JP2012186277A - Led selection apparatus, led selection program and method for selecting led - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide an LED selection apparatus which suppresses chromaticity dispersion while reducing the stock of LEDs.SOLUTION: A computer 10 identifies an LED module in which an LED is mounted thereon, shows the number of mounting LEDs, and comprises: a model information 83 for showing a chromaticity range, to which the LED module should belong; a memory part 150 for setting the number ratio of LED which is a combination of LEDs belonging to different chromaticity range and should belong to each chromaticity range; and storing combination information 84 showing combinations different mutually of LEDs in which a synthetic light formed by a plurality of LEDs having the number ratio being a chromaticity belonging to the chromaticity range showed by the model information 83; and a candidate LED for mounting selection part 170 for selecting an LED to be mounted on an LED module as the candidate LED for mounting by referring to the combination information 84 such that a luminescent color of the LED module belongs to the chromaticity range showed by the chromaticity range 83 and the number of the mounting LEDs becomes the number showed by the model information 83 in LED modules identified by the model information 83.

Description

  The present invention relates to an LED selection device, an LED selection program, and an LED selection method for selecting an LED to be mounted on an LED module.

Until now, a technique of mixing light of colored LEDs such as red, blue, and green using the principle of additive color mixing to obtain a target light color has been generally used in the field of displays and the like.
For white light as well, in order to solve the problem of light color variation of LEDs, a plurality of LEDs are similarly combined to achieve a target chromaticity range as combined light.
This LED combination method combines light with a target chromaticity range and each chromaticity range in contact with the outer periphery of the target chromaticity range, thereby providing combined light that falls within the target chromaticity range. Further, the number of LED lamps of the LED module is adjusted by adjusting the number of combinations of each chromaticity range in the outer periphery of the target chromaticity range (see, for example, Patent Document 1).

JP 2008-147563 A

  However, in the prior art, the combination pattern is determined based on the number of LED lamps of one LED module. Usually, for one LED type, there are a plurality of LED modules using the LED. The plurality of LED modules must be produced for several models in one production with the distribution of the chromaticity range of the LEDs in stock. For this reason, if an optimum combination pattern of LEDs is determined for each LED module and the LED is used, the LED having a good chromaticity range is used in the first LED module, and the LED used in the subsequent LED module is used. In this combination, many LEDs distributed in a biased chromaticity range remain. As a result, the LED utilization rate is high in the first LED module, but the LED utilization rate is worse in the later LED module. As a result, in the worst case, there is a situation where the number of LEDs in stock is sufficient, but there is no LED that can be used, and the LED module cannot be produced. Thus, conventionally, since the LED to be used is determined based on the number of LED lights of one LED module, when the entire production model is an LED usage target, the LED utilization rate is deteriorated. There was a problem. In other words, since the combination of LEDs to be used for each model was decided, there are many LEDs that can be used in the first model, but there is a problem that the LEDs that can be used are limited in models that will be produced later. there were.

  Furthermore, fluorescent lamps have been generally used in the lighting field. LEDs have a much larger chromaticity variation than fluorescent lamps. In order to achieve chromaticity variation equivalent to a fluorescent lamp with respect to a lighting fixture using LEDs, it is necessary to increase the number of divisions of the chromaticity range sections where the LEDs exist and to reduce the chromaticity range. At this time, in the prior art, there is a problem that the target chromaticity range cannot be further reduced because only the division of the chromaticity range adjacent to the outer periphery of the target chromaticity range is performed. Therefore, it has been necessary to stock the LEDs outside the target chromaticity range in the warehouse and divert them to other equipment to reduce the stock, or to discard the LEDs when diversion is impossible.

  An object of the present invention is to provide an LED selection device, an LED selection program, and an LED selection method that reduce the chromaticity variation range while suppressing the inventory of LEDs.

The LED selection device of this invention is
LED module identification information for identifying an LED module on which a plurality of LEDs are mounted, LED number information indicating the number of the plurality of LEDs mounted on the LED module, and the LED module to which the LED module belongs after mounting A production module information storage unit that stores module chromaticity information indicating a chromaticity range in association with each other;
A combination of LEDs belonging to different chromaticity ranges, wherein the ratio of the number of LEDs to belong to each chromaticity range is set, and the combined light from the plurality of LEDs of the number ratio is in the chromaticity range indicated by the module chromaticity information An LED combination information storage unit that stores a plurality of different combinations of LEDs that belong to chromaticity;
For the LED module specified from the LED module identification information stored in the production module information storage unit, the emission color of the LED module belongs to the chromaticity range indicated by the module chromaticity information, and is mounted LED to be mounted on the LED module by referring to the plurality of combinations stored in the LED combination information storage unit so that the number of LEDs to be the number indicated by the LED number information is a mounting candidate LED A mounting candidate LED selection unit to be selected is provided.

  ADVANTAGE OF THE INVENTION According to this invention, the LED utilization rate of the whole model of the LED lighting apparatus produced using the inventory of LED and the inventory can be made high. Therefore, the necessary number of models can be produced without having excessive LED inventory. Moreover, the range divided | segmented by the chromaticity range of LED can be made small, and the range of color variation can be made small.

