A roadway luminaire is provided which includes a mast mount docking station securable to an end of a pole mast. The mast mount docking station includes a power plug electrically coupled to the power conductors. The luminaire includes a corresponding power plug which is electrically and mechanically coupled to the mast mount docking station via a twist-lock feature including mating keys and keyways in the docking station and luminaire, respectively. The luminaire includes several plug-in components such as a plug-in photoelectric cell, a plug-in starter and a capacitor press-fit into a molded cavity in the luminaire. The power plug of the luminaire is adaptable to be used with all international voltages. The twist-lock feature provides for a fool-proof mechanical and electrical connection to ensure that the correctly rated luminaire is connected to the supply voltage.
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8. A method of installing or removing a roadway luminaire, the luminaire including a mast mount docking station for attachment to a pole mast, the luminaire and docking station including mating twist-lock connectors, the luminaire and mast mount docking station further including mating power plug connectors, the method comprising the step of:
twisting the luminaire with respect to the docking station to thereby mechanically and electrically connect and/or disconnect the mating twist-lock connectors and the mating power plug connectors.
6. A luminaire for mounting to a pole, comprising:
a mast mount docking station having a pole connection end including means for attaching the docking station to the pole and a coupling means at an opposite end of the docking station; and
a luminaire including a connection end having mating coupling means with the docking station coupling means such that the luminaire is removably coupled to the mast mount docking station by a twist-lock mating between the respective coupling means; wherein the pole connection end of the mast mount docking station includes an opening for receiving the pole having a plurality of removable knock-outs therearound for enlarging the opening to accommodate mast diameters of varying sizes.
7. A luminaire for mounting to a pole, comprising:
a mast mount docking station having a pole connection end including a means for attaching the docking station to the pole and a coupling means at an opposite end of the docking station; and
a luminaire including a connection end having mating coupling means with the docking station coupling means such that the luminaire is removably coupled to the docking station by a twist-lock mating therebetween, wherein the luminaire further includes a molded photoelectric control receptacle extending above a top portion of the luminaire and a molded electronics compartment extending below a bottom portion of the luminaire to provide hand holds to perform the twist-lock mounting of the luminaire to the docking station.
1. A luminaire for mounting to a pole which comprises:
a mast mount docking station including a clamp for attaching to the pole at one end of the docking station and a keyed coupling means at an opposite end of the docking station;
an electrical plug connector disposed in the coupling means end of the docking station;
a luminaire including a mating electrical plug connector for electrically connecting the mast mount docking station to the luminaire, the luminaire further including a connection end having keyways therein such that the luminaire is removably mechanically and electrically coupled to the mast mount docking station by a twist-lock mating between the mating electrical plug connectors and keyed coupling means of the mast mount docking station and the keyways in the connection end of the luminaire.
10. A roadway luminaire comprising:
a mast mount docking station having a pole connection end including means for attaching the docking station to the pole and a coupling means at an opposite end thereof;
a first plug connector having fixed contacts coupled to a power supply, the first plug connector being positioned at the coupling means end of the docking station;
a lamp assembly including a housing having a mating connection end and a central cavity enclosing an illumination lamp electrically connected to ballast circuitry, the mating connection end further including a second plug connector having fixed contacts electrically coupled to the ballast circuitry, wherein upon twist-locking the mating connection end of the lamp assembly housing to the docking station, the lamp assembly is removably mechanically coupled and the fixed contacts of the first plug connector interengage with the fixed contacts of the second plug connector to provide power to the illuminating lamp.
2. A luminaire as defined by
3. A luminaire as defined by
4. A luminaire as defined by
5. A luminaire as defined by
9. A method as defined by
11. A roadway luminaire as defined in
12. A roadway luminaire as defined in
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The present invention relates generally to luminaires for outdoor lighting and more particularly relates to a roadway luminaire which is easy to mount to a mast arm and easy to maintain due to a mounting arm assembly, a twist-lock feature, a fool-proof power plug and a plug-in replacement luminaire.
Poles for supporting luminaires for the illumination of roadways, parking lots and the like differ not only in that they have either a vertical end with a mast arm or an inclined end, but also in that the diameters of the poles vary. For example, some poles have approximately a horizontal end, the end often being at an angle of 5° to about 15° to the horizontal. This variety of pole constructions results in that luminaires are commonly manufactured and warehoused in a corresponding variety of constructions. Accordingly, it would be advantageous to have a universal mounting device for mounting a luminaire to a pole or mast arm.
