JP2013074008A - Led selection device, led selection program and led selection method - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide an LED selection device which reduces a range of unevenness in chromaticity, while restricting LED stock.SOLUTION: A mounting candidate LED selection unit selects at least one item of model information from model information in a storage unit. The mounting candidate LED selection unit accepts as its input the number of LED modules produced which belong to all of the selected model information. The mounting candidate LED selection unit generates a combined mounting pattern 120 consisting of plural mounting patterns on the basis of the selected model information, the number of units produced, and a combination table 84. The mounting candidate LED selection unit refers to the combination table 84 and LED stock information 82 for each mounting pattern to select a selectable number of sets corresponding to the mounting pattern from LEDs in stock which suit to a combination pattern having higher classification priority than others among the combination patterns included in the combination table 84.

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
A plurality of LED numbers information indicating the number of LEDs mounted on the LED module and module chromaticity information indicating the chromaticity range to which the combined light by the mounted number of LEDs indicated by the LED number information belongs Production module information storage unit for storing a plurality of model information having the same chromaticity range indicated by the module chromaticity information, with the mounting number indicated by the LED number information being different,
A combination of LEDs belonging to different chromaticity ranges, wherein a number ratio between the number of LEDs belonging to a specific chromaticity range and the number of LEDs belonging to another chromaticity range is set, and the number ratio LED combined information including a plurality of combination patterns to which the combined light of the plurality of LEDs indicates different combinations of LEDs having chromaticities belonging to the chromaticity range indicated by the module chromaticity information and is given priority is stored. An LED combination information storage unit;
The inventory number of LEDs belonging to each chromaticity range of the specific chromaticity range and the other chromaticity range indicated by each combination pattern included in the LED combination information stored in the LED combination information storage unit is registered. LED stock information storage unit for storing the LED stock information that has been made,
Select at least one model information from the plurality of model information stored in the production module information storage unit, input the number of LED modules produced for all the selected model information, and selected Based on the model information, the input number of LED modules produced, and the LED combination information stored in the LED combination information storage unit, all of the selected model information regarding the LED modules are input. The number of LEDs that can be produced and the emission color of the LED module of the model information to be produced belongs to the chromaticity range indicated by the module chromaticity information in the model information. Multiple mounting patterns are calculated, and a comprehensive mounting pattern consisting of the calculated mounting patterns is generated. For each mounting pattern of the integrated mounting pattern, the LED combination information is stored by referring to the LED combination information stored in the LED combination information storage unit and the LED inventory information stored in the LED inventory information storage unit. The number of LEDs that can be produced from the inventory LEDs corresponding to the combination pattern having higher priority among the combination patterns included in the number of LEDs that can be produced is indicated and produced. A light-emitting color of the LED module in the model information belongs to a chromaticity range indicated by the module chromaticity information in the model information; and a selection unit that selects a selectable pattern corresponding to the mounting pattern. It is characterized by.

  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. Moreover, since the priority is used, it can be used from an inventory LED that is desired to be used early. 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. The figure which shows notionally the selection process which the mounting candidate LED selection part 160 of Embodiment 1 performs. The figure which shows the process by which the total production number of models of the line <1> of the comprehensive mounting pattern 120 is calculated by the mounting candidate LED selection unit 160 of the first embodiment. The figure which shows the process by which the total production number of models of the line <2> of the comprehensive mounting pattern 120 is calculated by the mounting candidate LED selection unit 160 of 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 includes a server 8 that manages model production plan information 81, LED inventory information 82, model information 83, and combination information 84, and a chromaticity selection connected to the server 8 via a network. A computer 9 for managing coordinates, a computer 10 for managing combination information connected to the server 8 via a network, an LED sorter 11 and a taping machine 12 connected to the computer 9 via a network, and a network for the computer 10 It is comprised from the solder printer 13, the solder inspection machine 14, the self-insertion machine 15, the reflow furnace 16, the electrical inspection machine 17, and the optical inspection machine 18 connected through this.

(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. Each production model also has information on production priority (production priority).
(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 ratio of the number of LEDs that should belong to each chromaticity range (the number of LEDs 1 and the number of LEDs 2 in the first row indicate the number ratio) 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 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.

(Computer 9)
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. 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), mounting candidate LED selection unit 160 (selection unit), and LED usage determination unit 170. (Result output unit). 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.

  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 (also referred to as a combination table 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, it is assumed that among these, four divisions G13, G14, G18, and G19 belong to the target chromaticity range 70 indicated by hatching. 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)
It is written like this.
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”.
(5) In addition, the number of LEDs that are produced in our own factory or purchased from other LED manufacturers is large and the number of LEDs classified into the target chromaticity range is large. It is normally distributed so that the number of LEDs to be reduced. Therefore, in the item of “chromaticity range 1” in the combination table 84, the sections that tend to decrease the number of LEDs are arranged in order from the top, and the section priority is set for each combination pattern.

