aluminium forging services / Mechanical design / Product development & engineering services

IÂ 163


Sheet metal design

Aluminium die cast & extrusion design

Aluminium forging

Mechanical analysis

Rapid prototyping

Mechanical analysis Sheet metal design Aluminium die cast & extrusion design Aluminium forging Mechanical analysis

Does it work or not? A question you will hear repeatedly before a mechanical design is finalised. Nobody wants to invest time and money into the development of production tools and processes for a product that will need redesigning. To minimise the risk of losing time and money, we can provide stress and mold flow analyses before the next steps are taken.

This provides many advantages including fewer development cycles, a shorter overall product development time and your product on the market before competitor products. The result is that your profits are higher.

Even the smartest product in the world is of no use if it doesn’t work.

Rapid prototyping

Outcomes: Stress analysis Structural analysis Mold flow analysis Static calculations Analysis report service

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Mechanical analysis / Mechanical design / Product development & engineering services

IÂ 165


Sheet metal design

Aluminium die cast & extrusion design

Mechanical analysis

Aluminium forging

Rapid prototyping

Mechanical analysis Sheet metal design Aluminium die cast & extrusion design Aluminium forging Mechanical analysis Rapid prototyping

166

Stress analysis In continuum mechanics, stress is a physical quantity that expresses the internal forces that neighboring particles exert on each other. For example, when a solid vertical bar is supporting a weight, each particle in the bar pulls on the particles immediately above and below it. These macroscopic forces are actually the average of a very large number of intermolecular forces. It is important to understand the mechanics of this with the goal of assessing the effects and designing with them in mind. This is the only way to ensure the strength and reliability of produced items.

Structural analysis This is the study and determination of the effects of loads on physical structures and their components. It is necessary to carry out this analysis of any structure that must bear a load, ranging from soil strata to buildings and bridges, and of course, mechanical parts and machinery.

Static calculations Static analysis, static projection and static scoring are simplified analyses of the immediate effects of changes to a system. Such analyses typically produce poor correlation to empirical results as long-term effects are not calculated.

Analysis report service We will provide a full report of every Mold flow analysis In an ever more competitive market, analysis carried out. no company can afford flawed production and output, which wastes both time and money. For molded parts, it is a vital to evaluate the quality of the molds used, to ensure that all produced items are of the highest quality.

I Product development & engineering services / Mechanical design / Mechanical analysis services

Mechanical analysis services / Mechanical design / Product development & engineering services

IÂ 167


Sheet metal design

Aluminium die cast & extrusion design

Aluminium forging

Mechanical analysis

Rapid prototyping

Rapid prototyping Sheet metal design Aluminium die cast & extrusion design Aluminium forging Mechanical analysis Rapid prototyping

3D printing or additive manufacturing is a process by which you can create a 3D solid object of virtually any shape from a simple digital model. It is distinct from almost all other machining processing as they rely on the removal of material by methods such as cutting and drilling whereas 3D printing works based on an additive process, where successive layers of the chosen material are laid down on top of each other.

Only with a model of your product in hand can you understand what you have created.

This fast and easy way of producing physical models that enables prototypes to be produced within very short timescales, normally between 12 and 24 hours, and no more than 72 hours. This opens up many possibilities, from the design review of a complete product in 1:1 scale to the chance to test specific properties or parts of a prototype. There is no other technology on the market that can provide prototypes faster. Moreover, besides the speed of creation, it will make a world of difference to your business partners when you can present to them a functional 3D model.

Outcomes: Increased visualisation capabilities Easy detection of design flaws at an early development stage Time and cost savings

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I Product development & engineering services / Mechanical design / Rapid prototyping

Rapid prototyping / Mechanical design / Product development & engineering services

IÂ 169


Sheet metal design

Aluminium die cast & extrusion design

Aluminium forging

Mechanical analysis

Rapid prototyping

Rapid prototyping Sheet metal design Aluminium die cast & extrusion design Aluminium forging Mechanical analysis

Increased visualisation capabilities Rapid prototyping allows the 3D visualisation of a product straight after the drawings are completed in tactile 1:1 scale. Depending on the complexity of the model, it can take minutes or hours to create. Nothing can compare to a prototype in terms of its ability to show any design issues early in the development process.

Easy detection of design flaws at an early development stage Prototypes enable us to check the functionality of parts before any expensive tooling investment is made. Design flaws and other issues can, at this stage, be resolved.

Time and cost savings As everything is checked in advance, you need not worry about unpleasant surprises that would otherwise prolong the development time, increases costs and delay the release of your product to the market.