FIG. 3 illustrates a configuration of an LED module manufacturing system according to the first embodiment. 5 is a flow showing the operation of the LED module manufacturing system according to the first embodiment. FIG. 3 is a chromaticity diagram represented by CIE 1931 used in the first embodiment. FIG. 4 is a diagram for explaining chromaticity division according to Embodiment 1; FIG. 6 is a diagram illustrating LED combination information 84 according to the first embodiment. The figure which shows the 4-lamp mounting pattern table 104 of Embodiment 1. FIG. The figure which shows the 6 light mounting pattern table 106 of Embodiment 1. FIG. The figure which shows the 12 light mounting pattern table 112 of Embodiment 1. FIG. FIG. 4 is a diagram for explaining a relationship between chromaticity division and a combination ratio according to the first embodiment. FIG. 4 is a diagram illustrating a method for creating a comprehensive mounting pattern 120 according to the first embodiment. FIG. 3 is a diagram showing a comprehensive mounting pattern 120 according to the first embodiment. FIG. 4 shows an output result table 121 according to the first embodiment. FIG. 4 is another diagram showing an output result table 121 according to the first embodiment. FIG. 3 is a diagram illustrating a basic operation of the computer 10 according to the first embodiment.

Embodiment 1 FIG.
FIG. 1 is a diagram illustrating a hardware configuration of the LED module manufacturing apparatus according to the first embodiment.
Hereinafter, the configuration of the LED module manufacturing apparatus according to the first embodiment will be described with reference to FIG.

  The LED module manufacturing system 19 according to the first embodiment is connected to the server 8 via the network for managing the model production plan information 81, the LED inventory information 82, and the model information 83, and manages the chromaticity selection coordinates. A computer 9, a computer 10 connected to the server 8 via a network and managing combination information, an LED sorter 11 and a taping machine 12 connected to the computer 9 via the network, and a computer 10 connected via the network A solder printer 13, a solder inspection machine 14, a self-insertion machine 15, a reflow furnace 16, an electrical inspection machine 17, and an optical inspection machine 18.

(LED sorter 11)
The LED sorter 11 operates under the control of the computer 9, measures the chromaticity when the LED emits light, and sorts it into preset categories according to the measured chromaticity. Here, “sorting into preset categories” means sorting into any one of 25 categories “classifications” G01 to G25 described later in the description of FIG. Hereinafter, “classification” means G01 or the like.

(Taping machine 12)
The taping machine 12 operates under the control of the computer 9 and taps the LEDs sorted into the sections by the LED sorter 11 for each chromaticity section and uploads the number information of each taped LED to the computer 9. . In this way, the LED sorter 11 sorts the LEDs into chromaticity sections, and the taping machine 12 taps the sorted LEDs on the reels divided into the chromaticity sections. There is a possibility that the LED is lost due to an error or an inspection error. For this reason, the upload of the LED inventory information 82 of the server 8 to the database is the number of LEDs that have been finally taped. Note that the number of LEDs is counted in order to clarify the problems that occurred in each operation before the taping of the LEDs to the reel.

(Solder printer 13)
The solder printing machine 13 operates under the control of the computer 10, and solder is applied to the pads provided at the positions of the electrodes of the LEDs mounted on this board on the boards having different shapes, LED arrangements and quantities for each model. Print.

(Solder inspection machine 14)
The solder inspection machine 14 operates under the control of the computer 10, confirms the state of “solder” printed on the board by the solder printer 13, and inspects for any abnormality.

(Self-inserting machine 15)
The self-insertion machine 15 operates under the control of the computer 10, and the LEDs taped by the taping machine 12 and classified into “category” of each chromaticity range are displayed as model information 83, combination information 84 (combination table 84) of the server 8. In other words, the solder printer 13 inserts the solder on each printed circuit board so as to obtain a combination that falls within a desired chromaticity range. The LED inventory information 82 for each chromaticity range after the LED is inserted is uploaded to the server 8 via the computer 10. Each information is described below. Further, since the term “model production plan information 81” will appear later, it will be explained together.
(1) The “model production plan information 81” is information including the production number, production time, etc. of the model of the LED lighting device that uses the LED as a light source. It also has production priority information for each production model.
(2) “LED inventory information 82” refers to, for example, the inventory quantity of LEDs belonging to the categories G01 to G25 in FIG.
(3) “Model information 83” is information relating to the model of an LED lighting device that uses an LED as a light source. The model information 83 includes a product model number (LED module identification information) that identifies an LED module on which a plurality of LEDs are mounted, the number of LED lights (LED number information) indicating the number of LEDs mounted on the LED module, and LED mounting regarding the model. Information such as target chromaticity (module chromaticity information) indicating the chromaticity range to which the LED module should belong later is included.
(4) “Combination information 84” is a combination table 84 to be described later with reference to FIG. As shown in FIG. 5, “combination information 84” is a combination of LEDs belonging to different chromaticity ranges (G01, G20, etc.) (one combination of records in each row). In the combination information 84, the number ratio of LEDs to belong to each chromaticity range (the number of LEDs in the first row is 1, the number of LEDs indicates the ratio of the numbers) is set. The combination information 84 is a combination of LEDs having different chromaticities within the chromaticity range indicated by the target chromaticity (module chromaticity information) requested by the model information in the combined light of the plurality of LEDs in the number ratio.

(Reflow furnace 16)
The reflow furnace 16 operates under the control of the computer 10, and the board into which the LED is self-inserted by the self-insertion machine 15 is passed through the inside, and the board is heated and cooled with a prescribed temperature profile. The solder printed by 13 is melted, the electrode of the LED is fixed to the substrate with this solder, and the LED is mounted on the substrate.