  The basic operation of the computer 10 will be described with reference to FIGS. 6 to 14 show the operation of the mounting candidate LED selection unit 160, and FIGS. 15 and 16 show the operation of the LED usage determination unit 170. FIG. 17 is a diagram for explaining the operations of both the mounting candidate LED selection unit 160 and the LED usage determination unit 170.

(Outline of operation of mounting candidate LED selection unit 160)
The mounting candidate LED selection unit 160 selects at least one model information from the plurality of model information 83 stored in the storage unit 150. The following description of FIGS. 6 to 14 is based on the case where the mounting candidate LED selection unit 160 selects three models of four, six, and twelve from among the plurality of model information 83 stored in the storage unit 150. Although described, one model information selection (for example, only four lights) may be used. The mounting candidate LED selection unit 160 inputs the number of LED modules produced in all the selected model information 83. In the example described below, the number of units produced is 8 units, 10 units, and 5 units for each model information of 4 lights, 6 lights, and 12 lights. Then, the mounting candidate LED selection unit 160 selects based on the selected model information 83, the input number of LED modules produced, and the combination table 84 (FIG. 5 described later) stored in the storage unit 150. With respect to all the LED modules of the model information 83, “the number of LEDs that can produce the input production number is indicated, and the emission color of the LED module of the model information 83 to be produced is the target chromaticity (module A plurality of LED mounting patterns that belong to the chromaticity range indicated by the (chromaticity information) ”are calculated, and a comprehensive mounting pattern 120 (FIG. 11 described later) including the calculated mounting patterns is generated. The mounting candidate LED selection unit 160 refers to the combination table 84 and the LED inventory information 82 stored in the storage unit 150 for each mounting pattern of the general mounting pattern 120, so that among the combination patterns included in the combination table 84. From the stock LEDs corresponding to the combination pattern having a higher classification priority, the input production number indicates the number as close as possible to the number of LEDs that can be produced, and the light emission color of the LED module of the produced model information 83 is model information. The number of selectable sets (selectable pattern) corresponding to the mounting pattern that belongs to the chromaticity range indicated by the target chromaticity in 83 is selected.

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”. In this way, the “number of mounted patterns” of the LEDs is the ratio of the number of LED lamps mounted in each model and the number of LEDs registered in the combination table 84 (in the case of FIG. 5, 1: 1, 1: 2, and Alone).

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, 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.

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).

  The main operation of the following ST12 and ST13 is the mounting candidate LED selection unit 160. For each of the 532 mounting patterns of the general mounting pattern 120 in FIG. 11, the computer 10 (mounting candidate LED selection unit 160) reads the information of the combination table 84 from the server 8 (ST12).

  In ST13, the computer 10 (mounting candidate LED selection unit 160) refers to the read combination table (84) and the LED inventory information (82) of the server 8 to determine the total mounting pattern 120 from the LED inventory information 82. For each mounting pattern, select the number of sets indicated by “1: 2, 1: 1, single” (hereinafter referred to as the required number of sets). For example, if row <1>, select “40 sets, 0 sets, 8 sets” Alternatively, if it cannot be selected, the number of sets as close to the necessary number as possible is selected. The number of sets selected from the LED inventory information 82 is referred to as “selectable set number” (selectable pattern). In other words, the “selectable set number” is a combination of “1: 2” or the like that can produce the number of production of each model (for example, 8 units, 10 units, and 5 units for each model of 4, 6 and 12 lights). This indicates the number of sets (number of LEDs) as close as possible to the number of sets (number of LEDs), and the emission color of the LED module of the model information to be produced belongs to the chromaticity range indicated by the module chromaticity information in the model information. The number of sets corresponding to the required number of sets (mounting pattern).

FIG. 12 is a diagram conceptually showing this selection process performed by the mounting candidate LED selection unit 160.
A specific example will be described. For example, if the mounting candidate LED selection unit 160 is the mounting pattern of the row <1> of the general mounting pattern 120, “1: 2, 1: 1, single” is set to “48 sets, 0 sets” as the necessary number of sets. , 8 sets ”is attempted to be selected from the LED inventory information 82. In the case of the mounting pattern of the row <2>, “43 sets, 5 sets, 13 sets” is selected from the LED inventory information 82 as the required number of sets for “1: 2, 1: 1, single”. Try.

