一, Matching error between profile and structure
1. Dimensional deviation of aluminum groove
As the load-bearing body of linear lamps, the size deviation of aluminum slots is the primary issue. In a typical case, a commercial space had an aluminum groove width of less than 2mm, which prevented the light strip from being embedded and ultimately required the removal of the ceiling for rework.
Avoidance suggestions:
Plan the layout of the lighting fixtures in advance and accurately slot according to the dimensions of the profiles (such as 1.5cm wide and 1cm deep);
During long-distance transportation, suppliers are required to use wooden frames or paper tubes for packaging to avoid deformation of the aluminum groove.
2. Insufficient strength of embedded parts
In pre embedded installation, if crack prevention nets or hanging nets are not used for plastering, the joints between gypsum boards and profiles are prone to cracking. A residential project experienced three cracks six months later due to not being connected to the internet, with repair costs reaching 1.5 times the original installation cost.
Technical specifications:
When embedding aluminum slots, alkali resistant fiberglass mesh cloth (≥ 160g/㎡) should be laid on the surface;
When scraping putty, layer by layer construction should be carried out, with each layer thickness ≤ 2mm, to avoid cracking caused by excessive scraping in a single batch.
3. Insufficient bearing capacity of suspended ceiling structure
In a sunken installation, if the spacing between the ceiling keels exceeds 60cm, the profile may sag due to its own weight. A certain hotel project had a deformation rate of 12% due to excessive spacing between the dragon bones, which affected the overall aesthetics.
Solution:
Adopting encrypted keel (main keel spacing ≤ 60cm, secondary keel spacing ≤ 30cm);
Use lightweight aluminum materials (such as 6063-T5 aluminum alloy), with a single meter weight controlled within 0.5kg.
二, Electrical system configuration error
1. Transformer power mismatch
Low voltage light strips need to be powered by transformers, and insufficient power can cause a decrease in brightness at the end. A certain office space experienced a 40% decrease in brightness at the end due to a 100W transformer driving a 120W LED strip.
Calculation formula:
Transformer power ≥ total power of lamp strip × 1.2 (safety factor)
For example, to drive an 80W light strip, a transformer of ≥ 96W needs to be selected.
2. Concentrate the placement of transformers
Placing multiple transformers in a centralized manner can easily cause heat dissipation problems and shorten their lifespan. A certain shopping mall project had a failure rate of up to 35% due to the centralized installation of 10 transformers.
Optimization plan:
Transformer spacing ≥ 50cm, or adopting a split design;
Installed in locations such as air conditioning access points and above wardrobes for easy ventilation.
3. Unreasonable power cord layout
Failure to reserve live wires resulted in difficulties in later maintenance. Due to the fixed power cord in a certain residential building, the ceiling needs to be damaged when replacing the light strip, resulting in a 200% increase in maintenance costs.
Construction specifications:
Reserve a 20cm live wire at the corner for easy connection in the later stage;
Replace traditional wiring terminals with WAGO connectors to enhance reliability.
三, Construction error of light strip
1. Randomly cut the light strip
Cutting the light strip without following the marked area may cause some light beads to not light up. Due to cutting errors, 5 dark areas were formed in a certain restaurant, resulting in a 25% decrease in customer satisfaction.
Crop rules:
Cut only at the "shearable area" marked on the light strip (usually every 5cm or 10cm);
After cutting, use a multimeter to test the conductivity and ensure that the positive and negative poles are not reversed.
2. Lamp strip pollution
Staining the light strip with paint or dust can cause a decrease in light efficiency. A certain hotel project experienced a decrease in color temperature from 6000K to 3500K due to unprotected light strips, which affected the spatial atmosphere.
Protective measures:
Cover the surface of the light strip with masking paper before installation;
After painting, remove the decorative paper to prevent the paint from seeping into the lamp groove.
3. Welding process defects
Excessive temperature or time during welding of the light strip can damage the light beads. Due to welding errors in a certain exhibition project, 15% of the lamp beads failed, and the repair took 3 days.
Welding standards:
Use a 350 ℃ constant temperature soldering iron with a soldering time of ≤ 3 seconds;
After welding, use a magnifying glass to inspect the solder joints to ensure that there are no virtual or false welds.
四, Corner and splicing errors
1. The corner joint is not tight enough
If the corner is not cut at a 45 degree angle, it will cause light leakage. A residential staircase had a 5mm error in corner splicing, resulting in obvious light spots.
Key points of construction:
Use a woodworking saw or laser cutting machine to ensure a corner angle accuracy of ≤± 1 °;
Fill the gaps with black silicone after splicing to prevent light leakage.
2. Brightness attenuation at the joint
If the splicing area is not recharged, the brightness will be lower than other areas. A certain shopping mall project experienced a 30% decrease in brightness at the junction due to lack of power supply.
Power replenishment plan:
Add welding points at the joint or use non welding joints;
Ensure that the voltage at the junction is consistent with the main circuit.
五, System debugging and acceptance errors
1. Ignore color temperature consistency
The color temperature deviation of different batches of light strips exceeding 100K can lead to inconsistent spatial atmosphere. Due to color temperature deviation, the employee complaint rate in a certain office has increased by 18%.
Testing method:
Use a color temperature meter to detect the color temperature of each segment of the light strip, with an error of ≤± 50K;
Priority should be given to using the same batch of light strips within the same space.
2. Neglecting light efficiency testing
Failure to conduct illuminance testing may result in deviations between actual light efficiency and design. Due to insufficient illumination in a certain hotel room, an additional desk lamp is required to meet the lighting needs.
Testing standards:
Workplace illumination ≥ 300lx (office space), ≥ 150lx (residential space);
Uniformity ≥ 0.7, avoiding significant differences in brightness and darkness.
3. Lack of security checks
Failure to conduct insulation resistance and withstand voltage tests may pose safety hazards. A short circuit accident occurred in a certain shopping mall project due to insufficient insulation resistance, resulting in a direct economic loss of 500000 yuan.
Testing process:
Insulation resistance ≥ 2M Ω (500V megohmmeter);
Withstand voltage test 1500V/1min without breakdown.
六, Cost and maintenance errors
1. Neglecting power redundancy design
Failure to reserve power redundancy can lead to difficulties in later expansion. Due to insufficient transformer power, a commercial space is unable to add new light strips and needs to purchase new equipment.
Redundancy standard:
Total power redundancy ≥ 20%, meeting the expansion needs for the next 5 years.
2. Insufficient reserved channels for maintenance
Not reserving maintenance channels will increase the cost of later repairs. A residential building had to remove the entire gypsum board to replace the light strip due to the narrow light trough, resulting in a maintenance cost that was three times the original installation cost.
Design points:
The size of the inspection port is ≥ 30cm × 30cm, which is convenient for tools and personnel to operate;
The installation position of the transformer should be easy to disassemble.
3. Choose inferior accessories
Choosing low-priced accessories to reduce costs can lead to a shortened overall lifespan. A certain project has a failure rate of up to 50% due to the use of non-standard drive power supplies, and the replacement rate during the warranty period exceeds 80%.
Quality Control:
Select accessories that have passed UL and CE certification;
Require suppliers to provide a 3-year warranty commitment.
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