Process Planning and System Layout of Lamps - Engineering Project

This project delves into the process planning and system layout for the manufacturing of lamps, with a specific focus on LED technology. The project begins with an introduction to different types of lighting, including halogen, LED, and xenon, and highlights the advantages of LED lighting, such as energy efficiency, long lifespan, and durability. It then explores the LED value chain, detailing key components like secondary optics, LED chip encapsulation, and reflectors. The project also includes a market analysis of the global LED lighting market, its growth, and key players. Furthermore, it covers the LED production process, including raw materials, manpower requirements, and equipment. The project also provides an overview of project financials, including estimated costs, payback periods, and production capacity. Finally, it discusses advanced production system layout and component selection procedures for optimal design decisions.

Process Planning and system layout of Lamps
Introduction

Electric powered lamps promised much the flickering flame could not. These were to be
cooler, brighter, steadier and more pleasant to the optic eye without releasing poisonous,
dirty or perhaps noxious by-products. However, they did not begin that real way.
You will find three types of lighting which are required for production: Halogen, LED and
Xenon.
Men and women have decided that they need a lighting light bulb for their home or maybe
even business property lighting; next thing to consider is which kind of light bulb is best for
their requirements. In past years the particular obvious choice has become one particular, L.
E. Reasons plus d for that are quite a lot of. L. Digital. D lighting has changed light bulb
market significantly by improving methods how and what lighting is utilized in our own
houses. Listed here are listed 10 advantages that will L. E. D lamps have over their old
halogen lights, cFL, Inc and scent.
o Lengthy life time L. E. G lights have significantly lengthier lifetime than other kind of
lamps. Average lifetime of DIRECTED bulbs and diodes is definitely 50000 hours and
can are as long as 100000 hours. That can be a lot more than 10 years of non‐stop
operating. If you use LED lights otherwise you house lights and they are not really
continuously on, life time of just one bulb can reach two decades even.
o Lighting L. E. D lamps can produce more light making use of less energy that means
they are brighter than other lights available, for illustration, one M. E. D flood lighting
can produce same light compared to two or three halogen flood lamps and be as
bright.
o Less energy make use of, smaller sized electric bills one of main benefits of L. E. D
lighting is high luminous overall performance which means how well source of light
produces obvious light when compared with power usage.
o Sturdiness and Quality L. Electronic. D lights are built along with good quality and
high longevity. They come with different basic safety very safe covers, for example
aluminum plus a number of lights are water-proof. This is great for numerous outside
usage, as you can rely on your own L. E. D floodlight to suffer some more
complicated weather conditions like rain, storms, snow, other and hail.

The particular Light Giving out Diode, or perhaps LED, is an element that releases power
when the PN junction semiconductor is forward-biased, allowing the particular minority
carriers (electrons plus electron holes) to recombine on the PN junction. Amongst LED lights,
white L.e.d.s is now used increasingly since backlights for LCD Televisions, headlights, and
general light, and the application is growing. When compared to the existing gentle
lightweight, LEDs are small sized and sources; environment friendly; long-lived; quick in
response speed; available on pulse/AC/DC action; and allows result control. White LED
lighting does not use mercury, so that they are friendly and are strong devices
environmentally, and because these are long-lived, they are expected to change
incandescent lights as well as neon lights in the future. If white-colored LED lights do
substitute all existing light resources, the social and financial effects will be immense.
Furthermore, recent technological developments possess already been ongoing in the field
of incorporation and convergence with the healthcare, agriculture, maritime, and city areas.
LED lights are usually currently a norm regarding backlight units (BLU), auto lights, and
outdoor lamps, and applied products within real life that use LED lighting sources are
furthermore getting attention. Furthermore, LED-light-source used products in real life are
usually gaining attention. LED lamps are no trivial enhancements to improve the design idea
longer, but rather, LED products are increasing in the particular impact.
LED Lights - Summary
o LED lamp is a light-emitting diode (LED) product that is built into a lamp (or light
bulb) for use in light fittings.
o LED lights pass an electric current through a semiconducting material to illuminate
the particular light emitting diodes that give the particular bulb its name.
o The lights have already been proved to be more energy efficient, economically
practical and long-lasting than their particular conventional counterparts.
o While a good LED bulb last regarding 50, 000 hrs, this particular consumes 10W
electricity plus emits 80-100 lumens/watt, an excellent incandescent bulb last just for
1, 500 hrs periods, eat 60W and generates just 13 lumens/watt.
o LED lights are best suited for signs plus hints, night lights, lights, under cabinet
fixtures, and some indented light/down light applications.
o For house purpose, LED bulbs is available in the energy efficient range of 4W usually,
6W, 10W, 13W, 18W, 30W and 25W. (W = watts)

