LED lighting fixture assembly apparatus and method

Abstract

This invention relates to the field of lighting fixture manufacturing, specifically to an LED lighting fixture assembly equipment and method. It includes an assembly mechanism and a lamp housing loading mechanism. The light source board is placed on the assembly mechanism with the wires facing upwards. The assembly mechanism guides the wires to a vertical position and limits their movement. The lamp housing loading mechanism clamps the lamp housing, positioned at a set angle, directly above the light source board. Subsequently, the assembly mechanism pushes the light source board to engage with the lamp housing at the set angle. This invention overcomes two major technical challenges in the automated assembly of LED lighting fixtures: wire handling and angle control. Through multi-station continuous production and precise control, it significantly improves production efficiency. Automation replaces manual labor, ensuring consistency in product assembly angles and wire states, thus improving product quality. Wireless power supply, layered control, sensor feedback, and a stable mechanical structure collectively construct a highly efficient, stable, and intelligent automated assembly system.

Description

Technical Field

[0001] This invention relates to the field of lighting manufacturing technology, and in particular to an LED lighting fixture assembly equipment and assembly method. Background Technology

[0002] With the rapid development of semiconductor technology and the global advancement of energy-saving and environmental protection policies, LED lighting, with its significant advantages such as high efficiency, long lifespan, environmental friendliness, and flexible design, has completely replaced traditional lighting, becoming the mainstream and development direction of the lighting industry. Against this industrial backdrop, the manufacturing technology of LED lighting fixtures is also continuously evolving. Early assembly relied mainly on manual operation, resulting in low production efficiency and difficulty in ensuring consistency. Currently, the industry widely adopts automated or semi-automated specialized machines and assembly lines for production, achieving good results in the mass production of standard products.

[0003] Currently, because the light source board has wires connected to it, it is difficult to control the consistency of the wires. When assembling with the lamp housing, the wires need to pass through the holes on the top of the lamp housing, and the light source board and the lamp housing also need to be joined together at a set angle. It is difficult to automate this process, so this step is still done manually. Automation needs to be improved, and assembly consistency is difficult to guarantee. Summary of the Invention

[0004] The purpose of this invention is to address the problem in the prior art that the light source board and lamp housing need to be manually assembled by operators, and to propose an LED lighting fixture assembly device and assembly method.

[0005] On one hand, the present invention proposes an LED lighting fixture assembly device, including an assembly mechanism and a lamp housing feeding mechanism. The light source board to be assembled is placed on the assembly mechanism with the wires on the light source board facing upward. The assembly mechanism guides the wires to a vertical position and limits their movement. The lamp housing feeding mechanism clamps the lamp housing, which is placed at a set angle, and places it directly above the light source board. Then, the assembly mechanism pushes the light source board to be inserted into the lamp housing at a set angle. The assembly device is also equipped with a control system, which is connected to both the assembly mechanism and the lamp housing feeding mechanism.

[0006] Preferably, it also includes a turntable and a power device set at the bottom of the turntable to drive its rotation. Multiple sets of the merging mechanism are evenly arranged on the turntable along the circumferential direction, and the turntable rotates at a set angle each time.

[0007] Preferably, the merging mechanism is installed through the turntable, and a ring-shaped wireless charging mechanism is installed in the space below the turntable. Multiple wireless charging terminals are installed on the wireless charging mechanism, and each wireless charging terminal is located directly below a merging mechanism.

[0008] Preferably, the lamp housing feeding mechanism includes a conveying component and a clamping component; the conveying component continuously conveys the lamp housing, which is positioned and held at a set angle, to the clamping component, and the clamping component clamps the lamp housing and moves it directly above the light source plate.

[0009] Preferably, the conveying assembly includes a belt conveyor located outside the turntable and a limiting block disposed on the belt of the belt conveyor, and the lamp housing is positioned at an angle by means of the limiting block.

[0010] Preferably, the clamping assembly includes a transfer support frame located outside the turntable, a lateral moving device disposed on the transfer support frame, a vertical moving device disposed on the moving end of the lateral moving device, and a clamp disposed on the moving end of the vertical moving device.

