Contents:
1.Determine the list of materials
2.module production process
(1）the equipment required for the patch;
(2) Plug-in (if the DIP module production needs this production process, if the SMD module production does not need the plug-in process)
(3) Wave soldering
(4) After welding
(5) Test and module assembly
（6)Aging of semi-finished products
(7) Glue filling
(8)Aging of finished modules
3.cabinet assembly aging
4.the display site installation
5.Project acceptance
1.Determine the list of materials
After the product is finalized, it is necessary to make a detailed material list and B0M sheet:
The raw materials needed for the whole project should be listed on the list, including:
A list of materials for the module;
List of materials for the cabinet;
List of materials for the structure;
List of accessory equipment;
Make a complete list of materials, can do half the effect of the complete material can avoid in life
Extend the production week due to lack of materials during the production process and buy materials in a centralized rather than scattered purchase
Materials have a price advantage, which can reduce the cost of raw materials
2.module production process
（1）the equipment required for the patch;
Solder paste, printing press, patch machine, reflow soldering
Printing press: Apply the solder paste evenly on the PCB board to pay attention when printing, good contact pressing, printing table
The surface should ensure uniform thickness
SMT machine: Attach electronic components to PCB. Note:
Direction and polarity of components:
The pin of the component should be aligned with the pad package pin:
Reflow: Attach the components to the PCB board
The solder paste can be melted through the callback welding to weld the component to the PCB board. When over-reflow welding, note:
Set the temperature of each temperature zone:
Setting of each temperature zone time of reflow welding:
New SM high speed patch equipment
(2) Plug-in (if the DIP module production needs this production process, if the SMD module production does not need the plug-in process)
The LED light is fixed on the PCB according to the anode and cathode positions of the PCB screen printing, which is called the plug-in.
7 fully automatic insertion machines
The plug-in process requires attention to the following points:
Anti-static: static damage to LED lamp beads is obvious, the entire production pull needs to be well grounded, plug-in personnel
Must wear anti-static by the service can
Polarity: The long foot of the LED lamp bead is positive before the foot is cut, and the broken foot is negative, but after the foot is cut, the lamp foot is one
Sample length, so can not be judged from the length of the lamp foot positive and negative, and the lamp cup can not be determined is the negative, the technician needs to test before inserting the lamp to determine the positive and negative poles of the LED lamp foot.
(3) Wave soldering
Equipment required for wave soldering:
Fixture: The fixture of LED lamp bead is to ensure that the DIP LED lamp bead can be consistent when passing the wave soldering machine, which can ensure the uniformity and consistency of the DIP LED display effect.
Wave crest welder:
Wave soldering is a very important process in the production of 1LED display, need to pay attention to the following points:
Fixture and PCB board compatibility: the production of fixture must be consistent with the hole position of the product, after the wave soldering
To ensure the perpendicularity of the lamp
Spray the flux evenly and complete: the flux can make the solder at the peak of the wave good adhesion to the pad of the component
If the flux spray is uneven and does not cover the whole plate, this will cause virtual welding, false welding, and apply to the subsequent process belt
To trouble, but also affect the reliability and stability of the product,
Grounding: wave soldering must be well grounded
Ensuring the verticality of the LED lamp is an important problem to be solved in wave soldering, because the light of the lamp is emitted through the surface chip
The deviation of the lamp will cause the deviation of the luminous intensity and Angle waste, so that the luminance of the display is uneven.
Caused by the deviation of the color of each Angle, so that the effect and quality of the display image decline, so the wave soldering must be protected
Verify the verticality of LED lamp.
(4) After welding
Some large components can not be welded by wave soldering, such as power base, input and output interface pin, electrolytic electricity
Capacitance, etc., this requires manual welding, and we call this process post-welding
In addition to the welding components, the post-welding plate that has been crested and repaired is often not so complete as a person
Meaning, at this time, it is necessary to re-tinned some of the untinned pins after welding, and check some virtual welding and false welding on the board
Bad condition
Since the post welding operator is also in direct contact with the LED lamp bead, anti-static is a must, and the production table needs electrostatic treatment,
The operator must wear anti-static clothing.
(5) Test and module assembly
After welding the board, through the system can be lit up here must be tested to determine the quality of the board.