Rapid prototyping

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Rapid prototyping services / Mechanical design / Product development & engineering services

IÂ 171


Full luminaire development PRODUCT DEVELOPMENT REQUEST

TECHNICAL & COMMERCIAL NEGOTIATION & AGREEMENT Product specification and properties definition Cost and time schedule evaluation Development contract

DEVELOPMENT STAGES Industrial design Optical design Thermal design Electronic design Mechanical design

PROTOTYPING

TESTING Optical laboratory Thermal laboratory Electronic laboratory

PRODUCT COMPLETION, UPDATES & AFTER SALES SERVICES Release from development Pre-series Declaration of conformity Mass-production Product updates and after sales services Customisation Optimisation Luminaire replacement


Technical & commercial negotiation Product development request

& agreement

Development stages

Full luminaire development Our vast experience in the development of luminaires and related systems acts as a base from which we can offer this as a service to other manufacturers. We provide solutions that cover everything from the concept to the final product, within the framework of which we deliver a wide range of services across industrial, optical, thermal, electronic and mechanical design, all of which are supported by excellent supply chain management, full system testing and prototyping. Our experience of designing and delivering hardware and software solutions for home automation and controllers as well as industry-leading optical systems and nanotechnologies mean that we are truly able to provide the best luminaire full product development service you can imagine.

Prototyping

Testing

Product completion, updates & after sales services

The easiest and fastest way to get your product on the market is to tell us what you want and let us do the rest.


Technical & commercial negotiation

Product development request

& agreement

Development stages

Prototyping

Testing

Product completion, updates & after sales service

Product development request Product development request Technical & commercial negotiation & agreement Development stages

The first input we have from you, as a customer, is the specification of your request. In order that we know exactly what you want, we will ask you to fill in a product development form. All technical and commercial conditions are included in this document, and it acts as the base for each design stage and final evaluation of the product.

Prototyping Testing Project number Project name

Product completion, updates & after sales services

n/a

ial Commerc

Other

Customer

g

pricin omponent

d c

Shape of LIDC

3 5

industrial, grey frame, simple design Suspended, standard suspen sion accept

able

n/a

Aluminium and sheet steel

n/a n/a

20, PMMA clear/opal sandbl

n/a

asted cover

356 ºC 7

8 Square shaped reflector, MIRO7

<229

, clear diffuser

10 uniform

raw

Sketches/d

On behalf of customer nam e and signature blah blah blah blah blah

Beam angle according to reference produc t Lux level on illum. area 200 lx @ 1 m distance Other ges requirements 10 x 10 m placing grid, installa ings/ima tion height

4

6–8 m

Hot lumen at Ta 25 ºC Wattage

210 W

CCT

XXX, easy to change, precise difference between modules 5000 K

LED type

CRI

tes Project no

09/04/2014

High-bay luminaire for factory, 400 W metal-halide replace ment 300 x 300

Ceiling type/thickness

UGR

n form

XXX

Housing material

2

Definition date

Production halls

Dimensions Design Mounting type

Fixing plate material Gaskets IP n/a ge ortfolio/ran IK Product p Ta max pe ty Luminaire Preferred optic 1

Lifetime System efficacy Dimming

Through wiring

You remain in full control throughout the entire process.

Luminaire product definitio

blah blah blah blah blah blah blah blah blah blah

Shape

n/a

s/norms

Standard

However, if you would like to use your own product definition form, we are more than happy to adapt and endeavour to meets your needs.

HIGH-BAY XX

iLumTech contact XXX les hout modu 5 years wit Reference product n/a Application

e

aterial pric Target m Warranty

Estimate

000

The form can include drawings, pictures of competitor products and even indepth technical specifications regarding the optic, thermal, electronic and mechanical design.

2350 x 10

70

50,000 hours

open FIX n/a

Emergency unit n/a mer le by custo IEC class exchangab 1 or d reflec2tor Wiring Light source an n/a ation sign, orm inf n al tio r optical de Input voltage Addition CE certifica n manage 220–240 V sign, Divisio ercial, Driver ctronic de XXX nager comm manager ele n ma n isio isio Div D, ring, Div Additional inf ad of R& Heormati on n/a chanical enginee on nager me Distributi gement Division ma duct mana nager pro Division ma

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Product development request / Full luminaire development

I 177


Product development request

Technical & commercial negotiation & agreement

Development stages

Prototyping

Testing

Product completion, updates & after sales service

Technical & commercial negotiation & agreement Product development request Technical & commercial negotiation & agreement Development stages Prototyping Testing Product completion, updates & after sales services

Product specification and properties definition We will help you complete the product definition form. Here you will determine the exact specification of the product, for example, the luminaire type, its required performance, dimensions, what kind of control system you want and optical part preferences. These technical issues are evaluated, re-evaluated and optimised during project meetings, at which the responsible persons for your project from each R&D department and the commercial team will be present.