[0011] Preferably, the assembly mechanism includes an electrical control box that runs through the turntable, a lifting device that is mounted on the electrical control box, a support bucket that is mounted on top of the lifting device and used to support the bottom surface of the light source board, a lifting device that is vertically mounted on the electrical control box, an extension plate that is mounted on the top telescopic end of the lifting device, and a positioning ring that is mounted on the end of the extension plate to fit onto the light source board; a sub-control system and a power supply are mounted inside the electrical control box.

[0012] Preferably, cable management modules are symmetrically arranged on the extension plates on both sides of the positioning ring. The cable management module includes a telescopic device on the extension plate, a motor frame on the telescopic end of the telescopic device, an encoder motor on the motor frame, a support plate on the output end of the encoder motor, a U-shaped frame on the support plate, and a support rod rotatably mounted on the U-shaped frame. The top of each support rod is provided with a semi-circular ring. When the two semi-circular rings are joined together, they clamp the top of the wire to achieve vertical straightening of the wire. A pressure sensor is provided on the motor frame.

[0013] On the other hand, the present invention proposes an LED lighting fixture assembly method, comprising the following steps: S1. Place the lamp housing on the lamp housing feeding mechanism at the set angle, place the light source board on the support bucket, and clamp the top of the wire with two semi-circular rings to straighten the wire; S2. The lamp housing feeding mechanism clamps the lamp housing directly above the light source board and then lowers the lamp housing. S3. After the lamp housing descends and contacts the pressure sensor, the telescopic device drives the motor frame and its mechanism away from the positioning ring. At the same time, the encoder motor rotates at a certain angle, causing the two semicircular rings to move away from each other and eventually rotate to the outside of the lamp housing. S4. The lamp housing continues to descend and cover the light source plate. Finally, the lifting device lifts the light source plate upward to complete the assembly of the light source plate and the lamp housing.

[0014] Compared with existing technologies, this invention has the following beneficial technical effects: it overcomes the two major technical difficulties of wire processing and angle control in the automated assembly of LED lamps, and achieves a significant improvement in production efficiency through multi-station continuous production and precise control. Automation replaces manual labor, ensuring the consistency of product assembly angle and wire status, thus improving product quality. Wireless power supply, layered control, sensor feedback, and stable mechanical structure together construct an efficient, stable, and intelligent automated assembly system. Attached Figure Description

[0015] Figure 1 This is a schematic diagram of the structure of one embodiment of the present invention; Figure 2 for Figure 1 A structural diagram from another perspective; Figure 3 for Figure 1 A schematic diagram of the structure after removing the lamp housing; Figure 4 for Figure 1 A schematic diagram of the structure after removing the assembly mechanism; Figure 5 This is a schematic diagram of the assembly mechanism; Figure 6 for Figure 5 A partial cross-sectional diagram of the structure; Reference numerals: 1. Turntable; 2. Power unit; 3. Lamp housing feeding mechanism; 4. Wireless charging mechanism; 5. Position detection mechanism; 6. Assembly mechanism; 7. Position detection sensor; 8. Light source board; 9. Lamp housing; 10. Belt conveyor; 11. Belt; 12. Limit block; 13. Transfer support frame; 14. Lateral movement device; 15. Vertical movement device; 16. Fixture; 17. Mounting hole; 18. Electrical control box; 19. Isolation ring; 20. Lifting device; 21. Support barrel; 22. Wire; 23. Positioning ring; 24. Extension plate; 25. Telescopic device; 26. Motor frame; 27. Encoder motor; 28. Support plate; 29. ​​U-shaped frame; 30. Support rod; 31. Semicircular ring; 32. Pressure sensor; 33. Guide rod; 34. Lifting device. Detailed Implementation

[0016] Example 1; as Figures 1-2As shown, the present invention proposes an LED lighting fixture assembly device, including an assembly mechanism 6 and a lamp housing feeding mechanism 3. The light source board 8 to be assembled is placed on the assembly mechanism 6. Manual placement is more suitable because the placement angle of the light source board 8 needs to be considered. The wires 22 on the light source board 8 face upwards. The assembly mechanism 6 guides the wires 22 to a vertical position and limits their position. The lamp housing feeding mechanism 3 clamps the lamp housing 9, which is placed at a set angle, and places it directly above the light source board 8. Then, the assembly mechanism 6 pushes the light source board 8 to be inserted into the lamp housing 9 at a set angle. The assembly device is also equipped with a control system, which is connected to both the assembly mechanism 6 and the lamp housing feeding mechanism 3.