BROUGHT Value Chain
LED Value Chain
LED items can be classified into various types:
o Light giving out colors - LEDs can be found in red, orange, green and glowing blue
and so on.
o Outer surface area structure and trait from the diodes - LED could be classified into
round BROUGHT, square LED, rectangular BROUGHT, surface LED, side BROUGHT,
surface mount sub miniscule LED.
o According to the framework - LED based on construction can be classified into
complete epoxy resin packaging, steel base, ceramic base epoxy resin glass and
product packaging.
o Luminous intensity- Based on luminous intensity, there are regular brightness LED
(luminous strength 100mcd).

Key components of LED Lamp
A good DIRECTED lamp comprises following main sub units/parts:
Secondary Optical technologies: Secondary optics is used to produce the desired
appearance and ray pattern of the LED transmission lamp. It is known as the diffuser
component.

Optics or remote control phosphor separates the giving out photons, allowing different
phosphors to be interchanged in a lighting housing. This allows color heat to be changed
simply by slotting in a numerous phosphor.
LED chip encapsulates: The particular chip encapsulates provides humidity resistance and
soak up heat cycling stress, protecting the particular sensitive components. Their higher
transmittance and thermal balance help to design maintain lighting quality over a longer
period, whilst their unique chemistry provides minimal yellowing and damage.
Reflector: Reflectors provide ultra-high reflectivity for spreading the sunshine extensively.
Conformal coating/white representation: The conformal coating assists with moisture control
and solvent protection.
Thermal interface/ Portents: It helps in controlling benefit temperature of the LED by
giving proper insulation.
Adhesives intended for environment seals: Adhesives plus sealants play a crucial part in the
structural integrity associated with LED lamps and stress, shielding electronics from
environmental moisture and luminaries. These products ensure parts, like module lids and
foundation plates, provide a safe structure base for subcomponents and larger assemblies.

DIRECTED Lighting Marketplace - Worldwide Scenario
The global LED lights market is forecasted to achieve USD42. 7 billion by simply 2020 at a
CAGR associated with 13. 5% from 2014-2020. The fastest growing area is north the United
States expanding at a CAGR of fifteen. LED lights are expected to command ~20% share of
the global lights market by 2020. One of the LED types high lighting LED segment is
anticipated to grow rapidly and carry on and account for the highest market share, adding
over 60% of the overall market revenue.

LED Production - List of raw materials
Manpower requirement

List of machinery plus equipment
Much different equipment
Project Financials
Estimated project price
The total project cost of developing a LED manufacturing unit is INR500 Core. The facility
can manufacture LED lighting options for industrial segments, outdoor and indoor.
Project specifications

Payback period
Minimum practical size
Basis & Presumptions:
The basis for computation associated with production capacity has been used on the
particular single change basis on 75% effectiveness, the maximum capacity utilization upon
single shift basis, intended for 300 days in a complete year. During the first 12 months and
second period associated with operations, the capability usage is 60% and 80 percent
respectively. The device is anticipated to achieve full capacity usage from the third year
onwards, the wages and wages, cost of raw materials, utilities, lease, etc. are based on the
existing rates in. These cost elements are likely to vary with time plus region, Interest on
expression loan and working funds has been taken @ 16% on an average. This price might
vary based on the policy of economic institutions/agencies from time to time. The cost of
equipment and equipment refer to a specific make/model and the prices are usually
approximate, the break-even stage percentage indicated is of complete capacity use, the
task preparation cost, etc. anytime required could be considered underneath the pre-
operative expense.

Advanced production system layout
The lighting assemblies market is not static or even mature. In fact, solid condition lighting
technology continues to create at an extraordinary rate, plus thousands of new LEDs, gentle
motors, drivers, optics, fittings and heat sinks are usually launched to the market each year.
The Current Tools plus Design Process
Regarding current light source simulations tools, the consumer first selects the light supply,
then a drive current plus a temperature where the tool results efficiency and flux beliefs.
Some of the more sophisticated variations allow the customer to select the sunshine source,
a temperature, the particular target flux and focus on efficacy where the on the web device
will calculate the required ahead current to meet the target specs.