Additionally, current maintenance costs associated with roadway luminaires is extremely high. Particularly, maintenance is usually performed by licensed electricians to replace capacitors, ballasts, photoelectric controls, starters and complete luminaires. The average cost to replace/install a luminaire is approximately three times the cost of the luminaire itself, e.g. the cost of three men, two trucks and a trailer. There have been efforts in the past to overcome some of the maintenance problems associated with roadway illumination. For example, U.S. Pat. No. 4,937,718 discloses a roadway luminaire having the electrical components employed in the lamp ballasting circuitry mounted to a door member by means of a universal mounting bracket having a deformable planer construction. In this way, a variety of different sized components can be mounted using the disclosed bracket. Additionally, U.S. Pat. No. 4,538,217 discloses a flood light luminaire having all the electrical components mounted on a removable door casting to allow for servicing and maintenance. U.S. Pat. No. 4,791,539 discloses a luminaire having quick-disconnect components which one mounted on an electrical plate detachably secured to a support plate of the luminaire. The plate includes a quick disconnect for detaching the electrical plate from the support plate. However, maintenance of the luminaire is still costly and replacement of components of the ballasting circuitry is difficult and time consuming.
Another disadvantage of known roadway luminaires includes the possibility of replacing a luminaire with one of a different voltage. Currently, roadway lighting may be operated at voltages of 120, 208, 220, 230, 240, 277, 347 and 480 volts throughout the world. Accordingly, it is quite possible when replacing or repairing luminaires to use replacement parts rated for a different voltage. Thus, it would be advantageous to provide a luminaire which includes a means for keying the luminaire so that it can only be replaced by a luminaire which operates at the same voltage.
Yet another disadvantage of known roadway luminaires is the “hot wiring” of the luminaire, thus making replacement difficult and dangerous. In most cases, rather than shutting off the power to the roadway lighting, the lighting is repaired with power being supplied to the luminaire. Accordingly, only licensed electricians with proper protective gear generally perform replacements of luminaires. Thus it would be advantageous to have a luminaire which can be safely and easily replaced even with power being supplied to the luminaire.
In view of the present disadvantages of currently available roadway lighting devices, it is desirable to redesign the luminaire to be easy to install and maintain, provide a fool-proof replacement system which permits only luminaires of same voltage to replace a damaged luminaire and to make installation and maintenance most cost effective.
It is an object of the present invention to allow safe and easy installation and maintenance of roadway luminaires.
It is a further object of the present invention to provide an improved mounting system for a luminaire to a mast arm.
It is yet a further object of the present invention to provide a keyed power plug receptacle for connecting the luminaire to the power supply.
It is yet another object of the present invention to provide a luminaire which can be mounted to a mast arm assembly utilizing a simple twist-lock feature.
It is still a further object of the present invention to provide a luminaire having a plug-in starter module located externally on the luminaire housing for ease of replacement.
It is yet a further object of the present invention to provide a luminaire including an internal leveling device for proper positioning of the luminaire.
In accordance with the present invention, a luminaire for mounting on a pole, and more specifically, a roadway luminaire includes a mast mount docking station having a clamp for attaching to the pole at one end of the docking station and a keyed coupling means provided at an opposite end of the docking station and the luminaire having a connecting plate provided with keyways such that the luminaire is removably coupled to the mast mount docking station by a twist-lock mating between the keys and key-ways of the coupling means and connector plate. The mast mount docking station further includes an electrical plug connector located at the coupling end of the docking station and, the luminaire includes a mating electrical plug connector for electrically connecting the mast mount docking station to the luminaire. Specifically, the supply voltage is coupled to the electrical plug connector in the mast mount docking station and the mating electrical plug connector in the luminaire provides the supply voltage to the ballast circuitry and ultimately the lamp.
For ease of attachment of the mast mount docking station to the pole, the docking station includes a plurality of knock-outs for adapting to mast diameters of varying sizes. In this way, the mast mount docking station can be specifically adapted such that little space is left between the mast and the docking station to prevent animals and the like from entering the docking station. The docking station more specifically includes an upper mast assembly and a lower mast assembly. The upper mast assembly includes the clamp for attaching the docking station to the pole. The upper and lower mast assemblies are secured together by bolts such that the electrical plug connector mentioned above is secured therebetween. Additionally, the docking station may include a series of inclined steps located in the upper mast assembly to permit angles of tilt for leveling the luminaire.
