Patent Publication Number: US-2015077267-A1

Title: Modular light system and related methods

Description:
BACKGROUND 
     Embodiments discussed herein generally relate to aerial lighting used to provide visual warning of structures and overhead power lines, and more specifically, to a modular aerial light structure mounted on tall structures and power lines to provide warning to aircrafts. 
     The FFA has rules and protocols in place to provide safety for pilots and aircraft when navigating in the proximity of power company overhead power lines and facilities. One such FAA rule requires the installation of aerial warning lights to indicate overhead power lines and facilities. When light failure in the prior art warning light system is encountered, the root cause of the failure could be any one of the components in the light system at the top of the tower or at the power source located at the base of the tower. The aerial warning light could also be at an environmental zone requiring permits to enter, troubleshoot, and fix the source of the problem. Considerable time is typically needed to analyze the components to determine the source of the failure. In this way, each light failure is a unique and time consuming replacement project. 
     SUMMARY 
     The various embodiments of a modular warning light system for aerial vehicles have several features, no single one of which is solely responsible for their desirable attributes. Without limiting the scope of the present embodiments as set forth in the claims that follow, their more prominent features now will be discussed briefly. 
     Aspects of the present disclosure include a modular warning light system that includes a support, a light structure adjustably mounted onto the support, a warning light coupled to the light structure, and a power system coupled to the light structure. In one example, the power system can include a solar panel and a rechargeable battery, the solar panel being configured for charging the rechargeable battery, and the rechargeable battery being configured for powering the warning light. 
     The support can comprise a frame coupled to a base adjustably mounted on a steel lattice tower, a transmission tower, a distribution tower, or any structure at a plurality of predefined mounting points. The base can be mounted on the structure at predefined mounting points by a U-bolt fastened to a mounting bracket. 
     The light structure can be adjustably mounted to the frame of the support. The solar panel can be adjustably mounted to the light structure. 
     The power system can further comprise a dusk to dawn light controller configured for turning on the warning light below a certain ambient brightness. The dusk to dawn light controller can be further configured for charging the rechargeable battery at a certain ambient brightness. 
     A remote monitoring unit can be mounted to the light structure and be configured for monitoring the power system and wirelessly transmitting telemetry data of the power system. The telemetry data can include information indicating the warning light is not functioning or the power system is not functioning. 
     The modular warning light system can further include a  24  hour controller configured for controlling power to the warning light, an enclosure, and a fuse assembly inside the enclosure. 
     The frame comprises three legs extending to the base to form a triangular pyramidal structure. 
     The warning light can be mounted to a member of the light structure. The light structure can be rotatably mounted to the support. The solar panel can be rotatably mounted to the light structure. 
     The warning light can be powered by service power and the rechargeable battery can power the warning light  40  when service power is unavailable. 
     The light structure can comprise a plurality of members assembled together, with each of member having an adjustable length to adjust the overall size of the light structure and the angle of the members within the light structure. For example, the light structure can comprise a central member, a first cross member crossing the central member and rotatably mounted to the frame, a second cross member crossing the central member, an angled member extending from the second cross member, an extending member extending from the second cross member, and a mounting member extending from the extending member to the angled member. The light structure can further comprise a first mounting member support coupled between the extending member and the mounting member, and a second mounting member support coupled between the mounting member and the angled member. 
     The solar panel can be mounted to the mounting member. The rechargeable battery can be mounted on the mounting member. 
     A length of the angled member can be adjustable to adjust the angle of the solar panel. For example, the angled member can comprise a second angled sub member slidably insertable inside a first angled sub member. A plurality of through holes can be defined in one of the first angled sub member and the second angled sub member. At least one through hole can be defined in the other of the first angled sub member and the second angled sub member. One or more pins or fasteners can extend through the through holes of the first angled sub member and the second angled sub member to prevent the first angled sub member and the second angled sub member from sliding apart after the length of the angled member is determined. 