[0017] Furthermore, it also includes a turntable 1 and a power device 2 set at the bottom of the turntable 1 to drive its rotation. Multiple sets of assembly mechanisms 6 are evenly arranged on the turntable 1 along the circumference. The turntable 1 rotates at a set angle each time to achieve continuous production and improve production efficiency. In order to control the stopping position of the turntable each time, a position detection mechanism 5 is also set. The position detection mechanism 5 detects the position of the lamp housing 9 through a position detection sensor 7 set on the support frame, thereby indirectly controlling the position of the turntable 1. The control system is connected to the position detection sensor 7 for data transmission and to the power device 2 for control.

[0018] Furthermore, the merging mechanism 6 is installed through the turntable 1. Specifically, the turntable 1 is provided with mounting holes 17 for mounting the merging mechanism 6. A ring-shaped wireless charging mechanism 4 is installed in the space below the turntable 1. Multiple wireless charging terminals are provided on the wireless charging mechanism 4, and each wireless charging terminal is located directly below a merging mechanism 6. The merging mechanism 6 is charged through the wireless charging terminal to maintain the normal operation of the merging mechanism 6. The power unit 2 is located inside the wireless charging mechanism 4.

[0019] Example 2; as Figures 3-4 As shown, the present invention proposes an LED lighting fixture assembly device. Compared with Embodiment 1, this embodiment details the structure of the lamp housing feeding mechanism 3. Specifically, the lamp housing feeding mechanism 3 includes a conveying component and a clamping component. The conveying component continuously conveys the lamp housing 9, which is positioned and maintained at a set angle, to the clamping component. The clamping component clamps the lamp housing 9 and moves it directly above the light source plate 8.

[0020] The conveying assembly includes a belt conveyor 10 located outside the turntable 1, and a limiting block 12 set on the belt 11 of the belt conveyor 10. When the lamp housing 9 is placed, the limiting block 12 is used for angular positioning. Specifically, there are two synchronously driven belts 11 on the belt conveyor 10, and a limiting block 12 is set on each belt 11. The arc surface of each limiting block 12 has a cut surface, which is used to position the protruding positioning block on the inner wall of the lamp housing 9, thereby keeping the lamp housing 9 at a set angle.

[0021] The clamping assembly includes a transfer support frame 13 located outside the turntable 1, a lateral moving device 14 mounted on the transfer support frame 13, a vertical moving device 15 mounted on the moving end of the lateral moving device 14, and a clamp 16 mounted on the moving end of the vertical moving device 15. Specifically, the lateral moving device 14 and the vertical moving device 15 are both structures in which a motor drives a screw to rotate, the clamp 16 is a gripper cylinder, and the control system is connected to the lateral moving device 14, the vertical moving device 15, and the clamp 16.

[0022] Example 3; as Figures 5-6 As shown, this invention proposes an LED lighting fixture assembly device. Compared to Embodiment 1 or Embodiment 2, this embodiment details the structure of the assembly mechanism 6. Specifically, the assembly mechanism 6 includes an electrical control box 18 that runs through the turntable 1, a lifting device 20 mounted on the electrical control box 18, a support barrel 21 mounted on the top of the lifting device 20 to support the bottom surface of the light source board 8, a lifting device 34 vertically mounted on the electrical control box 18, an extension plate 24 mounted on the top telescopic end of the lifting device 34, and a positioning ring 23 mounted at the end of the extension plate 24 to fit onto the light source board 8. The electrical control box 18 contains a sub-control system and a power supply. The power supply is charged via a wireless charging mechanism 4. The sub-control system and... The control system is wirelessly connected; specifically, the light source plate 8 has symmetrical positioning surfaces on both sides, and other edges are arc-shaped surfaces. The inner wall of the positioning ring 23 has two raised positioning surfaces to position the light source plate 8, thereby ensuring that the light source plate 8 is at a set angle in the installation position; in addition, in order to maintain the stability of the extension plate 24 and the positioning ring 23, multiple guide rods 33 are vertically arranged on the electrical control box 18, and the extension plate 24 is provided with guide holes for the guide rods 33 to pass through; in an optional embodiment, the electrical control box 18 is also provided with an isolation ring 19, and the positioning ring 23, extension plate 24, lifting device 20, lifting device 34 and other structures are all located inside the isolation ring 19; the sub-control system is controlled and connected to the lifting device 20 and the lifting device 34.

