Zhongshan Dashuo Intelligent Equipment Co., Ltd.

LED Bulb Assembly Line

Instruction Book
Equipment composition: automatic riveting machine for lamp cap+bulb assembly
machine+3-minute aging line

Equipment provider: Zhongshan Dashuo Intelligent Equipment Co., Ltd.

Address: 1st Floor, No.19, Dong'an West Road, Guzhen, Zhongshan, Guangdong Province, China-528421

Tel.:0760-22385471

Website: https://dashuozhineng.en.alibaba.com/

Contact: Mr. Wang, Mobile: +86-18312647642(WhatsApp&WeChat)

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Company Profile
Zhongshan Dashuo Intelligent Equipment Company Limited was established in 2011 and is located in
Guzhen Town, Zhongshan City, Guangdong Province. We are a professional LED light processing
equipment manufacturer with rich technical reserves. We have dozens of processing equipment such as
sheet metal workshops, accessories processing workshops, large-scale laser cutting machines, bending
machines, large-scale CNC machines, precision carving machines, milling machines, CNC lathes, drilling
machines, and dozens of quality measuring instruments, with more than 40 employees.

We develop and produce LED driver test machines, DOB light source test machines, charger test machines,
LED bulb assembly equipment, down light assembly machines, hot-melt machines, glue dispensing
machines, test fixtures, etc. We have been exploring and innovating in the lighting industry, and we want to
provide the best products to our customers in the lighting industry.

Our mission: Making lamp production easier.

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Foreword---origin of the equipment

In recent years, the continuous transformation and upgrading of the manufacturing industry and the rising
labor costs have brought considerable challenges to the lighting industry. The heads of lighting factories
have also changed from focusing only on sales to optimizing production and manufacturing. Sometimes our
order profit is not low, but the production cost may be too high. In the entire lighting industry, most small and
medium-sized LED bulb manufacturers will face the following problems: the order quantity is not large, the
production line changes frequently, and the orders are unstable, but there is no suitable equipment to deal
with these problems. Through active communication with customers and keeping up with the industry trend,
we have summarized the following industry pain points: 1. With the uncertainty of orders, it is possible to
make T-bulb today and A-bulbs tomorrow, so we should consider the versatility of the equipment. 2. Small
and medium-sized factories may not have professional equipment technicians. At this time, we should
consider the simplicity of production line change. If the line change time is too long, the production efficiency
of the day will be affected. 3. The equipment cost should not be too high, but the reliability and stability
should be high. 4. It is best to have a flexible production mode without a fully automatic production line. If
any part of the fully automatic production line fails, the entire production line has to stop production.

Therefore, our Dashuo equipment came. Through continuous optimization and improvement in the past
three years, we finally launched universal A-bulb and T-bulb equipment. Different molds adapt to different
products. The production line is easy to replace and takes a short time. The front-end and back-end
equipment cooperate flexibly; from the automatic assembly of the lamp holder to the glue dispensing, press
cover, and aging of the rear end, the automated production of all processes realizes. The highlight is that
there is no influence between the front-end and the back-end equipment. No matter which machine is
abnormal, it will not affect the use of other equipment. While controlling the cost of equipment also ensures
the equipment’s reliability, considering the flexibility and ease of operation. Now, please refer to this
high-cost performance equipment.

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1.Diagram&dimensions
3D diagram

2.automatic 4.automatic assembly

5.laser marking machine
riveting machine machine for LED bulb
for lamp cap

1.chain conveyor to
press light source board

3.conveyor belt 6.aging line

Layout plan

Unit: mm

、
Overall dimensions of the complete assembly line: 8500mm(length)x3080mm(width)x1600mm(height).
Equipment introduction: This equipment is flexible, convenient, and easy to operate. Different molds fit
A-bulb and T-bulb with E27 lamp caps. Manually place the light source board into the lamp base and put it
into the chain mold, then the pressing device will press the light source board well. Next, let the lamp base
upside down and place it in the chain mold. The riveting machine will automatically pick the lamp base, place
lamp caps, test, fix rivets and tighten lamp caps. Qualified products will put into the conveyor belt. Then the
lamp base will be manually put into the assembly machine for glue dispensing, fix covers, and laser marking.
The finished product will automatically be put into the aging line and passes through the low-voltage and
high-voltage area, and finally enter the power test unit, the products that qualified power will put into the OK
basket, unqualified products will drop into the NG basket.