     A length of the central member can also be adjustable. For example, the central member can comprise a second central sub member slidably insertable inside a first central sub member. A plurality of through holes can be defined in one of the first central sub member and the second central sub member. At least one through hole can be defined in the other of the first central sub member and the second central sub member. One or more pins or fastener can extend through the through holes of the first central sub member and the second central sub member to prevent the first central sub member and the second central sub member from sliding apart after the length of the central member is determined. 
     Another aspect of the present disclosure includes a modular warning light system that includes an adjustable frame rotatably assembled to a mount, a light assembled to the adjustable frame and configured for charging the rechargeable battery, a solar panel adjustably mounted to the adjustable frame, and a battery mounted to the adjustable frame and configured for powering the warning light. 
     The mount can comprise a base and a frame fixed to the base. The base can have a plurality of predefined mounting points. 
     A remote monitoring unit can be mounted to the light structure and configured for monitoring the power system and wirelessly transmitting telemetry data of components of the modular warning light system such as the light, the battery, and the solar panel. 
     The modular warning light system can further include a dusk to dawn light controller configured for turning on the light below an ambient brightness and charging the rechargeable battery at a certain ambient brightness. The modular warning light system can also include a 24 hour controller configured for controlling power to the light, and a fuse assembly inside an enclosure. 
     The light can be powered by service power and the battery can be configured for powering the light when service power is unavailable. 
     The adjustable frame can comprise a plurality of members assembled together. Some of the plurality of members can have an adjustable length to adjust the size of the light structure and angle of the members within the adjustable frame. For example, the adjustable frame can comprise a central member, a cross member crossing the central member, an angled member extending from the second cross member, an extending member extending from the second cross member, and a mounting member extending from the extending member to the angled member. A length of the central member and the angled member can be adjustable. The adjustable frame can further comprise a first mounting member support coupled between the extending member and the mounting member, and a second mounting member support coupled between the mounting member and the angled member. 
     The solar panel can be mounted to the mounting member. The battery and the remote monitoring unit can also be mounted on the mounting member. 
     In another aspect of the present disclosure, a method of repairing a warning light system can include: visiting a job site having an alert, a failure, or both in or to a warning light system mounted above the ground on a structure; removing the warning light system having the alert or the failure; and mounting a working warning light system above the ground on the structure. The working warning light system can comprise a frame mounted on a base, an aircraft warning light coupled to the frame, and a power system coupled to the frame. The power system can comprise a rechargeable battery and a solar panel. The removing step can comprise use of an aerial vehicle. The working warning light system can further comprise a remote monitoring unit. The structure can be a transmission tower or a distribution tower. 
     The present application is further understood to include a method of manufacturing a modular warning light system and a method of using a modular warning light system. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The various embodiments of the present aerial light structure are now discussed in detail and with an emphasis on highlighting the advantageous features. These embodiments depict the novel and non-obvious features of the aerial light structure shown in the accompanying drawings, which are for illustrative purposes only. These drawings include the following figures, in which like numerals indicate like parts. 
         FIG. 1  is an isometric view of one embodiment of a modular light system. 
         FIG. 2  is an isometric view of another embodiment of the modular light system. 
         FIG. 3  is a front view of yet another embodiment of the modular light system. 
         FIG. 4  is a profile view of the modular light system of  FIG. 3 . 
         FIG. 5  is a profile view of a light structure and a power system of the modular light system. 
         FIG. 6  is a view of a warning light and a light plate of the modular light system. 
         FIG. 7  is a view of the light guide plate. 
         FIG. 8  is a view of a U-bolt to bracket assembly. 
         FIG. 9  illustrates a member of the light structure and a bracket. 
         FIG. 10  is a view of a member sleeved inside another member and fixed together. 
         FIG. 11  is a schematic block diagram of the power system components. 
     
    
    
     DETAILED DESCRIPTION 
     The following detailed description describes the present embodiments with reference to the drawings. In the drawings, reference numbers label elements of the present embodiments. These reference numbers are reproduced below in connection with the discussions of the corresponding drawing features. 