  The mounting candidate LED selection unit 160 collates the combination table 84 with the LED inventory information 82 for each mounting pattern (also referred to as each row) of <1> to <532> that is each row of the total mounting pattern 120 illustrated in FIG. However, it tries to select the required number of sets of “1: 2 combination”, “1: 1 combination”, and “single”.

(Selection of required number of sets from LED inventory information 82)
Next, taking the case of row <1> as an example, the necessary set number selection process performed by the mounting candidate LED selection unit 160 will be specifically described with reference to FIG. The mounting candidate LED selection unit 160 refers to the combination table 84 and the LED inventory information 82 and selects the required number of sets as follows. In this selection process, the combination table 84 shown in FIG. 5 is used. However, the classification priority is set in the left column of the combination table 84. With this classification priority, the LED that is desired to be used at the time of the selection process is used from the inventory. It is assumed that the lower the classification priority, the higher the priority (higher priority). Therefore, the higher the order of priority is in the upper row of the combination table 84.

  Note that row <1> in FIG. 12 indicates that each set of “1: 2, 1: 1, single” has “48 sets, 0 sets, 8 sets” as the required number of sets. “1 set” is not “0 set” but 20 sets. Accordingly, in the row <1>, the necessary set number selection processing for the row <1> will be described assuming that each necessary group of “1: 2, 1: 1, single” is “48 sets, 20 sets, 8 sets”. To do.

("1: 2, 1: 1, single" selection processing for row <1>)
In FIG. 12, the mounting candidate LED selection unit 160 refers to the combination table 84 and the LED inventory information 82 and checks from the row <1> of the total mounting pattern 120. At the start of the check, the LED inventory information 82 is the contents of the current inventory status, and the selected LED is subtracted from the LED inventory information 82 every time an LED is selected in the processing in the row. When shifting to the check of the next line, the state of the LED inventory information 82 is returned to the original current inventory state.

The mounting candidate LED selection unit 160 checks the row <1> as follows.
(1) The mounting candidate LED selection unit 160 performs the following process on the combination table 84 from a group having a higher segment priority toward a group having a lower priority. That is, as shown in FIG. 12, the following processing is performed from the top of the combination table 84 to the bottom row. The mounting candidate LED selection unit 160 recognizes that the required number of sets of “1: 2, 1: 1, single” in the row <1> is “48 sets, 20 sets, 8 sets”. The table 84 is checked in descending order of section priority.

(2) Since the classification priority 1 in the combination table 84 is a set of (G01, G20) = (1: 2), the mounting candidate LED selection unit 160 determines that (G01, G20) = (1: 2). Check. In other words, the mounting candidate LED selection unit 160 searches the LED inventory information 82 to determine whether 48 sets of classification priority 1 exist in the LED inventory information 82. That is, it is searched whether there are 48 LEDs belonging to G01 and 96 LEDs belonging to G20 in the LED inventory information 82. If it exists, a corresponding number of LEDs are selected from the LED inventory information 82, and the search for the (1: 2) group is completed. When an LED is selected from the LED inventory information 82 in each category priority check, the selected number of LEDs is subtracted from the LED inventory information 82.

(3) If 48 groups can not be selected for the group with classification priority 1, for example, only 30 sets out of the 48 sets that are the required number of sets can be selected from the group with classification priority 1 It is. In this case, the mounting candidate LED selection unit 160 does not jump to the check (G06, G20 search) of the group priority 8 that is the next (1: 2) set in the combination table 84 (FIG. 12). Then, the processing shifts to the check of the set of (G02, G25) = (1: 1) with the division priority 2. That is, the selection of the remaining “18 sets” in the (1: 2) group is temporarily suspended, and the next group priority group in the combination table 84 is checked. In this way, for example, instead of continuously selecting (1: 2) sets of LEDs, the check is shifted from the top to the bottom row in the combination table 84 in the order of segment priority. . By such an operation, an LED that is desired to be used earlier in stock is selected (used) according to the division priority.

  The group priority level 2 is shifted to the group priority level 2 group (1: 1), (1: 1) is included in the row <1> of FIG. 11, and (1: 1) This is because the required number of sets “20 sets” is not selected. Note that if the group of classification priority 2 is (1: 3) and the group of classification priority 3 is (1: 1), (1: 3) does not exist in the row <1>. The candidate LED selection unit 160 jumps over the row with the division priority 2 and proceeds to check the row with the division priority 3.

(4) When the mounting candidate LED selection unit 160 starts the check of (G02, G25) = (1: 1) with the division priority 2, the LED selected by the check with the division priority 1 is subtracted. The LED stock information 82 is searched for whether 20 sets of (G02, G25) = (1: 1) can be selected. When 20 sets can be selected, the corresponding LED is subtracted from the LED inventory information 82, the (1: 1) group check is completed, and this time, the pending (1: 2) group is continued. The selection process is started.