Development contract The result of the technical and commercial negotiation and agreement process is the final development contract and confidentiality agreement. Here, all conditions and the commencement date of development are stated.

During the product definition phase, we will encounter our first obstacles, to which we will endeavour to find suitable solutions to prevent delay later in the development process. Every discussed detail will be recorded in your product definition documentation and sent to you to double check. This gives you added assurance that the foundation we build upon is precisely according to your wishes. Cost and time schedule evaluation Based on the final definition, we will prepare a time schedule, which contains project milestones. You can discuss your feelings about the project based on the documentation provided at these milestones. You will also receive a cost evaluation, which is the quote divided according to development costs and tooling expenses. Commercial conditions, including the price and payment conditions, along with the time schedule, are part of the overall development contract as well as the signed product development form.

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I Full luminaire development / Technical & commercial negotiation & agreement

You define what you want from your product and we will take it from there.

Name Address Address Address Tel Mob Email

Price offer for the development of a escalator luminaire Project name Type of luminaire

XXX_ESCALATOR LED luminaire, recessed

Requested time of finishing Requested service Date of offer Validity of offer

engineering sample 24th July 2014 development of the luminaire according to the specification 17th June 2014 17th July 2014

The price offer includes Concept and design Mechanical design Thermal design Electronic design Optic design Comercialisation

Concept preparation, Industrial design of the main part of the luminaire Mechanical engineering Thermal evaluation Full electronic design, electrical safety tests Evaluation and calculation, Optic design, Photometric measurements Reports, Prototyping, 2x sample (3D printed)

The price offer does not include

Tooling (if it is needed, according to the production)

Total price for development

26,000 €

Development time schedule

iLumTech, spol. s.r.o., 906 02 Dojč 419, Slovakia • T +421 0123 456789 • ilumtech@ilumtech.eu • www.ilumtech.eu prepared by Zuzana Masárová, zuzana.masarova@oms.sk