     The present system, device, and method of aerial lighting comply with the FAA required aerial lights and have easily installed and removal features. Historically, aerial light systems were connected to electrical service for its power. Such service was not immediately available from the tower itself, and in remote areas, the relative scarcity of service caused problems for powering aerial tower light systems. Thus, aspects of the present disclosure include a self-contained aerial lighting system. The lighting system includes a framed structured with lights, power, and control circuits that can be packaged at ground level as a modular system and installed on site, such as on top of a transmission or distribution tower. 
     In one example, the power utilized in the self-contained system includes solar cells and rechargeable battery cells. During the day, the solar cells power the system and charge the battery cells. At night, the system draws its power from the battery cells. In another example, the system is further equipped with features to enable connection to electrical service. Thus, the alternative lighting system may draw power from service power and use renewable power as backup. In another example, a lighting system is provided that uses renewable power but has an optional connection for service power in the event the renewable power source is not reliable. In some embodiments, as further discussed below, the frame of the system, device and method is of an A frame design. In other embodiments, the frame may be rectangular, or irregular, or of any design rigid enough to handle the high wind loads found at or near the tops of towers. In addition, the system, device and method will allow installation by a helicopter. A feature of this design is its relative size, weight, simple, and easy connectivity mechanisms for mounting with just about any steel lattice design. Thus, the disclosed lighting system and method can be connected to multiple tower types. The components may include various tilting and pivoting structures to permit mounting the system generally horizontally or at an angle. The fitting and pivoting structures further permit aligning the solar cells with the sun and the position of the warning light. With its modular structure, the system, device and method can be removed and replaced as a unit, making each installation and replacement a matter of standardized tasks. 
     In the drawings,  FIG. 1  illustrates an embodiment of a modular light system  10  in accordance with aspects of the present disclosure is illustrated.  FIG. 2  illustrates another embodiment of a modular light system  10 . Both embodiments will be described herein and the descriptions for each element and limitation below can be applied to either embodiment. 
     Referring initially to  FIG. 1 , the modular light system  10  in accordance with aspects of the present disclosure includes a support  30 , which has a frame  34  and a base  32 , a light structure  20  adjustably mounted onto the support  30 , a warning light  40  coupled to the light structure  20  or the support  30 , and a power system  50  for powering the warning light  40  of the light structure  20  mounted on the support  30 . 
     The power system  50  includes one or more solar panels  52  and at least one rechargeable battery  54 . The solar panel  52  is configured for charging the rechargeable battery  54 . The rechargeable battery  54  is configured for powering the warning light  40 . In an example, the modular light system  10  is pre-assembled and operational using the power from the power system  50  to power the warning light  40 . Thus, in this example, the modular light system  10  is a single assembly unit which can be installed quickly onto a lattice tower or any other structure, and removed and replaced quickly should there be a problem or issue with the modular light system  10 . 
     A new or replacement modular light system  10  can be replaced or installed using a helicopter, a crane, or other device and the removed modular light system  10  returned to a service center where it can be diagnosed and fixed. This eliminates the guess work that sometimes occur on the job to diagnose and repair the problem in less than ideal conditions. In other examples, peripheral devices or brackets can separately be mounted or installed on-site to the light system  10 . For example, extra brackets and extra fasteners may be added at the job site as opposed to being installed in the shop along with the system. 
     The support  30  includes a frame  34  coupled to a base  32 . The support  30  can be a rigid structure made from a high strength material configured to withstand high wind loads, such as from steel or stainless steel with rigid composite material being a workable alternative. The support  30  can be coated for rust resistance, such as painted, galvanized, or both. The support  30  can be made from a plurality of rigid sections assembled to form a fixed structure to accommodate a variety of light structures  20 . 