  On the other hand, when 20 sets cannot be selected, the process shifts to the next check of the segment priority 3 in the combination table 84, and the partition priority of the combination table 84 is shifted downward.

(5) The mounting candidate LED selection unit 160 has LEDs satisfying the required number of sets “48 sets, 20 sets, 8 sets” of “1: 2, 1: 1, single” in the row <1>. Until selected, the partition priority in FIG. 12 is lowered and the check continues.

(6) Through the above processes (1) to (5), the mounting candidate LED selection unit 160 has the required number of sets “48 sets,“ 1: 2, 1: 1, single ”in the row <1>. For “20 sets, 8 sets”, selectable number of sets (A set, B set, C set) is selected from the LED inventory information 82.

The mounting candidate LED selection unit 160 shifts the check of the combination table 84 in FIG. 12 in order of the division priority from top to bottom, but sometimes exceeds the next division priority as described above. This is a case where it is not necessary to check the row of the division priority, and is a case like the following (A) and (B).
(A) This is a case where the necessary number of groups has already been selected. For example, in the process of checking the combination table 84, it is assumed that the required set number 48 of (1: 2) in the row <1> has already been selected in the check of the row with the division priority 1. Then, it is assumed that the mounting candidate LED selection unit 160 has finished checking the division priority 7, and the (1: 1) required set number 40 has not yet been selected. In this case, after the segment priority 7, the segment priority 8 is skipped, and the process shifts to (1: 1) check of the segment priority 9.
(B) This is a case where the comprehensive mounting pattern 120 does not have a set of the classification priorities in the combination table 84. That is, when row <1> is a set for “1: 2, 1: 1, single”, segment priority 2 is (1: 3), and segment priority 3 is (1: 1), Next to the division priority 1, it jumps to the division priority 3.

(Remember the selection results)
The mounting candidate LED selection unit 160 displays “1: 2, 1: 1, single” in the row <1>, “the necessary number of sets or the maximum number of sets close to the number of necessary sets” (number of selectable sets). Is selected from the LED inventory, the information is stored. For example, for the required number of sets 48 of (1: 2), 30 sets are selected at the division priority 1 of the combination table 84, 10 sets are selected at the division priority 8, and eventually 40 sets are selected, and (1: 1) For the required number of groups 40, 20 sets are selected in the combination table 84 for the division priority 2 and 15 sets for the division priority 3 and 5 sets for the division priority 4 (FIG. 5). When three items are selected with the division priority 91, these selection results are stored.

(Check each set of “1: 2, 1: 1, single” for row <2>)
For the required number of sets “43 sets, 5 sets, 13 sets” in the row <2> in FIG. 12, the mounting candidate LED selection unit 160 performs the same process as in the row <1>. The mounting candidate LED selection unit 160 returns the state of the LED stock information 82 to the current stock state when the processing of the previous row <1> is completed. That is, the mounting candidate LED selection unit 160 returns the LED inventory information 82 to the current inventory state every time processing of each row of the comprehensive mounting pattern 120 is completed.

  Thereafter, similarly, the mounting candidate LED selection unit 160 checks up to the row <532> of the total mounting pattern 120. In this case, the LED stock information 82 is the same for every row. By the selection processing of the necessary number of sets for the rows <1> to <532> in FIG. 12 by the mounting candidate LED selection unit 160, “1: 2, 1: 1” for each row (mounting pattern) of the total mounting pattern 120. , “Single”, the number of selectable sets “A, B, C” (FIG. 12) is selected from the stock.

(Breakdown of production volume)
Next, with reference to FIGS. 13 and 14, the process of calculating the production rate of each model from the number of selectable sets “A, B, C” and calculating the production rate will be described. When the number of selectable sets is calculated for each row of the comprehensive mounting pattern 120, the mounting candidate LED selection unit 160 calculates the total number of models produced from the number of selectable sets as follows.

  A description will be given taking the line <1> of the integrated mounting pattern 120 as an example. In the following description, the required number of sets in the row <1> is “1: 2, 1: 1, single” = “48 sets, 0 sets, 8 sets”, and the necessary number of sets is actually out of stock. The number of selectable sets selected is “40 sets, 0 sets, 8 sets”.

