In recent years, LED light assembly technologies have been widely used among LED manufacturers and developers, and have sustained an exponential growth trend. The popularity of LED light assembly is attributed to the advantages of LEDs, such as tiny dimension, high efficiency, low energy consumption, flexible design and versatility.
In fact, a large number of companies are dedicated to the design, assembly and manufacturing of LED lamps, and MOKOLight is no exception. Given that it is one of the industry-leading LED assembly manufacturers in China, this article will mainly focus on the LED light assembly process in its factory.
What Is LED Light Assembly and Its Benefits
LED light assembly is a process of connecting the various parts of the LED lamp together including LED chips, PCB board, LED drivers, housing, covers, end caps, etc., resulting in a functional finished lamp.
LED lights can be assembled either automatically or manually. Automated assembly involves the placement of thousands of diodes on the circuit board via precise and efficient Surface-Mount Technology (SMT) equipment. However, in manual or hand assembly, skilled technicians utilize certain professional tools to place LED components individually on the circuit board.
Automated LED light assembly can not only greatly reduce labor costs, but also dramatically improve production efficiency. Due to its small dimension, the LED is easy to assemble. LED lights are designed to be environmentally friendly and reduce carbon emissions. Compared with traditional lighting systems, the components of LED light assembly can provide higher light efficiency while consuming less power energy.
In terms of cost-effectiveness, LED light assembly using solid-state lighting technology is superior to other lighting technologies, with lower labor and product costs.
Applications of LED Light Assembly
Presently, there are numerous applications for LED light assembly technology, and there will be many more in the future. The applications of LED light assembly in the solid-state lighting technology are listed as follows:
- Backlighting
- Spotlighting
- LED modules, strips, tubes, walls, bulbs and screens
- Street lighting
- Signage
- Video displays and lighting
- Decorative panels
- Automotive lighting
- marine lighting
- And more
Raw Materials Required for LED Light Assembly
For the 10W LED light assembly, the raw materials required are given below:
- Connecting wire
- Heat sinks
- LED chips
- Metallic cap holder
- Miscellaneous parts
- Plastic body
- Material for LED lamp packaging
- Rectifier circuit
- Filter
- Reflector plastic glass
- Solder flux
Machinery Required for LED Light Assembly
You should select the right machinery based on the type of LED lights you desire to produce. Below is the list of the major machines required for LED light assembly:
- High speed LED mounting machine
- LED candlelight assembly machine
- LED chip SMD mounting machine
- PCB assembly machines for LED
- Assembly machines for LED lights
- LED tube light assembly machine
In addition to these heavy machineries, the LED light assembly also requires the following small equipment:
- Continuity tester
- Soldering machine
- Sealing machine
- Packaging machine
- Small drilling machine
- Lux meter
- LCR meter
- Digital multi-meter
- Oscilloscope
LED Light Assembly Process at MOKOLight
LED light assembly is a crucial step in the process of LED light manufacturing. During the assembly process, the quality of LED finished lamps is well checked and guaranteed. The following steps are the LED light assembly process in our factory.
Soldering the PCB Board
This process involves mounting all the auxiliary electronic components and wires onto the circuit board using solder. In this way, the function of the lighting fixture can be played to the maximum in the actual application process.
Wiring in Aluminum Housing
Then, we will carefully place the various wires connecting to the circuit board, power supply and switch carefully in and around the aluminum housing according to the design. The wires should be arranged in a neat and orderly manner because perhaps no one wants to see the wires of their lights are in a mess everywhere.
Connecting the Power Supply
Next, it’s time for the insertion of the power unit into the aluminum housing. The power supply unit can regulate the current to achieve lighting control functions of the fixture, such as adjusting the light brightness and color temperature.
Covering the Lighting Fixture
The final step in LED light assembly is to cover the lamp, after all the internal components have been installed properly. These components are enclosed inside the aluminum housing by the PC cover and end caps. The PC cover allows the fixture to distribute light evenly and it actually acts as a diffuser.
By now, the entire LED lamp is fully assembled and can be shipped right away. But before packaging and shipping, the LED lights should undergo a final test to ensure they function properly and are of high quality.
Performance and Functionality Testing
To guarantee the stability, durability and functionality of our lamps delivered to you, it’s wise to check whether they meet the high standards. So what do our tests include?
Lighting Test
The first is the inspection of lighting. We need to learn about the following aspects:
Can all the LED beads glow and yield the same intensity of light?
Can the fixture produce sufficient flux according to its specifications?
Is there any color differences in the light emitted by the LED beads of the fixture?
Finally, the LED functions such as dimming and color temperature change are normal?
If everything goes smoothly, we will move on to the next test.
High-Voltage Test
The test is aimed at reducing damage to the fixtures caused by high voltages and sudden power surges. To protect the new fixtures from unstable voltages, they are subjected to high voltage test before they are shipped.
In this way, we can make sure that our clients get access to cost-effective and durable lighting fixtures.
Waterproof Test
Each type of lighting fixtures has different waterproof grade, which is known as the IP (Ingress Protection) rating. To test whether they live up to the assigned IP rating, we often place the lighting fixtures in a humid environment.
Aging Test
What exactly is the LED aging test? In essence, it is a reliability test to check whether the LED lights conform to the set standards. To determine the average lifetime of lamps under different conditions, we will conduct a dedicated aging test. Through this rigorous testing, the performance and stability of the LED lights will be enhanced.
Insulation Test
Once the lamp is turned on, instantaneous pulse voltage and high current will be generated. If the current leaks too much, it will cause harm to the human body. So the insulation test aims to ensure that the fixture is completely insulated and safe to use. It is apparent that anyone wouldn’t like to buy a leaky LED lamp.
If the LED fixture passes all the tests, then the LED light assembly process ends, indicating that the packaging stage begins.
IPQC in LED Light Assembly& Manufacturing
For LED light assembly and manufacturing, we have a strict product quality control system, including three major inspection stages: IQC, IPQC and FQC. Among them, IPQC namely in-process quality control, is the inspection carried out in the production process. It is intended to monitor or adjust the production process as necessary to bring it into compliance with the specifications.
According to different requirements, every LED product has different quality control standards. We have dedicated personnel responsible for the IPQC inspection. If they detect any quality issues or defective products, they will take immediate action to solve them. In order to ensure quality, all the features of LED lights are monitored.
First Piece Inspection
For mass production, in order to prevent volume quality issues, we will inspect the first or first few items, which is called first piece inspection or first article inspection. Only after passing through the inspection, the manufacturing process can be continued. In this way, it can ensure that our production process is capable of consistently delivering the LED fixtures that complies with the specifications.
Process Inspection
Process inspection is to check whether the parameters of the product match the specifications or standards during the manufacturing process. Its purpose is to avoid large quantities of unqualified products from flowing into the next process. Therefore, the process inspection should not only test the products, but also check the main process elements that affect the product quality.
Approved or Rejected
Semi-finished LED lamps will proceed the accepting or rejecting steps after they are being tested for quality in the previous steps. If the product is fine, it will enter the final inspection control process; if the product is defective, it will be sent to repair or other corrective measures will be followed up.
How Does MOKOLight Differ From Others in LED Light Assembly
At MOKOLight, we provide one-stop LED light assembly, design and manufacturing services, including PCB fabrication, wire harness assembly, box build assembly, BGA assembly, plastic assembly and performance testing. In all, we have loads of experience in LED finished lamp assembly, LED driver assembly, LED controller assembly, etc. We are capable of delivering cost-effective solutions while maintaining top-notch product quality. Welcome to discuss with our professional sales and we will help you find an unique lighting solution for your company.