     The base  32  can be adjustably mounted on a steel lattice tower or any other structure at any number of mounting points or locations. Most commonly, the system  10  is mounted at or near the top of the lattice structure so that the warning light  40  is held out to be the tallest point on the tower. Once mounted, the base  32  supports the frame  34  and the rest of the components of the light system  10 . The base  32  can be mounted to any steel lattice tower at designated mounting points using a number of known prior art fastening devices, including U-bolts, clamps, metallic straps, anchoring bolts, and flanges. The number of mounting points can be one, two, three, four, or more. For example, the base  32  may be provided with a footing arrangement and the steel lattice with a corresponding footing arrangement so that when the base  32  is raised to the top of the steel lattice, the corresponding footing arrangements mate. 
     The base  32  can also be bolted directly to the tower. The base  32  can also be mounted to the steel lattice tower by a bracketing system. The base  32  can also be mounted to the tower using U-bolts see  FIG. 8 , such as a U-bolt  70  fastened to a mounting bracket  75 , as previously discussed. The base  32  can be made of any material such as steel or alloys. The base  32  can be rectangular, triangular, or any shape, including irregular. For example, the base  32  can be made of L shaped channels joined together by welding or by fastening means. The base  32  should be light enough to be raised by a helicopter, a crane, or a hoist, yet strong enough to accommodate the structures and equipment. 
     The frame  34  is attached to the base  32  at one or more locations between the frame and the base. The frame  34  can embody a number of upstanding structures, such as being formed by a number of brackets so that the assembled frame has a certain length, width, and height. For example, the frame  34  can be shaped like a tripod having three legs mounted to a base  32  at three locations of the frame. The base  32  can have a matching footprint, such as being triangular for attaching to the base of the three legs, or a different footprint so long as means are provided to attach the frame to the base. The means can be any number of known prior art devices, including U-bolts, metal straps, fasteners, brackets, wing nuts, welding, etc. The frame  34  can be built from round tubing, rectangular tubing, bars, or any combination of materials to form a variety of upstanding structures to accommodate and support the light frame structure  20 , components of the power system  50  and any peripheral device, such as an alarm or alert system for alerting a user or operator of a failure or error signal. 
     The light structure  20  can be a rigid structure, can be made from a high strength material configured to withstand high wind loads, such as from steel or stainless steel, or alloys, with rigid composite material being a workable alternative. The light structure  20  can also be coated for rust resistance, such as painted, galvanized, or both. The support  30  can be made from a plurality of rigid sections assembled to form a fixed structure to accommodate a variety of components. The light structure  20  can be made from round tubing, rectangular tubing, bars, I-channel (standard or wide-flange), C-channel, L-angle channel, (equal or unequal legs), structural Tee channel, or any combination of materials to form a variety of structures to accommodate and support the power system  50 . The light structure  20  can be rotatably mounted or fixed directly to the frame  34  by U-bolts  70  and brackets  75  (see, e.g.,  FIG. 8 ) for example. The light structure  20  can also be adjustable in size, such as by telescoping lengths, and configuration to accommodate a variety of power systems  50 . For example, the light structure  20  can be configured to allow for a variety of angles and sizes required for the power system  50 . 
     In the embodiment of  FIG. 1 , the light structure  20  is an A-frame structure comprising two first members  220  and two second members  225  intersecting the two first members  220 . In one embodiment, as shown in  FIG. 2 , the light structure  20  includes a plurality of members assembled together, each of the plurality of members having an adjustable length to adjust the size of the light structure and angle of the members within the light structure  20 . For example, the light structure  20  includes a central member  21 , a first cross member  22  crossing the central member  21 , a second cross member  24  crossing the central member  21 , an angled member  23  extending from the second cross member  24 , an extending member  25  extending from the second cross member  24 , and a mounting member  26  extending from the extending member  25  to the angled member  23 . 