  FIG. 13 is a diagram illustrating a process in which the total production number of models for the row <1> is calculated by the mounting candidate LED selection unit 160. With reference to FIG. 13, a description will be given of a process in which the mounting candidate LED selection unit 160 calculates the number of units produced for each model (breakdown of production units) and the total number of units produced for model <1>. The mounting candidate LED selection unit 160 selects each mounting pattern table of (a), (b), and (c) of FIG. 13 based on the selectable set number “40 sets, 0 sets, 8 sets” in the row <1>. Referring to FIG. 4, the selectable set number “40 sets” is returned to the number of models as follows. The mounting candidate LED selection unit 160 first produces the planned number of productions in the order of 4 lamps, 6 lamps, and 12 lamps for the selectable set number “40, 0, 8” of “1: 2 combination”. Check if it can be done.

(S01; 4 lamp models)
That is, it can be read that the 4-lamp mounting pattern table 104 in (a) indicates the number of sets such as “1: 2 combination” necessary for one 4-lamp model. The same applies to (b) and (c). Therefore, for "1: 2 combination", in order to produce 8 of the planned number,
1 (set / unit) × 8 (unit) = 8 sets are required.
The selectable set number of “1: 2 combination” is “40 sets”. Therefore,
40 (set) -8 (set) = 32 sets> 0
For the four-lamp model, eight of the planned number can be produced for the “1: 2 combination”.

(S02; 6-light model)
Next, the mounting candidate LED selection unit 160 confirms whether the planned number of 10 units can be produced for the 6-lamp model as seen from the “1: 2 combination” as in the case of the 4-lamp model. That is, the current selectable set number is “32 sets” (8 sets consumed for 4 lights). In addition, in order to produce 10 planned units for “1: 2 combination”,
2 (sets / units) × 10 (units) = 20 sets are required. Therefore,
32 (set)-20 (set) = 12 sets> 0
For the 6-lamp model, 10 units can be produced for the “1: 2 combination”.

(S03; 12-lamp model)
Finally, the mounting candidate LED selection unit 160 confirms whether or not five of the planned number can be produced for the 12 lamp models as seen from the “1: 2 combination” as in the case of the 6 lamp models. That is, the number of currently selectable sets is “12 sets” (of 40 sets, 8 sets for 4 lights and 20 sets for 6 lights are consumed). In order to produce the planned number of 5 for “1: 2 combination”,
4 (sets / units) × 5 (units) = 20 sets are required. Therefore,
12 (set) -20 (set) =-8 sets <0
It becomes. Therefore, the mounting candidate LED selection unit 160 determines that the planned number of five cannot be produced. And
From the current number of units 12 (sets) ÷ 4 (sets / units) = 3 units, it is determined that 3 units out of the planned number of units can be produced.

(S04: Breakdown of production volume)
With the above processing, the mounting candidate LED selection unit 160 satisfies the necessary number of sets for “1: 1 combination” and “single”, so the number of selectable sets of “1: 2 combination” is a bottleneck. Thus, it is determined that “8 units, 10 units, 3 units” can actually be produced for each model of “4 lights, 6 lights, 12 lights”.

(Calculation of total production)
The mounting candidate LED selection unit 160 is the total of the breakdown of the production number.
From 8 units + 10 units + 3 units = 21 units, 21 units that are total production units are calculated.

(Calculation of production rate)
The mounting candidate LED selection unit 160 determines the production ratio (21 units / unit) from 23 units, which is the total of the planned number of each model of “4 lights, 6 lights, 12 lights” and the total production number of 21 units. 23 units) × 100% = 91% (FIGS. 12 and 13).

(About row <2>)
Next, with regard to the line <2>, a process for calculating the breakdown of the number of production etc. will be described with reference to FIG.
FIG. 14 is a diagram showing a process in which the total number of models produced for the row <2> is calculated by the mounting candidate LED selection unit 160. The number of necessary sets in the row <2> is “1: 2, 1: 1”. , Alone ”=“ 43 sets, 5 sets, 13 sets ”. For this required number of sets, the number of selectable sets actually selected from the inventory is “40 sets, 3 sets, 13 sets”. That is, it is assumed that the combination of (1: 2) and (1: 1) is less than the required number of sets.

The mounting candidate LED selection unit 160 performs a process of calculating a possible production number in the same manner as in the case of the row <1> in FIG. That is, regarding “1: 2 combination”, as shown in FIG.
A total of 43 sets of 8 sets + 20 sets + 15 sets = 43 sets are required. For 12 lamp models,
Because there are only 40 sets-28 sets = 12 sets,
Only 12 sets ÷ 3 (sets / unit) = 4 units can be produced. Therefore, for “1: 2 combination”, it is calculated that “8 units, 10 units, 4 units” can be produced for each model of “4 lamps, 6 lamps, 12 lamps”, and 22 units can be produced in total.

