TW201505751A - An automated manufacture system of LED lamp - Google Patents

Abstract

An automated manufacture system of LED lamp is provided. The system comprises an automated assembly mechanism, an automated aging mechanism connected with the automated assembly mechanism, an automated detection device connected with the automated aging mechanism, an automated packaging device connected with the automated detection device, an automated transport device connected with the automated packaging device, and a master control unit connecting the automated assembly mechanism, the automated aging mechanism, the automated detection device, the automated packaging device and the automated transport device. The automated assembly mechanism sequentially comprises a conductive lamp holder, a working station for automatically assembling lamp sockets, a working station for assembling radiators, a working station for bonding wires and a working station for detecting energization. By the automated design of each process, the manpower cost is substantially reduced, and the production efficiency is improved.

Description

LED lamp intelligent production system

The invention relates to the field of production of LED lamps, in particular to the structure of a smart production system for LED lamps.

LED lamps are a new type of energy-saving and environment-friendly products, and countries around the world have designated legislation to replace traditional incandescent lamps.

The LED lamp has low working voltage, adopts DC drive mode, ultra-low power consumption, and the electro-optical power conversion is close to 100%. Compared with the traditional light source, the LED lamp can save more than 80% energy. The LED lamp uses cold light source to make the glare small, LED lamp Better environmental protection, no ultraviolet and infrared rays in the spectrum, no harmful substances in use, waste can be recycled, no pollution, no mercury, safe to touch, is a typical green lighting source, LED lamps are solid cold Light source, epoxy resin package, anti-vibration, no loose parts in the lamp body, no shortcomings such as filament light-emitting, heat deposition, light decay, etc. The service life can reach 60,000 to 100,000 hours, which is the service life of traditional light source. More than 10 times, LED lamps have stable performance and can work normally under low temperature and high temperature environment.

However, compared with the traditional incandescent lamp, the structure of the LED lamp is more complicated. In the prior art production, most of the traditional manual work is performed, one is that there are many process steps and the efficiency is low; the second is that the labor cost is high, resulting in high product price. Third, the consistency of the product is difficult to control. It is not difficult to see that the prior art still has certain defects.

It has been known that various inconvenient problems have been made. In order to provide articles that are more in line with actual needs, the inventors have conducted research and development to solve the problems that are easily caused by conventional use.

The main object of the present invention is to provide a smart production system for LED lamps, which saves labor costs, improves production efficiency, and realizes the utility of fully automated production.

In order to achieve the above object, the structure of the present invention is: including for use outside the lamp cap An automatic assembly mechanism for assembling a lamp, a lamp body, a heat-conductive and insulating double-sided tape, a light source plate and a lamp cover into a semi-finished product of the LED lamp; and an automatic assembly mechanism for placing the semi-finished product of the LED lamp obtained from the automatic assembly mechanism on the carrier An automatic aging mechanism for performing aging detection; and an automatic detecting device connected to the automatic aging mechanism for detecting the performance of the semi-finished product of the LED luminaire obtained from the automatic aging mechanism; and an automatic detecting device connected to the automatic detecting device An automatic packaging device for automatically packaging the obtained LED lamp qualified product; and an automatic transportation device connected to the automatic packaging device for transporting the product obtained by the automatic packaging device to the warehouse; and connecting the automatic assembly mechanism and the automatic aging mechanism , automatic detection device, automatic packaging device and automatic control unit of the total control unit.

Further, the automatic assembly mechanism is provided with a frame, the frame is provided with a guide rail, and the movement clamp is disposed on the guide rail.

Further, the automatic assembly mechanism along the guide rail sequentially comprises: a lamp body upper line device, a lamp cap loading device, an electric board loading device, a cable management device, a bending and pressing device, a lamp cap outer device, a glue coating device, Light source panel assembly device, circuit soldering device, and lampshade assembly device.

Further, each device corresponds to a corresponding robot.

