A LED bulb was produced in 3 seconds, and some LED companies did it. This is the power of automated production. Some LED entrepreneurs have a solid foundation and have realized fully automated production early; others have not been particularly well funded, and have introduced semi-automated production lines, which not only take into account costs but also increase production efficiency. There are still some companies waiting to see, but they are also watching closely and waiting for maturity.
It is foreseeable that automated production is an inevitable trend. With the introduction of “machine substitution†support and capital subsidy policies, the process of LED enterprise production automation will accelerate.
With the rise in labor prices, the “demographic dividend†of Chinese manufacturing is disappearing. LED lighting companies are faced with the high cost of labor and the decline of profits. Therefore, in the LED lighting enterprises, the "machine substitution" has gradually emerged, that is, the intelligent technology transformation of LED enterprises is carried out by using robots, automatic control equipment or automated assembly lines. To achieve the purpose of reducing staff, increasing efficiency, improving quality, and ensuring safety.
Advantages of automated production equipment for LED lamps
The automatic production of LED lamps is realized by introducing various sensing technologies, image processing technologies and online detection technologies to realize light source modules (light boards, light bars, wicks, etc.), power modules, and covers, heat sinks, and lamp holders. ), lens, insulation sleeve and other accessories for automatic alignment and loading and unloading, automatic assembly, automatic aging, online detection, automatic sub-bin, automatic coding and other functions. At the same time, the information technology is used to integrate the production process data and the light color data of the product inspection to realize the information sharing of the production process quality control, purchase and sales and after-sales service, and the management is more efficient.
The following is an example of the types of automated production equipment, for reference only.
Bulb lamp automatic assembly production line
(1) Employment: 1 person.
(2) Production speed: 1.5k/h.
(3) Features: including automatic feeding, automatic positioning, automatic assembly, automatic line, automatic online welding, automatic detection, automatic waste rejection, automatic riveting, automatic recording of product files. Introduce intelligent image recognition technology instead of manual visual inspection or mechanical positioning; use a large number of robots to carry materials, the material runs smoothly, the speed is fast, and the repeated operation precision is high; the high-precision linear guide is used to carry the tooling plate, which has high precision and noise relative to the chain. Low, low wear, long life and easy maintenance; high speed CPU, large capacity data storage, high speed data link transmission, high sensitivity sensing, super abnormal error correction and fault tolerance.
Bulb semi-automatic assembly line
(1) Employment: 3-5 people.
(2) Production speed: 1.2k/h.
(3) Features: Man-machine hybrid assembly line. The non-standard parts of the bulbs are assembled and assembled (such as power boards, heat sinks and light boards), which are assembled manually, without complicated automated mechanical equipment, which greatly reduces the cost. The standard parts and standard assembly of the bulb (such as screw, rivet and riveting) are mechanically automated and loaded, saving manpower.
Tube lamp automatic assembly production line
(1) Employment: 2 people.
(2) Production speed: 1.0k/h.
(3) Features: including automatic feeding, automatic positioning, automatic cutting, automatic assembly, automatic glue, automatic online welding, automatic line, automatic detection, automatic waste rejection, automatic recording of product files. The main line adopts the synchronous belt to carry the tooling board and each station runs independently, which is convenient and quick to assemble and maintain. The intelligent image recognition technology is introduced to replace the manual visual inspection or mechanical positioning. The robot is used to carry materials in a large amount, and the material runs smoothly, fast and repeats. High precision operation; high-precision linear guides for carrying tooling plates, high precision with respect to chain conveying, low noise, low wear, long life and easy maintenance.
Distributed LED lighting intelligent production line
(1) Employment: 7-8 people.
(2) Capacity: 1.2K/h, monthly average production capacity >900,000 (based on 22 hours of work per day).
