Angle adjuster and lighting apparatus with angle adjuster

An angle adjuster is configured by disposing a first driver for driving a horizontal rotation frame (horizontal direction rotator) to rotate in the horizontal direction and a second driver for driving a vertical rotation frame (vertical direction rotator) to rotate in the vertical direction on the horizontal rotation frame. This configuration can reduce the size of the angle adjuster and a lighting apparatus with the angle adjuster.

FIELD

The present invention relates to an angle adjuster for adjusting an angle of an operation target through remote control and a lighting apparatus with the angle adjuster.

BACKGROUND

For example, Patent Literature 1 discloses an illumination apparatus for adjusting an angle of an illumination lamp installed on a ceiling by operating movable switches in a switch box attached to a wall. This illumination apparatus has a horizontal driving unit that drives an illumination lamp in the horizontal direction and a vertical driving unit that drives the illumination lamp in the vertical direction disposed in a vertical row, and the total length thereof becomes long. Accordingly, an angle adjuster is desired to be reduced in size, for example, for applying the angle adjuster to a ceiling-embedded downlight.

SUMMARY

An angle adjuster according to the present invention for adjusting an angle of an operation target includes a frame body, a horizontal direction rotator, a vertical direction rotator, a first driver and a second driver. The horizontal direction rotator is rotatably supported in a horizontal direction by the frame body. The vertical direction rotator is rotatably supported in a vertical direction by the horizontal direction rotator. The operation target is fixed to the vertical direction rotator. The first driver drives the horizontal direction rotator. The second driver drives the vertical direction rotator.

DETAILED DESCRIPTION

An embodiment of the present invention will now be described with reference to the accompanying drawings. The embodiment exemplifies what is called a universal downlight that is attached to an embedded hole previously provided to an indoor ceiling as a lighting apparatus1with an angle adjuster2. Hereinafter, an up-and-down direction inFIG. 1is referred to as a “vertical direction” for convenience. A direction (for example, a right-and-left direction inFIG. 1) vertical to the vertical direction is referred to as a “horizontal direction”. The vertical direction described below includes a perpendicular direction, but is not limited to this. Hereinafter, “rotation in the horizontal direction” indicates rotation around a straight line elongating in the vertical direction (in the embodiment, especially a straight line corresponding to the center line of the lighting apparatus1) as a rotation shaft. Hereinafter, “rotation in the vertical direction” indicates rotation around a straight line elongating in the horizontal direction (in the embodiment, especially a straight line perpendicular to the center line of the lighting apparatus1) as a rotation shaft.

As illustrated inFIG. 1, the lighting apparatus1includes a fixed frame3(frame body) embedded in an embedded hole. As illustrated inFIG. 2, the fixed frame3is a resin molded member formed in a cylindrical shape. A plurality of (in the embodiment, three) fixtures4(seeFIG. 1) for fixing the fixed frame3to the embedded hole is attached on the outer periphery of the fixed frame3at equal intervals along a peripheral direction. A reflecting member59is attached to the fixed frame3.

As illustrated inFIG. 1, the lighting apparatus1includes a horizontal rotation frame5as a horizontal direction rotator. As illustrated inFIG. 3, the horizontal rotation frame5is a resin molded member that includes a shaft unit6and an outer flange7formed on the outer periphery of the shaft unit6, and is formed in an annular shape. The outer flange7in the horizontal rotation frame5is slidably supported by an inner flange8(seeFIG. 2) formed on the inner periphery of the fixed frame3. In this manner, the horizontal rotation frame5is rotatably supported in the horizontal direction by the fixed frame3.