Further, the guide rail comprises: a first curved guide rail, a second curved guide rail, a first linear guide rail, and a second linear guide rail, wherein the first curved guide rail and the second curved guide rail are disposed opposite each other; the first linear guide rail and the second linear guide rail The linear guides are arranged in parallel; one end of the first linear guide is connected to one end of the first curved guide rail, and the other end of the first linear guide is connected to one end of the second curved guide; one end of the second linear guide and the first The other end of an arcuate rail is connected, and the other end of the second linear rail is connected to the other end of the second arcuate rail.

Further, the LED luminaire semi-finished product obtained by the automatic assembly mechanism is transported to the automatic aging mechanism by a robot.

Further, the automatic detecting device includes a tenth robot, an eleventh robot, an integrating sphere, a voltage detecting unit, a current detecting unit, a communication detecting unit, a control circuit detecting unit, a sensor detecting unit, and a motor driving detecting unit. And the detecting machine; the voltage detecting unit, the current detecting unit, the communication detecting unit, the control circuit detecting unit, the sensor detecting unit and the motor driving detecting unit are respectively connected to the detecting machine.

Further, the automatic packaging device comprises: a lamp automatic packaging machine and an automatic a cartoning machine for automatically packaging the qualified products of the LED lamps obtained by the automatic detecting device; the automatic cartoning machine is used for passing the LED lamps packaged by the automatic packaging machine of the lamp The product is packed.

Further, the automatic packaging device further includes: an automatic boxing robot for placing the packaged LED lamp qualified product into a box on the automatic cartoning machine; the automatic transportation device is provided with an automatic a transport vehicle, the automatic transport vehicle is provided with a shelf; the LED light fixture intelligent production system further comprises: a dispensing device, configured to stack the products obtained by the automatic packaging device onto the shelf; the stacking and stacking product The rear shelves are transported to the warehouse by automated transport.

The intelligent production system and the working method of the LED lamp of the invention can save labor cost and improve production efficiency by automatically designing each process.

54‧‧‧ lamp coat

55‧‧‧ lamp holder

56‧‧‧Light body

57‧‧‧thermal insulating double-sided tape

58‧‧‧Light source board

59‧‧‧shade

5‧‧‧Automatic assembly mechanism

42‧‧‧Aging access station

4‧‧‧Automatic aging mechanism

2‧‧‧Automatic detection device

1‧‧‧Automatic packaging device

3‧‧‧Automatic transport device

50‧‧‧rails

52‧‧‧Mobile fixture

51‧‧‧Rack

53‧‧‧ Robot

43‧‧‧Transmission orbit

41‧‧‧ Shelf

40‧‧‧ eighth manipulator

22‧‧‧Eleventh Robot

21‧‧‧10th manipulator

20‧‧·score ball

23‧‧‧Voltage detection unit

30‧‧‧Transportation vehicle

31‧‧‧ Shelf

In order to enable the reviewing committee to better understand the techniques, means, and effects of the present invention in order to achieve the intended purpose, the preferred embodiments of the present invention will be described in detail with reference to the drawings. And the advantages, when you can get a deep and specific understanding.

In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings used in the embodiments or the description of the prior art will be briefly described below. Obviously, the drawings in the following description are only Some embodiments of the invention may also be used to obtain other figures from these figures without departing from the art.

The first figure is an exploded perspective view of the LED lamp of the present invention.

The second figure is a perspective view of the present invention.

The third figure is an exploded perspective view of the automatic assembly mechanism of the present invention.

The fourth figure is a perspective view of the automatic aging mechanism in the second drawing of the present invention.

Figure 5 is a perspective view of the automatic detecting device of the present invention.

Figure 6 is a top plan view showing the implementation of the automatic transport device of the present invention.

In order to make the objects, technical solutions and advantages of the embodiments of the present invention more clear, the following The technical solutions in the embodiments of the present invention will be clearly and completely described in conjunction with the embodiments of the present invention and the accompanying drawings. It should be noted that the described embodiments are only a part of the embodiments of the invention, and not all of the embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative efforts are within the scope of the present invention.