(3) Features: According to different LED bulb structure and process assembly mode, the production line is reasonably arranged, and different types of bulbs can be produced in the same production line; through intelligent robot or manual connection to LED lamps automatic aging detection integration Line, the complete solution for fully automated, intelligent assembly, aging and inspection of LED lamps with the lowest cost; unique flexible body design, non-stop production, failure of a certain process site of intelligent production line, instant detachable bus, carry out Quick maintenance, the process site can be produced by manual replacement during the inspection; the introduction of intelligent image recognition technology instead of manual visual inspection or mechanical positioning.
Fully automated production line for LED lamps
(1) Employment: 8-10 people.
(2) Capacity: The monthly average production capacity is >900,000 (based on 22 hours of work per day).
(3) Features: Only 8-10 workers can complete the production capacity of more than 200 traditional manual production lines, saving labor costs of more than 600 million yuan per year. Automatic assembly, automatic aging, automatic detection, automatic packaging and other system solutions between the four modules, the whole process does not require manual intervention; the introduction of identity traceability, automatic automatic inspection of lamps, effectively improve quality monitoring; unique flexible line design, downtime Without stopping production, a certain process site of the assembly line is faulty, and the bus can be detached from the bus for quick maintenance. During the maintenance, the process site can be produced by manual replacement; intelligent image recognition technology is introduced instead of manual visual inspection or mechanical positioning.
LED lamp automation production needs to be improved
1, LED lamps to achieve standardization, in order to large-scale automated production.
At present, China's LED industry standards are numerous and chaotic, and not uniform. The standard technical indicators are backward. According to the traditional standard development process, it takes 1-2 years from standard development to standard implementation. However, the LED lighting industry as an emerging industry, the development of its industrial technology can be described as ever-changing, and the standards are often implemented during the promotion. Not in line with industry reality. The standard implementation feedback is poor. After the current LED lighting industry standard is completed, it fails to fully consider the benefit evaluation and feedback optimization work in the standard implementation process, resulting in the standard not being effectively modified and not reflecting the actual reality of the industry.
2. There are many varieties and specifications of LED lamps, which restricts their automatic production.
There are many types of LED lamps, new material applications, technological breakthroughs, and refurbishment of the style structure, which brings difficulties to the automated production of LED lamps. Is it possible to use automated production equipment for any kind of LED luminaires, if possible, different types of LED luminaires corresponding to automated production equipment, general-purpose LED luminaires automated production equipment, compared to the two, which method produces more products Meet the standards and better quality. In addition, the intelligent automated production line for the development and manufacture of a certain LED lamp has not been successfully debugged. This luminaire may have been updated. The new materials and new structure will make the original assembly process no longer applicable, resulting in the original funds. And waste of human input.
3, the intelligent production line is expensive, making it difficult for LED manufacturers to determine.
The intelligent automatic production of LED lamps introduces various sensing technologies, image processing technologies, automatic assembly technologies and on-line inspection technologies. The equipment is costly, the domestic automated production line is millions of yuan, and the imported automation production line is tens of millions of dollars. Lamp manufacturers are discouraged. This requires equipment developers and manufacturers to grasp a "degree", is it necessary to apply various advanced technologies to the automation equipment, how much operator can reduce the number of operators, how much efficiency, and how much product quality Designers need to weigh carefully. Lamp manufacturers need a practical, reliable, cost-effective production line or equipment, rather than a beautiful landscape that can't be used.
4. How to consume these huge production capacity for large-scale automated production of enterprises .
Whether it's OEM production for other companies or building channels on their own, these are just a way for automated production companies to consume capacity. Only these production capacity can successfully find a market. Under the situation that the machine is fully open, automation and large-scale production will bring about cost reduction and profitability of the enterprise.
Incentive policies for “machine substitutionâ€
For the implementation of the "machine substitution" technical transformation project, the enterprise that declares the "machine substitution" pilot and meets the "machine substitution" standard requirements, the state and local governments give financial subsidies and various policy incentives.
Dongguan
Dongguan is the country that “returns the earliest and exchanges the most aheadâ€. More than 60% of industrial enterprises have carried out “machine substitutionâ€.