Regarding the “1: 1 combination”, as shown in FIG. 14, only 5 sets are required for the 12-lamp model. On the other hand, since there are only 3 sets of “1: 1 combinations”,
Only 3 sets ÷ 1 (set / unit) = 3 units can be produced. Therefore, for "1: 1 combinations"
It is calculated that “8 units, 10 units, 3 units” can be produced for each model of “4 lamps, 6 lamps, 12 lamps”, and a total of 21 units can be manufactured. Therefore, as shown in FIG. 14, the number of units produced in the models “4 lights, 6 lights, 12 lights” is a selectable set of “1: 1 combination” rather than the selectable set number of “1: 2 combination”. The number becomes the bottleneck, becoming “8 units, 10 units, 3 units”, and a total of 21 units can be produced. Therefore, the production rate is
(21 units / 23 units) x 100% = 91%
It becomes.

  Similarly, the same processing is performed for the rows <3> to <532>. In the above description, the breakdown of the number of production, the total number of production, the production rate, etc. are calculated based on the number of selectable sets for each row selection process. First, rows <1> to <532> It is also possible to calculate the number of selectable sets for each, and then calculate the breakdown of the number of production, the total number of production, the production rate, etc. for each row.

(Production priority)
(1) The model production plan information 81 input from the server 8 includes the production priority of production (priority different from the division priority in the combination table 84) in addition to the number of models to be produced. In this example, the model production plan information 81 is
It is assumed that production priorities in the order of 4 lamps> 6 lamps> 12 lamps are included. The production of 4 LED modules is given the highest priority, followed by 6 lights, and the production priority of 12 lights is the lowest. In this case, the computer 10 (LED usage determining 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 production priority are used. The number of units (MAX 8 units) that can be produced is determined based on the inventory LEDs indicated by the LED inventory information 82, then 6 lamps (MAX 10 units) and finally 12 lamps (MAX 5 units) are determined. In FIGS. 13 and 14, the number of selectable sets was confirmed in the order of (a) 4-lamp model, (b) 6-lamp model, and (c) 12-lamp model.
When the production priority is given in the order of 4 lamps> 6 lamps> 12 lamps, the number of selectable sets is confirmed in this order. If the production priority is given in the order of 12 lamps> 6 lamps> 4 lamps, in FIGS. 13 and 14, (c) 12 lamp models, (b) 6 lamp models, (a) 4 lamp models. The number of selectable sets will be confirmed in order. When the production priority is not given, the confirmation order of FIGS. 13 and 14 (a), (b), and (c) may be arbitrary, for example, default setting may be used.

(Output of results)
FIGS. 15 and 16 are diagrams showing different types of output result tables 121 </ b> A and 121 </ b> B output by the LED usage determining unit 170 (result output unit) of the computer 10. 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% ), Output results including the number of production and the breakdown of production can be output. The output result output from the LED usage determination unit 170 includes “selectable set number, breakdown of production number, production number, production rate” and selectable set corresponding to each mounting pattern of the total mounting pattern 120 shown in FIG. Information on the segment priority used to select the number (described later) and the like can be included.

(Output result table 121A)
FIG. 15 is a diagram including a mounting pattern that can produce a total of 23 LED modules, that is, 8 of 4 lights, 10 of 6 lights, and 5 of 12 lights. The mounting pattern <1> in the output result table 121A of FIG. 15 has a production rate of 100%, and this indicates that 23 of the 23 units to be produced can be produced with the LEDs in stock. The mounting pattern <2> is also 100%. 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. However, as shown in FIG. 15, when there are a plurality of mounting patterns having a production rate of 100%, a mounting pattern having a higher category priority is selected from the category priorities set in the combination table 84. In the case of FIG. 15, it is assumed that only the mounting patterns <1> and <2> (referred to as row <1>) are 100%. In this case, looking at the “used segment priority”, the row <1> uses the segment priorities 1, 8, and 90. Row <2> uses segment priority 1, 2, 8, 90. The row <2> is a mounting pattern having a high category priority in that the category priority 2 is used for the row <1>. Therefore, the LED usage determination unit 170 selects the row <2> among the rows <1> and <2>, and selects the row <2> when producing a total of 23 units of 4, 6, and 12 lights. It is determined that a total of 23 LEDs should be produced with the LEDs belonging to the division priority corresponding to the selectable set number and the selectable set number in the selection process.

(Output result table 121B)
FIG. 16 shows an output result table 121B when the contents are different from the output result table 121A of FIG. The computer 10 (LED usage determining unit 170) outputs the information in FIG. 16, and the user can select a desired mounting pattern from the output result table 121B 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. 16, the production rates of the mounting patterns <1> to <3> are 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. 16, the computer 10 (LED use 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). Further, as a rule set in advance, as described in the output result table 121A of FIG. 15, when there are a plurality of the same ratios, a higher segment priority is used among the segment priorities used for selecting the number of selectable sets. You may make it select the mounting pattern of the selectable set number used.

