Description:FORM 2

THE PATENTS ACT, 1970
[39 of 1970]

&
THE PATENTS RULES, 2003

COMPLETE SPECIFICATION

(Section 10; Rule 13)
Title
THERMAL PLATE PRESSING MACHINE FOR USE IN LED BULB ASSEMBLY LINE

Applicant:

SKYQUAD ELECTRONICS & APPLIANCES PRIVATE LIMITED
12-50/4/A, Adj to Industrial Estate, Medchal
Medchal District, Hyderabad - 501401,
Telangana, India

An Indian Company

The following specification particularly describes the application and the manner in which it is to be performed.

FIELD OF THE INVENTION
The present disclosure relates to a machine used in assembling of LED Bulb and more particularly, the present invention relates to newly designed machine for pressing the thermal plate into bulb housing in LED Bulb assembly line.

BACKGROUND OF THE INVENTION
The following description of related art is intended to provide background information pertaining to the field of the disclosure. This section may include certain aspects of the art that may be related to various features of the present disclosure. However, it should be appreciated that this section be used only to enhance the understanding of the reader with respect to the pre-sent disclosure, and not as admissions of prior art.

A Thermal plate is a critical component of an LED bulb as it is used to hold the electronic circuit board inside the LED bulb, to be fitted in bulb housing. The thermal plate has to be properly placed in the bulb housing. Therefore, the placement of thermal plate into the housing requires hydraulic press.

At present, the hydraulic press used in the pressing machine to press the thermal plate is fitted into a metal column which acts as a supporting pillar while pressing thermal plate; and this is a standard design of pressing machine which is currently used in LED Bulb Assembling Unit.

During the production process, there are scenarios when a lot of material received will have variation in the dimension of thermal plate and bulb housing. This results in variation in the pressure applied for the fitment. The variation of pressure, sometimes lead to bending of metal column where on the hydraulic cylinder is fitted. This results in breakage of bulb housing and bending of thermal plate. A small variation in the positioning of the metal column disrupts the indexing of the rotating plate. This leads to damaging of whole lot of bulb housing and thermal plate in an automated OR semi-automated LED bulb assembling unit until the operator recognizes the problem when it occurred in the first step. The damage of bulb housing and thermal plates lead to loss of raw materials, instability in the flow process of assembly line and will not be able to complete the work order quantity originally required

Therefore, the existing thermal plate pressing machine used in LED assembling line results in high product defect rate, low efficiency. Also, it is difficult to adapt to production replacement of LED bulbs of different models or sizes using the existing pressing machine.

To eliminate the above-mentioned problems and reduce rejections there exists a need to provide a uniquely designed machine for pressing the thermal plate into the bulb housing which is stable and can withstand the pressure variations during the production process.

OBJECTIVES OF THE INVENTION
In accordance with the present invention, the primary objective is to provide a thermal plate pressing machine in LED bulb assembly line, which aims to solve the problem of loss of raw materials, damage in structure of pressing machine thereby improving overall efficiency.

Another objective of the present invention is to provide uniquely designed platform for housing the driving cylinder thereby solving the problem of bending of metal column during the operation of pressing of thermal plate in LED Bulb Assembly line.

SUMMARY OF THE INVENTION

A thermal plate pressing machine (100) for use in LED bulb assembly line, the thermal plate pressing machine consisting of a cabinet (110); a rotary plate (120) including plurality of holding fixtures (130); characterized in that the thermal plate pressing machine comprises of plurality of mounting frames (140-160), positioned perpendicular to the cabinet (110) to form a triangular base a cylinder driving platform (170) housed on the triangular base and screwed on mounting frames (140-160) at (410-430) wherein the open-ended side of the platform which runs from mounting frames (140) and (160) is at 90o angle to its adjacent sides, then grooved inside from both the sides and finally coming outward to form a circular shape at the open-ended corner (410) is configured to house the pneumatic cylinder (190).

BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGs

The present disclosure may be understood when read in conjunction with the following drawings:

Fig. 1 illustrates a schematic perspective view of the present invention according to an embodiment of the present invention.

Fig. 2 illustrates a schematic front view of the present invention according to an embodiment of the present invention.

Fig. 3 illustrates an enlarged schematic view of the Cylinder Driving Platform of the present invention

Fig. 4 illustrates a schematic top view of the present invention according to an embodiment of the present invention.

Fig. 5 illustrates the length of the mounting frame of the present invention according to an embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

Having described the main features of the invention above, a more detailed and non-limiting description of a preferred embodiment will be given in the following paragraphs with reference to the accompanying drawings.

In all the figures, like reference numerals represent like features. Further, the shape, size and number of the machine shown are by way of example only and it is within the scope of the present invention to change their shape, size and number without departing from the basic principle of the invention.

All through the specification including the claims, the technical terms and abbreviations are to be interpreted in the broadest sense of the respective terms and include all similar items in the field known by other terms, as may be clear to persons skilled in art. Restriction or limitation if any referred to in the specification, is solely by way of example and understanding the present invention.

The major application of the Thermal Plate Pressing Machine is for pressing the thermal plate in bulb housing during the assembling of LED Bulb. Though a Thermal Plate Pressing Machine has been developed previously, it had a flawed design which led to bending of the metal column supporting the driving cylinder, breakage of bulb housing and bending of thermal plate as compared to the machine of the present invention.