Confidentiality agreement

of and ct matter here of the subje in respect hereof. the Parties after the date iLumTech spol s.r.o. ding between both Parties on or able, understan tives of unenforce ement and Dojč 419 representa a voidable or entire agre authorised to be void, to agree on esse Dojč 02s the expr906 g signed by nt jurisdiction The Parties undertake writin in Agreement pete pt This com exce Slovakia nal of 6. effect. modified t or other tribu inue in full force and shall not be Party 1 by any cour cont provision. in ement be held nt shall nevertheless the invalid out of or of this Agre eme tes arising pursued with ision Agre es dispu prov in this Parti And any Any of If held front of the 7. provisions of Slovak. ration to be the intent national the remaining most closely meets with the Law decided by an arbit Inter ce the of rdan s y Rule in acco Bratislava. provision that shall be finall with the Arbitration construed n shall be otherwise, Party 2 governed by and d of its accordance place of the arbitratio be settled Industry in ed to a refun h may not nt shall be . The merce and shall be entitl such rules Com This Agreeme this Agreement, whic of party with ber 8. ing “Parties” ce the andktogether rdan Cham with each a “Party” the winn connection t at the Slova rator appointed in accowith this Agreement ration Cour arbitrators. of the Arbit accordance e, by one arbit award of the menced in discussions will necessitate disclosure of Commerc d in the information in relation to ________________. Such Chamber exchange eedings com willgnize that the Parties be reco is contemplated Development agreement rationIt proc : nses shall of both Parties. In each arbit , while such expe concerning the technology and business affairs written below n of the nses of information authorisatio tive date last legal expe the written le per as of the effec nt follows: Version emeas eering samp red only upon handled be agre willthis be delive Author It is agreed that this information uted t. One (1) engin of 14/04/14 authority may Samples to have exec On behalf or departmen al agreement. Comments Article 3 – a competent s.r.o. Parties here sting agency spol the mutu Revised version eof, Tech requested by wher lly 17/04/14 iLum As used in this agreement: 1. from the reque lied to the Client after In witness Product officia the pt is obtained and 18/04/14 Revised version of orally, will be supp recei disclosed les l (whether other the to samp g. Parties officia the of ent one by Any an information supplied ded that for developmin writin 23/04/14 Revised version “Information” shall mean all documents and other a) of to above. and provi e the price offer or otherwise) for the Purpose Client, referred in On behalf demonstration by ed form, ad material other or includ m is in documentary 24/04/14be Revised version luminaire type thet it, in “Proper use” shall mean use solely for the Purpose. b) mus mean the Party receiving es Revised version furnishing information, and “The Recipient” shall CEO erty ring “The Disclosing Party” shall mean the party c) rsky, lectual prop pendic ings, manufactu es. imir Leva le 4 – Intel Ap Artic should be design, draw particular case. r. mark xx. e Parti RNDr. VladParty itsPurpose e.g.Disclosing This trade By:The nsabout the Permitted agreement with the th and entered into limited to, the othe is of and made with 3/2014 isio “Authorised Contact” shall mean all communications ing, but not d) the ent the Productt of g Date: 21/0 s prov Product includ ndin t shall reemsell addressed to: The Clien Ag rsta rty rights of the ou emen prope Between this ctual unde llane agreand all intelle to d e ce ts t th any t an en Mis Product. , twshall 1: Name & email of customer contact e.g. By: e.g ithouown emend to the relate 12 – copy endm The Clien that rial 14 For Party re t al avoid le mate 3/20 e.g. to am contact FE ag of en in email 21/0 & ic other tire ures ig represented by For Party 2: Name Date: and Art ssary meas tools reem and all e or en , which is hereinafter called “the Client” take the nece e Ag the not be used by the Recipient ived on ations by the Recipient ifictreated ain shall n th as confidential, shall be cally and shall e secr directly concerned All Information furnished by the Disclosing Partyl mod rece is notets 2. contparty who And has in Trad the Client publi third assig other person Alby the Recipientshtoallany icores le 5 – eration with it which has ndArtic except for Proper Use, shall not be disclosed atconsent, ion its coop the Disclosing Party’s prior written without pe s know-how the Recipient partyto any third party ing thnot ment n. the Proper Use and shall not be disclosed by either its Ap to third partie t. provider dgshall te ent d iLumTech le unica show; know spol. lopm can s N Recipient r.o. an the whose registered office is comm t The Deve except for any of the Information which at or know 906 mes publically 02 Dojč,ectio n with the Clien beco Contract, use nac RNDr. Vladimír emen thehereinafter eratio of is in conn 419, Slovak Republic, company number , which coop or 34 132 333 , represented by activity theParty or becomes free of restriction to afterLevársky Agre referred isrty his andpa to as “the Development provider” the expiration revealed to it was way through Thisdisclosed to it by the Disclosing , each is already known to the Recipient at the date ess, whether a) shall not, even learnt in any pies Client’s busin ent provider he may have ix… lopm obligation the disclosure or use in question, or which al co of by the Recipient of related to the breach inits anyDeve The reason forigin public (except or pend to the er the public doma the Client and the Development al all information . is or becomes generally known or freely available Ap o b) provider ovid denti re notatentered are hereinafter ment collectively referred to rve as prconfi in tw r manufactu as the “Parties”. hereunder), or was entitled to make such d and presemente as a result of this agree assembly and/o any customer wn up or use in question, by a third party who provider shall regar on theDdisclosure op the restriction of free sourc ra for Recipient, el s the to any disclosed ent is oyee c) ted, der from Dev The Developm this Agreement, ent provi of training empl disclosed or dissemina eived, or of the unrestricted disclosure, the process WHEREAS the Developm to be rial or data conc Clientand ed byunder is developing, without violating any of the Recipients obligations permitlighting half that the thessary essential to producing learnor norselling or other mate is independently developed by the Recipient d) on or regulations or with a court solutions. minate,and administrative order,Oprovided n be nece laws lutely ams, practices se nor disse abso progr is lawful and disclo it reasonable is required to be disclosed to comply with applicable all sses, e) not takes that t the Recipient shall s, proce WHEREAS of such disclosure if possible and that Exce the Client desires pt to