Relying on huge demographic dividends, China has become the world's largest LED manufacturing base. However, as the demographic dividend continues to disappear, China must continue to maintain this scale of manufacturing advantages, and must carry out industrial upgrading, from manual manufacturing to intelligent manufacturing, and the production process is highly automated.
Throughout the LED industry chain, it is not difficult to find that the automation of chips and packages in the upper and middle reaches is relatively high, while the automation of assembly of downstream LED lamps is relatively weak. As the price of LED lighting is becoming more and more civilian, the scale benefits are becoming more and more prominent, and the labor cost is getting higher and higher. Many SMEs are overwhelmed.
For a time, the fully automatic production line has become the focus of attention of major manufacturers. In theory, full automation can significantly reduce labor costs, and become a life-saving straw. However, in fact, due to the high cost of equipment and the rapid changes in LED lighting technology, the lighting automation market has always been in the embarrassing situation of “thunder and heavy rainâ€: equipment companies are actively deploying, but lighting manufacturers have introduced many concerns.
Automate or scale down
As a major manufacturing country for LED lighting products, China has a 21% market share in the world with cost advantages and a complete supply chain. Among them, large-scale production is the magic weapon for domestic LED lighting companies.
Scale requires a large amount of labor. However, as the price of LED lighting is decreasing day by day, the high labor cost brings a considerable burden to the company's net profit, and the overall market is sluggish, causing the company's profits to plummet and the survival pressure to rise sharply.
On this basis, LED lighting companies such as Mulinsen, Aoqisi Optoelectronics, Yuanhui Optoelectronics, etc. have invested in LED automated production lines, fundamentally improving production efficiency, and producing high-quality LED products in a few seconds, bringing enterprises More benefits.
The industry believes that the fully automatic production line can not only effectively reduce the cost of employment, ensure product quality, standardize the quality of the industry, double the production capacity, and enhance the overall competitiveness of the enterprise, while improving the overall manufacturing level of the industry.
Taking an automated LED downlight production line as an example, only three operators are required. In the traditional LED lamp assembly process, there are more than 20 processes including assembly of various kits, power supply components, and finished product packaging. A total of 27 operators are required, and the labor cost is saved by nearly 90%, and the yield is as high as possible. 98% or more.
Nowadays, in the increasingly fierce competition in the LED lighting market, it is no longer appropriate to continue to use the traditional manual production mode, and the introduction of LED lighting automated production lines can effectively improve production efficiency. LED luminaires automate centralized feeding, automatic assembly, automatic aging, automatic detection, automatic coding, automatic packaging, and information integration, and achieve 1500 production capacity per hour (taking LED bulbs as an example) Achieve 100% online quality inspection and data traceability.
In addition, automated production equipment instead of labor can not only reduce the impact of human factors, improve the one-time pass rate of products, ensure product quality, enhance product competitiveness, but also speed up processing, improve accuracy and reliability, and achieve warehouse area. And the effective use of space, further reducing the overall cost of the enterprise.
Equipment company active layout
Since last year, a "machine substitution" boom in which smart equipment has replaced labor input is sweeping through developed industries such as Guangdong, accelerating the pace of "machine substitution" in the Pearl River Delta region and promoting the automation of the LED lighting industry.
According to relevant data, in 2014, China's LED lighting automation production accounted for less than 5%. In 2017, the proportion of automated production is expected to exceed 30%, and the equipment market will increase from less than 100 million yuan in 2014 to 600 million yuan in 2017. about.
In view of the huge market prospects, Zhongwei Optoelectronics, Hyun Shuo Optoelectronics, Dazu Laser, Lianshuo Technology and other domestic automation equipment companies have laid out the field of LED lighting automation production. From the point of view of the division and the taping machine in the field of packaging, we have entered the field of production line automation equipment, and launched a series of automated equipment products around the idea of ​​high reliability and high stability. From packaging and tape-making equipment to automation, now it mainly serves three major fields: LED lighting, photoelectric display and 3C.
However, some insiders also said that although full automation is the future development trend, the enterprises entering the field at this stage are still in the early stage of investment. Due to the long return on investment, the fully automated production line is still in the trial stage, and the market has not yet risen. Enterprises without strong financial strength simply do not dare to enter.
Semi-automatic is more popular
In the face of the enthusiasm of equipment companies, lighting companies have been slow. In the domestic LED lighting production, there are not many enterprises that introduce fully automatic production lines, and only limited to more than ten well-known LED lighting companies such as Mulinsen, Op Lighting, Lidaxin, Sunlight Lighting, Debang, etc. limited.
At this stage, the process is at a relatively mature stage, and each family has formed its own process system. Because the back-end automation investment is very large, everyone is in a wait-and-see state, see how the industry is doing.
Undoubtedly, the introduction of fully automatic production lines requires huge cost investment in the early stage. The return on investment and output has become the most considered issue for LED lighting companies before they introduce fully automated production lines. Zhao Yutao said that the investment in automation equipment, customers return to the year, the customer is more willing; one year and a half back to the customer, the customer can tolerate; two years can not recover the cost, the customer is generally not considered.
The standard for realizing machine substitution is that if a fully automated equipment is used on a certain product, the cost can be recovered within two years. For more than two years, we will not consider it. At present, it is still relatively semi-automatic, and the flexibility of the fully automatic LED lighting production line is not very good.
Fully automated equipment is hard to change, and now the application side process changes too much. In the case of such contradictions, the combination of man-machine and semi-automatic equipment is more flexible and more suitable for the current LED lighting enterprises. In the era of LED lighting that is not a stock, the production capacity has to consider whether sales can keep up. In view of the customized and personalized market demand, semi-automatic is still the choice of lighting companies.
The high-quality, high-efficiency lighting automatic production line is about 4 million yuan / article, while the man-machine hybrid line is about 1.5 million yuan / article. In terms of the domestic market, 20% of enterprises will use fully automatic production lines, and another 80% will adopt human-machine hybrid lines. On the other hand, to study the structure of lighting fixtures, I hope to do some universal kits that meet fully automated production.
At the same time, downstream lighting companies want to be compatible, but at this stage of automation equipment, unless the process materials of the products are very similar, it is difficult to achieve compatibility. To make automation equipment easier to use, it is important to work with customers. Nowadays, most customers are more willing to start from the product stage, and the real automation is to develop automation equipment from the product development stage, materials and process structure.
Obviously, at this stage, it is not the best time for the fully automated production line of LED lighting to cut in. It takes a certain time for fully automated to be fully promoted. With the further concentration of the LED lighting market and the market share being mastered by a few companies, the spring of fully automated production lines is coming.
The main circuit of the equipment is the full bridge controlled circuit and the trigger circuit is the programmable integrated circuit. The phase-shifting, fixed width and modulation of the pulse are all digitized, and it does not need any adjustment for the section of the trigger. It has the features of high reliability, high pulse symmetry, strong anti-interference ability, quick reaction, as well as the advantages of no heat-generating, constant current, energy-saving which is compared with the discharge with the electrical resistance.
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