Luminaire Design for Wipro lighting

wipro lighting july 2009

shivajinagar, Pune

summer internship

about the company the mother

Wipro Limited is a Rs. 8170 crore, diversified corporate having interests in Information Technology, Healthcare, Infrastructure Engineering and Consumer Care.

the daughter

Wipro Lighting is part of the Wipro Consumer Care & Lighting Division of Wipro Limited. this division is in the business of manufacturing and marketing Wipro brand of luminaires, lamps and accessories.

“at the forefront of creativity and innovation in lighting solutions, it caters to both institutional and retail consumers, and offers the latest and best technology across numerous application areas.�

wipro lighting

aims and aspirations what they offer

•Brightness Management lighting products for Modern Offices •High End Lighting Control and Architectural Dimming System •Lighting system for Healthcare Centres •Clean Room application products for Pharmaceutical & F&B Industry •High Intensity Discharge lamp Luminaires for Manufacturing Sector •Exclusively designed Architectural Street lighting products for City Roads and Highways •International Landscape Lighting products for Gardens, outdoor areas •Exclusively design Lighting products for Oil Retail outlets •High End Digital electronic ballast range with International certification

“at wipro lighting, innovation is a never-ending journey. our passion for innovation and quality drives us to develop and deliver new products and solutions for our customers. wipro lighting has been at the forefront of providing creative lighting solutions for modern workspaces, healthcare centres, pharmaceutical industry, manufacturing, roads and highways, landscape etc. we have helped customers create a cheerful environment and meet their energy saving needs through our various offerings.”

wipro lighting

structure of the organization Wipro limited Mr. Azim Premji

Wipro infotech

Wipro consumer care & lighting Mr. Vineet Aggarwal

Wipro lighting and furniture Mr. Parag

Product design group Mr. Alok Ghonsikar

where i belong

structure of the organization Wipro lighting Mr. Parag

Lighting design Mr. Makrand

Materials and Manufacturing Mr. Manoj Khera

Sales

Mr. Sailesh Tokekar

Product design group Mr. Alok Ghonsikar

tool designers Mr. Sanjay Rane Mr. Rohan

customization

product design

Mr. Rupesh

prototyping

Mr. Krishna Panchal

detailing

Ms Shilpa Marathe Mr. Mohan VP ME

Mr. Janardhan Panchal Mr. Mayuresh Kulkarni

where i belong

my project design of bulkhead luminaire

time frame : 6 weeks product domain : general lighting, surface mounted luminaire area of use : industry, maintenance areas, domestic need : recent venture into infrastructural projects outdated product needed to be phased out contemporary light sources

introduction

history the term

A bulkhead is a retaining wall, such as a bulkhead within a ship or a watershed retaining wall. It may also be used in mines, to contain flooding.

A bulkhead is the physical partition that divides an airplane into different classes or sections. Typically, a bulkhead is a wall but can also be a curtain or screen

the starting point

“Fig. 60 shows another form of bulkhead fitting designed to economize lamps. As will be understood, it is fixed in a hole cut in the bulkhead to receive it, say between two cabins, the flange shown being screwed to the woodwork, and the light showing on either side. This fitting is most frequently used where a permanent light is required. It would hardly do for cabin lamps, except in special cases—as, though it could be arranged for a switch in either cabin to turn on the light, neither could turn it off if the switch in the other cabin was closed, which would hardly be convenient for an officer who wanted to turn in during his watch below, if his light happened to belong to the next cabin too, and the owner of that cabin to want the light burning.”

Marine Engineers” (1892)

- Walker, Sydney F.: “Electric Lighting for

present status

A bulkhead luminaire is typically a strong, robust industrial lighting fixture which is used as a low cost, general purpose luminaire.

introduction

anatomy, structure and details

form analysis

parts and assembly

form analysis

analysis of competition

research phase

PHILIPS NXC 101/ FXC 101 pros • sturdy build quality. better finishing due to pressure die casting • cover retaining ring makes it look neat and adds better pressure on gasket •tighter fitting gasket adds to cleaner look and uniform sealing • robust proportions, consistent with industrial aesthetic • high IP rating (IP 65) makes it ideal for industrial usage • same luminaire for CFL and GLS lamps (only ballast mounting tray added for CFL ) • powder coated wire guard looks more elegant, more precise manufacturing cons • comparatively difficult to maintain and service • bulky, machine like aesthetic makes it unsuitable for domestic use • mounting detail may create instability • higher cost • concave shaped base of housing could have become a reflector if ballast was better accommodated • clear PMMA cover looks flimsy, fragile. thermoforming doesn’t allow good finishing (compared to injection molded)

significant features

PHILIPS NXC 101/ FXC 101

usability/servicability 5

4

techno aesthetic detailing

3

manufacturing quality

2

1

0

ruggedness/ durability

visual appeal

FXC 101 NXC 101 UTOPIA

uniqueness/ differentiability

adaptability to environment

quantitative analysis

HAVELLS RUGBY

pros • finer build quality. better finishing even from gravity die casting • cover retaining ring integrated with wire guard looks more elegant, more precise • smaller dimensions and slimmer proportions fits well into domestic use • same luminaire for CFL and GLS lamps, versatile • concave base of housing, painted white on inner surface, acts as reflector • cover retaining frame requires only 2 screws to open • have accomplished graduation into a wall light segment, without adding cost cons • white color difficult to maintain • mounting detail through the housing requires full disassembly • restricted to domestic use due to size (visual bulk/robustness lacking) and IP 43 rating • requires retrofit CFL, can accommodate only 8W • CFLs should be given importance if domestic market is the focus