As illustrated inFIG. 1, the lighting apparatus1includes a vertical rotation frame9as a vertical direction rotator. As illustrated inFIGS. 4 and 5, the vertical rotation frame9is a resin molded member formed in a substantially cylindrical shape. The vertical rotation frame9includes a pair of flat side walls10and11disposed parallel to a shaft plane. A pair of bosses12and13is provided on the external surface of the side walls10and11, respectively. The bosses12and13are disposed on a straight line (on the same straight line) perpendicular to the shaft line of the vertical rotation frame9. One end of hollow shafts14and15(seeFIGS. 8 and 10) is engaged with the inner periphery of the bosses12and13, respectively. The other end of the hollow shafts14and15, in other words, the part of the hollow shafts14and15projecting from the bosses12and13is supported by corresponding shaft bearings16and17(seeFIG. 3) formed on the outer flange7of the horizontal rotation frame5. In this manner, the vertical rotation frame9is rotatably supported centering on the shaft line of the hollow shafts14and15in the vertical direction by the horizontal rotation frame5.

As illustrated inFIG. 1, the vertical rotation frame9has a mounting board19on which a plurality of (for example, three) light-emitting diodes (LEDs)18serving as an operation target as a light source is mounted, a heat sink20to which the mounting board19is fixed, and a lens21for adjusting a light distribution angle of light emitted from the light source disposed thereon. In the embodiment, illustrations and detailed explanation on peripheral apparatuses of the LEDs18are omitted in order to simplify the description of the specification and the drawings.

The angle adjuster2includes a first driver23that drives the horizontal rotation frame5to rotate in the horizontal direction and a second driver33that drives the vertical rotation frame9to rotate in the vertical direction. As illustrated inFIGS. 1 and 6, the first driver23includes a first motor24as a drive source and a first gear mechanism25that transmits power generated by the first motor24to the horizontal rotation frame5. The first motor24is fixed to a first bracket26attached to the horizontal rotation frame5so as to dispose a rotation shaft24A vertically (perpendicularly). A stepping motor is applied to the first motor24, and a lead wire (not illustrated) extending from the first motor24is inserted into a shaft hole of the hollow shaft14and is connected to a drive circuit (not illustrated) fixed to the vertical rotation frame9.

The first gear mechanism25includes a first stepped spur gear28that is rotatably supported by a first pin27(seeFIG. 1) joined to the first bracket26, and is provided with a small gear29(first gear) and a large gear30(second gear). In the first stepped spur gear28, the small gear29is engaged with a first pinion31fixed to the rotation shaft24A of the first motor24, and the large gear30is engaged with internal teeth32formed along the inner periphery of the fixed frame3.

As illustrated inFIGS. 1 and 7, the second driver33includes a second motor34as a drive source and a second gear mechanism35that transmits power generated by the second motor34to the vertical rotation frame9. The second motor34is fixed to a second bracket36attached to the horizontal rotation frame5so as to dispose a rotation shaft34A horizontally. A stepping motor having an identical shape (same type) as that of the first motor24is applied to the second motor34, and a lead wire (not illustrated) extending from the second motor34is inserted into a shaft hole of the hollow shaft15and is connected to a drive circuit (not illustrated) fixed to the vertical rotation frame9.

The second gear mechanism35includes a second stepped spur gear38that is rotatably supported by a second pin37(seeFIG. 7) joined to the second bracket36and is provided with a small gear39(first gear) and a large gear40(second gear). In the second stepped spur gear38, the large gear40is engaged with a second pinion41fixed to the rotation shaft34A of the second motor34, and the small gear39is engaged with external teeth42(seeFIG. 4) provided to the side wall11of the vertical rotation frame9and formed along a circular arc centering the rotation shaft (boss13) of the vertical rotation frame9.

The first stepped spur gear28and the second stepped spur gear38have an identical shape. In other words, the small gear29(first gear) and the large gear30(second gear) in the first stepped spur gear28and the small gear39(first gear) and the large gear40(second gear) in the second stepped spur gear38have an identical shape. Similarly, the first pinion31fixed to the rotation shaft24A of the first motor24and the second pinion41fixed to the rotation shaft34A of the second motor34have an identical shape.