theofexten ent provider to mark outsource Clien Disclosing Party received prior written notice t. such the development the extentuct, Developm , patents, trade and production of an “All purpose the disclosure. disclosure and, if possible, to minimize the (the Product). red by the , know-how Prod surface mount diffusor luminaire” actions to obtain confidential treatment for such of ical information assembled or manufactu ods, techn nt list, meth to protect the Information , used necessary e. Cliereasonably make such arrangements as eare ed, developedinformation).the Development sal free of charg The Recipient will take such precautions and 3. ned, creat its own confidentialWHEREAS of th to protect provider is a company with a place Clients dispo the Recipient would technical at the half take and makedesig of business at 906 ill02ofDojč, Information rial with industrial of the received by it (and in any event no less than those facilities to develop, and is willing mate419, Slovak Republic, where it has sufficient ndix 1, will be On be in its Proper Use of the confidential nature ings, to as are concerned develop e in Appe the Product fixtur forbly thedraw Client The Recipient will inform such of its employees Documents under the terms and conditions as loped – assem 6 ts, deve le Agreement. this to the pursuant onen Artic set forth herein. g. related to received and of the obligation to protect the Information photos of comp drawings of the toolin NOW, ing agreed mentation, The Parties includ docuTHEREFORE, have file ical der’s as ical follows: provi techn Party. techn the Disclosing k) and or trade secret is granted or implied by The Development contains, in English, a sh and Slova No license under patent, copyright, trademark 4. ArticleParties tooling (in Engli mentation This docu the 1of– Appointment aftercates five years a period ofprope rty certifi by all Parties and shall remain in force for ificati on, spec This Agreement shall be effective when it is signed 5. s in Europe. The Client herewith appoints the Development and ordinance have ceased to do business together. sdevelop s provider Product s, code to the dard ation the sell “All purpose Stan to regul to or – as surface “the Product” 7 Recipient shall either return mount diffusor luminaire” hereinafter Party,lethe If, in order cable laws, referred the first written request of the DisclosingArtic to with all appli ean standards. t. Information Upon termination of this Agreement, and at to retain one copy of the shall comply relevant Europ . Except that the Recipient will be permitted the Clien ent provider rmity with all destroy any Information given to it hereunder The Development provider accepts are borne by confoappointment. The Developm uct is in such ly with ing from this satisfy regulatory compliance or legal requirements. that the Prod costs result ment and comp der guarantees red, then the ant to this Agree cate is requi of the lopment proviArticle – Development uct is pursu The Deveany party2certifi Product Information proprietary ific third ent of the Prod not relieve either Party of its obligation toinprotect Europe, a spec and developm n Termination or expiration of this Agreement shall desig the The development re that of the Product is governed by the received hereunder in confidence. der will ensu specification that is attached hereto ent provi specification as Appendix 1. Any change The Developm ndix 1. will be agreed in writing between the Client and the by registered or deviation in the Development provider. The ons of Appe diatelyspecification the deviation will be logged. The specification updated imme the specificati contains Product definition be terminated 2 and Appendix 1) thatwill be appended and terms. ment may article ination n, the Agree ification (see Early term The Development provider shall natio contained herei of the spec Article 8 – keepnthe tion informed deviaof the progress of the project during rtant sions for termi ment or Client a month) impo provi or teleconference periodical review ss calls. meetings usly expre (minimum once of the AgreeDuring these meetings / calls the Development provider willinreport dice to any way as serio costs (if there al breac arehany changes), ged such on three parameters: Without preju anya)funda ment chan has s of timing and t. letter in case ptedb)by one of the Partie the Clien ownership of structure or cannot be acce c) quality (actual status ofe the development). Contract. wher the legal ct from the also take place could reasonably expe n may written reportparty will be provided to the Client. The Such terminatio Athat the other surface se Client will formulate purpo result comments the “All Development provider shall implement within 1 week theafter the submission to affect the comments. lopment of ment will start.of the report. The ract for the deve facture agree n of the Cont total amount ment the manu Expiratio Both Parties may modify Timing of ation phase and the Article 9 – lopment agree the Product development deve but only after preliminary agreement. after the realis been paid. After the ment expires ndix 2 has ent agree in Appeis design of ioned the Product This developm The aire” ment a very important element in the Agreement. or lumin The Client will approve the design phase (drawings), prototype phase, mount diffus in three phases: concept . realisation phase ment (first production samples). ation Agree nation of the and compens ving the Indemnity n of the termi date of recei d by reasothe Article 10 – After each phase (concept, prototype, through the realisation) Client within 7 days will can be lodge lopmentand evaluate If no written approval give . written approval to start the next phase. compensa istion Product deve given after each phase, the project ment to the Agree indemnity or stop and only theup related will cost 2 of to the evaluated phase will be charged No claims for provider’s costs rdance with Appendix to the Client. ent lopm During the all in acco concept arestep of the Deve phase and after each (concept, prototype, realisation), pay for ition these costs remarks the cond Development of the Client the r The Client shall provider and adapt where needed. The work needed will take d unde intor account the e and unde for the adaptation cycles are included finally settle registered notic ns, shall be in theVienn Agreement. a (Vienna by negotiatio ber in The price reso n for the design lutio and development is based on the may not be settled Economic Cham ute ral conditions Disp which – , Fede attached 11 as ian the Appendix le price ment (if there are any changes inthis 2. The Development provider may Artic Agreedevelopment) re of the Austr change al Centbut only after preliminary written agreement ection with product ational Arbitr with the Client. of or in conn Rules. of the Intern arising out e with the said Conciliation All disputes in accordanc Arbitration and ators appointed the Rules of or more arbitr Rules) by one Between

