As we all know,  “dispensing” is widely used in LED packaging technology, such as potting, molding, etc., then with the rapid development of LED lighting, displaying, automotive lighting, obviously,  it needs higher LED quality, higher color consistency, and higher efficiency.

According to market needs,  Zmotion develops vision motion controllers to achieve all kinds of dispensing. Through customer trust and cooperation, now our motion controllers can be used in many automated dispensing applications, like, glue path detection, speaker following dispensing, 5-axis linkage dispensing, PCB board following dispensing, and so on. And these solutions are mature and complete enough.

Today, Zmotion brings one another dispensing solution for you, that is, automated motion control in LED spraying, specifically,  LED fluorescent powder spraying.

The LED fluorescent powder spraying process is one key step to make white LED and specific color temperature, which can solve color difference, light uneven, yellow circle, color edge problems, then ensuring average spraying thickness and precisely controlling LED color concentration.

| LED Fluorescent Powder Adhesive Spraying Technology:

In white LED packaging process, it needs to make the fluorescent powder glue at first through fully mixing fluorescent powder, silicone, and the thinner, and put it in the adhesive spraying machine, then compress air to atomize the phosphor glue into fine particles, forming a uniform mist that is evenly sprayed onto the surface of the LED substrate.

The coating process of phosphor glue determines the quality and performance of white LED light color to a large extent. If the coating thickness is uneven, it will cause the emitted light to be partially yellowish or blueish, and some key parameters of high-power LED will decrease, such as light conversion efficiency, heat dissipation performance and color rendering index.

However, there are 3 common LED fluorescent powder dispensing solutions in the market shown as below:

Generally, the operator holds the spraying gun to spray the preset phosphor glue into needed area.

For this method, it is not suitable in mass production due to slow speed. Most importantly, quality can’t be ensured because it is hard to achieve average and consistent thickness.

This kind of dispensing machine mainly uses the needle to dispense.

Even if it is faster than manual operation, it can’t achieve continuous dispensing, after all, it needs the axis Z to download at LED board specified position, which means the efficiency is limited. Except the efficiency, not precise enough, especially when the dispensing area is small. Not precise means the quality.

Through automatic machine, the phosphor glue can be sprayed into target area automatically through the nozzle.

Compared former two, this one is more intelligent. However, sometimes, the output pressure is not stable, even appearing blocking. It will cause uneven glue sprayed, that is, quality can’t be ensured well. Moreover, you need to clean and maintain frequently, the time and cost are increased.

| Next, let’s see Zmotion LED Adhesive Spraying Solution:

We use our machine vision motion controller to achieve automatic dispensing, which integrates motion control with vision control.

It can spray LED phosphor glue continuously with different trajectory types through XY control. You can flexibly adjust the spraying speed, area range, the glue mixing ratio and throughput , depending on your real production needs. In this way, it simplifies the process to be applied LED color spectrum and color temperature requirements. The color temperature coating range is 3000~9000, and the applicable thickness of powder spraying is 10 microns~1500 microns.

In addition, Zmotion vision motion controller supports high-speed PSO (position synchronized output), PWM, path planning, multi-axis synchronous following , these functions can achieve smooth, precision dispensing path and stable glue output. All kinds of dispensing process can be realized.

Because itself supports vision and motion functions, the fluorescent powder can be atomized evenly, make sure the dispensing quantity is consistent.

Therefore, for Zmotion LED spraying solution, mass production is no problem, and it can do high-speed and high-precision dispensing. Promote your production efficiency & quality, reduce the production cost.

--more function & detail description--

*Easy Programming*

Visual programming, easy to learn, understand, and use.

*Centralized Color Temperature *

Dispensing valves can be screw valve / pneumatic / piezo valve to distribute color temperature centrally.

*Higher Efficiency*

When the machine is standby, the nozzle can automatically clean, no need extra time to do that, promoting the efficiency.

*Higher Precision*

Through the vision function “CCD automatic positioning and needle position correction”, it can recognize LED board direction and position automatically, then spray it averagely and precisely, increasing the spraying precision.

And it supports the automatic anti-curing function to prevent glue from blocking the nozzle, ensure uniform and consistent spraying thickness, reduce material waste, and improve resource utilization in the production process.