The angle adjuster2includes a controller for remotely controlling the first driver23(first motor24) and the second driver33(second motor34) using wireless communication and accordingly operating an irradiation direction of the lighting apparatus1by wireless. The controller includes a transmitter (remote controller) that is operated by an operator, a receiver that is provided to the vertical rotation frame9and receives control radio waves transmitted from the transmitter, and a control apparatus that controls operation of each of the motors24and34based on the control radio waves received by the receiver. The conventional technique is applied to the controller. Thus, detailed explanation and illustrations related to the controller are omitted in order to simplify the description of the specification and the drawings.

In the embodiment, the angle adjuster2defines the shape of the small gear29and the large gear30in the first stepped spur gear28, and accordingly the shape of the small gear39and the large gear40in the second stepped spur gear38having an identical shape as that of the first stepped spur gear28so that a rotation angle (angular displacement) of the horizontal rotation frame5in the horizontal direction upon input of one pulse to the first motor24is identical or substantially equal to a rotation angle (angular displacement) of the vertical rotation frame9in the vertical direction upon input of one pulse to the second motor34. In other words, a change gear ratio between the first gear mechanism25and the second gear mechanism35is determined so that a rotation angle (angular displacement) of the horizontal direction rotator in the horizontal direction upon input of one pulse to the first driver23is identical or substantially equal to a rotation angle (angular displacement) of the vertical direction rotator in the vertical direction upon input of one pulse to the second driver33.

As illustrated inFIGS. 1 and 8, the angle adjuster2includes a limit switch43that is attached to the first bracket26and electrically detects rotation operation of the horizontal rotation frame5in the horizontal direction. A lever43A of the limit switch43is rotated (seeFIG. 8) by either of two projections44and45(seeFIG. 2) formed on the inner flange8of the fixed frame3. Accordingly, the angle adjuster2detects a limit of the set rotation angle and uses the detected limit for motor control such as stopping operation of the first motor24. In the embodiment, the limit switch43and the two projections44and45can restrict a rotation angle of the horizontal rotation frame5in the horizontal direction to ±90 degrees.

The angle adjuster2further includes a horizontal rotation restriction mechanism that mechanically restricts rotation operation of the horizontal rotation frame5in the horizontal direction when the horizontal rotation frame5rotates beyond the limit switch43. As illustrated inFIG. 9, the horizontal rotation restriction mechanism is configured by a notch46formed by notching a substantially half periphery out of the outer periphery of the outer flange7in the horizontal rotation frame5, contact units47and48(seeFIG. 3) formed on both ends of the notch46, and a projection49formed on the inner flange8in the fixed frame3. The horizontal rotation restriction mechanism mechanically restricts a rotation angle of the horizontal rotation frame5in the horizontal direction within a predetermined range by making either one of the contact units47and48formed on the outer flange7contact with the projection49formed on the inner flange8in the fixed frame3.

As illustrated inFIG. 1, the angle adjuster2includes two limit switches51and52that are attached to the second bracket36and electrically detect rotation operation of the vertical rotation frame9in the vertical direction. An actuator of either one of the limit switches51and52is pushed in by corresponding rib53or54(seeFIG. 4) formed on the side wall11of the vertical rotation frame9(seeFIG. 10that illustrates only the limit switch51and the corresponding rib53for convenience). Accordingly, the angle adjuster2detects a limit of the set rotation angle and uses the detected limit for motor control such as stopping operation of the second motor34. In the embodiment, the two limit switches51and52and the corresponding ribs53and54can restrict a rotation angle of the vertical rotation frame9in the vertical direction to ±40 degrees.

The angle adjuster2further includes a vertical rotation restriction mechanism that mechanically restricts rotation operation of the vertical rotation frame9in the vertical direction when the vertical rotation frame9rotates beyond the limit switches51and52. The vertical rotation restriction mechanism is configured by a pair of contact pieces55and56(seeFIG. 1) disposed on the first bracket26at intervals in the horizontal direction, and corresponding ribs57and58formed on the side wall10of the vertical rotation frame9. The vertical rotation restriction mechanism mechanically restricts a rotation angle of the vertical rotation frame9in the vertical direction within a predetermined range by making either one of the contact pieces55and56provided to the first bracket26contact with the corresponding rib57or58formed on the side wall10of the vertical rotation frame9.