ID Task name XXX XXXXXXX PROJECT 1 1 Administration 2 1.1 Project definition meeting 3 1.2 Project kick-off 4 2 Development 5 2.1 Concept and design 6 2.2 Optical design 7 2.2.1 Optical solution design 8 2.2.2 Optical measurements and evaluation 9 2.3 Mechanical design 10 2.3.1 Product design and construction 11 2.3.2 Thermal evaluation and simulation 12 2.4 Electronic design 13 2.4.1 Component selection 14 2.4.2 Electronic design and schematics 15 3 Milestone 1 16 4 Prototype assembly 17 4.1 Quotations and commercialisation 18 4.2 Tooling production and prototype production 19 4.3 Prototype evaluation 20 4.3.1 Thermal management 21 4.3.2 EMC measurement 22 4.3.3 Electrical safety testing 23 4.3.4 Optical measurements 24 5 Product release 25 5.1 Documentation evaluation 26 5.2 Datasheet creation 27 5.3 Release meeting 28 6 Milestone 2 29 7 Production ramp-up 30 7.1 Pre-series planning 31 7.2 Pre-series 32 7.3 Pre-series evaluation 33 7.4 Mass-production approval 34 8 Certification

Duration 136 days 2 days 1 day 1 day 29 days 10 days 10 days 8 days 2 days 19 days 16 days 3 days 10 days 2 days 8 days 0 days 65 days 6 days 50 days 9 days 3 days 2 days 2 days 2 days 3 days 1 day 1 day 1 day 0 days 37 days 1 day 10 days 1 day 1 day 30 days

Start 08.04.14 08:00 08.04.14 08:00 08.04.14 08:00 09.04.14 08:00 10.04.14 08:00 10.04.14 08:00 28.04.14 08:00 28.04.14 08:00 12.05.14 08:00 28.04.14 08:00 28.04.14 08:00 22.05.14 08:00 10.04.14 08:00 10.04.14 08:00 14.04.14 08:00 26.05.14 08:00 27.05.14 08:00 27.05.14 08:00 04.06.14 08:00 13.08.14 08:00 13.08.14 08:00 18.08.14 08:00 20.08.14 08:00 22.08.14 08:00 26.08.14 08:00 26.08.14 08:00 27.08.14 08:00 28.08.14 08:00 28.08.14 08:00 02.09.14 08:00 02.09.14 08:00 08.10.14 08:00 22.10.14 08:00 23.10.14 08:00 22.08.14 08:00

Finish 23.10.14 17:00 09.04.14 17:00 08.04.14 17:00 09.04.14 17:00 26.05.14 17:00 25.04.14 17:00 13.05.14 17:00 09.05.14 17:00 13.05.14 17:00 26.05.14 17:00 21.05.14 17:00 26.05.14 17:00 25.04.14 17:00 11.04.14 17:00 25.04.14 17:00 26.05.14 17:00 25.08.14 17:00 03.06.14 17:00 12.08.14 17:00 25.08.14 17:00 15.08.14 17:00 19.08.14 17:00 21.08.14 17:00 25.08.14 17:00 28.08.14 17:00 26.08.14 17:00 27.08.14 17:00 28.08.14 17:00 28.08.14 17:00 23.10.14 17:00 02.09.14 17:00 21.10.14 17:00 22.10.14 17:00 23.10.14 17:00 07.10.14 17:00

Predecessors

2 3 5 7 5 13 10 3 13 9, 11, 12 15 17 18 20 21 22 19 25 26 27 28 34 31 32 22

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Technical & commercial negotiation Product development request

Development stages

& agreement

Prototyping

Testing

Product completion, updates & after sales service

Development stages Product development request Technical & commercial negotiation & agreement Development stages Prototyping Testing Product completion,