[0023] Cable management modules are symmetrically arranged on the extension plates 24 on both sides of the positioning ring 23. Each cable management module includes a telescopic device 25 on the extension plate 24, a motor frame 26 at the telescopic end of the telescopic device 25, an encoder motor 27 on the motor frame 26, a support plate 28 at the output end of the encoder motor 27, a U-shaped frame 29 on the support plate 28, and support rods 30 rotatably mounted on the U-shaped frame 29. Each support rod 30 has a semi-circular ring 31 at its top. When the two semi-circular rings 31 are joined together, they clamp the top of the wire 22, achieving vertical straightening of the wire 22. A pressure sensor 32 is installed on the motor frame 26. The sub-control system is connected to the pressure sensor 32 for data transmission. The sub-control system is also connected to the telescopic device 25 and the encoder motor 27. All 7 are controlled and connected. After the lamp housing 9 descends and contacts the pressure sensor 32, the telescopic device 25 drives the motor frame 26 and its mechanism away from the positioning ring 23. At the same time, the encoder motor 27 rotates at a certain angle, so that the two semicircular rings 31 move away from each other and finally rotate to the outside of the lamp housing 9. Then the lamp housing 9 continues to descend and cover the light source plate 8. Finally, the lifting device 20 lifts the light source plate 8 upward to complete the assembly of the light source plate 8 and the lamp housing 9. Specifically, a rotating rod is set on the U-shaped frame 29, and the bottom of the support rod 30 is connected to the middle of the rotating rod. A limit ring is set on the rotating rod, and a torsion spring is sleeved on the rotating rod. The two ends of the torsion spring are connected to the U-shaped frame 29 and the limit ring respectively. When the two semicircular rings 31 are in contact, they are in a state of mutual compression, thereby maintaining effective traction on the wire 22.

[0024] Example 4; The present invention proposes an LED lighting fixture assembly method, which uses the LED lighting fixture assembly equipment of Example 3, and specifically includes the following steps: S1. Place the lamp housing 9 on the lamp housing feeding mechanism 3 at a set angle, place the light source board 8 on the support barrel 21, and clamp the top of the wire 22 with two semi-circular rings 31 to straighten the wire 22. S2. The lamp housing feeding mechanism 3 clamps the lamp housing 9 directly above the light source board 8, and then lowers the lamp housing 9. S3. After the lamp housing 9 descends and contacts the pressure sensor 32, the telescopic device 25 drives the motor frame 26 and its mechanism away from the positioning ring 23. At the same time, the encoder motor 27 rotates at a certain angle, causing the two semicircular rings 31 to move away from each other and eventually rotate to the outside of the lamp housing 9. S4. The lamp housing 9 continues to descend and cover the light source plate 8. Finally, the lifting device 20 lifts the light source plate 8 upward, completing the assembly of the light source plate 8 and the lamp housing 9.

[0025] In summary, this invention overcomes two major technical challenges in the automated assembly of LED lighting fixtures: wire processing and angle control. Through multi-station continuous production and precise control, it achieves a significant improvement in production efficiency. Automation replaces manual labor, ensuring the consistency of product assembly angle and wire status, thus improving product quality. Wireless power supply, layered control, sensor feedback, and stable mechanical structure together construct an efficient, stable, and intelligent automated assembly system.

[0026] The embodiments of the present invention have been described in detail above with reference to the accompanying drawings. However, the present invention is not limited thereto. Various changes can be made within the scope of knowledge possessed by those skilled in the art without departing from the spirit of the present invention.

Claims

1. An LED lighting fixture assembly device, characterized in that, The assembly equipment includes a assembly mechanism (6) and a lamp housing feeding mechanism (3). The light source board (8) to be assembled is placed on the assembly mechanism (6), with the wires (22) on the light source board (8) facing upwards. The assembly mechanism (6) guides the wires (22) to a vertical position and limits their position. The lamp housing feeding mechanism (3) clamps the lamp housing (9) placed at a set angle and places it directly above the light source board (8). Then, the assembly mechanism (6) pushes the light source board (8) to be inserted into the lamp housing (9) at a set angle. The assembly equipment is also equipped with a control system, which is connected to both the assembly mechanism (6) and the lamp housing feeding mechanism (3).