     The light structure  20  can further include a first mounting member support  27  coupled between the extending member and the mounting member  26 , and a second mounting member support  28  coupled between the mounting member  26  and the angled member  23 . The light structure  20  can be mounted to the frame  34  of the support  30  via brackets  29  and fasteners. The brackets  29  can also be used to help support the second cross member  24   
     The light structure  20  can be adjustably mounted to the frame  34  of the support  30 . The adjustment of the light structure  20  with respect to the frame  34  can be by rotation, translation, or both. The light structure  20  can be mounted to the frame  34  using U-bolts  70  and brackets  75  (see  FIGS. 8 and 9 ), or other fastening means. 
     The solar panel  52  can be mounted to the mounting member  26 . The solar panel  52  can be mounted to a solar mounting bracket  37  which can facilitate adjustment of the solar panel  52  by translation and rotation to maximize the amount of light received by the solar panel  52 . A length of the angled member  23  can also be adjustable to provide additional adjustment for the solar panel  52  such as an angular adjustment. 
     Referring to  FIGS. 3-5 , the angled member  23  can include a first angled sub member  230  and a second angled sub member  235  slidably insertable inside the first angled sub member  230 . A plurality of through holes can be defined in either the first angled sub member  230  or the second angled sub member  235 , and at least one through hole can be defined in the other of the first angled sub member  230  and the second angled sub member  235  to adjust a length of the angled member  23 . A pin or fastener can extend through the through holes of the first angled sub member  230  and the second angled sub member  235  to prevent the first angled sub member  230  and the second angled sub member  235  from sliding apart after the length of the angled member  23  has been adjusted, as shown in  FIG. 10 . 
     The length of the central member  21  can also be adjustable. The central member  21  can include a first central sub member  210  and a second central sub member  215  slidably insertable inside the first central sub member  210 . A plurality of through holes are defined in one of the first central sub member  210  and the second central sub member  215 , and at least one through hole is defined in the other of the first central sub member  210  and the second central sub member  215 . A pin or fastener can extend through the through holes of the first central sub member  210  and the second central sub member  215  to prevent the first central sub member  210  and the second central sub member  215  from sliding apart after the length of the central member  21  is determined, as shown in  FIG. 10 . 
     The warning light  40  is coupled to the support  30  or light structure  20  and configured for warning or alerting aircraft or other aerial vehicles of the presence of a tower, building, or other large structure. Referring to  FIG. 1 , the warning light can be coupled to ends of the first members  220 . Referring to  FIG. 2 , the warning light  40  can be mounted to a central member  21  of the light structure  20  via a light plate  42  and a mounting pole  46  extending from the light structure  20 , central member  21 , or support  30 . Referring also to  FIGS. 6 and 7 , the light plate  42  can be a flat plate with two holes  43 ,  44  defined therein for attaching to the warning light  40  and the mounting pole  46  respectively. The holes  43 ,  44  can be round, slotted or any other shape. 
     The mounting pole  46  has a first end attached to the light plate  42  and a second end attached to the central member  21  of the light structure  20 . The mounting pole  46  can have an outer diameter slightly smaller than an inner diameter of the central member  21  of the light structure  20 , so that the mounting pole  46  can slide into the central member  21  and fastened to the central member  21  with fasteners. In the illustrated embodiment the first end engages in the slotted hole  44  of the light plate  42 . 
     The warning light  40  is electrically coupled to the power system  50 . The warning light  40  is powered by the rechargeable battery  54 . Alternatively, the warning light  40  can be powered by service power and the rechargeable batteries  54  can be configured for powering the aircraft warning light  40  when service power is unavailable, such as for backup. The warning light  40  can have one or more bulbs such as an LED, halogen, fluorescent, or incandescent, as long as the warning light is bright enough and free from obstructions. The warning light  40  can be a pair of warning lights  40  or more than two warning lights. The color of the light radiated by the warning light  40  can be any color such as blue, red, or orange. For example, the warning light can be a 12 VDC dual red LED light head. 
