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Software Speeds Changes at Lighting Manufacturer

In-grade lighting is a popular outdoor fixture style for illuminating architectural details, as well as fountains, sculptures and landscaping. The fixtures are flush-mounted into soil, sand, concrete and other substances, and must withstand heavy wear from environmental changes and occasionally being driven over by utility carts.

With between 40 and 50% of this lighting market worldwide, design engineers at Hydrel, Sylmar, CA, need speed on their side when developing new models and improving existing lines. One such project took two years and required a 3-man team. "It took so long," says Charles Poppenheimer, a senior industrial designer who was part of the team, "because the fixtures can be ordered in literally tens of thousands of configurations due to their modular design and the number of options available for each module." There was concern over retooling costs for the line, a problem partially resolved when the company was purchased by Lithonia Lighting after the first year of design work.

Using software from CADKEY Marlborough, MA, greatly aided the project, according to Poppenheimer. "We shared files constantly, with all three of us working on different aspects of the same jobs," he says. STL files from the drawings were used to create models for performance testing that otherwise would have too many variables for analysis software. Poppenheimer also points out that the software, which he's used since version 3.0, permitted rapid and robust modeling of detailed prototypes "right down to the screws." Hydrel then went on to build most of the production tooling straight from the solid models, eliminating possible inaccuracies from misinterpretation of 2D drawings. Exploded drawings instructed assemblers on how to build modules in the different configurations, with more than 340 subassembly drawings that Poppenheimer put up on his walls. "Practically everyone in the company," he says, "tech support, customer service, marketing --used these drawings to understand the product line and its myriad variations." Which probably made light work for everyone.

--RM

For more information:

Circle 420 - Hydrel, or connect directly to their website via the Online Reader Service Program at http://www.OneRS.net/101dfx-420

Circle 421 - CADKEY, or connect directly at http://www.OneRS.net/101dfx-421