With respect to the twist-lock feature, the luminaire may be coupled to the mast mount docking station by a 15° to about 30° rotational movement of the luminaire with respect to the docking station. This rotational movement provides both electrical and mechanical connection. More specifically, upon rotation, the power plugs of the mast mounting docking station and luminaire, respectively, are electrically connected and the keys of the docking station are mechanically connected to the connector plate of the luminaire in the same motion. The luminaire also preferably includes a molded photoelectric control receptacle extending above a top portion of the luminaire and a molded capacitor compartment which extends below a bottom portion of the luminaire to provide hand holds for performing the twist-lock mounting of the luminaire to the docking station.
With respect to the electrical connectors, each of the connectors is provided with a series of crenulations, each crenulation being identified with a specific voltage rating to cover the spectrum of all available international voltages. The twist-lock feature for mating the connectors is provided with keyways which ensure that only corresponding voltage rated connectors are operatively coupled together.
The roadway luminaire of the present invention also includes a lower housing in which the ballast circuitry is mounted to a surface thereof such that the starter receptacle opens externally to an assembled upper and lower housing assembly and the starter module includes a plug-in connector to electrically couple the starter to the receptacle without the use of tools. Likewise, the upper housing is provided with a photoelectric control cell receptacle integrally molded to a top surface thereof. The luminaire includes a plug-in photoelectric cell which can be selectively inserted into the receptacle and replaceable without the use of tools. Lastly, the lower housing includes a cavity for receiving a capacitor of the ballast circuitry. The capacitor is press-fit into the cavity for insertion and/or removal without the use of tools. Accordingly, maintenance of the luminaire is simple and fast.
Also disclosed is a method of installing or removing a roadway luminaire, the luminaire including a mast mount docking station for attachment to a pole mast. The luminaire and docking station having mating twist-lock connectors, the method comprising the step of twisting the luminaire with respect to the docking station to thereby mechanically couple and/or release the mating twist-lock connectors. The method is further defined such that the luminaire and mast mount docking station include mating power plug connectors and wherein the step of twisting the luminaire also electrically connects and/or disconnects the mating power plug connectors.
Lastly, a method of manufacturing a housing for a luminaire is disclosed. Specifically, the method includes the steps of molding a composite to form the housing including a dome section surrounding an area of the lamp; coating an inner surface of the dome section with urethane; vacuum metalizing the inner surface of the dome section with aluminum; and coating the inner surface of the dome section with acrylic to form a reflective surface.
A preferred form of the luminaire, as well as other embodiments, objects, features and advantages of this invention, will be apparent from the following detailed description of illustrative embodiments thereof which is to be read in connection with the accompanying drawings.
PREFERRED EMBODIMENTS
Preferably, the upper housing 2 is formed of long-life, weather and corrosion resistant fiber reinforced polymer construction. Known luminaires usually include separate reflectors that are typically stamped of aluminum and are supported in the dome portion of the luminaire housing. In the present invention, the reflector 16 is integrated into the upper housing 2. More specifically, the upper housing is preferably a compression molded composite with the reflective surface geometry 51 being formed during the molding process.
The preferred embodiments of the upper housing 2 and reflective surface include either a natural housing finish or a simulated metal finish. In a preferred embodiment of the upper housing 2, the interior reflective surface 16 is base coated with a urethane, then vacuum metalized with aluminum and top coated with an acrylic. Thus, a reflective surface is provided on the interior of the dome portion only and all other surfaces are unfinished. Furthermore, the upper housing may be pigmented grey during the molding process to achieve to simulated metal finish discussed above.
The upper housing 2 also includes a photoelectric control cell socket for receiving a plug-in photoelectric controller 24. The photoelectric control cell socket is integrally formed during the molding process in a top section of the upper housing to provide for an unobstructed line-of-sight for the photoelectric control cell 24. The socket is preferably a standard three terminal, polarized, locking-type socket.
As shown in
The ballast circuitry in the lower housing 4 is electrically connected to the upper housing 2, i.e. the lamp socket via a multiple pin connector (not shown). Most known luminaires have the ballast circuitry mounted in the upper housing whereas the present invention mounts all the components of the ballast circuit in the lower housing. This design allows for easy maintenance when the lower housing is swung open. Furthermore, the entire lower housing assembly may be replaced simply by unplugging the multiple pin connector and lifting the lower housing off the upper housing hooks 26. Alternatively, the type of luminaire can be changed by replacing the lower housing with one having a different ballast circuit. Accordingly, the maintenance procedure for the luminaire of the present invention is greatly simplified. To repair a failed luminaire, the maintenance worker would check the lamp, the photoelectric control cell and the starter. If none of these appear to be the problem, the entire lower housing can be replaced. Alternatively, the entire luminaire can be replaced by twisting the luminaire 10 off the mast mount docking station 6 and twisting on a new one. The twist-lock feature of the present invention will be described in greater detail below.
