electronic flares
Mars International was founded in 1964 to deliver electrical and
mechanical assemblies and finished goods through our extensive world-class
manufacturing network. Pioneering a global offshore manufacturing
strategy, we are global leaders in the contract manufacturing industry.
The following case study will demonstrate our flair for innovation.
The Challenge
Our client needed a visual distress signal as a replacement for
traditional chemical flares for the marine industry as required by the
Coast Guard. It needed to be handheld and contain certain distress beacons
like a flash pattern incorporating several optical colors.
The challenge in the product design and development was that our engineers
needed to meet a strict lighting pattern, according to the Coast Guards
specifications. It also needed to be battery operated, remain visual for a
minimum required time, waterproof, and remain upright when deployed in the
water. The additional challenge meant it needed to be easy to deploy and
operate in an emergency.
Our engineers concluded that we needed to design the optics first to
ensure we could accomplish the required flash and lighting pattern before
looking at the encasement design.
The Design Process
Our engineers used purchased software to predict the lighting pattern of
the optic used and followed up with testing in our laboratory, using a
goniometer to measure the actual output to confirm the results.
Because the specifications required the device to meet a certain load
light, our engineers used the goniometer, a large measuring machine that
could deploy a full 360 degrees sphere to measure points of light. The
testing included measuring each individual point for light output that
went beyond the specifications.
With the optical portion resolved, our engineers now had proof of concept.
The optical design was housed into an enclosure creating a device that now
had to meet further specifications. It needed to be completely waterproof,
had to float, and remain upright with a certain amount of tolerance.
Fitted with a printed circuit board inside and the batteries on top, the
batteries needed the capacity to stay lit for a specified amount of time.
The design took into consideration, if a user is injured or disabled, they
need to be able to turn it on easily in an emergency situation. Designed
with a one-meter long lanyard attached, it could be clipped onto a life
vest. The bungee cord around the outside meant the user could tie it off
to a portion of the boat making it ergonomically user friendly.
Ongoing Feedback
Throughout the concept and design stage, our engineers conferred with our
clients regularly to elicit their feedback to ensure the project stayed on
track. It was important that the design not only met the Coast Guards
specifications, it also had to meet our client’s approval at each stage of
the project.
Occasionally Mars engineers have free reign in the design and
manufacturing of a product. However, in this case, we preferred to confer
with the client throughout the project and make changes along the way.
We’ve found this is the best approach to keep the end goal closest to what
the client wants.
The Results
The results speak for itself – the device is easily used in an emergency
situation
As an alternative to a chemical flare that expires every four years, all
you need to do with this innovation is to replace the battery in the
electronic version. An Electronic flare is kinder to the environment as
you don’t need to deal with chemical disposal as required with expired
traditional flares.
The electronic flare has a huge advantage over chemical flares with many
states making a big push to reduce chemical waste and the monitoring of
improper disposal. It also allows those in the chemical industry of marine
safety to switch to an electronic flare as an alternative keeping their
own businesses viable as new regulations are introduced.
Vision for the Future
Mars International engineers developed something unique by using our
specialized optical measuring equipment differentiating ourselves with our
proprietary optical design. Our point of difference is we have created an
alternative to a lens solution. This LED pattern distributes light
according to the coast guard requirements without a lens.
To speak with one of our experts about global manufacturing technology and
services, contact us at Mars International on 908-233-0101 to discuss how
our engineers can bring your concept into the future.