As shown in the first to sixth figures, the smart production system of the LED lamp of the present invention comprises a lamp cap casing 54, a lamp cap 55, a lamp body 56, a thermally conductive insulating double-sided tape 57, a light source plate 58, and a lampshade 59. The automatic assembly mechanism 5 assembled into the semi-finished product of the LED lamp, and the automatic aging mechanism 4 for connecting the semi-finished LED lamp obtained from the automatic assembly mechanism 5 to the aging access station 42 for aging detection is connected with the automatic assembly mechanism 5. And an automatic detecting device 2 connected to the automatic aging mechanism 4 for detecting the performance of the semi-finished product of the LED lamp obtained from the automatic aging mechanism 4, and an LED connected to the automatic detecting device 2 for obtaining the LED obtained from the automatic detecting device 2. The automatic packaging device 1 for automatic packaging of the luminaire qualified product, and the automatic transportation device 3 connected to the automatic packaging device 1 for transporting the product obtained by the automatic packaging device 1 to the warehouse, and connecting the automatic assembly mechanism 5, automatic The aging mechanism 4, the automatic detecting device 2, the automatic packaging device 1, and the total control unit (not shown) of the automatic transport device 3.

The automatic assembly mechanism 5 is provided with a frame 51 on which a guide rail 50 is disposed, and a movement clamp 52 is disposed on the guide rail 50.

Preferably, the automatic assembly mechanism 5 along the direction of the guide rail 50 includes: a lamp body upper line device, a lamp cap loading device, an electric board loading device, a cable management device, a bending line device, a lamp cap outer device, and a glue coating device. Device, light source panel assembly device, circuit soldering device, and lampshade assembly device. It should be noted that each of the above devices is equivalent to a workstation for assembling and completing the LED lamp. The moving jig 52 starts from the lamp body uppering device, and sequentially passes through the lamp body upper device and the lamp cap along the direction of the guide rail 50. The loading device, the electric board loading device, the cable management device, the bending line device, the lamp cap outer device, the glue applicator device, the light source panel assembly device, the circuit soldering device and the lampshade assembly device finally complete the assembly of the LED lamp.

Preferably, each device corresponds to a corresponding robot, and since the shape and size of the raw materials of each process and the work to be performed are different, the embodiment is preferably provided for each device. A robot corresponding to it.

The lamp body uppering device is configured to pass the robot on the wire uppering device 53 The lamp body 56 is placed on the moving jig 52, and the moving jig 52 with the lamp body 56 is moved to the cap loading device; the cap loading device is used to pass the cap 55 through the manipulator on the cap loading device. Mounted to the lamp body 56 on the moving jig 52, and thus the moving jig 52 is moved to the electric board loading device; the electric board loading device is used to electrically connect the manipulator through the electric board The plate is loaded into the semi-finished product on the moving fixture 52 moved from the lamp cap loading device, and the moving jig 52 is moved to the wire management device; the wire management device is used to pass the robot on the cable management device Straightening the wires on the electrical board, and moving the clamp 52 to the bending line device; bending the line device for conducting the wires on the electrical board by a robot on the bending line device The bending is performed, and then the moving jig 52 is moved to the cap outer casing; the cap outer fitting device is used for loading the cap 54 onto the cap 55 through the manipulator on the cap outer fitting device, and the cap 54 is attached. get on Tightly, the wire protruding from the base 54 is cut off, and the base is further pressed into the base 55, and the moving clamp 52 is moved to the coating device; the glue application is used to pass the glue coating device. The robot applies a thermal conductive adhesive on the lamp body 56 (such as the thermal conductive insulating double-sided adhesive 57 shown in the first figure), and then moves the clamp 52 to the light source panel assembly device; the light source panel assembly device is used to pass the light source panel assembly device. The upper robot assembles the light source panel 58 onto the lamp body 56, and fixes the light source panel 58 to move the clamp 52 to the circuit soldering device; the circuit soldering device for mechanically passing the soldering device Hand soldering the light source panel 58 and the poles on the electrical board to electrically connect the light source panel 58 and the electrical panel, thereby moving the clamp 52 to the shade assembly device; the shade assembly device for passing the shade The robot on the assembly device assembles the lamp cover 59 to the lamp body 56, including the lamp cover 59 adhesive and the lamp cover 59; thus a preliminary LED lamp (because it has not undergone aging, quality inspection, etc.) LED lamps can be referred to the initial semifinished product LED lamps) have been assembled.