The following describes the action of the embodiment.FIG. 12is a perspective view illustrating the lighting apparatus1, and is a view especially illustrating an initial state of the angle adjuster2. In the initial state of the angle adjuster2, a rotation position of the horizontal rotation frame5(horizontal direction rotator) in the horizontal direction is 0 degrees, and a rotation position of the vertical rotation frame9(vertical direction rotator) in the vertical direction is 0 degrees. In the initial state of the angle adjuster2, an irradiation direction of the lighting apparatus1is a just-under direction (perpendicular direction).FIG. 13is a view illustrating the lighting apparatus1where the angle adjuster2is in an initial state viewed from another sight different from the sight inFIG. 12.

An operator operates a remote controller (controller) so as to remotely control an irradiation direction of the lighting apparatus1(hereinafter simply referred to as an “irradiation direction”). For example, when the irradiation direction is inclined from 0 degrees of an initial state to a clockwise direction at a sight in A direction inFIG. 12, operation of a remote controller operated by an operator causes the rotation shaft34A of the second motor34to rotate in a direction specified by a rotation angle (angular displacement) corresponding to the number of pulse input. The rotation of the rotation shaft34A of the second motor34is transmitted to the second gear mechanism35through the second pinion41, and is decelerated and transmitted to the vertical rotation frame9through the large gear40(second gear) of the second stepped spur gear38engaged with the second pinion41, the small gear39(first gear) of the second stepped spur gear38, and the external teeth42engaged with the small gear39.

In this manner, the vertical rotation frame9rotates in the vertical direction so as to incline the irradiation direction to a specified angle as illustrated inFIG. 14.FIG. 15is a perspective view illustrating the lighting apparatus1in a state corresponding to the state inFIG. 14, and is a perspective view illustrating the lighting apparatus1viewed from another sight different from the sight inFIG. 14.

For example, when the lighting apparatus1is in a state illustrated inFIG. 15and the irradiation direction is rotated in the horizontal direction, in other words, when the irradiation direction (irradiation shaft) is moved (rotated) along the side of a circular cone whose center line corresponds to the shaft line (center line of the embedded hole) of the lighting apparatus1, operation of a remote controller operated by an operator causes the rotation shaft24A of the first motor24to rotate in a direction specified by a rotation angle (angular displacement) corresponding to the number of pulse input. The rotation of the rotation shaft24A of the first motor24is transmitted to the first gear mechanism25through the first pinion31, and is accelerated and transmitted to the horizontal rotation frame5through the small gear29(first gear) of the first stepped spur gear28engaged with the first pinion31, the large gear30(second gear) of the first stepped spur gear28, and the internal teeth32engaged with the large gear30.

In this manner, the horizontal rotation frame5rotates in the horizontal direction so as to rotate the irradiation direction (irradiation shaft) in the horizontal direction while an inclination angle with respect to a perpendicular line is kept. The explanation is given individually on the rotation operation of the horizontal rotation frame5in the horizontal direction by the first driver23and the rotation operation of the vertical rotation frame9in the vertical direction by the second driver33, but the controller can control the first driver23and the second driver33at the same time through the operation of a remote controller operated by an operator. In other words, the angle adjuster2can perform the rotation operation of the horizontal rotation frame5in the horizontal direction and the rotation operation of the vertical rotation frame9in the vertical direction at the same time.

This embodiment exerts the following effects. According to the embodiment, the angle adjuster2is configured by disposing the first driver23for driving the horizontal rotation frame5(horizontal direction rotator) to rotate in the horizontal direction and the second driver33for driving the vertical rotation frame9(vertical direction rotator) to rotate in the vertical direction on the horizontal rotation frame5. Applying this angle adjuster2can reduce the size of the lighting apparatus1, especially shorten the total length thereof, and, for example, can provide the lighting apparatus1suitable for a ceiling-embedded universal downlight that is restricted in depth. Forming the internal teeth32that configures the first gear mechanism25on the inner periphery of the fixed frame3can make not only the size of the angle adjuster2in the horizontal direction but also the outer diameter of the fixed frame3smaller as compared with the case of forming the external teeth on the outer periphery of the fixed frame3, and can provide the lighting apparatus1capable of corresponding to a smaller embedded hole.

