LED Highway Lighting Manufacturers

We have been designing world-leading LED road sign illumination to meet stringent standards for many years. Our first generation of LED solutions reduced power consumption by a third (a factor of three) compared to the incumbent fluorescent source by using off-the-shelf LED optics to direct light where it’s needed.

By customising the LED optical system, we could eliminate overly complex power supply electronics and thus improve reliability in a second-generation design. In addition, we increased efficiency by a further factor of over 4. As a result, these customised LED optical systems are ten times more efficient and environmentally friendly.

A paradigm of the combined application of custom LED optics and what we call ‘driverless’ electronics technology:

Significantly reduced power consumption

Significantly increased reliability

Reduced glare, custom optics, ‘driverless electronics’

Reduced cost

Product differentiation through customisation

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The Challenge

To offer highly innovative, first-in-class LED road sign illumination from the first brief. In addition, we will continuously improve the design as new LED optic & electrical technologies become available.

LED engine thermally designed for a 10-year appliance service life under extreme thermal conditions

Tight colour (CCT) binning

High-temperature application

Ease of assembly in a mass production environment

Kanban mass volume supply model

The Solution

As with many breakthrough LED applications, the journey started with a thorough understanding of the specifications from the first principles.

In this case, the challenge was to precisely illuminate the road sign and nothing else, with a tight specification on both absolute illumination (lux on the sign) and range of illumination (light/dark area ratio). Ray tracing CAD software was used to model the illuminance iteratively, and appropriate LEDs were selected along with off-the-shelf optics.

Trials were conducted with a calibrated CCD imaging camera that could automatically capture hundreds of illuminance measurements in a single frame offering super-efficient optical metrology. We rapidly completed the electronics and mechanical designs of the first-generation systems to allow for quick volume manufacture.

Second-generation LED road sign illuminations were later enabled with the simultaneous adoption of 3 innovative technologies:

LED optic customisation

Multi-die small form factor LEDs

Driverless electronics

While ‘driverless’ electronics can drastically reduce cost and increase reliability, there is usually a significant reduction in efficiency. This issue was balanced out by the design of full-custom optics.

A close-up photograph of a one-way traffic sign on a highway. The sign indicates traffic flow in one direction. The image conveys the concept of traffic regulation and road signage.

A close-up photograph showing an LED circuit board. The board features intricate circuitry and components, indicating sophisticated electronics design. The image conveys the concept of LED technology and electronic circuitry.

The Result

The result of all this innovation was a best-in-class series of LED road sign illumination designs which enjoy a leading performance, exceptional reliability, long service life and low manufacturing cost.