It should be noted that the guide rail may be linear or other shapes to conform to the movement of the moving clamp 52. Preferably, the embodiment adopts a guide rail, and the guide rail includes: a first curved guide rail. a second curved guide rail, a first linear guide rail, a second linear guide rail, the first curved guide rail and the second curved guide rail are disposed opposite to each other; the first linear guide rail is disposed in parallel with the second linear guide rail; one end of the first linear guide rail is first One end of the curved guide rail is connected, the other end of the first linear guide is connected to one end of the second curved guide rail; one end of the second linear guide is connected to the other end of the first curved guide rail, The other end of the two linear guides is connected to the other end of the second curved rail. Adopting the above-mentioned guide rail, the structure is simple and practical, and its ring shape The design can also be designed with multiple straight edges according to the characteristics of the factory building, thereby avoiding the shortage of the structure such as the rotating disc assembly line and the space utilization rate is not high, thereby improving the production operation efficiency; at the same time, saving energy, cost.

Preferably, the LED lamp semi-finished product obtained by the automatic assembly mechanism 5 is transferred to the automatic aging mechanism 4 by a robot, and the LED lamp semi-finished product is subjected to aging operation, and the unqualified LED lamp semi-finished product is rejected.

Preferably, the automatic aging mechanism 44 is provided with a flow-through transport track 43 and an aging access station 42 connected to the transfer track 43; the aging access station 42 includes two rows of oppositely disposed shelves 41, and An eighth robot 40 disposed in the middle of the shelf 41.

The automatic detecting device 2 includes a tenth robot 21, an eleventh robot 22, an integrating sphere 20, a voltage detecting unit 23, a current detecting unit (not shown), a communication detecting unit (not shown), and a control circuit detecting a unit (not shown), a sensor detecting unit (not shown), and a motor drive detecting unit (not shown); the voltage detecting unit, the current detecting unit, the communication detecting unit, the control circuit detecting unit, and the sensor The detecting unit and the motor drive detecting unit are respectively connected to a detecting machine (not shown).

After the semi-finished products of the LED lamp are tested by the above-mentioned aging, automatic detection, etc., the final finished LED lamp (ie, a semi-finished LED lamp after a series of tests) is passed, and then the final LED lamp needs to be packaged. And transported to the warehouse and finally shipped.

Preferably, the automatic packaging device 1 comprises: a lamp automatic packaging machine and an automatic cartoning machine, wherein the lamp automatic packaging machine is used for automatically packaging the LED lamp qualified products obtained by the automatic detecting device 2 (ie, for a single package) The LED lamp is packaged, and the qualified product of the LED lamp is loaded into the packaging box); the automatic cartoning machine is used for packing the qualified products of the LED lamp packaged by the automatic packaging machine of the lamp (ie, a plurality of LEDs are installed) The box of the qualified product of the lamp is loaded into the package). Preferably, the automatic packaging device 1 further comprises: an automatic packing robot for placing the packaged LED lamp qualified product into the box on the automatic cartoning machine. The packaged LED luminaire qualified product needs to be stored, that is, the package is stored in the warehouse by the automatic transport device 3 provided in this embodiment.

Preferably, the automatic transport device arrangement 3 has an automatic transport vehicle 30 on which a shelf 31 is disposed.

