Energy-saving lamps built by man and machine

Citation

(1998), "Energy-saving lamps built by man and machine", Assembly Automation, Vol. 18 No. 3. https://doi.org/10.1108/aa.1998.03318caf.006

Energy-saving lamps built by man and machine

Energy-saving lamps built by man and machine

Keywords Automation, Manufacturing

A new manufacturing system for SLI Lighting, of Shipley, makes energy-saving lamps using automatic and manual stations to their fullest advantage. The system was conceived, designed, built and commissioned by Modular Automation of Birmingham (Plate 4).

Plate 4The Modular Automation manufacturing system

The assembly line has sufficient built-in flexibility to handle bayonet (BC) and screw-in (ES) fitting lamps with two variations of each, without re-tooling. Operations that require human dexterity are performed by manual operators, while the fully automatic stations handle all other functions, including quality control and test.

The line starts with three manual stations. The first loads the glass tube; the second carefully places the electronic circuit board and lines up the four connecting wires by eye; and the third adds a retaining sleeve and crimps the wires to size. The crimping tool was designed by SLI but made specifically for the purpose by another Modular Industries company, Modular Precision.

The system is programmed to recognise whether it is working on BC or ES lamps through a control panel that also handles functions such as alarm priorities and the pre-heat settings for a later soldering operation.

Manual stations place and secure the end caps in place. This requires the operator to locate the connecting wires into two small holes in the plastic cap. This can be performed easily by an experienced operator but would be impractical and expensive to achieve automatically.

An automatic station then trims the wires to the correct length and again recognises the difference between a BC fitting that has both live and neutral connections at the top, and an ES fitting that has a single central live with the neutral welded to the screw body.

Automatic stations then solder and polish the contact-making connections and weld the neutral connector for the ES lamp. Before completion the system automatically performs flash and continuity tests and ensures that the lamp performs correctly within an appropriate voltage range.

This is the second assembly system made by Modular Automation for SLI. The first improved productivity tenfold and helped significantly to reduce manufacturing costs.

For further information contact: Donna Nolan, Modular Automation, Talbot Way, Small Heath Business Park, Birmingham, UK. Tel: +44 (0) 0121 766 7979; Fax: +44 (0) 0121 766 6385.