  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). “Deployment” means that when the computer 10 selects, for example, the mounting pattern <2> in FIG. 16, 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. The LEDs selected in the distribution are naturally individual LEDs selected according to the division priority.

  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. That is, when the computer 10 selects the mounting pattern <2> in FIG. 16, the number of 12 lights is insufficient. 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. 17 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, calculates the number of selectable sets for each mounting pattern, breaks down the production number of each model that can be produced from the number of selectable sets, and total production Calculate the number of units and the production rate. Then, the LED use determination unit 170 uses the calculation results of the mounting candidate LED selection unit 160, the comprehensive mounting pattern 120, the LED inventory information 82, the combination information 84, and the like to output result tables 121A and 121B (FIGS. 15 and 16). ) Is generated and output.

In this way, by finding the optimal LED mounting pattern for the entire model that you want to produce, select the combination of LEDs based on the priority such as the division priority and the production priority, and deploy to each production model. As a result, the LED inventory in the production plant can be reduced. In particular, by using the division priority, since it is possible to use the LED that is desired to be used earlier among the stock LEDs, the LED can be used efficiently. Therefore, it is possible to reduce the number of LEDs that are disposed of by reducing the unevenness of the number of LEDs in each chromaticity range and averaging the LEDs in stock, and CO ₂ emissions by reducing the number of LEDs that are disposed The amount 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 selection program.

In the present embodiment, the model production plan information 81 is
Although the case where the priority of the order of 4 lights> 6 lights> 12 lights was included was explained,
When giving priority to combinations that use a large number of LEDs,
The order of priority of 12 lamps> 6 lamps> 4 lamps may be included, and there are a plurality of models with the same number of lamps (for example, a model using four LEDs, and the shape of the lighting fixture A and the shape of the lighting fixture B are different. (If different)
The priority of the order of 4 lights (lighting fixture A)> 6 lights> 4 lights (lighting fixture B)> 12 lights may be included.

  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.

Claims (6)

