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www.us-
tech.com
June, 2016
Energy Focus Builds LED Boards for U.S. Government
Continued from page 36
the entire 98-foot, automated line was not only assembled, but was building boards. It was an unprece- dented accomplishment to have the equipment unpacked, set up, inter- connected, and working together without any major issues. According to Trail, the equipment he chose for the line was picked specifically for its quality, speed and consistency.
slot to ensure that they do not touch, but remain stacked. Each of the four magazines can accommodate 50 pan- els. The magazines have been stacked in an effort to save space, which reduced the amount of space needed on the line from 16 to 8 feet. When a magazine is full, it is re- moved with the help of an Aluma Lift, and from there the boards go to functional test and to final assembly,
The full production line assembled and operational. “What we did isn’t magic, it’s
done every day,” says Trail. “The magic is that it was done on four-foot boards, and that the 98-foot line was up and running in two days. In my 35 years in this industry, nothing of this scope or technology has ever hap- pened before.”
A Fine Line In order to handle the boards
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and all the necessary machines, the line had to be no more than 98 feet long. Fully-automated, it is capable of producing a four-foot LED board every six seconds. With this sort of technology, the company is closer to realizing its goal of creating LED lighting in the U.S. that uses one- third of the energy of fluorescent bulbs. The fixtures currently made on the line are designed to replace four-foot fluorescent tubes, and are solid state and all-LED. The line starts with a Proma-
tion board loader where the boards are set in as a stack. Suction cups pick up a board and place it on the conveyor. From there, it goes into a Juki/GKG printer, which is one of only a few in the world that can han- dle boards of that size. Next, the PCBs move to a transfer conveyor and into a Juki pick-and-place sys- tem, which places 65,000 compo- nents per hour — roughly half a mil- lion per day. The placement process is sequential and utilizes a total of four machines. The boards then leave the four
placement machines and go into a Promation workcell, which is fol- lowed by Juki’s 10-zone convection reflow oven. Because the boards are four feet long, they use all 10 of the zones. After reflow, the boards are in- spected by a Viscom S3088 AOI sys- tem, where every component is ac- counted for. The AOI system syn- chronizes the entrance and exit con- veyors in order to accurately process the four-foot boards; the first third of the board is processed and exited while the middle third is brought in, and is then followed by the final third.
Post-inspection, the boards go Soldering, Desoldering and Rework Solutions Since 1958.
to Promation magazine loaders to stack. Due to the number of boards, each one is slid into its own magazine
where they are prepared for ship- ping. Each four-foot board is slid into a clear plastic housing with caps on either end.
Focused on LEDs LED lighting provides numer-
ous benefits over fluorescent light- ing, and Energy Focus hopes to bring them to the industry. Advantages of the technology include a longer lifes- pan than fluorescent lamps, a signif-
In order to compete with offshore manufacturers in Asia in the assembly
of four-foot LED boards, the process had to be
completely automated and capable of producing
1 million LED assemblies per year, on one shift.
icant cut in energy cost, near inde- structibility, as well as being much easier to dispose of. Fluorescent lights lose about 60 percent of their brightness over the course of a year, while LED lights lose only 6 percent. Also, unlike fluorescent lighting, quality LED lights do not flicker, which has been shown to contribute to cataracts. The company believes that pro-
ducing these fixtures in the U.S. will place it in a leadership position in the North American industry. At the same time, the company strengthens its core capabilities and competitive advantages to ensure that it meets current customers’ needs, while preparing to meet the industry’s needs of tomorrow. As well as manu- facturing LED technology, Energy Focus educates and assists clients in the adoption of advanced LED prod- ucts, and also develops, designs, tests, and validates new products. The company is committed to making a difference in the industry, one lighting module at a time. Contact: Energy Focus, Inc.,
32000 Aurora Road, Suite B, Solon, OH 44139 % 440-715-1300 fax: 440-715-1301 E-mail:
orders@energyfocusinc.com Web:
www.energyfocusinc.com r
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