(1) Dongguan is the pioneering place to open the fiscal and tax support for “machine substitutionâ€. In January 2014, the Dongguan Municipal Government’s No. 1 document “Several Opinions on Further Supporting the Development of the Real Economy†arranged for the upgrading of the CNC equipment of 12 million yuan subsidized enterprises, and set up a special fund for “machine substitution†in Dongguan, from 2014. It has invested 200 million yuan each year and has supported 600 million yuan for three consecutive years to support the implementation of “machine substitutionâ€. The maximum subsidy ratio can reach 15% of the total equipment.
(2) On September 29, 2015, the Dongguan Municipal Government executive meeting reviewed and approved three policy documents on “machine substitutionâ€, and provided all-round support from “introduction, investment, creation, sales, financing, and insuranceâ€. Dongguan is striving to develop into one of the important gathering areas of advanced equipment manufacturing industry in the province and even the whole country. According to the plan, by 2016, Dongguan will strive to achieve an industrial output value of 35 billion yuan for the industrial robot intelligent equipment industry, with an average annual growth rate of about 20%, and to create a group of leading enterprises with independent intellectual property rights, domestic and internationally renowned industrial robot intelligent equipment.
(3) Enterprises that are key technologies and core products of the advanced equipment manufacturing industry shall be subsidized by the construction cost after approval, and subsidized according to 25% of the actual investment of the project construction (including site renovation and decoration, display product installation and commissioning, office equipment purchase, etc.). The maximum subsidy is no more than 3 million yuan.
(4) In 2016-2018, the provincial government will arrange 100 million yuan of special funds and 100 million yuan of special funds for Dongguan's financial support each year to jointly establish “special funds for provincial and municipal construction†to promote the development of financial leasing business and small and medium-sized enterprises. Device update upgrade replacement. Through three years of pilot time, we will instigate financial institutions and service organizations to provide financing support for SMEs of not less than 2 billion yuan per year. By 2018, the balance of financial leasing contracts in the city will reach 5 billion yuan. Starting in 2016, SMEs can participate in “machine substitution†through financial leasing. If the enterprise obtains the money through the financial leasing, the China Development Bank will guarantee 80% of the guarantee to the enterprise, and the Dongguan government will guarantee 20%. If the enterprise makes money in the future, it can be realized according to the interest paid.
Shenzhen
From 2014 to 2020, Shenzhen Municipal Finance will arrange 500 million yuan each year, using direct subsidies, equity financing, and loan interest subsidies to subsidize robots, wearable devices and smart equipment industries for 7 consecutive years. According to the plan, by 2020, Shenzhen will build a leading domestic and world-famous manufacturing base for robots, wearable devices and smart equipment industries, with an added value of more than 200 billion yuan.
Guangzhou
On December 29, 2014, the Guangzhou Municipal Government executive meeting reviewed and approved the “Work Plan for Accelerating the Development of Advanced Equipment Manufacturing Industry and Promoting a New Round of Technological Transformation to Realize Industrial Transformation and Upgradingâ€. It is planned to strive for the output value of advanced equipment manufacturing industry by 2017. More than 1.1 trillion yuan, more than 60% of the industrial enterprises above designated size have basically completed a new round of technological transformation, applying intelligent manufacturing equipment such as industrial robots.
(1) Financial support: Since 2015, Guangzhou Municipal Finance has arranged special funds for three consecutive years to support enterprises to implement technological transformation.
(2) Land use protection: Guangzhou will prioritize annual land use plan indicators for advanced equipment manufacturing projects with an investment of more than 1 billion yuan. Priority is given to supporting high-quality technological transformation projects with an investment intensity of more than 5 million yuan/mu. Improve the efficiency of industrial land use, and encourage enterprises to implement “zero-increased land†technological transformation.
Foshan
On May 13, 2015, Foshan Supporting Enterprises promoted the “Machine Substitution†Implementation Plan officially for comments. According to the plan, by 2017, more than 3,000 enterprises in the city will complete the “machine substitutionâ€, and more than 50% of the industrial enterprises above designated size will complete a new round of technological transformation. At the same time, within three years, Foshan will invest 53 million yuan each year for enterprises to carry out “machine substitutionâ€; enterprises can purchase a complete set of automated production lines and production system transformation, up to a subsidy of 1 million yuan.