Industrial design This is the process of preparing 3D designs using 3D CAD modelling software. The process allows us to implement any adjustments you wish to make immediately. Optical design We prepare optical designs according to the requested illumination, beam angle, LIDC, UGR and efficiency and efficacy specifications. The optical designers also take into account the materials asked for or can offer new technologies based on our internal research.

updates & after sales services

Thermal design The thermal design process starts with the simulation and suggestion of appropriate heatsinks made of optimised materials that ensure the smallest possible luminaire. We focus on self-designed and highly effective forged heatsinks that boast excellent thermal conductivity properties despite their compact size. Our thermal designers cooperate in detail with other departments and engineers to ensure the best thermal management for the chosen electronic components of the luminaire.

Electronic design The electronic department prepares electronic designs for PCBs as well as suggesting the most suitable components and electrical schemes. They can also propose the software and interface needed for touch panels, computers and other devices in order to make control of the luminaire as easy and flexible as possible.

Development follows a defined and proven path that ensures a satisfactory outcome.

Mechanical design Our mechanical designers and engineers prepare sheet metal, die cast and extrusions designs according to the type of luminaire, using the advanced CATIA 3D CAD software. The designers ensure that the desired mechanical properties are provided, especially in the case of requested IP and IK protection ratings.

Project preparation Product definition • Product definition form

Development conditions • Time schedule • Milestones

Commercial conditions • Cost evaluation • Price quotation

Development contract

Design OFFICIAL START

Concept and design • Form and shape definition • Sketches and renders

Optical design • Optical solution • Optical measurements and evaluation

Electronic design • Component selection • Electronic schematics

Thermal design • Thermal simulation • Thermal evaluation

Mechanical design • Mechanical engineering • Prototyping

Milestone 1 • Drawings • Schematics

Measurements • Thermal, photometric, EMC, mechanical and electrical safety tests

Evaluation • Prototype evaluation meeting • Analysis of measurement results

Preparation of documentation • Technical drawings, BOM • Wiring schematics, BOM

Product release • Release meeting

Milestone 2 • Prototypes • Test reports

Mass-production approval • Code activation • Final technical documentation

OFFICIAL END

Prototyping Preparation • Tooling production • Prototype production

Pre-series, kick-off & certification Pre-production planning • Pre-production • Datasheet and installation manual

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Pre-production evaluation • Pre-production analysis • Documentation update

Certification • External certification • Self-declaration

Development stages / Full luminaire development

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Technical & commercial negotiation Product development request

& agreement

Development stages

Prototyping

Testing

Product completion, updates & after sales service

Prototyping Product development request Technical & commercial negotiation & agreement Development stages Prototyping Testing Product completion, updates & after sales

Nowadays, speed is a key factor in the successful development of a product. Faster is better and ultimately saves money. Therefore, we have at hand our own stateof-the-art prototype workshop where we can create prototypes of almost the same quality as the final product within very short timeframes. With our own industrial 3D printer, we can produce prototypes in as little as 12 hours, and no more than 24 hours. Additionally, our mechanical workshop is equipped with a wide range of traditional machines that allow for turning, milling, cutting, bending and welding so we can

provide fully functional prototypes and samples within just a few working days. We can also manufacture prototype PCBs and equip prototype luminaires with these PCBs in order to perform all necessary luminous flux, thermal and EMC measurements. Our ability to provide functional prototypes at such an early stage of development guarantees high flexibility and minimal investment as every mechanism and property of the product is checked before tooling, further minimising losses.

How quickly your product enters the market can be the difference between success and failure.

services

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Prototyping / Full luminaire development

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Technical & commercial negotiation Product development request

& agreement

Product completion, updates & after sales Development stages

Prototyping

Testing

service

Testing Product development request Technical & commercial negotiation & agreement Development stages Prototyping Testing Product completion, updates & after sales services

We have some of the best equipped inhouse laboratories in Europe, and can provide our customers with extensive and indepth services thanks to the array of tests we can perform side-by-side with our other services. This provides development flexibility and speed not possible if these tests needed to be outsourced. Another advantage is that tests can be performed on final prototypes before they go to the next stage, tests that would normally be very time consuming. Additionally, it means that when the final product is sent for certification and other required external testing, for example, ENEC, UL, CE and others, it cannot fail as the tests have already been done. Additional to these standard measurements, we also have a remote controlled long-term test facility where we can stress test luminaire prototypes prior to their release to production. This process ensures that the final product is of the standard you need.