A plurality of LED numbers information indicating the number of LEDs mounted on the LED module and module chromaticity information indicating the chromaticity range to which the combined light by the mounted number of LEDs indicated by the LED number information belongs Production module information storage unit for storing a plurality of model information having the same chromaticity range indicated by the module chromaticity information, with the mounting number indicated by the LED number information being different,
A combination of LEDs belonging to different chromaticity ranges, wherein a number ratio between the number of LEDs belonging to a specific chromaticity range and the number of LEDs belonging to another chromaticity range is set, and the number ratio LED combined information including a plurality of combination patterns to which the combined light of the plurality of LEDs indicates different combinations of LEDs having chromaticities belonging to the chromaticity range indicated by the module chromaticity information and is given priority is stored. An LED combination information storage unit;
The inventory number of LEDs belonging to each chromaticity range of the specific chromaticity range and the other chromaticity range indicated by each combination pattern included in the LED combination information stored in the LED combination information storage unit is registered. LED stock information storage unit for storing the LED stock information that has been made,
Select at least one model information from the plurality of model information stored in the production module information storage unit, input the number of LED modules produced for all the selected model information, and selected Based on the model information, the input number of LED modules produced, and the LED combination information stored in the LED combination information storage unit, all of the selected model information regarding the LED modules are input. The number of LEDs that can be produced and the emission color of the LED module of the model information to be produced belongs to the chromaticity range indicated by the module chromaticity information in the model information. Multiple mounting patterns are calculated, and a comprehensive mounting pattern consisting of the calculated mounting patterns is generated. For each mounting pattern of the integrated mounting pattern, the LED combination information is stored by referring to the LED combination information stored in the LED combination information storage unit and the LED inventory information stored in the LED inventory information storage unit. The number of LEDs that can be produced from the inventory LEDs corresponding to the combination pattern having higher priority among the combination patterns included in the number of LEDs that can be produced is indicated and produced. A light-emitting color of the LED module in the model information belongs to a chromaticity range indicated by the module chromaticity information in the model information; and a selection unit that selects a selectable pattern corresponding to the mounting pattern. LED selection device characterized by this. The selection unit includes:
The model information selected by the mounting candidate LED selection unit from the selectable patterns generated for each mounting pattern of the total mounting pattern, the input production number, and the LED combination information storage unit store the model information. The LED selection device according to claim 1, wherein a production possibility ratio indicating a ratio of the number of units that can be actually produced to the number of productions input by the mounting candidate LED selection unit is calculated based on combination information. The LED selection device further includes:
In the case where there are a plurality of ones with the same ratio among the production ratios calculated for each of the selectable patterns calculated by the selection unit, the same ratios based on the classification priorities from which the selectable patterns are selected. The LED selection device according to claim 2, further comprising: a result output unit that specifies one of the selectable patterns and outputs the specified selectable pattern. The selection unit includes:
2. When selecting the model information from a plurality of the model information stored in the production module information storage unit, two or more model information is selected. 4. The LED selection device according to any one of 3. Computer
A plurality of LED numbers information indicating the number of LEDs mounted on the LED module and module chromaticity information indicating the chromaticity range to which the combined light by the mounted number of LEDs indicated by the LED number information belongs Production module information storage unit for storing a plurality of pieces of model information having the same chromaticity range indicated by the module chromaticity information, with the mounted number indicated by the LED number information being different.
A combination of LEDs belonging to different chromaticity ranges, wherein a number ratio between the number of LEDs belonging to a specific chromaticity range and the number of LEDs belonging to another chromaticity range is set, and the number ratio LED combined information including a plurality of combination patterns to which the combined light of the plurality of LEDs indicates different combinations of LEDs having chromaticities belonging to the chromaticity range indicated by the module chromaticity information and is given priority is stored. LED combination information storage unit,
The inventory number of LEDs belonging to each chromaticity range of the specific chromaticity range and the other chromaticity range indicated by each combination pattern included in the LED combination information stored in the LED combination information storage unit is registered. LED inventory information storage unit for storing the LED inventory information
Select at least one model information from the plurality of model information stored in the production module information storage unit, input the number of LED modules produced for all the selected model information, and selected Based on the model information, the input number of LED modules produced, and the LED combination information stored in the LED combination information storage unit, all of the selected model information regarding the LED modules are input. The number of LEDs that can be produced and the emission color of the LED module of the model information to be produced belongs to the chromaticity range indicated by the module chromaticity information in the model information. Multiple mounting patterns are calculated, and a comprehensive mounting pattern consisting of the calculated mounting patterns is generated. For each mounting pattern of the integrated mounting pattern, the LED combination information is stored by referring to the LED combination information stored in the LED combination information storage unit and the LED inventory information stored in the LED inventory information storage unit. The number of LEDs that can be produced from the inventory LEDs corresponding to the combination pattern having higher priority among the combination patterns included in the number of LEDs that can be produced is indicated and produced. A selection unit that selects a selectable pattern corresponding to the mounting pattern, in which the emission color of the LED module of the model information belongs to the chromaticity range indicated by the module chromaticity information in the model information;
LED selection program to function as An LED selection method performed by an LED selection device,
The production module information storage unit
A plurality of LED numbers information indicating the number of LEDs mounted on the LED module and module chromaticity information indicating the chromaticity range to which the combined light by the mounted number of LEDs indicated by the LED number information belongs A plurality of pieces of model information having the same chromaticity range indicated by the module chromaticity information, and the mounting number indicated by the LED number information is different;
LED combination information storage unit
A combination of LEDs belonging to different chromaticity ranges, wherein a number ratio between the number of LEDs belonging to a specific chromaticity range and the number of LEDs belonging to another chromaticity range is set, and the number ratio LED combined information including a plurality of combination patterns to which the combined light of the plurality of LEDs indicates different combinations of LEDs whose chromaticities belong to the chromaticity range indicated by the module chromaticity information and is given priority is stored. ,
LED inventory information storage unit
The inventory number of LEDs belonging to each chromaticity range of the specific chromaticity range and the other chromaticity range indicated by each combination pattern included in the LED combination information stored in the LED combination information storage unit is registered. Stored LED inventory information,
The selection part
Select at least one model information from the plurality of model information stored in the production module information storage unit, input the number of LED modules produced for all the selected model information, and selected Based on the model information, the input number of LED modules produced, and the LED combination information stored in the LED combination information storage unit, all of the selected model information regarding the LED modules are input. The number of LEDs that can be produced and the emission color of the LED module of the model information to be produced belongs to the chromaticity range indicated by the module chromaticity information in the model information. Multiple mounting patterns are calculated, and a comprehensive mounting pattern consisting of the calculated mounting patterns is generated. For each mounting pattern of the integrated mounting pattern, the LED combination information is stored by referring to the LED combination information stored in the LED combination information storage unit and the LED inventory information stored in the LED inventory information storage unit. The number of LEDs that can be produced from the inventory LEDs corresponding to the combination pattern having higher priority among the combination patterns included in the number of LEDs that can be produced is indicated and produced. LED selection characterized by selecting a selectable pattern corresponding to the mounting pattern in which the emission color of the LED module of the model information belongs to the chromaticity range indicated by the module chromaticity information in the model information Method.