It is foreseeable that automated production is an inevitable trend. With the introduction of “machine substitution†support and capital subsidy policies, the process of LED enterprise production automation will accelerate.
With the rise in labor prices, the “demographic dividend†of Chinese manufacturing is disappearing. LED lighting companies are faced with the high cost of labor and the decline of profits. Therefore, in the LED lighting enterprises, the "machine substitution" has gradually emerged, that is, the intelligent technology transformation of LED enterprises is carried out by using robots, automatic control equipment or automated assembly lines. To achieve the purpose of reducing staff, increasing efficiency, improving quality, and ensuring safety.
Advantages of automated production equipment for LED lamps
The automatic production of LED lamps is realized by introducing various sensing technologies, image processing technologies and online detection technologies to realize light source modules (light boards, light bars, wicks, etc.), power modules, and covers, heat sinks, and lamp holders. ), lens, insulation sleeve and other accessories for automatic alignment and loading and unloading, automatic assembly, automatic aging, online detection, automatic sub-bin, automatic coding and other functions. At the same time, the information technology is used to integrate the production process data and the light color data of the product inspection to realize the information sharing of the production process quality control, purchase and sales and after-sales service, and the management is more efficient.
The following is an example of the types of automated production equipment, for reference only.
Bulb lamp automatic assembly production line
(1) Employment: 1 person.
(2) Production speed: 1.5k/h.
(3) Features: including automatic feeding, automatic positioning, automatic assembly, automatic line, automatic online welding, automatic detection, automatic waste rejection, automatic riveting, automatic recording of product files. Introduce intelligent image recognition technology instead of manual visual inspection or mechanical positioning; use a large number of robots to carry materials, the material runs smoothly, the speed is fast, and the repeated operation precision is high; the high-precision linear guide is used to carry the tooling plate, which has high precision and noise relative to the chain. Low, low wear, long life and easy maintenance; high speed CPU, large capacity data storage, high speed data link transmission, high sensitivity sensing, super abnormal error correction and fault tolerance.
Bulb semi-automatic assembly line
(1) Employment: 3-5 people.
(2) Production speed: 1.2k/h.
(3) Features: Man-machine hybrid assembly line. The non-standard parts of the bulbs are assembled and assembled (such as power boards, heat sinks and light boards), which are assembled manually, without complicated automated mechanical equipment, which greatly reduces the cost. The standard parts and standard assembly of the bulb (such as screw, rivet and riveting) are mechanically automated and loaded, saving manpower.
Tube lamp automatic assembly production line
(1) Employment: 2 people.
(2) Production speed: 1.0k/h.
(3) Features: including automatic feeding, automatic positioning, automatic cutting, automatic assembly, automatic glue, automatic online welding, automatic line, automatic detection, automatic waste rejection, automatic recording of product files. The main line adopts the synchronous belt to carry the tooling board and each station runs independently, which is convenient and quick to assemble and maintain. The intelligent image recognition technology is introduced to replace the manual visual inspection or mechanical positioning. The robot is used to carry materials in a large amount, and the material runs smoothly, fast and repeats. High precision operation; high-precision linear guides for carrying tooling plates, high precision with respect to chain conveying, low noise, low wear, long life and easy maintenance.
Distributed LED lighting intelligent production line
(1) Employment: 7-8 people.
(2) Capacity: 1.2K/h, monthly average production capacity >900,000 (based on 22 hours of work per day).
(3) Features: According to different LED bulb structure and process assembly mode, the production line is reasonably arranged, and different types of bulbs can be produced in the same production line; through intelligent robot or manual connection to LED lamps automatic aging detection integration Line, the complete solution for fully automated, intelligent assembly, aging and inspection of LED lamps with the lowest cost; unique flexible body design, non-stop production, failure of a certain process site of intelligent production line, instant detachable bus, carry out Quick maintenance, the process site can be produced by manual replacement during the inspection; the introduction of intelligent image recognition technology instead of manual visual inspection or mechanical positioning.