(Electrical inspection machine 17)
The electric inspection machine 17 operates under the control of the computer 10 and checks the conduction state of the module board on which the LED is mounted by passing through the reflow furnace 16 and inspects whether the LED is mounted without an electrical problem. . The module substrate that has been determined to be acceptable by the electrical inspection machine 17 proceeds to the inspection process by the optical inspection machine 18. Note that the module board that has been determined to be rejected by the electric inspection machine 17 is not a product, and is discarded if the defective part is corrected or cannot be corrected in the correction process.

(Optical inspection machine 18)
The optical inspection machine 18 operates under the control of the computer 10 and powers on the LED module board that has passed through the electrical inspection machine 17 without any problem, and emits the LED to inspect whether it is within a desired chromaticity range. . The module substrate that has been determined to be acceptable by the optical inspection machine 18 is used in a lighting fixture and shipped as a product. The module substrate that has been determined to be rejected by the optical inspection machine 18 is not a product, and is discarded if the defective portion cannot be corrected or cannot be corrected in the correction process.

  FIG. 2 is a flowchart showing the flow of the LED module production program. Next, the operation (production program) of the server 8 and the computers 9 and 10 of the LED module manufacturing system 19 of FIG. 1 will be described with reference to FIG.

The operation of the LED module manufacturing system 19 includes a chromaticity classification block 1, an inventory information block 2, an optimum combination calculation block 3, and an LED mounting instruction block 4.
(1) The chromaticity classification block 1 is controlled by the computer 9.
The chromaticity classification block 1 uses the LED sorter 11 to measure the optical characteristics of the LED obtained by purchasing from an LED manufacturer for the production of the LED module, and the measurement result of the optical characteristics of the LED is determined in advance. This block is classified into chromaticity ranges (G01, G02, etc. in FIG. 4).
(2) The chromaticity classification block 1 is controlled by the server 8.
The inventory information block 2 is a block for organizing the remaining LED inventory of the previous production and the LEDs classified in the chromaticity classification block 1 as inventory information.
(3) The optimum combination calculation block 3 is controlled by the computer 10.
The optimum combination calculation block 3 is a block for calculating a combination of used LEDs that provides the best LED utilization rate from the model production plan information 81.
(4) The LED mounting instruction block 4 is controlled by the computer 10. The LED mounting instruction block 4 is a block for expanding the combination determined by the optimum combination calculation block 3 to individual models.

(Computer 9)
In FIG. 2, the computer 9 controls the chromaticity classification block 1 as described above. The computer 9 outputs the chromaticity classification information obtained in the chromaticity classification block 1 to the server 8.

(Server 8)
The server 8 controls the inventory information block 2 as described above. The server 8 reflects the LED inventory information 82 after reflecting the chromaticity classification information (classification information G01, G02 and the like in FIG. 4) input from the computer 9 in the current LED inventory information 82. The model information 83 and the combination information 84 input by the operator are output to the computer 10. Further, the server 8 outputs the model production plan information (1) input from the operator to the computer 9 and the computer 10, respectively.

(Computer 10)
The computer 10 controls the optimum combination calculation block 3 and the LED mounting instruction block 4 as described above. Based on the model production plan information 81, LED inventory information 82, model information 83, and combination information 84 input from the server 8, the computer 10 determines the number of LED modules produced ("deployment" described later). The LED inventory information 82 reduced due to the use of LED module production is fed back from the computer 10 to the server 8. As shown in FIG. 1, the computer 10 includes a storage unit 150 (production module information storage unit, LED combination information storage unit, LED inventory information storage unit), a mounting candidate LED selection unit 160, and an LED determination utilization unit 170. . The storage unit 150 stores model production plan information 81, LED inventory information 82, model information 83, combination information 84, and the like. The mounting candidate LED selection unit 160 targets the LED module identified from the model information 83 (LED module identification information) stored in the storage unit 150, and the emission color of the LED module is the target chromaticity requested by the model information 83 ( The combinations stored in the storage unit 150 so as to belong to the chromaticity range indicated by the module chromaticity information) and so that the number of mounted LEDs becomes the number of LED lamps indicated by the model information 83 (the number indicated by the LED number information). By referring to the information 84, an LED to be mounted on the LED module is selected as a mounting candidate LED. Moreover, the LED determination utilization part 170 refers to the LED inventory information 82 memorize | stored in the memory | storage part 150, and the mounting candidate LED selected by the mounting candidate LED selection part 160 can be utilized for an LED module as inventory. Determine.

  Next, a specific operation of each block will be described.

FIG. 3 is a chromaticity diagram represented by CIE1931.
FIG. 4 is a diagram illustrating chromaticity division according to the first embodiment.
3 and 4 show information that is the basis of LED sorting by the LED sorter 11.

<Chromaticity classification block 1>
In the chromaticity classification block 1, an LED necessary for the manufacturing factory is produced in the own factory or another LED manufacturer based on the model production plan information 81 by each LED lighting apparatus or each LED module in the manufacturing factory input by the operator to the server 8. (ST1 and ST2). The computer 9 measures the chromaticity and luminous flux of the obtained LED with the LED sorter 11 (ST3). The measurement of the luminous flux in ST3 is for examining the amount of light output from the LED, and can be substituted with a luminous intensity value, an illuminance value, or the like. Based on the measured chromaticity and luminous flux of the LEDs, these LEDs are classified into predetermined chromaticity range sections (ST4).