The test mainly detects the following aspects:
LED dead lights, dark lights:
Whether the electronic components are broken:
Components have virtual welding, false welding phenomenon:
Signal timing is correct:
Module assembly: Assemble the tested module on the bottom shell and mask
Light up the tested products and judge the quality of the whole screen
The aging of semi-finished products is more important for mass production, and the aging of semi-finished products can affect the whole life
Make an evaluation of the production, find the quality problems in the production process, and solve them in time to improve the production quality.
Ensure product reliability and reduce risks
(6) Aging of semi-finished products
The tested products are focused on lighting, and the quality of the whole screen is judged
Aging of semi-finished products is more important for mass production. When aging of semi-finished products, it can affect the whole life
Make evaluation of production, find quality problems in the production process and solve them in time to improve the production quality.
Ensure product reliability and reduce risks
(7) Glue filling
For outdoor products, it is necessary to fill the glue and waterproof, so the bottom shell of the module must be installed first, and then turn to the glue filling group
Glue, let the glue set naturally, then fix the plastic mask to the module.
When assembling the module, it is necessary to ensure the vertical degree of the lamp to avoid the deviation of the lamp by human factors. At the same time, when assembling, note
The force of the electric batch should not damage the bottom shell and mask of the module because of excessive force
To fill the glue:
When producing outdoor waterproof products, glue needs to be poured on the surface of the module to play a waterproof role
Nowadays, electronic potting glue is generally used, and the glue is automatically poured into the surface of the module by hand or by machine.
When filling glue, pay attention to:
Glue should be mixed evenly, the amount of glue is moderate, not too little, not too much can not be very good waterproof, too much affect the hair of the lamp
Light Angle and mask assembly
- Aging of finished modules
Gathering the modules filled with glue into the kit together to light the test is called aging
The aging of the finished module is mainly to do an overall evaluation of the screen body, such as the life and decay of the lamp and the screen body
Color difference phenomenon, realistic Angle, play the quality of graphics and so on
3.cabinet assembly aging
cabinet assembly materials:
cabinet(standard cabinet generally has a fan aviation cabinet with power and signal aviation seat):
Power supply (5V switching power supply, power base plate):
Modules:
Signal connecting wire (strip, network cable):
Power cables (5V power cables between modules, 220V power cables between power supplies):
Screws, nuts, copper posts, screw batches:
Control system:
cabinet assembly process:
l, install the module on the box:
- Connect the signal connection line between the module:
3, connect module 5Y power line:
- Install the power supply, and connect the 5V power cable on the module to the power supply:
5, the power supply between the 220V power cable connection, if there is a fan and aviation seat, together connected:
6, install LED receiving card, and the LED receiving card output and LED module input interface connected, and to the LED receiving card connected to the 5V power cable.
cabinet aging steps:
- Install the cabinet on the steel structure of the workshop;
Connect the box power cord to supply power to the LED display; Connect the signal line between the cabinet;
Test the power supply before connecting the power supply, whether there is short circuit between modules;
Connect to the power supply, system debugging:
Deal with problems that occur.
4.the display site installation
Before installing the display screen, the following work needs to be done:
Determine the frame structure on site;
A detailed understanding of power distribution systems;
Understanding of control platform systems;
A clear understanding of the location of the ancillary facilities;
And the personnel and tools needed to install the display.
Display installation and commissioning process:
- The screen body installation installs the box to the outer frame structure, and the box is usually connected (the same as the production box)
Will do a good job of connecting the piece) connection, to ensure that the gap between the box is minimal, the surface of the screen body is flat,
- Wiring including power cord and signal line:
The power cable includes the power cable between boxes and the power cable between the distribution system and the screen body. The signal cable includes the cable connection between boxes. The sealed boxes are connected with aviation heads.
- Install auxiliary facilities such as air conditioning, exhaust fan, sound equipment and so on
Test whether there is a wrong connection between the power lines short-circuit phenomenon system signal direction is consistent, there is no external metal caused by abnormal short-circuit circuit
5, power debugging
Through the control system software setting, check whether the wiring of the screen body is correct, whether the module is displayed normally, and whether the signal is transmitted normally
Input, whether the image can be normally transmitted and displayed
6, the outer frame edge, training customers to use, such as the use of operating software to play various files and images, as well as the screen body common
Problem handling methods, etc
5.Project acceptance
The above is about the LED display production process and art requirements of the full content, LEGIDATECH COMPANY with full color display and
LED display unit board wholesale, mainly committed to domestic and foreign professional engineering customers and distribution merchants, and provide
For high quality, high performance LED display. For our domestic and foreign customers to provide LED display solutions.