In the embodiment, the angle adjuster2is configured by using stepped spur gears having the same shape as the first stepped spur gear28embedded in the first gear mechanism25and the second stepped spur gear38embedded in the second gear mechanism35to engage the small gear29(first gear) of the first stepped spur gear28with the first pinion31fixed to the rotation shaft24A of the first motor24and the large gear40(second gear) of the second stepped spur gear38. In this manner, the stepped spur gears28and38having the same shape are selectively used as the acceleration side and the deceleration side. Accordingly, stepping motors having the same shape (same type) can be used as the first motor24and the second motor34, and the first driver23and the second driver33, and furthermore the angle adjuster2can be simply configured. In addition, standardizing components that form an apparatus can improve productivity and reduce manufacturing costs at the same time. Most of the first driver23and the second driver33are formed by common components. Accordingly, weight balance of a whole apparatus is easily equalized and an angle can be smoothly adjusted by disposing the first driver23and the second driver33symmetrically with respect to the center line (in the embodiment, a straight line corresponding to the rotation shaft of the horizontal rotation frame5) of the lighting apparatus1or a light axis of the lighting apparatus1. Similarly, disposing the first driver23and the second driver33symmetrically with respect to a straight line corresponding to the rotation shaft of the horizontal rotation frame5provides a disposed position capable of minimizing the size of each component in order to rotate the vertical rotation frame9in the vertical direction without interfering with the first driver23and the second driver33. The shape of the stepped spur gears28and38is selected so that a rotation angle (angular displacement) of the horizontal rotation frame5in the horizontal direction upon input of one pulse to the first motor24is identical or substantially equal to a rotation angle (angular displacement) of the vertical rotation frame9in the vertical direction upon input of one pulse to the second motor34. Accordingly, the control of the controller can be simplified, and manufacturing costs can be reduced while reliability can be improved. Furthermore, the angle adjuster2has both a function of electrically detecting a rotation angle of the horizontal rotation frame5and the vertical rotation frame9and a function of mechanically restricting rotation of the horizontal rotation frame5and the vertical rotation frame9. These functions can surely prevent damage of an apparatus and eventually improve reliability of the apparatus.

Embodiments are not limited to the embodiment described above, and for example, can be configured as follows. The controller can be configured by installing a plurality of lighting apparatuses1on a ceiling and connecting each of the lighting apparatuses1through wireless communication so as to remotely control the lighting apparatuses1at the same time through one remote controller. In the controller, remote control through wireless communication is not limiting, and, for example, an operating unit operated by an operator and the angle adjuster2may be connected by wire. A light source (operation target) is not limited to the LEDs18, and, for example, a krypton bulb is applicable. The embodiment exemplifies the ceiling-embedded lighting apparatus1, but the lighting apparatus1that is connected to an arm and the like and is hung from a ceiling surface or a wall surface and the lighting apparatus1that is supported by a base connected to an arm are applicable. The motors24and34are not limited to stepping motors, and direct-current (DC) motors, direct-current (DC) brushless motors, alternating-current (AC) motors and the like are applicable. Also in this case, current control by the controller can be simplified by making a rotation angle (angular displacement) of the horizontal rotation frame5in the horizontal direction identical or substantially equal to a rotation angle (angular displacement) of the vertical rotation frame9in the vertical direction. In the embodiment, the motors24and34are used as drive sources of the first driver23and the second driver33, but the angle adjuster2can be configured so that an angle of a light source (operation target) is adjusted by manual operation, for example, operation of a lever and the like.

The present invention can reduce the size of an angle adjuster and a lighting apparatus with the angle adjuster.