If you guys want to go into detail about how an LED light is made, click on our website, Todayalljobs24.
Many companies look for people with light manufacturing experience, so they hire them. In this entire article, I will tell you in detail how light manufacturing is done so that you can also easily apply for this job.
I will tell you what process is used to manufacture light and what it is called. Such as
- Pick and Place
- Quality Testing
- Tool Shop
- Metal Workshop
- Plastic Section
- Assembly Section
Pick-and-place, quality testing, tool shop, metal workshop, plastic section, and assembly section—if you would like to learn more about these, please click on our website Todayalljobs24.
Here, various components are automatically placed onto the PCB. In this department, the boards are produced—using both manual methods and automated machines—and their quality is subsequently checked. I will now explain the entire process of how a PCB (Printed Circuit Board) is manufactured.
Pick and Place
What you can say is that the motherboard is made of light, and there is a design section; that is, this PCB, that is, the printed circuit board, is designed, prepared in blocks, and stored, and then you can see here, not only linguistically but also interestingly, there is an entire line that automatically produces this printed circuit board through this machine.
So the first thing that happens is that the printed circuit board is installed. This is what you can see; it is an automatic machine. It has a special type of paste material that is applied to it. It is a gray-colored paste material, and it is applied only to the circuit that has been designed.
It is a little sticky. The purpose of this is that whatever components are placed on this circuit stick to their right place, and then this circuit, which is the printed circuit board, comes forward.
These are CNC machines. These CNC machines are programmed inside the CNC machine. There is definitely an expert worker who is watching to ensure that everything is happening according to its own plan, and that there is no compromise on quality.
Then what happens is this pick-and-place machine, which picks these components and then places them in their original place.
So these are LED lights; according to how many watts of LEDs are to be made, they distribute them and paste as many LEDs as there are on this circuit. After the LEDs are installed, the other important components are also placed on it regularly through a CNC computerized machine, and multiple components are installed on it; there is a whole factory inside an LED. I will show you inside.
Look at how a capacitor is installed, an IC is installed, an inductor is installed, a fuse is installed, and resistance is installed inside it.
All these things are installed, and what happens with all these things? First, the life of the light increases; it improves, its efficiency improves, and the consumption of electricity it has to make is also controlled by these same things through these same components, whether it is 4 watts or 8 watts, 12 watts, the lights of different watts that are produced.
So when a PCB is ready, the printed circuit board is automatically shifted forward inside a furnace and heated for a specific time so that all these components that are on this board are pasted well. Then its quality is checked to see if it is what is required.
They want to know whether it is prepared according to quality standards or not. After that, the vote is sent forward. So, let me tell you how quality works: what are the things that are taken care of in it?
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Table of Contents
Quality Testing
After coming out of the oven, the quality of the printed circuit board is checked, but in the interesting pick-and-place section, not only are the printed circuit boards for the LED builds like the ceiling lights made, but the boards for the tube lights we see are also made here.
It has a separate production line, and in the same way, first a driver is made on the machines, on which different components like capacitors and multiple components are pasted, and at the same time, a separate board is made for the LED lights, and then they are connected in a UPS, and from this, a tube light is made.
Besides production being done here, a lot of care is taken about the quality, and after each process, the quality is checked; as soon as the printed circuit boards are ready, they are also checked.
The quality check experts regularly check the quality of each board. It is seen that all the LEDs are working. In addition, the capacitor installed on it is fulfilling its function. Its life, which they guarantee, will be the same.
Its consumption, which is 5 watts, should be 5 watts so that the consumer does not have to pay more on electricity bills. After checking all these things, if there is a problem, it is also repaired here.
This thing is fixed and addressed, and then these boards are prepared; then they are sent to the further assembly section. So this was it, but the board, that is, the printed circuit board, which you can actually say is the bone or the brain of the light, and the rest of the plastic components that are produced inside it, the components of the screen, are produced here in the world. I will tell you how they are produced inside the park light.
What else happens in LED light quality testing? If you want to go into detail, click on our website Todayalljobs24.
Tool Shop
I have already told you how a printed circuit board is made in pick-and-place suction, and at this moment, we are inside the tool shop, where all the components of the outer body of the light, whether they are metal or plastic, are made
R&D Die Shop
And I will tell you that the R&D die shop basically makes dies here, that is, molds, from which later bulk production is done. So the procedure that generally happens in any die shop is the same here. First, a drawing is made on the computer, and this drawing is then later made into a mold using CNC machines.