*Higher Integration & Lower Cost*

Vision motion controller VPLC series integrate hardware with software, supporting motion control, vision control, and IO control together, which can replace the traditional solution of “control card + vision + PLC”. Then reduce initial purchase and maintain costs. At the same time, powerful integration means fast data interaction speed.

  (1)    Vision Control

It mainly uses dual-Mark to do positioning.

When it is homed, move two Mark points to center position of camera view, record the center position of two coordinate systems at the same time to determine the relative coordinate that corresponds to Mark point.

And while running, it only needs to take the picture for Mark point (no need to repeat shooting and positioning) because the product position is fixed (relative to Mark point). After that, it can dispense.

(2)    Motion Control

[Array Process]

After selected needed row range, it can do linear array operation. The device can create multiple consistent graphics rapidly. For above, use point A, B, C to generate the array graphic. Production efficiency and consistency are promoted.

[Rectangle Spraying]

The rectangle spraying starting point located in rectangle left corner, parameters include spraying length, width, and path space.

In real programming, its length and width can be determined by recording needle’s coordinate difference values. The starting coordinates are the current coordinate values when the rectangular spray programming is confirmed. It can significantly improve the efficiency and quality of the glue spraying operation and ensure the uniformity and consistency of the glue spraying process.

(3)    Specific Process

(1) Hardware Configuration: Zmotion Vision Motion Controller VPLC532E

VPLC532E is an EtherCAT vision motion controller based on Linux system. It can run offline and has rich built-in vision and motion control functions, which greatly simplifies the configuration process of vision and motion control projects. And the data interaction in the core is fast, which can significantly reduce time and cost investment.

In addition, for VPLC series vision motion controllers, it is easy to install and disassemble. It only needs a small space, and can be seamlessly integrated with other control unit components (such as servo drives, sensors, encoders, control valves, etc.), providing a complete end-to-end vision motion control solution.

VPLC532E machine vision motion controller supports 32 axes at most. There are 24+6 digital inputs (4 support high-speed latching), 12+6 digital outputs (4 support high-speed PWM and PSO), 6 high-speed pulse axes + encoder feedback. The speed can be up to 10M.

(2) Software Configuration: Zmotion Free Visual Vision Dispensing Development Software RTSys

A. Software Introduction

This software can be downloaded from here.

RTSys combines rich vision with motion functions. For this dispensing solution, you only need to configure simple parameters, no need complex development again.

It can quick to build needed vision dispensing program, the development cycle is shorter, the cost is less.

Suitable Applications: bonding, spraying, sealing, pouring, bottom filling, glue dripping, line/arc/circle dispensing, etc.

B.  Software Advantages

[Rich Functions]

The software supports needed and rich functions: various dispensing trajectories (point, line, circle, arc, continuous, array), on & off glue in advance, manual teach, camera teach, etc.

[Vision Correction]

When the product is in any position with any angle, vision will recognize automatically to complete dispensing.

[Friendly Interface]

It is easy to program, debug in the software, and interface is clear. You can make it jog and teach in vision graphic.

(1)    Flexible Trajectory Planning

Easy to program multi-segment trajectory with guidance, you can freely specify the dispensing trajectory, preset quadrilateral filling path.

Improve dispensing efficiency and quality.

(2)    Precise Pressure Adjusting

The ratio valve controls the voltage output through electric signal.

Achieve high-precision pressure adjustment.

(3)    Quick Abnormal Processing

It will give alarm information in real-time, when there is abnormal situation, you can  see alarm message and process in time.

(4)    Function of Cleaning

It will automatically execute clean task according to preset program, like, regularly clean the nozzle and atomizer automatically.

(5)    Function of Adding Glue

Control axis Z download to set position through preset parameters.

(6)    Function of Unloading

After processed, it will move the product to set position for unloading.

(7)    Function of Run Testing

Through empty operation, it can test and verify whether the dispensing trajectory in the programming is correct.

That's all, thank you for your reading -- Zmotion Vision Motion Controller “LED Adhesive Spraying” Solution

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Zmotion Technology  provides motion control card, motion controller, vision motion controller, expansion module and HMI. ( more keywords   for Zmotion: EtherCAT motion control card, EtherCAT motion controller, motion control system, vision controller, motion control PLC, robot controller, vision positioning...)

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