Most of the current market’s existing LED light bars’ structural designs are only pointed to realize the function and appearance. And the spare parts’ compatibility had seldom been taken into consideration. So too many spare parts will be produced out even they actually have the same functionality. Then you have to open many molds, to manage many spare parts, to use many workers for assembling. All these factors will finally push up the light bar’s production cost.

To kick off such headache, we has developed SMARTSUN platform to realize light bar’s standardization and modularization.

Here are the 3 steps:

• On the condition of satisfying light bar’s function and appearance, we adjust its overall layout and design.
• All the spare parts which have the similar sizes and share the same function will be optimized and designed to be compatible components for different light bars.
• To design different models at the same time for better optimization.

Below pictures are from the traditional light bar. To realization its lighting function, too many lens have been designed with different lengths and structures.

And our light bar lens are made to be the same lengths and structures, which can be applied onto different models, such as TA71 mini bar, TA92 15” mini bar, and TA91 full length exterior light bar.

TA71 series mini light bar:

TA92 series 15 inches mini light bar:

TA91 series full size light bar:

Innovative structural and electronics design greatly upgrades our lights interference and anti-interference level.
When using our auto lights on the vehicles, we have to satisfy such law enforcement:

• To protect our lights’ normal function from being interfered by the electronic products on the vehicles.
• To make sure our lights’ radiation signal won’t interfere the vehicles’ electronic products.

So we have to take EMC compatibility into consideration when doing the warning lamp’s electronic design. And we must strictly follow EMC standards to meet CISPER 25 Class 3 requirements.
The popular shielding to satisfy CISPER 25 Class 3 is like the picture below(use a small metal cage covering the EMI source):

Our solution is to use a one-piece metal frame as shielding as photo below:
By adjusting and optimizing the metal frame’s overall design, we can not only satisfy the light’s structural function, but also reach much better performance for EMI shielding and heat dissipation.

Usually most of the LED beacon manufacturers will design and produce their product as exploded view picture below:

To get a 360 degree lighting performance, the optical design has to vertically place many pieces PCB board onto the controlling board. And it leads to a complicated product structure and complex assembling.

To make it simple, we combines the LEDs PCB board and controlling PCB into one piece.

Then by innovative optical design, the LEDs lighting source is reflected by the lens toward the same direction.

Electronics innovation:

• Innovative heat dissipation PCB design
  This light’s heat accumulates greatly and rapidly when it is working. Good heat dissipation must be guaranteed to ensure stable LEDs performance for much longer serving time. At the beginning, we had adopted the double-sided aluminum PCB for better heat dissipation. However due to its unstable quality, we finally turn to FR4 fibre-glass PCB.

This is the FR4 fibre-glass PCB:

First we open heat dissipating windows at the back of the PCB as the white circle shows:

Second more holes have been opened for heat dissipating purpose.

After testing we found that above FR4 PCB optimization can perfectly solve the light’s heat dissipation problem.

Light bar’s flexible flash pattern controlling design from SMARTSUN.

Existing light bar can only control each module’s flash pattern instead of individual LED PCB’s. So it limits end customer’s demand of controlling each LED PBC’s flash pattern.

Now the light bars from SMARTSUN can precisely and flexibly control the flash patterns of each LED PCB, such as 180 degree/360 degree retro flashing. And these flash patterns can be customized as per specific requirement. Our electronics controlling system is realized by new type of synchronous rectification driving circuits. Its advantages are as follow:

• Electronic driving efficiency is above/equal to 90%.
• Electronic driving stability is guaranteed by auto lighting standard solution.
• EMC anti interfering capacity is high by adopting specially designed IC.

Light bar PCB designing diagram:

Contact us for more updated trend of our LED light bar development.