Then this mold is further processed here using multiple machines, and then processed using an EDM machine, so all the holes inside it are refined and improved using an electric discharge machine.
Then there are multiple machines in which the total is fixed; it is rotated, and at the same time, its polishing and finishing are done.
When the mold is well prepared, then the product that is on top of the mold starts to be produced. As you have been told, not only steel components are made, but also plastic components are produced. Now, how are these components being produced in bulk? I will tell you in different sections.
Metal Workshop
Now let me tell you about the metal workshop, where various metal tools are made from MS sheet. Covers are made, which are applied to the outer body of the light, and for this, we use specially made MS sheet coil.
We fold this coil and cut it into different sizes on these cutting machines, and then, according to the mold and die that were prepared in the die shop, different pieces are extracted in certain shapes through a hydraulic press machine.
So these different pieces that come from the MS sheet are then taken to another metal tool shop and made through different machines.
They are given a cup-like shape, and after that, the outer body of the light is made. Well, what happens with this steel outer body is that the more the light is used, the better its efficiency is.
Its outer body becomes stronger because the plastic body does not melt due to the heat, so it also works for safety. Well, when the metal bodies are ready, to increase their durability and life, they are regularly sent to the paint shop, where powder coating is done inside the paint shop, and then, after seeing the heat when it is ready at a specific time, it is sent to the assembly section.
Well, now I have told you how a metal outer body is prepared. Now I will tell you how the regular plastic outer body and the cups are prepared. There is a separate section for this.
Plastic Section
So after the metal section, now I will tell you about the plastic section. I told you earlier that we manufacture all the metal bodies ourselves. It also has powder-coated paint on it. Its quality is checked. And the best part is that there are quality control people at every step.
The injection molding machines that are installed here are where different types of plastic covers are made.
And you can say that another very common part is called a diffuser. That is also manufactured; there are different machines. Somewhere, bulbs are being made; somewhere, downlights are being made.
And in this downlight, on one side there is a cup which is its back cover, and on the other side there is this diffuser. It is made of a special type of plastic material, and what is its function?
It does not focus the light in one place but spreads it. In the same way, the back cover body of the bulb is also separate; the cup is separate, and the cover on top of it is also made of a diffuser, made of special material.
So here too, at the same time, the quality control people keep checking the quality of the product at every step.
And best of all, they have an extrusion section here where the pattern lights are being made, which are conventional lights, just like our tube lights. So, tube lights used to be made of glass, but now their plastic diffuser is also made large.
For this, special types of extrusion machines have been installed, in which the plastic is continuously molded and then later its shape is formed according to a mold, and cutting is done.
So, these pattern lights of different sizes and different designs are also being produced. So, when the plastic material is ready, all the details of the product are regularly printed on them, especially on their back covers, using a laser printing machine, and then they are sent to the assembly section, where they are assembled, and the product is produced.
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Assembly Section
After all the components are prepared, they move to the assembly section, where different assembly lines assemble them. First, I have told you that first, the PCB or driver board that is prepared in the end press department is connected with different wires.
After applying the varnish, a special type of heat-resistant solution is applied to it; gel is applied, and after the gel, the metal cover that was made on it is inserted, and then, at the same time, this plastic body is applied later, on which all its details are also printed.
Each process that you, as a worker, are carrying out, each process is being strengthened by applying screws.
Strings are being placed on the press because they are also called downlights, that is, fall-saving lights, which are installed in fall-saving, and today there is more of a trend. So when the light is ready and finally inside it, then you say the diffuser is also made of plastic.
It is applied with a special material, and after applying it, when the Venturi light is ready, it is then brought to the quality table. Best practice, as I told you, quality control is definitely kept an eye on every process in this factory, and the quality team is still here, which is watching each process.
It is even seen that the spring that is to be held has also been prepared according to the specification. So, after looking at each and every detail, they come to the quality table and visually inspect it. After everything is done, it is packed.
First, it is in a plastic bag; then again, let’s say, it is in a paper bag; it is packed inside it, it is packed in cartons and kept in the warehouse, and from here it is exported everywhere.
Not only are the bulbs assembled on the same assembly line, but even today, conventional lights are being made into Pak Light, a substitute for tube lights.
There are LED lights, but they are in the shape of cube lights. They are also being manufactured here on a single line. After being assembled, they are packaged and exported all over the world.
If you want to know more about the assembly section, click on our website, Todayalljobs24.
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