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2.Applicable product

Adapts to A-bulb and T-bulb

with E27 lamp cap, all
production process

3.Instructions for production process

5 6

2 4 13 14 15
7
19
12

8 16

9 20

17
21
3
1
10 18
11

1.manually place the light source board 2.press light source board
3.automatically pick lamp body 4.touch screen(control panel)
5.lamp cap feeder&automatically place lamp cap 6.measure lamp wattage
7.cut wire and bend wire 8.rivets feeder&fix rivets
9.tighten lamp cap
10.unloading qualified product and sorting unqualified product.
11.conveyor belt 12.manually feed lamp body and covers
13.conveyor belt for covers 14.press light source board
15.glue supply and dispensing 16.automatically press covers
17.Laser marking machine
18.automatically transfer the bulb into the aging line
19.3-mibute aging line 20.measure lamp wattage
21.unloading qualified product and sorting unqualified product.

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4.Diagram for production process

1 2 3

insert the light source

insert the wires spread the wires
board into the lamp body

6 5 4

the robotic arm transfers the

press light source board place the lamp body into
lamp body into the assembly
the chain mold

7 8 9

automatically place lamp cap measure lamp wattage

cut wire&press wire

12 11 10

cut wire&press wire graphic

fixed rivet feed&fix rivets

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13 14 15

tighten lamp cap unloading qualified product and feed lamp body and covers
sorting unqualified product. to assembly machine

18 17 16

Fix covers Glue dispensing Press light source board

19 20 21

Logo Unload finished product Load finished product

to aging line

24 23 22

sorting OK product and NG product the unit to measure wattage generic aging line

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5. All molds for the assembly line

1.chain mold

There are altogether 26 molds on the chain. It is suggested to open a set of

molds for products of different specifications.

Punching-press mold: one mold can only press one diameter of light source
board.

2.molds of automatic riveting machine

The automatic riveting machine has 8 molds to place lamp bases, one
mold can fit 3 bulbs of different diameters in the same series. The normal
sizes of T-bulb are T50\T60\T70\T80\T100\T115\T125\T135.Then
T50&T60 shares one mold, T70&T80 shares one mold, T100,T115, T125,
T135 share one mold, one series of bulbs need 3 sizes of molds, each size
has 32 molds.
Special instructions: If the bulbs with similar diameters cannot share one
mold, another mold shall be opened.

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3.the molds to dispense glue and fix covers

8 bottom molds for lamp bases, these

molds are in the assembly machine, and
the different shapes of bulbs need
different molds. One bottom mold can be
in common use similar sizes of bulbs in
the same series, if one series has 8
different sizes of bulbs, then you need to
open at least 2 sets of bottom molds,
each set has 8 pieces.
Special instructions: If similar sizes of
bulbs can’t share one mold, another mold
shall be opened.

The molds to fix covers.

This set of molds contain 4 parts, they are
punch-press mold, suction mold, transition
mold and annular mold. Different
diameters of bulbs need different suction
cover molds.

Equipment Name Mold Name Quantity Notes

1.chain conveyor to Locating mold 26 pieces Every bulb needs a mold

press light source board
Punching-press mold 1 piece Every bulb needs a mold

2.automatic riveting
machine Locating mold for lamp cap 8 pieces As per your samples

3.automatic assembly
Molds set for assembly machine
machine 1 set Every bulb needs a mold

Special instructions: the molds will customize as per your bulb samples, and the cost of molds is as per
sample quantity and sizes.

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6.technical parameters
Semi-automatic bulb assembly line

Item Specification Notes

Applicable product A-bulb(A45-A90) and T-bulb(T50-T135) E27 lamp cap

Production capacity 1200 pieces\hour

Front-end equipment 3KW + 3-minute aging line 5KW,

Total power
total 8 KW

Electrical requirement AC220V, 50-60Hz，wit reliable grounding

0.5-0.8MPa, recommend 15KW air compressor+100L

Compressed air
air storage tank

Overall dimensions 8500mm*3080mm*2000mm (length*width*height)

Total weight 2500Kg.

7.Instructions for configuration

Item Specification Control Method

1.chain conveyor to
press light source board divider+high precision big torque step motor driving PLC+touch screen

2.automatic riveting
machine divider+high precision big torque step motor driving PLC+touch screen

3.Conveyor belt 220V gear motor speed regulator

4.Semi-automatic
assembly machine divider+high precision big torque step motor driving PLC+touch screen

5.Laser marking
machine Dedicated 30W laser marking machine computer

big torque step motor+high precision gear motor

6.aging line driving PLC+touch screen

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