  In ST3, the LED sorter 11 measures LED chromaticity according to the CIE1931 chromaticity diagram shown in FIG. In the chromaticity diagram of FIG. 3, for example, ranges corresponding to daylight white equivalent 5, white equivalent 6 and bulb color equivalent 7 are shown. FIG. 4 shows the chromaticity classified using the range corresponding to the light bulb color equivalent 7 in the chromaticity diagram of FIG. In FIG. 4, the range corresponding to the light bulb color equivalent 7 in the chromaticity diagram of FIG. 3 is divided into chromaticity ranges from G01 to G25. The LED sorter 11 holds the contents of FIG. 4 as information, and based on this information, the LED sorter 11 classifies the LED from G01 to G25 according to the chromaticity coordinates of the result of measuring the LED. To do. In FIG. 4, the number of divisions of the chromaticity range is described as 25 divisions, but this is only an example. Since the chromaticity range, luminous flux range, or target chromaticity range of the LED that can be obtained differs depending on the type of LED used for each product, the number of divisions is not limited to 25 divisions.

  In ST4, for each LED classified into a predetermined chromaticity range category such as G01 by the LED sorter 11, the computer 9 grasps the quantity of each LED for each chromaticity range category (ST5).

<Inventory information block 2>
In the inventory information block 2, the server 8 classifies each chromaticity range at the time of the previous LED module production, but again grasps the inventory of the remaining LEDs that are not used (ST6), and the chromaticity classification block 1 The total of the LED inventory classified in step 1 is obtained, and it is grasped how the LED inventory is distributed for each chromaticity range category (ST7). In ST7, the total of LED inventory obtained by the server 8 is stored as the LED inventory information 82 of the server 8.

<Optimal combination calculation block 3>
In the optimal combination calculation block 3, the computer 10 (mounting candidate LED selection unit 160) classifies the types of LED modules to be produced for each LED type from the model production plan information 81 (ST1) input by the operator to the server 8. (ST8). The models classified according to the type of LED each have a different number of LEDs to be mounted per board, and the number of boards on one carrier board is different. Different. For this reason, the computer 10 (mounting candidate LED selection unit 160) reads these pieces of information from the database of the model information 83 of the server 8 (ST9). Next, the computer 10 (mounting candidate LED selection unit 160) grasps the “number of mounting patterns” of LEDs from the read information on the number of LEDs mounted on each production model (ST10). The “number of mounting patterns” indicates each row in the tables of FIGS. Each of the rows in FIGS. 6 to 8 is a “mounting pattern”.

  Here, a mounting pattern determined by the combination method of LEDs for reducing chromaticity variation and the number of mounted LEDs, which is executed by the computer 10 (the mounting candidate LED selecting unit 160 and the LED use determining unit 170) will be described.

  FIG. 5 shows combination information 84 stored in the server 8. The combination table 84 in FIG. 5 is determined in advance and stored in the server 8. Each row of the combination table 84 is referred to as a “combination pattern”.

(Combination pattern)
Hereinafter, the “combination pattern” will be described. In the classification shown in FIG. 4, the classified chromaticity is divided into 25 sections from section G01 to section G25. For example, among these, the four divisions G13, G14, G18, and G19 belong to the target chromaticity range 70 indicated by diagonal lines. The combination table 84 in FIG. 5 shows combinations of LEDs that become combined light belonging to the target chromaticity range 70 in FIG. For example, the first row of the combination table 84 indicates that combined light belonging to the target chromaticity range 70 can be obtained by combining one LED belonging to G01 and two LEDs belonging to G20.
Using this as the number ratio,
(G01: G20) = (1: 2)
Notation is as follows.
Similarly, the second line in FIG.
(G02: G25) = (1: 1)
It is shown that.
That is, the following contents.
(1) In FIG. 4, G01 is a section away from the target chromaticity range 70. At this time, one LED (G) of G01 is combined with two LEDs (2k) belonging to G20 near the target chromaticity range 70.
That is, (G01: G20) = (1: 2).
As a result, the light color of G01 is pulled by the light color of G20, and the combined light becomes the combined light belonging to the target chromaticity range 70, that is, the combined light belonging to any section of G13, G14, G18, and G19. .
(2) Also, LEDs that are classified into G02 and G25 are combined one by one.
That is, (G02: G25) = (1: 1).
Accordingly, similarly, the combined light belongs to any one of G13, G14, G18, and G19 in the target chromaticity range 70.
(3) Moreover, the LED classified into G13 of the target chromaticity range 70 enters the target chromaticity range 70 alone.
(4) In this way, LEDs of the same model can be obtained by combining G01 and G20 in a 1: 2 relationship, G02 and G25 in a 1: 1 relationship, or using G13 alone. The chromaticity variation between modules can be reduced. In other words, a light color belonging to the target chromaticity range 70 can be realized using an LED that does not belong to the target chromaticity range 70. Each row of the combination table 84 indicates such a “combination pattern”.

  The basic operation of the computer 10 will be described with reference to FIGS.

Each model (LED module) to be produced has a predetermined number of LEDs to be mounted on the substrate.
FIG. 6 shows the four-lamp mounting pattern table 104 generated by the mounting candidate LED selection unit 160. The computer 10 (mounting candidate LED selection unit 160) generates the four-light mounting pattern table 104 from the information of four lights and the combination table 84. This is a 4-lamp mounting pattern table 104 showing combinations of (G01: G20), (G02: G25), and G13 (single) when four LEDs are mounted on one substrate.
(1) For example, in the case of a model in which four LEDs are mounted on a board, based on the combination table 84, as shown in FIG.
(G01: G20) = (1: 2)
The “number of mounting patterns” can be made up of “one way” consisting of four LEDs.
(2) Also, (G02: G25) = (1: 1)
Assuming that two LEDs are two sets, the “number of mounting patterns” of four LEDs can be “one”. In this way, the number of mounting patterns when mounting four LEDs in a combination of 1: 2 or 1: 1 is “4”.

