Adaptive LED Mounting System for Lens Alignment and Defect Reduction
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Solution Overview
Problem
The existing methods for mounting LED elements on a board and lenses to achieve high luminance often result in defective products when the LED element is significantly deviated from its preset position, causing the lens to protrude from the board edge, leading to increased defect rates.
Innovation Solution
A mounting system that includes board operation execution machines and a control device with units for precise LED element mounting, deviation amount acquisition, and adaptive lens mounting based on threshold values, ensuring the lens is positioned correctly to avoid protrusion and maintain high-quality LED lamp production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If the lens is mounted using the LED element position as reference to achieve alignment, then the light emitting unit coincides with the lens optical axis and luminance increases, but when the LED element is significantly deviated, the lens protrudes from the board edge and becomes a defective product
Solution Approach 1:
The patent applies dynamics by making the lens mounting strategy adaptive rather than fixed. The control device dynamically selects between two mounting approaches (alignment-based or position-based) depending on the measured LED element deviation, allowing the system to adjust its behavior based on actual conditions to avoid defects while maintaining luminance optimization when possible
Solution Approach 2:
The patent changes the parameter of lens mounting position determination from a single fixed method to a conditional selection between two methods. When LED element deviation is within tolerance, the lens mounting position is determined by alignment with the LED element; when deviation exceeds tolerance, the lens mounting position is determined by a preset position on the board, preventing protrusion defects
2Reliability
If the lens is always mounted at a preset position regardless of LED element position, then lens protrusion is avoided, but the light emitting unit does not coincide with the lens optical axis and luminance decreases
Solution Approach 1:
The system dynamically adjusts the lens mounting strategy based on the LED element position accuracy. When the LED element is mounted with acceptable precision, the system switches to alignment-based mounting to maximize luminance. When the LED element position is significantly deviated, the system switches to preset position mounting to prevent defects, thus optimizing luminance under favorable conditions while ensuring reliability under unfavorable conditions
Data Source
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AI summary
Provided is a mounting system which mounts an LED element on a board and mounts a lens so as to cover the LED element, in which control devices 100, 102, and 104 which control operations of operating machines 12, 14, and 16 include an LED element mounting unit 130 which mounts the LED element in a predetermined mounting position, a deviation amount acquisition unit 132 which acquires a deviation amount between a mounting position and the predetermined mounting position of the LED element, a first lens mounting unit 134 which mounts the lens on the board using a position of the LED element mounted on the board as a reference, when the deviation amount is smaller than a threshold value, and a second lens mounting unit 136 which mounts the lens in a preset position on the board, regardless of the position of the LED element mounted on the board, when the deviation amount is equal to or greater than the threshold value. Therefore, it is possible to manufacture an LED lamp having high quality and to decrease the percentage of defect.