Fully automated production line for LED lamps
(1) Employment: 8-10 people.
(2) Capacity: The monthly average production capacity is >900,000 (based on 22 hours of work per day).
(3) Features: Only 8-10 workers can complete the production capacity of more than 200 traditional manual production lines, saving labor costs of more than 600 million yuan per year. Automatic assembly, automatic aging, automatic detection, automatic packaging and other system solutions between the four modules, the whole process does not require manual intervention; the introduction of identity traceability, automatic automatic inspection of lamps, effectively improve quality monitoring; unique flexible line design, downtime Without stopping production, a certain process site of the assembly line is faulty, and the bus can be detached from the bus for quick maintenance. During the maintenance, the process site can be produced by manual replacement; intelligent image recognition technology is introduced instead of manual visual inspection or mechanical positioning.
LED lamp automation production needs to be improved
1, LED lamps to achieve standardization, in order to large-scale automated production.
At present, China's LED industry standards are numerous and chaotic, and not uniform. The standard technical indicators are backward. According to the traditional standard development process, it takes 1-2 years from standard development to standard implementation. However, the LED lighting industry as an emerging industry, the development of its industrial technology can be described as ever-changing, and the standards are often implemented during the promotion. Not in line with industry reality. The standard implementation feedback is poor. After the current LED lighting industry standard is completed, it fails to fully consider the benefit evaluation and feedback optimization work in the standard implementation process, resulting in the standard not being effectively modified and not reflecting the actual reality of the industry.
2. There are many varieties and specifications of LED lamps, which restricts their automatic production.
There are many types of LED lamps, new material applications, technological breakthroughs, and refurbishment of the style structure, which brings difficulties to the automated production of LED lamps. Is it possible to use automated production equipment for any kind of LED luminaires, if possible, different types of LED luminaires corresponding to automated production equipment, general-purpose LED luminaires automated production equipment, compared to the two, which method produces more products Meet the standards and better quality. In addition, the intelligent automated production line for the development and manufacture of a certain LED lamp has not been successfully debugged. This luminaire may have been updated. The new materials and new structure will make the original assembly process no longer applicable, resulting in the original funds. And waste of human input.
3, the intelligent production line is expensive, making it difficult for LED manufacturers to determine.
The intelligent automatic production of LED lamps introduces various sensing technologies, image processing technologies, automatic assembly technologies and on-line inspection technologies. The equipment is costly, the domestic automated production line is millions of yuan, and the imported automation production line is tens of millions of dollars. Lamp manufacturers are discouraged. This requires equipment developers and manufacturers to grasp a "degree", is it necessary to apply various advanced technologies to the automation equipment, how much operator can reduce the number of operators, how much efficiency, and how much product quality Designers need to weigh carefully. Lamp manufacturers need a practical, reliable, cost-effective production line or equipment, rather than a beautiful landscape that can't be used.
4. How to consume these huge production capacity for large-scale automated production of enterprises .
Whether it's OEM production for other companies or building channels on their own, these are just a way for automated production companies to consume capacity. Only these production capacity can successfully find a market. Under the situation that the machine is fully open, automation and large-scale production will bring about cost reduction and profitability of the enterprise.
Incentive policies for “machine substitutionâ€
For the implementation of the "machine substitution" technical transformation project, the enterprise that declares the "machine substitution" pilot and meets the "machine substitution" standard requirements, the state and local governments give financial subsidies and various policy incentives.
Dongguan
Dongguan is the country that “returns the earliest and exchanges the most aheadâ€. More than 60% of industrial enterprises have carried out “machine substitutionâ€.
(1) Dongguan is the pioneering place to open the fiscal and tax support for “machine substitutionâ€. In January 2014, the Dongguan Municipal Government’s No. 1 document “Several Opinions on Further Supporting the Development of the Real Economy†arranged for the upgrading of the CNC equipment of 12 million yuan subsidized enterprises, and set up a special fund for “machine substitution†in Dongguan, from 2014. It has invested 200 million yuan each year and has supported 600 million yuan for three consecutive years to support the implementation of “machine substitutionâ€. The maximum subsidy ratio can reach 15% of the total equipment.