It uses better gear box having higher wattage to increase the accuracy and performance of the machine. The compact mechanical structure of the overall machine and cylinder driving platform make the machine robust.

A particular advantage of the cylinder driving platform is that it prevents any displacement of the driving cylinder from its position during the pressing of thermal plate into the bulb housing which may occur due to variation in pressure thereby preventing any pause in assembly line.

Inventive Feature of the present invention

Mechanical Structure
Figure 1 shows a thermal plate pressing machine (100) consisting of cabinet (110); a rotary plate (120) including plurality of holding fixtures (130); plurality of mounting frames (140), (150 - not visible) and (160) running perpendicular to the cabinet (110). The upper side of the mounting frame (140), (150) and (160) are connected to each other to form a triangular base (not shown) for the housing the uniquely designed cylinder driving platform (170). The inner side of the platform is configured with top pressing tool (180) facing downward towards the rotary plate (120). The platform houses a pneumatic cylinder (190) on its upper side. The pneumatic cylinder is connected to and air supplying pipe (not shown) to perform its function. A proximity sensor (200) is housed on supporting sheet which runs parallel to the cylinder driving platform (170).

Referring to Figure 2, the cabinet (110) comprises of motor (300); gearbox (310) and variable frequency drive (320), switch (330), push buttons (340) and emergency switch (350). During the operation, the switch (330) is used to start the machine (100). The push buttons (340) represent the on/off button for switch on/off the machine during the normal course of operation. The cabinet is also configured with emergency switch to stop the operation of thermal plate pressing machine during an emergency situation.

In accordance with present invention, Figure 3 represents an enlarged schematic view of the cylinder driving platform (170). This unique design of cylinder driving platform is finalized after multiple trails conducted in assembly line during the operation. The platform (170) is housed on a triangular base and is screwed on mounting frames (140), (150) and (160) at (410), (420) and (430 – not visible). The open-ended side of the platform which runs from mounting frames (140) and (160) is at the 90o angle to its adjacent sides, then grooved inside from both the sides and finally coming outward to form a circular shape at the open-ended corner (410). This circular portion of the open-ended corner houses the pneumatic cylinder (190).

Preferably, the pressing mechanism includes the mounting frames (140), (150) and (160), a cylinder driving platform (170) and a pneumatic cylinder (190). The mounting frames form an L-shaped structure and is vertically fixed on the top of the cabinet (110), and the pneumatic cylinder is vertically fixed on the top of the cylinder driving platform (190), and the top pressing tool (180) is horizontally arranged on the output end of the driving cylinder. The diameter of the pressing tool at bottom end (450) is 50 mm.

Figure 4 illustrates various dimensions in accordance with an embodiment of the present invention.

Calculations
Referring to the present invention, the mounting frame (140) for pneumatic cylinder acts as a cantilever beam fixed at one end and it can be depicted as per figure 5.
We calculated the maximum deflection at a given conditions of a cantilever fixed at one end and loaded at end point and calculations are as follows.
Calculation of deflection of cantilever fixed at one end, in this case it is a supporting beam:

Deflection at end of the beam (Yb) = WL3/3EI
Where as
W = Load on the beam
L = Length of the beam
E = Modulus of elasticity of beam material (Standard value for the steel is 200 Gega Pascals)
I = Moment of Inertia

Given parameters for the calculation of deflection are as below.

Pressure inside the pneumatic cylinder = 6 bar = 0.6 N/mm2
Diameter of pressing tool bottom end upon which 6 bar pressure is applied = 50mm
L = Length of the mounting frame is 80mm i.e. length of the cantilever
d = Depth of the plate is 8mm.
b = Width of the plate is 140mm
W = Pressure of pneumatic cylinder x Cross sectional area upon this pressure is applied (pressing tool bottom end diameter)
W = 0.6 x π/4 50^2
W = 0.6 x 3.1428/4 x 50 x 50
W =1178.55 N

I (Moment of Inertia) = b x d3/12 (In this case the plate is solid)
I = 140 x 803/12 = 59,73,333 mm4

Deflection of the plate (Yb) = W x L3 / 3 x E x I

Deflection of the plate (Yb) = 1178.55 x 803 / 3 x (200 x 103) x 59,73,333

= 0.00016 mm

Conclusion:
The resulting deflection is so minimal which will not damage either bulb housing or thermal plate.
, Claims:Claims

We claim

1. A thermal plate pressing machine (100) for use in LED bulb assembly line, the thermal plate pressing machine consisting of a cabinet (110); a rotary plate (120) including plurality of holding fixtures (130); characterized in that the thermal plate pressing machine comprises of
a. plurality of mounting frames (140-160), positioned perpendicular to the cabinet (110) to form a triangular base;
b. a cylinder driving platform (170) housed on the triangular base and screwed on mounting frames (140-160) at (410-430) wherein
the open-ended side of the platform which runs from mounting frames (140) and (160) is at 90o angle to its adjacent sides, then grooved inside from both the sides and finally coming outward to form a circular shape at the open-ended corner (410) is configured to house the pneumatic cylinder (190).

2. A thermal plate pressing machine (100) as claimed in claim 1 wherein the mounting frames forms an L-shaped structure and is vertically fixed on the top of the cabinet (110)

3. A thermal plate pressing machine (100) as claimed in claim 1 wherein the pneumatic cylinder is vertically fixed on the top of the cylinder driving platform (190).