     The power system  50  includes a solar panel  52  and a rechargeable battery  54 . The solar panel  52  is configured for charging the rechargeable battery  54 . The solar panel  52  is adjustably mounted to the light structure  20 . The solar panel  52  can also be rotatably mounted to the light structure  20 . The solar panel  52  can be rotatably mounted to a solar panel mounting bracket  37 . The solar panel  52  and the solar panel mounting bracket  37  can also be coupled to a solar panel post  38  coupled to the light structure  20 . The solar panel  52  can include a set of photovoltaic modules coupled to an inverter, if necessary, a solar tracker, and wiring. The photovoltaic modules can include a connected assembly of solar cells. The solar panel  52  can include crystalline silicon modules or thin film modules such as rigid thin film modules and flexible thin film modules. Solar trackers increase the amount of energy produced per module by sensing the direction of the sun and tilting the modules for maximum exposure to the light. For example, the solar panel  52  can be a 50 watt solar panel  52  such as the BP® Solar BP350J. More than one solar panel  52  can be used. 
     The rechargeable battery  54  can be a lithium-ion battery, nickel metal hydride battery, photovoltaic battery, or any type of battery capable of storing and releasing energy from the solar panel  52 . The number of rechargeable batteries  54  can be one or more, at least sufficient enough to power the warning light  40  from dusk till dawn or extended period of darkness. For example, the rechargeable battery  54  can be a 12V battery such as the Deka® Solar Voltaic 12V battery. More than one rechargeable battery  54  can also be used. 
     The power system  50  can further include a dusk to dawn light controller  56  configured for turning on the warning light  40  below a predetermined ambient brightness. The dusk to dawn controller  56  recognizes brightness and activates a light switch. The dusk to dawn light controller  56  is electrically coupled to the warning light  40  and the rechargeable battery  54 . The dusk to dawn light controller  56  can also be configured for charging the rechargeable battery  54  at a certain ambient brightness. 
     The modular light system  10  can also include a remote telemetry unit (RTU) or a remote monitoring unit  58  mounted to the light structure  20  or support  30 . The remote monitoring unit  58  can be configured for monitoring the power system  50  and wirelessly transmitting telemetry data of the power system  50 . The telemetry data can include information such as indicating the warning light  40  is not functioning or not powered on, the power system  50  is not functioning, voltage is not discharged from the batter or batteries, voltage/current to the warning light  40  reads below a certain threshold, and the status of the charging system, etc. The telemetry can be sent to a central location receiving the data to alert and activate crews to fix or replace the modular light system  10 . For example, the remote monitoring unit  58  can be the On-Ramp Wireless™ Remote Monitoring Unit. 
     The modular light system  10  can also include a 24 hour controller  60  configured for controlling power to the warning light  40 . 
     The modular light system  10  can also include an enclosure  62  and a fuse assembly  64  inside the enclosure  62 . The fuse assembly  64  provides protection from a surge in power or current to each or some of the components. The enclosure  62  can be made of any material such as plastic, metal, or nonmetal to protect the fuse from environmental pollutants and contaminants such as rain, dust, or debris. For example, the enclosure can be the Stahlin® environmental enclosure. 
     The rechargeable battery  54 , the fuse assembly  64  and the enclosure  62 , the  24  hour controller  60 , the remote monitoring unit  58 , and the dusk to dawn controller  56  can be mounted on the mounting member  26  or directly to the light structure  20 . The mounting member  26  can be a planar member, one or more vertical bars, one or more horizontal bars, or any other element so long as components can be mounted. 
     Although limited embodiments of the modular light system  10  and their components have been specifically described and illustrated herein, many modifications and variations will be apparent to those skilled in the art. For example, the various component parts may incorporate different materials, some sub-assemblies may be unitarily formed, etc. Furthermore, it is understood and contemplated that features specifically discussed for one modular light system  10  may be adopted for inclusion with another modular light system  10  embodiment, provided the functions are compatible. Accordingly, it is to be understood that the modular light system  10  and their components constructed according to principles of the disclosed device, system, and method may be embodied other than as specifically described herein. The disclosure is also defined in the following claims.