(2) On September 29, 2015, the Dongguan Municipal Government executive meeting reviewed and approved three policy documents on “machine substitutionâ€, and provided all-round support from “introduction, investment, creation, sales, financing, and insuranceâ€. Dongguan is striving to develop into one of the important gathering areas of advanced equipment manufacturing industry in the province and even the whole country. According to the plan, by 2016, Dongguan will strive to achieve an industrial output value of 35 billion yuan for the industrial robot intelligent equipment industry, with an average annual growth rate of about 20%, and to create a group of leading enterprises with independent intellectual property rights, domestic and internationally renowned industrial robot intelligent equipment.
(3) Enterprises that are key technologies and core products of the advanced equipment manufacturing industry shall be subsidized by the construction cost after approval, and subsidized according to 25% of the actual investment of the project construction (including site renovation and decoration, display product installation and commissioning, office equipment purchase, etc.). The maximum subsidy is no more than 3 million yuan.
(4) In 2016-2018, the provincial government will arrange 100 million yuan of special funds and 100 million yuan of special funds for Dongguan's financial support each year to jointly establish “special funds for provincial and municipal construction†to promote the development of financial leasing business and small and medium-sized enterprises. Device update upgrade replacement. Through three years of pilot time, we will instigate financial institutions and service organizations to provide financing support for SMEs of not less than 2 billion yuan per year. By 2018, the balance of financial leasing contracts in the city will reach 5 billion yuan. Starting in 2016, SMEs can participate in “machine substitution†through financial leasing. If the enterprise obtains the money through the financial leasing, the China Development Bank will guarantee 80% of the guarantee to the enterprise, and the Dongguan government will guarantee 20%. If the enterprise makes money in the future, it can be realized according to the interest paid.
Shenzhen
From 2014 to 2020, Shenzhen Municipal Finance will arrange 500 million yuan each year, using direct subsidies, equity financing, and loan interest subsidies to subsidize robots, wearable devices and smart equipment industries for 7 consecutive years. According to the plan, by 2020, Shenzhen will build a leading domestic and world-famous manufacturing base for robots, wearable devices and smart equipment industries, with an added value of more than 200 billion yuan.
Guangzhou
On December 29, 2014, the Guangzhou Municipal Government executive meeting reviewed and approved the “Work Plan for Accelerating the Development of Advanced Equipment Manufacturing Industry and Promoting a New Round of Technological Transformation to Realize Industrial Transformation and Upgradingâ€. It is planned to strive for the output value of advanced equipment manufacturing industry by 2017. More than 1.1 trillion yuan, more than 60% of the industrial enterprises above designated size have basically completed a new round of technological transformation, applying intelligent manufacturing equipment such as industrial robots.
(1) Financial support: Since 2015, Guangzhou Municipal Finance has arranged special funds for three consecutive years to support enterprises to implement technological transformation.
(2) Land use protection: Guangzhou will prioritize annual land use plan indicators for advanced equipment manufacturing projects with an investment of more than 1 billion yuan. Priority is given to supporting high-quality technological transformation projects with an investment intensity of more than 5 million yuan/mu. Improve the efficiency of industrial land use, and encourage enterprises to implement “zero-increased land†technological transformation.
Foshan
On May 13, 2015, Foshan Supporting Enterprises promoted the “Machine Substitution†Implementation Plan officially for comments. According to the plan, by 2017, more than 3,000 enterprises in the city will complete the “machine substitutionâ€, and more than 50% of the industrial enterprises above designated size will complete a new round of technological transformation. At the same time, within three years, Foshan will invest 53 million yuan each year for enterprises to carry out “machine substitutionâ€; enterprises can purchase a complete set of automated production lines and production system transformation, up to a subsidy of 1 million yuan.
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