FIG. 7 shows a six-light mounting pattern table 106. The computer 10 (mounting candidate LED selection unit 160) generates the six-light mounting pattern table 106 from the information of six lights and the combination information 84. FIG. 7 is a diagram showing a “mounting pattern” when six LEDs are mounted on a substrate.
If it is a model that mounts 6 LEDs on the board,
(G01: G20) = (1: 2)
The number of mounting patterns in the case of 6 LEDs is “7 types”, for example, if 2 sets are set as 2 sets.

  FIG. 8 shows a 12-light mounting pattern table 112. The computer 10 (mounting candidate LED selection unit 160) generates a 12-lamp mounting pattern table 112 from the information of 12 lights and the combination table 84. FIG. 8 is a diagram illustrating that the “number of mounting patterns” when mounting 12 LEDs is “19”. Thus, the “mount pattern number” of LEDs is determined by the number of LED lamps mounted on each model.

In the description here, the combination of LEDs that belong to the target chromaticity range 70 is determined by the number ratio of the LEDs. However, regarding the combination of LEDs, the combination ratio also changes due to the influence of the light quantity of each LED such as the luminous flux, illuminance, and luminance.
FIG. 9 is a diagram for explaining the influence of the light amount of the LED on the combination of LEDs. The chromaticity range divided into 25 in FIG. 4 and the “combination ratio” (such as (G01: G20) = (1: 2) described above) that belongs to the target chromaticity range 70 are as shown in FIG. In addition, even if the LEDs are combined in the minimum light quantity and maximum light quantity ranges in the LED specification range, the chromaticity division and combination are performed so as to fall within the target chromaticity range 70.
The chromaticity range 71 is
(G01, G20) = (MIN, MAX).
That is, the chromaticity range of the combined light when the light amount of the LED belonging to G01 is the minimum and the light amount of the LED belonging to G20 is the maximum is shown.
Similarly,
The chromaticity range 72 is
(G01, G20) = (MAX, MIN).
That is, the chromaticity range of the combined light when the light amount of the LED belonging to G01 is maximum and the light amount of the LED belonging to G20 is minimum is shown. And, the chromaticity range 73 shown by diagonal lines is a combination of one LED belonging to the G01 range and two LEDs belonging to the G20 range.
Each LED
(G01, G20) = (MIN, MAX) to (MAX, MIN)
The range of the chromaticity of the synthesized light that can be produced when Therefore, the combination table 84 of FIG. 5 stored in the server 8 can be made into a finer combination by using a “combination pattern” (each row of the combination table 84) determined from the light amount and the chromaticity. Therefore, in the case of an LED having a specification with a wide minimum and maximum light quantity, the utilization factor of the LED can be improved.

(532 mounting patterns)
Next, the computer 10 (mounting candidate LED selection unit 160) is a total pattern of combinations of “mounting patterns” (hereinafter referred to as a comprehensive mounting pattern 120 (mounting candidate LEDs), which will be described later with reference to FIGS. 10 and 11) as a whole model. Is calculated (ST11). The total number of LED combinations is the product of the mounting patterns of each model.
For example,
It is assumed that there are a model in which four LEDs are mounted, a model in which six LEDs are mounted, and a model in which twelve LEDs are mounted. In this case, as described in FIGS. 6 to 8, the number of mounting patterns is 4, 7, and 19, respectively. Therefore, in the three models, the total number of mounting patterns is the table shown in FIGS. 6 to 8. The product of
That is,
The total number of mounting patterns = 4 × 7 × 19 = 532, which is a total of 532 “total number of mounting patterns 120”.
FIG. 10 shows how to obtain the total mounting pattern 120 for a total of 532 patterns.
FIG. 11 shows the obtained total mounting pattern 120.
Hereinafter, the comprehensive mounting pattern 120 will be further described.

The computer 10 (mounting candidate LED selection unit 160)
“1: 2, 1: 1, single”
Determine how many sets of each pattern you need.

For example,
8 models with 4 LEDs,
10 models with 6 LEDs,
Assume that 5 units with 12 LEDs are produced.
in this case,
In the patterns of the mounting patterns 4-1, 6-1 and 12-1 shown in FIGS.
1: 2
(1 set x 8 units) + (2 sets x 10 units) + (4 sets x 5 units) (Formula 1)
48 sets are needed.
Also, 1: 1 is
(0 set x 8 units) + (0 set x 10 units) + (0 set x 5 units) (Formula 2)
Therefore, it is unnecessary.
For singles,
(1 set x 8 units) + (0 set x 10 units) + (0 set x 5 units) (Formula 3)
8 sets are needed.
Similarly, in the patterns of mounting patterns 4-1, 6-1 and 12-2, 1: 2 is (1 set x 8 units) + (2 sets x 10 units) + (3 sets x 5 units)
43 sets are required.
1: 1 is (0 set x 8 units) + (0 set x 10 units) + (1 set x 5 units)
Therefore, 5 sets are required.
For singles,
(1 set x 8 units) + (0 set x 10 units) + (1 set x 5 units) requires 13 sets. The following is omitted.