significant features

HAVELLS RUGBY

usability/servicability 5

4

techno aesthetic detailing

3

manufacturing quality

2

1

0

ruggedness/ durability

visual appeal

RUGBY UTOPIA

uniqueness/ differentiability

adaptability to environment

quantitative analysis

Bajaj BJBE 19 pros • deep drawn housing is a distinguishing factor ( innovative approach ), also enables smoother finish on housing • BJBE has step in body to accommodate gasket neatly • tighter fitting gasket adds to cleaner look and uniform sealing • robust rectangular form looks contemporary • only 2 screws require opening for lamp replacement • specifically made for CFLs, hence dimensionally appropriate cons • higher initial cost (as with all CFL luminaires) • mounting through back wall requires full disassembly • lack of wire guard breaks association with bulkheads (one associates it with wall lights) • prismatic glass pattern is passé. more contemporary look needed • wire management requires improvement

significant features

Bajaj

usability/servicability

BJBE 19

5

4

techno aesthetic detailing

3

manufacturing quality

2

1

0

ruggedness/ durability

visual appeal

BJBE 19 UTOPIA

uniqueness/ differentiability

adaptability to environment

quantitative analysis

Wipro WKG13 pros • hinge detail in wire guard allows great ease of lamp replacement • consistent with industrial aesthetic • wall mounting details add greater stability when mounted • low cost cons • poor precision ( tolerances ), manufacturing quality and finishing • gasket unevenly held by wire guard causes low IP rating ( 43 ) and makes entire product look crude • holder attachment and wiring details are crude • “mechanical” detailing but proportions look “domestic”. doesn’t look “heavy-duty” • overall crude appearance and poor quality do not befit a brand like Wipro.

significant features

Wipro WKG14 pros • contemporary look and materials • polycarbonate cover doesn’t require wire guard • slimmer sleeker proportions, more appropriate for CFLs • higher tolerances and tighter fits put it in a different league as far as perceived quality goes • ease of lamp replacement (2 screws) • much better gasket material (silicon), and tighter fit enable higher IP (54) • graduation into wall light segment. cons • due to plastics used, it may not meet regulations in infrastructural applications • mounting requires full assembly on the spot, may not be suitable for locations such as service chutes, etc as installation points are difficult to reach • higher cost, due to included ballast • lack of wire guard breaks association with the name “bulkhead”

significant features

Wipro WKP 13/ WKP 14

techno aesthetic detailing

ruggedness/ durability

usability/servicability

manufacturing quality

visual appeal

WKP13 WKP14 UTOPIA

uniqueness/ differentiability

adaptability to environment

quantitative analysis

comparative chart Brand

PHILIPS

BAJAJ

HAVELLS (rugby)

CROMPTON GREAVES

WIPRO

product code

FXC 101

NXC 101

BJDB 100

BJBE 19

LHKL01160099

IBH11

CBH10

WKP13

WKP14

light source

PL-S 9W

GLS 60W

GLS 100W

CFL-S 9W

GLS 100W or CFL TU 8W retro

GLS 100W

CFL 10W

GLS 40/60/100W

TC-S 9W

IP 43

IP 54

350

725

IP rating cost (INR) housing cover retaining frame cover wire guard holder dimensions colours application

IP 54 600

IP 54 790

PDC aluminium (LM-6) powder coated same as above clear/opal PMMA

frosted glass

MS powder coated ?

?

202x118x120 grey/red

grey/black

stairways, corridors, security areas

IP 43

370

725

320

GDC aluminium

deep drawn aluminium

GDC aluminium powder coated

IP 43 330

525

PDC aluminium (LM6)

GDC aluminium ABS (UV painted stabilized)

(epoxy powder coated)

GDC aluminium powder coated

prismatic glass

milky glass

glass

glass

PC (UV stabilized)

electro-galvanised MS

zinc plated

nr

ceramic BC

?

zinc plated

nr

integrated (with cover retaining frame)

?

?

ceramic BC

?x125x115 235x115x115 white

white

porches, balconies, basements, garages, staircases, driveways, cable gantries, etc.

nr

ceramic BC/E27

CFL

212x107x95

194x126x117.5

195x100x110

205x77x75

matt white

stove enamel finish

white

?

passages, conveyors, security walls, cable tunnels, pathway lights, staircase lighting, corridors, lobbies

weatherproof, security lighting entrance areas, public access in industries, housing colonies, and circulation areas, staircases warehouses

product specs

comparative chart

techno aesthetic detailing

ruggedness/ durability

usability/servicability

manufacturing quality

visual appeal FXC 101 NXC 101 BJBE 19 RUGBY WKP13 WKP14

uniqueness/ differentiability

adaptability to environment

quantitative comparison

Wipro vs. the rest

techno aesthetic detailing

ruggedness/ durability

usability/servicability

manufacturing quality

visual appeal FXC 101 NXC 101 BJBE 19 RUGBY WKP13 WKP14

uniqueness/ differentiability

adaptability to environment

quantitative comparison

final solution

product specs

• optional CFL 9W TC-S / GLS 60 W • optional wire guard • IP 54 (hopefully) • hinge able diffuser/wire guard

product dimensions

final solution

product renderings

final outcome •discipline of reaching on time…sitting for 8 hours, in one place and working.

•samples!!everywhere..

•group dynamics without hierarchy...

•formal clothes..every day!

•concept testing…photometry •design process…well defined, but too linear.

•last but not the least..the product will get launched soon (as of 20th dec

2009)

overall experience