Automated Production Process
BIOLIGHT Co., Ltd. is a new equipment for quality development and strictly manages quality through various tests
that need to be carried out according to road conditions while driving.
PROCESS 01
PROCESS 02
The laser glass tube cutting process is performed by the automated system to laser the quartz glass tube to specification, and the cut (body) material is automatically screened by the automated computer control program and then moved to next process by the conveyor system.
PROCESS 01
The sealing process is a process in which the exhaust pipe and the main pipe are automatically inserted to heat the end section of the glass tube, and then the heated end section is formed to join the two sides.
The bonded process completed is automatically screened 100% by an automated computer control program before being moved to the next process by the conveyor system.
PROCESS 02
The bridge process is a process in which two molybdenum wires are molded and processed so that the filaments can be fixed in the glass tube at high temperatures and emit light.
The operation process automatically cuts the wire at the first 2 points to the specified specifications, molds the wire so that the filament can be secured, and then wraps the heated quartz glass rod around the two molded wire stems and melts them together.
The processed bridge process is automatically screened 100% by the automated computer control program before moving to the next process.
PROCESS 03
The mounting process is the preparation process inside the halogen bulb so that the filament can glow inside the bulb when voltage is applied by securing the filament to the bridge.
The work process is produced by a set specification by automatically injecting materials such as filaments, bridges, molybdenum wires, molybdenum foil, etc.
The processed products are automatically screened 100% by the automated computer control program and then moved to the next process by the conveyor system.
PROCESS 04
The pinch sealing process is a process in which the mount completion (filament) is placed inside the quartz glass tube and the lower part of the main body tube is heated to a high temperature of 1,800°C or higher to seal with the pinch mold.
The process automatically injects the mounting product and the main body tube product, and special mixing gas is injected into the main body to suppress the generation of internal filament oxidation when heating the main body with high heat.
Heat the lower part of the main body sequentially, and when the lower part is completely bent, dip the shape with pinch mold to seal it.
PROCESS 05
The exhaust process injects the sealing finished product into the installation, cleans the interior of the sealing product with a special blend of gas, and vacuums the interior of the sealing product with a high vacuum pump.
When the inside of the sealing material is in high vacuum, put halogen gas into the sealing material, cool the halogen gas inside the sealing material with liquefied nitrogen (-170 °C), heat the exhaust pipe with a heating burner, and cut the tap.
From this point on, the halogen gas-sealed light bulb begins its life as a light bulb.
PROCESS 06
PROCESS 07
The capsule lighting process automatically injects light bulbs produced in the exhaust process by an automated installation and illuminates the filament by applying a 12V or 24V voltage to each bulb.
The lighted bulb is automatically loaded into the palette by the transfer conveyor system and moved to the next process after undergoing a light-free inspection of the light center of the filament, the exterior of the bulb, and the dimensions of the bulb by the vision system.
PROCESS 07
The capping & focusing process automatically injects the semi-finished bulb and each assembly part, which is secured to the jig.
The assembly parts fixed to the jig are controlled by the vision system information entered to control the movement of the servo motor x, y, and z axis unit, and the filament portion of the bulb accurately matches the set value before completing with laser welding.
The assembled product is moved to the next process by the conveyor system.
PROCESS 08
PROCESS 08
The top-coating process is a process in which a coating is made on the surface of the glass tube end of the bulb to inhibit the light of the bulb illuminated from the vehicle's headlamps directly forward.
The process sequence automatically injects the assembled product to form a film with BLACK coated paint at the end of the glass tube surface and dries the paint at high temperatures.
Products that have been dried after the formation of the film will be moved to the next process by the conveyor system.
PROCESS 09
The 100% vision & marking process inspects assembled products with automated vision equipment to automatically determine and screen quality and defects.
The product that is OK during the vision inspection is completed by marking [brand name, part number, specification, date of manufacture, origin, and other customer requirements] on the surface of the BASE using an inkjet printer according to the input value.
The finished product will be moved to the next process by the conveyor system.
PROCESS 10
The finished product lighting process is the last process of production and assembled. The finished products inspect by an automated detection system.
At this time, [Distraction lamp, Ampere Underfed (A), Under-welded resistance value (mΩ)] Determine and screen defects, and select products that have completed the lighting test. Upon extraction from the facility, the examiner will visually screen the appearance.
Products that have been inspected are loaded onto the loader and stored in the 72-hour aging space for aging.
PROCESS 11
The automatic finished product lighting process is the final inspection process before shipment, and the product that has been aging for 72 hours applies the most similar environmental conditions to the facility to conduct the lighting test.
The purpose of the final automated lighting system is to detect minor changes caused by repeated lights on/off of light bulbs and the heating conditions of light bulbs so that no single defect can be leaked. These efforts are an unremitting effort to realize BIOLIGHT's customer satisfaction in order to prevent the leakage of even one single defect out of a million.
“Do not Accept! Build! Ship! a Defect!”
PROCESS 12
THE BEST QUALITY WITH HIGH-TECHNOLOGY
More brightly, More safely...
Head office and Factory
46, Saneopdanji 1-ro, Eomo-myeon, Gimcheon-si, Gyeongsangbuk-do, Republic of Korea
T. +82-54-439-0252 F. +82-54-439-0254
E-mail. sns@biolightbulbs.co.kr
Gwangmyeong Office
67, Saebitgongwon-ro, XI TOWER A-dong 2107
Gwangmyeong-si, Gyeonggi-do, Republic of Korea
T. +82-2-6954-0252 F. +82-2-6954-0253
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