  The total mounting pattern 120 in FIG. 11 formulates how to obtain the above (Formula 1) to (Formula 3) for 532 patterns. In other words, the number of sets of combinations such as “1: 2” is obtained by viewing the number of 1: 2, 4, 6 and 12 lamps obtained from FIGS. 6 to 8 as coordinates (X, Y, Z). And the inner product of the number of 4 lights, 6 lights and 12 lights as coordinates (a, b, c).

  For all 532 mounting patterns of these LEDs, the computer 10 (mounting candidate LED selection unit 160) reads the information of the combination table 84 from the server 8 (ST12). The computer 10 (LED usage determination unit 170) examines the LED inventory information 82 of the server 8 based on the combination pattern in the combination table 84, thereby outputting output results to be output for 532 mounting patterns of LEDs (described later). The output result table 121) shown in FIGS. 12 and 13 is calculated (ST13). The computer 10 (LED usage determination unit 170) calculates an output result as follows.

(1) The model production plan information 81 input from the server 8 includes the priority of production in addition to the number of models to be produced. In this example, the model production plan information 81 is
Assume that the priority of the order of 4 lamps> 6 lamps> 12 lamps is included. The production of 4 LED modules is given the highest priority, then 6 lights are given priority, and the production priority of 12 lights is the lowest. In this case, the computer 10 (LED usage determination unit 170) checks the possibility of production with 532 mounting patterns. For example, when checking the mounting pattern <1>, the four lights with the highest priority are selected. The number of LEDs (MAX 8) that can be produced is determined based on the inventory LED indicated by the LED inventory information 82, then 6 lights (MAX 10) and finally 12 lights (MAX 5) are determined. Then, the production rate, the number of produced units, the breakdown of the produced units, etc. are obtained, and the output results are output as an output result table 121 as shown in FIGS.

  12 and 13 are diagrams showing an output result table 121 output by the computer 10 (LED usage determining unit 170). If the computer 10 (LED usage determination unit 170) takes the mounting pattern <1> as an output result as an example, the number of sets of mounting patterns “48, 0, 8”, the production rate (number of units that can be produced out of 23 units% ) Outputs the number of units produced and the breakdown of the number of units produced.

  FIG. 12 is a diagram including a mounting pattern that can produce a total of 23 LED modules, including 8 units of 4 lights, 10 units of 6 lights, and 5 units of 12 lamps. The mounting pattern <1> in the output result table 121 of FIG. 12 has a production rate of 100%, and this indicates that 23 of the 23 units to be produced can be produced with the stock LEDs. When there is a mounting pattern with a production rate of 100%, the computer 10 (LED usage determination unit 170) determines to produce each type of LED module with the mounting pattern, and selects the mounting pattern. . When there are a plurality of mounting patterns having a production rate of 100%, a rule for selecting which one is to be selected is set in advance in the computer 10 (LED usage determining unit 170). For example, a rule of selecting a mounting pattern with a small number or a rule of selecting a mounting pattern with the largest total number of LEDs may be used. Alternatively, a rule of selecting a mounting pattern including a combination pattern of a pair of LEDs apart from the target chromaticity range 70 in the section of FIG.

  FIG. 13 is a diagram showing an output result table 121 when there is no mounting pattern with a production rate of 100%. The computer 10 (LED usage determination unit 170) outputs the information in FIG. 13, and the user can select a desired mounting pattern from the output result table 121 in FIG. For example, when mounting pattern <2> is selected, four lamps, eight lamps, ten lamps, and twelve lamps can be produced. Even when there is no mounting pattern with a production rate of 100%, it is possible to select a mounting pattern by setting a predetermined selection rule in the computer 10 (LED usage determination unit 170). For example, the mounting pattern with the highest production rate may be selected. In FIG. 13, the production rate of the mounting patterns <1> to <3> is the same rate. In such a case, you may set so that the mounting pattern in which many LED modules with high production priority are contained may be selected. In this setting, in the example of FIG. 13, the computer 10 (LED usage determination unit 170) selects the mounting pattern <2>. The computer 10 (LED usage determination unit 170) selects a mounting pattern according to a preset rule for each mounting pattern (ST14).

  In the LED mounting instruction block 4, the computer 10 (LED usage determining unit 170) uses the selected mounting pattern to develop an optimal LED combination for each individual model (ST15). “Development” means that when the computer 10 selects, for example, the mounting pattern <2> in FIG. 13, the “LED combination” such as “1: 2” is actually set to four 4 lights, 6 lights. This means that the LED module is distributed to 10 units and 2 units of 12 lamps.

  For actual production, the optimal combination of LEDs developed in ST15 for each individual LED module is not mounted on each board, but a metal board is used to mount the LEDs on the carrier board. Several boards are mounted and mounted together. Further, if the material of the substrate is a resin substrate, it is a continuous substrate in which several single substrates are connected, and this continuous substrate is divided after mounting the LED. In order to adopt such an LED mounting method, the LED mounting instruction on the module substrate determines the number of units mounted on the carrier board or the number of continuous substrates, and the LED is used (ST16). ).

By the operation of each block in the flow shown in FIG. 2 described above, the number of used LEDs is fed back to the server 8 from the computer 10 (LED usage determining unit 170). The server 8 subtracts the fed back LED quantity from the database of the LED inventory information 82 of the server 8 (ST17).
If the required quantity of LED modules to be produced has been reached, production ends.