Preferably, the LED lamp intelligent production system further comprises: a dispensing device for stacking the product obtained by the automatic packaging device 1 (ie, a package containing the qualified products of the LED lamp) onto the shelf 31 The shelves after the stacked products are transported to the warehouse by the automated transport vehicle 30.

The working method of the intelligent production system of the LED lamp comprises the following steps: 1) firstly adopting an automatic assembly mechanism for the lamp cap 54 of the LED lamp, the lamp cap 55, the lamp body 56, the heat conductive insulating double-sided tape 57, the light source plate 58, and the lamp cover 59. 5 assembled into a semi-finished product of the LED lamp, and then the semi-finished product of the LED lamp is fixedly mounted on the guide rail 50 by the moving clamp 52 and advanced to the transfer track 43 of the automatic aging mechanism 4 at a certain speed; 2), the eighth robot 40 automatically takes the semi-finished product of the LED lamp together The carrier moves away from the transport track 43 and carries it to a corresponding position on the shelf 41. The eighth robot 40 moves simultaneously in the horizontal direction and the vertical direction during the transport process, and the LED light fixture semi-finished product together with the transport track 43 Statically placed on the shelf 41, the electric aging operation is performed in the automatic aging mechanism 4, and the automatic aging mechanism 4 is an indispensable part in all production lines, and its existence can timely find problems in the semi-finished products of the LED lamps. ; 3), after the aging of the semi-finished products, the tenth robot 21 automatically grabs two LED lamps and semi-finished products from the assembly line and puts them into the automatic detection device. On the top, it must be operated at normal temperature and normal pressure for 10 minutes before being tested, and then placed on the automatic detection device to perform integration detection of the ball, voltage, current, communication, control circuit, sensor and motor drive. The function of this line segment is controlled and connected with the total control unit to achieve orderly integration. The line of the integrating sphere is used to detect the luminous flux, color temperature, color rendering index, wavelength and color coordinates of the LED lamp semi-finished product. Alarm on the control system, and display the cause of the fault, and then the eleventh robot 22 steps in 4.8 seconds / beat, each time the speed automatically removes the defective product, the qualified LED lamp semi-finished product flows into the next process, LED The quality of the semi-finished products of the luminaire depends on whether the automatic detecting device 2 can effectively detect it; 4) After the testing, the individual products are packaged and then sent to the spare box position through the automatic packaging device 1 The automatic packing robot is layer-by-layer and automatically sealed and bundled. The bundled box is automatically sent to the standby rack for transportation. It can be packed well. The product is modified and effectively protected during transportation and is not damaged by external force; 5) when the package is filled by the automatic transport vehicle 30 in the automatic transport device 3 31 Follow the pre The fixed line is sent to the warehouse (not shown), and the automatic transport device 3 transfers the finished product, which saves storage space, and replaces the traditional manual transportation, saving labor resource costs.

In the step 2), the total control unit analyzes the aging result generated by the automatic aging mechanism 4, automatically forms an archive file for the defective product, and prints the mark.

In step 3), the qualified product forms a classification instruction according to the light, color and electric parameter indexes of the total control unit, and automatically performs the division.

The intelligent production system of the LED lamp of the invention greatly saves the labor cost and improves the production efficiency by automating the design of each process.

The above-described embodiments are merely illustrative of one embodiment of the present invention, and the description thereof is more specific and detailed, but is not to be construed as limiting the scope of the invention. It should be noted that a number of variations and modifications may be made by those skilled in the art without departing from the spirit and scope of the invention.

The above description of the preferred embodiments of the present invention is not intended to limit the scope of the present invention, and the scope of the invention should be limited to the following claims. And the approximate structure should be included in the present invention.

