Military Spotlight System — A Domestic LED Solution to Recurring Field Failures

A major Turkish land platform manufacturer transferred the spotlight programme for its tank and armoured vehicle family to TEDEG Defence after repeated field failures with the previous supplier. The spotlight provides long-range illumination and target marking during night operations. The field profile is demanding: rain, mud, high altitude, continuous vibration and round-the-clock duty. This is a competitor-takeover reference project.

The incumbent product showed failure modes that fed into one another in the field:

• Water ingress: inadequate sealing led to short circuits inside the housing and fogged optics in rain.
• Gear wear: the gear profile in the DC motor drive train wore quickly, and spare parts took a long time to arrive.
• Electronics failures: weak overcurrent protection and EMI made burnt driver boards a routine field report.

The result was a growing maintenance burden and a real risk of losing capability during critical operations.

TEDEG redesigned the T-Light military spotlight with a layered engineering approach that tackles each failure at its root cause.

The new design addressed the root causes of the water ingress, gear wear and board burnout that had kept recurring with the previous product, and fault reports from the field fell markedly.

• The sealed enclosure resolved fogged optics and internal short circuits in rain and mud at the design level.
• Motion system maintenance can be done at the vehicle by swapping the gear cartridge in the field.
• With an LED source, lamp replacement is no longer a routine maintenance item.
• Domestic supply sped up spare parts and technical support.

The customer has asked for the solution to be adapted to other vehicle variants as well.