  If the production quantity of LED modules is insufficient compared to the required number, the process returns to ST11, the total of LED mounting patterns is calculated for the remaining required models, and the optimal mounting pattern is obtained again. In other words, when the computer 10 selects the mounting pattern <2> in FIG. 13, there are insufficient three 12 lights. About these 3 units | sets, it returns to ST11 again and repeats the same process. When the number of LED modules that can be produced is 0 as a result of calculating the LED mounting pattern again, the process is terminated. Alternatively, the process is completed when the necessary number of remaining LED modules can be produced (ST18).

  FIG. 14 is a diagram summarizing the operations of the computer 10 described above. The mounting candidate LED selection unit 160 of the computer 10 generates the 4-lamp mounting pattern table 104, the 6-lamp mounting pattern table 106, and the 12-lamp mounting pattern table 112 from information such as the model production plan information 81 obtained from the server 8. Then, the mounting candidate LED selection unit 160 generates a comprehensive mounting pattern 120. Next, the LED usage determination unit 170 generates and outputs the output result table 121 (FIGS. 12 and 13) using the general mounting pattern 120, the LED inventory information 82, and the combination information 84.

Thus, by obtaining an optimum combination pattern of LEDs for the entire model to be produced and deploying it to each production model, the LED utilization rate is improved as a whole, and the inventory of LEDs in the production factory can be reduced. Thereby, about the LED which is in stock, the deviation of the quantity of LED of each chromaticity range can be decreased, and the quantity of LED which becomes disposal can be reduced by averaging. Therefore, since the number of LEDs that are disposed of can be reduced, CO ₂ emissions can be reduced.

  In addition, by reducing the inventory of LEDs in the production plant, it is possible to significantly reduce the number of LEDs that need to be discarded without being used when the model is updated, such as when changing LEDs. A method for manufacturing a module can be provided.

  Further, since the LED inventory is reduced, it is possible to reduce the space of the warehouse where the LED inventory is placed in the production factory, and the LED inventory management is facilitated.

  Further, by using a method of combining two or more LEDs with respect to one LED, such as 1: 2, as an LED combination method, the chromaticity range to be divided can be reduced, and the range of chromaticity variation to be combined light is further reduced. be able to.

  In the above embodiment, the LED selection device has been described. However, the operation of the LED selection device can be grasped as an LED selection method or an LED secret program.

  1 chromaticity classification block, 2 inventory information block, 3 optimal combination calculation block, 4 LED mounting instruction block, 5 chromaticity range equivalent to daytime white, 6 chromaticity range equivalent to white, 7 chromaticity range equivalent to light bulb color, 8 Server, 9 computers, 10 computers, 11 LED sorter, 12 Taping machine, 13 Solder printer, 14 Solder inspection machine, 15 Self-insertion machine, 16 Reflow furnace, 17 Electrical inspection machine, 18 Optical inspection machine, 19 LED module manufacture System, 70 target chromaticity range, 71, 72, 73 chromaticity range, 81 model production plan information, 82 LED inventory information, 83 model information, 84 combination information, 104 4-lamp mounting pattern table, 106 6-lamp mounting pattern table, 112 12-light mounting pattern table, 120 total mounting pattern, 121 output result Buru.

The operation of the LED module manufacturing system 19 includes a chromaticity classification block 1, an inventory information block 2, an optimum combination calculation block 3, and an LED mounting instruction block 4.
(1) The chromaticity classification block 1 is controlled by the computer 9.
The chromaticity classification block 1 uses the LED sorter 11 to measure the optical characteristics of the LED obtained by purchasing from an LED manufacturer for the production of the LED module, and the measurement result of the optical characteristics of the LED is determined in advance. This block is classified into chromaticity ranges (G01, G02, etc. in FIG. 4).
(2) The inventory information block 2 is controlled by the server 8.
The inventory information block 2 is a block for organizing the remaining LED inventory of the previous production and the LEDs classified in the chromaticity classification block 1 as inventory information.
(3) The optimum combination calculation block 3 is controlled by the computer 10.
The optimum combination calculation block 3 is a block for calculating a combination of used LEDs that provides the best LED utilization rate from the model production plan information 81.
(4) The LED mounting instruction block 4 is controlled by the computer 10. The LED mounting instruction block 4 is a block for expanding the combination determined by the optimum combination calculation block 3 to individual models.

(Server 8)
The server 8 controls the inventory information block 2 as described above. The server 8 reflects the LED inventory information 82 after reflecting the chromaticity classification information (classification information G01, G02 and the like in FIG. 4) input from the computer 9 in the current LED inventory information 82. The model information 83 and the combination information 84 input by the operator are output to the computer 10. In addition, the server 8 outputs model production plan information 81 input by the operator to the computer 9 and the computer 10, respectively.

(Computer 10)
The computer 10 controls the optimum combination calculation block 3 and the LED mounting instruction block 4 as described above. Based on the model production plan information 81, LED inventory information 82, model information 83, and combination information 84 input from the server 8, the computer 10 determines the number of LED modules produced ("deployment" described later). The LED inventory information 82 reduced due to the use of LED module production is fed back from the computer 10 to the server 8. As shown in FIG. 1, the computer 10 includes a storage unit 150 (production module information storage unit, LED combination information storage unit, LED inventory information storage unit), a mounting candidate LED selection unit 160, and an LED usage determination unit 170. . The storage unit 150 stores model production plan information 81, LED inventory information 82, model information 83, combination information 84, and the like. The mounting candidate LED selection unit 160 targets the LED module identified from the model information 83 (LED module identification information) stored in the storage unit 150, and the emission color of the LED module is the target chromaticity requested by the model information 83 ( The combinations stored in the storage unit 150 so as to belong to the chromaticity range indicated by the module chromaticity information) and so that the number of mounted LEDs becomes the number of LED lamps indicated by the model information 83 (the number indicated by the LED number information). By referring to the information 84, an LED to be mounted on the LED module is selected as a mounting candidate LED. In addition, the LED usage determination unit 170 refers to the LED inventory information 82 stored in the storage unit 150, and determines whether or not the mounting candidate LED selected by the mounting candidate LED selection unit 160 can be used as an inventory for the LED module. Determine.