1‧‧‧Automatic packaging device

2‧‧‧Automatic detection device

3‧‧‧Automatic transport device

4‧‧‧Automatic aging mechanism

5‧‧‧Automatic assembly mechanism

Claims (10)

An intelligent production system for an LED lamp, comprising: an automatic assembly mechanism for assembling a lamp cap jacket, a lamp cap, a lamp body, a heat conductive and insulating double-sided tape, a light source plate and a lamp cover into a semi-finished product of the LED lamp; An automatic aging mechanism connected to an automatic assembly mechanism for placing an LED lamp semi-finished product obtained from the automatic assembly mechanism on a carrier for aging detection; and connected to the automatic aging mechanism for detecting automatic aging from the aging device An automatic detecting device for the performance of the semi-finished product of the LED lamp obtained by the mechanism; and an automatic packaging device connected with the automatic detecting device for automatically packaging the qualified product of the LED lamp obtained from the automatic detecting device; and the automatic packaging device An automatic transport device for transporting the product obtained by the automatic packaging device to the warehouse; and connecting the automatic assembly mechanism, the automatic aging mechanism, the automatic detecting device, the automatic packaging device, and the automatic transportation The total control unit of device one. The LED lamp intelligent production system according to claim 1, wherein the automatic assembly mechanism is provided with a frame, and a rail is disposed on the frame, and a moving fixture is disposed on the rail. The LED lamp intelligent production system according to claim 2, wherein the automatic assembly mechanism is sequentially disposed along the direction of the guide rail, comprising: a lamp body uppering device, a lamp cap loading device, and an electric device. A plate loading device, a cable management device, a bending device, a lamp housing integration device, a glue application device, a light source panel assembly device, a circuit welding device and a lamp cover assembly device. The LED lamp intelligent production system according to claim 3, wherein each device has a corresponding robot. The LED lamp intelligent production system of claim 3, wherein the guide rail comprises: a first curved guide rail, a second curved guide rail, a first linear guide rail, and a second linear guide rail. The first curved guide rail and the second curved guide rail are disposed opposite to each other; the first linear guide rail is disposed in parallel with the second linear guide rail; one end of the first linear guide rail is connected with one end portion of the first curved guide rail, and the first linear guide rail is connected to the other One end is connected to one end of the second curved rail; one end of the second linear guide and the other end of the first curved rail Connected, the other end of the second linear guide is connected to the other end of the second curved rail. The LED lamp intelligent production system according to claim 1, wherein the LED lamp semi-finished product obtained by the automatic assembly mechanism is transported to the automatic aging mechanism by a robot. The intelligent lighting production system for an LED lamp according to claim 1, wherein the automatic aging mechanism is provided with a conveying track for running water, and an aging access station connected to the conveying track; The aging access station includes two rows of oppositely disposed shelves and an eighth robot disposed in the middle of the shelf. The LED lamp intelligent production system according to claim 1, wherein the automatic detecting device comprises a tenth robot, an eleventh robot, an integrating sphere, a voltage detecting unit, and a a current detecting unit, a communication detecting unit, a control circuit detecting unit, a sensor detecting unit, a motor driving detecting unit and a detecting machine; the voltage detecting unit, the current detecting unit, the communication detecting unit, and the control circuit detecting The unit, the sensor detecting unit and the motor driving detecting unit are respectively connected to the detecting machine. The intelligent lighting production system for an LED lamp according to claim 1, wherein the automatic packaging device comprises: a lamp automatic packaging machine and an automatic cartoning machine, wherein the lamp automatic packaging machine is used for The qualified products of the LED lamps obtained by the automatic detecting device are automatically packaged; the automatic cartoning machine is used for packing the qualified products of the LED lamps packaged by the automatic packaging machine of the lamp. The intelligent lighting production system for an LED lamp according to claim 9, wherein the automatic packaging device further comprises: an automatic packing robot for placing the packaged LED lamp qualified product into the a box on the automatic cartoning machine; the automatic transport device is provided with an automatic transport vehicle, and the automatic transport vehicle is provided with a shelf; a dispensing device for stacking the products obtained by the automatic packaging device into the On the shelf; the shelf after the stacking of the product is transported to the warehouse by the automatic transport vehicle.