Oliver Dross

Free-form integrator array optics

A new design method of free-form Kohler integrator array optics is presented. Only few solutions to the integrator design problem are known, which apply for specific and simple source and targets (for instance, flat integrator lenslet arrays when the source and target are squares located at infinity). The method presented here find more general solutions and the resulting optics is formed by two arrays of free-form optical surfaces (which can be either reflective of refractive). The contour curves of the array units are also obtained from the design. Two types of Kholer integrators will be defined, depending if they integrate only along one direction across the source (one-directional integrators) or in the two directions (two-directional integrators). This design method has been applied for an ultra-compact high efficiency LED low beam head lamp producing a legal pattern independently of the chip luminance variation and permitting LED position tolerances of ±200 microns. The ray tracing proves that the high gradient (0.32) and its vertical position in the pattern remain invariable when chip is moved.

The XR nonimaging photovoltaic concentrator

The performance of the XR solar concentrator, using a high efficiency multi-junction solar cell developed recently by Spectrolab, is presented. The XR concentrator is an ultra-compact Nonimaging optical design composed of a primary mirror and a secondary lens, which can perform close to the thermodynamic limit of concentration (maximum acceptance angle for a given geometrical concentration). The expected acceptance angle of the concentrator is about ±2 deg for a geometrical concentration of 800x (a Fresnel lens and secondary system typically has ±0.6 deg of acceptance for 300x of geometrical concentration). This concentrator is optimized to improve the irradiance distribution on the solar cell keeping it under the maximum values the cell can accept. The XR concentrator has high manufacturing tolerance to errors and can be produced using low cost manufacturing techniques. The XR is designed with the Simultaneous Multiple Surface (SMS) design method of Nonimaging Optics. Its application to high-concentration photovoltaics is now being developed in a consortium led by The Boeing Company, which has recently been awarded a project by the US DOE in the framework of the Solar America Initiative.

Advanced PV concentrators

It is essential to obtain high values of tolerance for PV concentrators because manufacturing process always implies some accuracy errors. In this way, three new free-form concentrators are presented here, combining high geometric concentration and high tolerance (high acceptance angle). This is achieved by using the SMS3D design method, which is the most advanced method to design free-form surfaces in non-imaging optics. Uniform illuminance on the cell is important as well, for proper behavior and durability of the system, so our three designs will have homogenizer elements. We have added a homogenizer rod to one of the designs while for the other two Ko¿hler integrator configurations have been chosen. Concentration, acceptance angle and uniformity values obtained are shown in results section.

Primary optics for efficient high-brightness LED colour mixing

In SSL general illumination, there is a clear trend to high flux packages with higher efficiency and higher CRI addressed with the use of multiple color chips and phosphors. However, such light sources require the optics provide color mixing, both in the near-field and far-field. This design problem is specially challenging for collimated luminaries, in which diffusers (which dramatically reduce the brightness) cannot be applied without enlarging the exit aperture too much. In this work we present first injection molded prototypes of a novel primary shell-shaped optics that have microlenses on both sides to provide Köhler integration. This shell is design so when it is placed on top of an inhomogeneous multichip Lambertian LED, creates a highly homogeneous virtual source (i.e, spatially and angularly mixed), also Lambertian, which is located in the same position with only small increment of the size (about 10-20%, so the average brightness is similar to the brightness of the source). This shell-mixer device is very versatile and permits now to use a lens or a reflector secondary optics to collimate the light as desired, without color separation effects. Experimental measurements have shown optical efficiency of the shell of 95%, and highly homogeneous angular intensity distribution of collimated beams, in good agreement with the ray-tracing simulations.

Köhler integration in color mixing collimators

Köhler integrating lenslet arrays can provide collimated, uniform, and color mixed beams from an array of sources of arbitrary color. The integration can be achieved with two lenslet arrays after collimation, with lenslet arrays embedded into certain collimators or close to the sources before collimation with a double sided lenslet shell. The degree of color mixing of the different approaches can be less than ideal. We have investigated the main mixing degradation mechanisms both in the near and in the far field and quantified them for certain source and architecture combinations. From this analysis we can derive simple design rules for successful color mixing.

Data Format for Ray File Standard

A working group for the Illuminating Engineering Society (IES) recently published the TM-25 standard file format for disseminating source ray data. This presentation will inform the community of the results.

Data format standard for sharing light source measurements

Optical design requires accurate characterization of light sources for computer aided design (CAD) software. Various methods have been used to model sources, from accurate physical models to measurement of light output. It has become common practice for designers to include measured source data for design simulations. Typically, a measured source will contain rays which sample the output distribution of the source. The ray data must then be exported to various formats suitable for import into optical analysis or design software. Source manufacturers are also making measurements of their products and supplying CAD models along with ray data sets for designers. The increasing availability of data has been beneficial to the design community but has caused a large expansion in storage needs for the source manufacturers since each software program uses a unique format to describe the source distribution. In 2012, the Illuminating Engineering Society (IES) formed a working group to understand the data requirements for ray data and recommend a standard file format. The working group included representatives from software companies supplying the analysis and design tools, source measurement companies providing metrology, source manufacturers creating the data and users from the design community. Within one year the working group proposed a file format which was recently approved by the IES for publication as TM-25. This paper will discuss the process used to define the proposed format, highlight some of the significant decisions leading to the format and list the data to be included in the first version of the standard.