(532 mounting patterns)
Next, the computer 10 (mounting candidate LED selection unit 160) is a total pattern of combinations of “mounting patterns” (hereinafter referred to as a comprehensive mounting pattern 120 (mounting candidate LEDs), which will be described later with reference to FIGS. 10 and 11) as a whole model. Is calculated (ST11). The total number of LED combinations is the product of the mounting patterns of each model.
For example,
It is assumed that there are a model in which four LEDs are mounted, a model in which six LEDs are mounted, and a model in which twelve LEDs are mounted. In this case, as described in FIGS. 6 to 8, the number of mounting patterns is 4, 7, and 19, respectively. Therefore, the total number of mounting patterns for the three models is the table shown in FIGS. 6 to 8. The product of
That is,
The total number of mounting patterns = 4 × 7 × 19 = 532, which is a total of 532 “total number of mounting patterns 120”.
FIG. 10 shows how to obtain the total mounting pattern 120 for a total of 532 patterns.
FIG. 11 shows the obtained total mounting pattern 120.
Hereinafter, the comprehensive mounting pattern 120 will be further described.

In the above embodiment, the LED selection device has been described. However, the operation of the LED selection device can be grasped as an LED selection method or an LED selection program.

Claims (4)

LED module identification information for identifying an LED module on which a plurality of LEDs are mounted, LED number information indicating the number of the plurality of LEDs mounted on the LED module, and the LED module to which the LED module belongs after mounting A production module information storage unit that stores module chromaticity information indicating a chromaticity range in association with each other;
A combination of LEDs belonging to different chromaticity ranges, wherein the ratio of the number of LEDs to belong to each chromaticity range is set, and the combined light from the plurality of LEDs of the number ratio is in the chromaticity range indicated by the module chromaticity information An LED combination information storage unit that stores a plurality of different combinations of LEDs that belong to chromaticity;
For the LED module specified from the LED module identification information stored in the production module information storage unit, the emission color of the LED module belongs to the chromaticity range indicated by the module chromaticity information, and is mounted LED to be mounted on the LED module by referring to the plurality of combinations stored in the LED combination information storage unit so that the number of LEDs to be the number indicated by the LED number information is a mounting candidate LED An LED selection device comprising: a mounting candidate LED selection unit to select. The LED selection device further includes:
An LED inventory information storage unit that stores LED inventory information in which the number of LEDs in the chromaticity range indicated by the combination stored by the LED combination information storage unit is registered;
An LED that determines whether or not the mounting candidate LED selected by the mounting candidate LED selection unit is available to the LED module as stock by referring to the LED stock information stored in the LED stock information storage unit The LED selection device according to claim 1, further comprising a usage determination unit. Computer
LED module identification information for identifying an LED module on which a plurality of LEDs are mounted, LED number information indicating the number of the plurality of LEDs mounted on the LED module, and the LED module to which the LED module belongs after mounting A production module information storage unit that stores module chromaticity information indicating a chromaticity range in association with each other;
A combination of LEDs belonging to different chromaticity ranges, wherein the ratio of the number of LEDs to belong to each chromaticity range is set, and the combined light from the plurality of LEDs of the number ratio is in the chromaticity range indicated by the module chromaticity information An LED combination information storage unit for storing a plurality of different combinations of LEDs that belong to chromaticity,
For the LED module specified from the LED module identification information stored in the production module information storage unit, the emission color of the LED module belongs to the chromaticity range indicated by the module chromaticity information, and is mounted LED to be mounted on the LED module by referring to the plurality of combinations stored in the LED combination information storage unit so that the number of LEDs to be the number indicated by the LED number information is a mounting candidate LED Mounting candidate LED selection unit to select,
LED selection program to function as An LED selection method performed by an LED selection device,
The production module information storage unit
LED module identification information for identifying an LED module on which a plurality of LEDs are mounted, LED number information indicating the number of the plurality of LEDs mounted on the LED module, and the LED module to which the LED module belongs after mounting The module chromaticity information indicating the chromaticity range is stored in association with each other,
LED combination information storage unit
A combination of LEDs belonging to different chromaticity ranges, wherein the ratio of the number of LEDs to belong to each chromaticity range is set, and the combined light from the plurality of LEDs of the number ratio is in the chromaticity range indicated by the module chromaticity information Memorize a plurality of different combinations of LEDs that belong to the chromaticity,
The mounting candidate LED selection unit
For the LED module specified from the LED module identification information stored in the production module information storage unit, the emission color of the LED module belongs to the chromaticity range indicated by the module chromaticity information, and is mounted LED to be mounted on the LED module by referring to the plurality of combinations stored in the LED combination information storage unit so that the number of LEDs to be the number indicated by the LED number information is a mounting candidate LED LED selection method characterized by selecting.