2. The LED lighting fixture assembly equipment according to claim 1, characterized in that, It also includes a turntable (1) and a power device (2) set at the bottom of the turntable (1) to drive it to rotate. Multiple sets of the assembly mechanism (6) are evenly arranged on the turntable (1) along the circumferential direction. The turntable (1) rotates at a set angle each time.

3. The LED lighting fixture assembly equipment according to claim 2, characterized in that, The assembly mechanism (6) is set through the turntable (1), and a ring-shaped wireless charging mechanism (4) is set in the space below the turntable (1). Multiple wireless charging terminals are set on the wireless charging mechanism (4), and each wireless charging terminal is located directly below an assembly mechanism (6).

4. The LED lighting fixture assembly equipment according to claim 1, characterized in that, The lamp housing feeding mechanism (3) includes a conveying component and a clamping component; the conveying component continuously conveys the lamp housing (9) which is positioned and held at a set angle to the clamping component, and the clamping component clamps the lamp housing (9) and moves it directly above the light source plate (8).

5. The LED lighting fixture assembly equipment according to claim 4, characterized in that, The conveying assembly includes a belt conveyor (10) located outside the turntable (1) and a limiting block (12) set on the belt (11) of the belt conveyor (10). The lamp housing (9) is positioned at an angle by the limiting block (12) when it is placed.

6. The LED lighting fixture assembly equipment according to claim 4, characterized in that, The clamping assembly includes a transfer support frame (13) located outside the turntable (1), a lateral moving device (14) disposed on the transfer support frame (13), a vertical moving device (15) disposed on the moving end of the lateral moving device (14), and a clamp (16) disposed on the moving end of the vertical moving device (15).

7. The LED lighting fixture assembly equipment according to claim 1, characterized in that, The assembly mechanism (7) includes an electrical control box (18) that runs through the turntable (1), a lifting device (20) that is mounted on the electrical control box (18), a support bucket (21) that is mounted on the top of the lifting device (20) and used to support the bottom surface of the light source plate (8), a lifting device (34) that is mounted vertically on the electrical control box (18), an extension plate (24) that is mounted on the top telescopic end of the lifting device (34), and a positioning ring (23) that is mounted at the end of the extension plate (24) to fit onto the light source plate (8); a sub-control system and a power supply are installed inside the electrical control box (18).

8. The LED lighting fixture assembly equipment according to claim 7, characterized in that, A cable management module is symmetrically arranged on the extension plates (24) on both sides of the positioning ring (23). The cable management module includes a telescopic device (25) arranged on the extension plate (24), a motor frame (26) arranged on the telescopic end of the telescopic device (25), an encoder motor (27) arranged on the motor frame (26), a support plate (28) arranged on the output end of the encoder motor (27), a U-shaped frame (29) arranged on the support plate (28), and a support rod (30) rotatably arranged on the U-shaped frame (29). A semi-circular ring (31) is arranged on the top of each of the two support rods (30). After the two semi-circular rings (31) are joined together, they clamp the top of the wire (22) to achieve vertical straightening of the wire (22). A pressure sensor (32) is arranged on the motor frame (26).

9. A method for assembling LED lighting fixtures, using the LED lighting fixture assembly equipment described in claim 8, characterized in that, Includes the following steps: S1. Place the lamp housing (9) on the lamp housing feeding mechanism (3) at the set angle, place the light source plate (8) on the support barrel (21), and clamp the top of the wire (22) with two semi-circular rings (31) to straighten the wire (22); S2. The lamp housing feeding mechanism (3) clamps the lamp housing (9) directly above the light source plate (8) and then lowers the lamp housing (9). S3. After the lamp housing (9) descends and contacts the pressure sensor (32), the telescopic device (25) drives the motor frame (26) and its mechanism away from the positioning ring (23). At the same time, the encoder motor (27) rotates at a certain angle, so that the two semicircular rings (31) move away from each other and eventually rotate to the outside of the lamp housing (9). S4. The lamp housing (9) continues to descend and cover the light source plate (8). Finally, the lifting device (20) lifts the light source plate (8) upward to complete the assembly of the light source plate (8) and the lamp housing (9).

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