Thermal laboratory Our new, high-tech thermal laboratory is equipped with a wide array of devices, such as: • Two thermal chambers • DAQ system • IR thermometer • Thermal imager • Thermal test centre – a test facility for air handling luminaires

We can peform almost every test you could possibly need in-house, keeping development times to a minimum.

Electronic laboratory We can perform many tests within our state-of-the-art electronic laboratory, including: • Electrical safety tests • EMC testing • Electronic devices functional tests • Long-term tests • DALI compatibility tests

Optical laboratory In our optical laboratory you will find the following equipment plus more: • Goniophotometer RiGO 801 • Luminance meter with single lens reflex optical system • Luminance analyser and lux meter • Integration sphere • Scatterometer • Spectrometer • 3D scanner

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Testing / Full luminaire development

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Product completion, updates & after sales service

Technical & commercial negotiation Product development request

& agreement

Prototyping

Development stages

Testing

Product completion, updates & after sales services

Product development request Technical & commercial negotiation & agreement Development stages Prototyping Testing Product completion, updates & after sales services

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Third party testing After finalisation and testing of the prototype, if certification by a third party is required, the product is sent to the appropriate certification laboratory. As we perform all tests in-house beforehand, the possibility that the product fails any official laboratory tests is eliminated. This ensures that the final release of your product to the market is not unnecessarily delayed. Release from development Once we have the test reports and certificates issued by the certification laboratories, the next step is to release the product from R&D. During the release meeting, the final prototype, as well as test reports and samples, are compared to the product definition form. If the result is satisfactory, the product is released from development following a defined release protocol that needs to be signed by all responsible parties. At this point, all datasheets and instructions are already prepared additional to the internal codes and a final bill of materials (BOM). When the product is officially released from development, you are also supplied with all technical documentation. At this stage, you can check the documentation and any necessary corrections will be made. Final technical documentation is only provided once all issues have been resolved.

Pre-series Between the development and massproduction of the product, there is a step called pre-series. At this point, production engineers check the luminaire and its production in terms of assembly, based on the prepared technical documentation and assembly instructions. If any corrections need to be made before the product enters mass production, this is the time when they are implemented. Once the pre-series phase in completed, the product it released to mass-production. Product updates and after sales services iLumTech does not only develop products, but can also provide continued support through product updates. As technologies progress at a rapid rate, especially in the case of LED, it is necessary to modify products during their lifecycle to ensure they are current. We will arrange generation updates to keep your product one step ahead of the competition by changing the technologies used or modifying aspects of the design to meet the latest standards. To ensure that we remain as flexible as possible in terms of updating, we will offer you the choice of upgrading to the latest generation LEDs or of keeping those originally used at a reduced cost. The choice is entirely up to you.

I Full luminaire development / Product completion, updates & after sales services

Customisation We are also able to adjust your existing products according to specific request. This can cover anything from modification of the mounting, optical system, dimensions and construction of the luminaire, to the adding of air slots, sensors and emergency kits.

Based on the OMS UX-RELAX A8, this luminaire was modified to be suitable for continuous line installation with space at the sides for insertion of acoustic isolation.

Optimisation As the Technological Revolution progresses, new methods for the production of materials and solutions are innovated faster than ever, which inevitably means that older ones become obsolete or hard to find and in turn more costly. If your products contain such elements, your production costs may get too high and your profit margin too low. It is also possible that the materials and solutions you use exhibit qualities that are not necessary for your application, yet you pay for them nevertheless. We know that finding the best materials and solutions can make the difference between success and failure, and can help you find the most suitable, viable and practical options for your products, resulting in simplified construction, more efficient assembly, reduced costs and higher profits. Luminaire replacement Customers do not always want to update the whole infrastructure of their building in order to replace the lighting. As a result, you may wish to develop a luminaire suitable to be a direct replacement of a current product, to keep existing customers by offering them a simple and effective solution. To this end, we can prepare new products based precisely on the defined parameters of an old product.

Based on the OMS EL-AVIOR MOTION, this luminaire houses three fully and independently adjustable 60Âş beam angle AVIOR MOTION spotlights in one suspended box along with their control gears.

Product completion, updates & after sales services / Full luminaire development

IÂ 187

Profile for Zuzana Nadim

iLumTech - Book of services 2014  

The book which describes all services which iLumTech offers - concept and design, optical design, thermal design, electronic design, prototy...

iLumTech - Book of services 2014  

The book which describes all services which iLumTech offers - concept and design, optical design, thermal design, electronic design, prototy...

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