Furthermore, the upper and lower mast assemblies 64, 66 are provided at one end with a thin wall section 72 which may be removed, similar to a “knock-out” in a junction box, thereby allowing the mast mount docking station to receive mast arms of different dimensions and to provide a relatively close fit therewith to prevent animals from entering the mast mount docking station. The upper and lower mast assemblies are provided at the opposite end with a keyed connector 73, 75 for mating connection with the twist-lock plate 46 shown in
The twist-lock feature of the present invention is provided by the interface between the mast mount docking station 6 and the luminaire 10, such that the male and female plugs 37, 74, respectively, are electrically connected upon the mechanical connection of the luminaire 10 to the mast mount docking station 6. Preferably, the twist-lock is accomplished by a rotational movement of the luminaire with respect to the mast mount docking station ranging from about 15° to about 30°. The twist-lock feature provides both electrical connection between the male and female plugs as well as mechanical connection of the luminaire to the mast mount docking station. Furthermore, the twist-lock feature provides for fool-proof voltage matching between the power source and the luminaire attached thereto. Specifically, the key/keyways of the mast mount docking station and locking plate of the luminaire are designed so that only corresponding voltage male and female plugs may be electrically connected. Additionally, mechanical stops are provided at the key/keyway interface for providing a stop against over mechanical rotation.
Accordingly, the luminaire of the present invention is simple to install due to the two piece design, i.e., the mast mount docking station 6 and the luminaire fixture 10, which are electrically and mechanically connected via a twist-lock feature. Also, once the mast mount docking station is installed, repair and/or replacement of the luminaire is simplified and can be done “hot” since the power is connected to the luminaire by means of the mating power plugs. Furthermore, general maintenance of the luminaire has also been simplified by eliminating all unnecessary hardware, e.g. providing a plug-in photoelectric control cell, a plug-in starter, and a lower housing door latch which requires no tools to open. Additionally, the design of the lower housing which includes the ballast circuitry can easily be electrically disconnected form the upper housing by unplugging a swing open exposing the inner portion of the upper housing and an inner surface of the lower housing. The lower housing 4 includes mounted thereon the ballast circuitry to electrically power the luminaire. The lower housing is capable of swinging to a closed position enclosing the luminaire and is held closed via a latch 32. Preferably, the latch 32 can be released without the use of tools to open the luminaire for repair and maintenance.
Also shown in
In a second embodiment, the lock-plate 46, as shown in
Referring to
In an alternate embodiment, the gasket 34 is fitted to the lower housing as illustrated in FIG. 7. Specifically, the gasket 34 is positioned such that the lens and the edge portion of the lower housing are trapped beneath the gasket.
The upper housing 2 also provides a mounting surface for a power plug 36. In the embodiment shown in
The upper housing 2 is further provided at its plug connection end with a groove for receiving an o-ring seal 42. The groove is designed to include interference flanges 44 so that the o-ring 42 can be fixedly press-fit into the housing without the use of a bonding agent. The o-ring seal 42 provides for a water-tight seal between the luminaire and the mast mount docking station 6. The functional relationship of the locking plate 46 and the mast mount docking station 6 will be described later in greater detail.
As previously discussed, the lower housing 4 is maintained in a closed position with respect to the upper housing by means of a latch 32. As shown in
Alternatively, the latch 32 may be an external toggle-type latch, similar to latches commonly used on a lunch box. Such a latch is illustrated in
The lower housing 4 as shown in
The lower housing 4 further includes a starter receptacle 61 integrated therein. The starter 63 is part of the ballast connector and being lifted off the hooks of the upper housing for simple replacement. In the alternative, the entire luminaire can be quickly and easily replaced simply by twisting off the old luminaire and twisting on a new one. The luminaire of the present invention also provides power plugs capable of being adapted to all presently available international voltages and a fool-proof keying system to allow only corresponding voltage luminaires to be coupled to the mast mount docking station.
Various changes to the foregoing described and shown structures would now be evident to those skilled in the art. Accordingly, the particularly disclosed scope of the invention is set forth in the following claims.
Zimmerman, Thomas A., Bilson, Edward Bernard, Wedell, Mark Taylor, Ellis, III, Glenn A., Kauffman, Rick W.
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