The LED module is the most important component of the LED display screen. The quality of the LED module directly determines the image display effect of the screen.
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If you are curious or considering purchasing an LED display, understanding the production process of LED screens can help you gain a better understanding.
UNIT LED display factory is willing to show you every detail of the LED display production process.
The UNIT LED display showroom is a window to showcase the company's leading LED products and innovative solutions. It aims to provide customers with the opportunity to visit and experience them on-site.
The showroom displays a variety of featured products, including high-definition holographic screens, creative displays, and interactive floor tile screens, covering various application scenarios from commercial advertising to interactive experiences.
Customers can personally experience the excellent display effects and flexible application methods of each product, and gain an in-depth understanding of the latest developments in LED display technology.
As a leader in industry innovation, UNIT LED's showroom not only demonstrates its strong technical strength but also provides customers with customized solutions.
The showroom allows customers to fully understand how to apply these advanced products to different business needs through intuitive displays.
Customers from all over the world are welcome to visit and discuss the future of LED displays with us.
Have you ever looked sideways at the outdoor LED screen with stunning visual effects on the streets of the city center? Have you ever invested in an attractive LED video wall for your studio or indoor stage?
If you are interested in LED displays, you may think about learning about LED screen manufacturing process.
How is the LED display manufactured? What equipment will play a role in the LED screen manufacturing process?
As a manufacturer engaged in the production and sales of LED modules and LED displays for many years, UNIT LED wants to show you every detail of the process of LED panel manufacturing.
This post will help you get a better understanding of LED display products.
There are many types of LED displays. In addition to the conventional led panel, there is also a transparent led display, poster led screen, and so on.
According to specific project information and special requirements of customers, such as working environment, display content, usage, etc., it is necessary to finalize the product. Only by determining the various indicators of the product can we better meet the needs of customers.
At this stage, the professional business person will communicate with you in detail to make an accurate solution. You need to provide as much information as possible for them to make a judgment. The following issues need attention:
Generally speaking, it includes 3 aspects: indoor or outdoor? full-color? pixel pitch?
According to the installation environment of the display screen, confirm whether to use an indoor or outdoor led display.
At present, the market is dominated by full-color led displays. Single-color or double-color led displays can only display specific colors.
The viewing distance and the size of the display screen are two factors that determine the pixel pitch. Appropriate spacing brings the best viewing effect and a reasonable budget range.
The brightness of the product can be adjusted before the display screen leaves the factory. Therefore, before Led screen manufacturing, it is necessary to determine the brightness of the display screen according to the customer's on-site installation environment.
Generally speaking, the brightness of the outdoor led display is - cd/m2 (Nits). The brightness of the indoor led display is 800- cd/m2 (Nits).
Select the installation method according to the site installation environment. The following points should be considered:
(1) Select the Cabinet
For indoor and outdoor fixed LED displays, you can choose a simple box or a sealed box. For rental led displays that need to be moved frequently, standardized and lightweight cabinets will be suitable.
In addition to the on-site environment, the weight and structural stability of the screen body also needs attention.
(2) Structural Design
The structural design of the display screen should pay attention to the following aspects:
Reliability. A solid structure is a prerequisite for safety. The bearing capacity of the structure should be greater than 20% of the weight of the display screen itself.
Flatness. The flatness of the structure directly affects the flatness of the display screen. So it will affect the display effect.
How to ensure good flatness? The first is to ensure the flatness of the welding. Secondly, the structural frame and the cabinet of the display screen are completely combined.
Integrity. In addition to the display screen body, the display structure also includes other auxiliary areas: drainage channels, air conditioners, wrapping areas of the outer structure, outdoor lightning protection facilities, etc. There are several aspects to consider in the early stages of design.
Convenience. The structural design needs to facilitate the installation and maintenance of the display. Necessary maintenance channels and cable passages are indispensable.
After determining the product type, a detailed bill of materials needs to be made.
BOM means Bill of Material. It helps the computer identify the composition of the products manufactured by the enterprise and all the materials involved. In led screen manufacturing, the projects involved include:
LED display module
LED screen cabinet
LED display structure
Auxiliary equipment list
A complete material list is helpful for led display making. The integrity of materials can avoid the prolongation of the production cycle and delayed delivery caused by raw materials in the production process. At the same time, centralized purchase of raw materials saves time and money compared to scattered purchases.
How is SMD led module produced? What tests have a batch of qualified led display modules gone through? Let's read now!
(1) LED lamp baking
High-quality Led lamp is the key factor for the good visual effect of led display. If the LED lamp beads are not baked well, the follow-up module will have a dead light phenomenon and affect the normal display effect.
Therefore, baking it before use can solve the problem of moisture in the lamp bead and ensure the quality of the lamp bead.
(2) IC & LED SMT
Equipment required for IC & LED SMT: stencils, printing machine, SMT machine, reflow soldering machine.
The role of the stencil is to fix the driver element to the PCB. There are two kinds of stencils, red glue, and solder paste.
The red glue stencil is used to fix the components to the board, and the original components are soldered to the PCB by wave soldering. The solder paste stencil is to solder the components attached to the board on the PCB through a reflow soldering machine.
The thickness of stencils: red glue-0.15mm. Solder paste-0.12-0.15mm
The purpose of the printing machine is to apply red glue or solder paste evenly on the PCB.
Attention should be paid when printing: the stencil and PCB need to be in good contact and pressed tightly. Then, the printing surface should be uniform in thickness.
The SMT machine is a core equipment on the production line of the SMT industry. It is mainly used to mount electronic components onto circuit boards. SMT means Surface Mount System. SMT is configured after a dispenser or screen printing machine, and the surface mount component is accurately placed on the PCB by moving the mounting head.
IC SMT needs to brush solder paste on the board first, and then attach electronic components such as IC, resistors, capacitors, power & signal sockets to the PCB. Finally, it is strengthened by reflow soldering.
The steps of surface mounting of lamp beads are similar to the IC SMT process.
Precautions for SMT:
Orientation and polarity of components.
The component pins should be aligned with the pad package pins.
(3) Semi-finished Product Test
Problems can be found by performing a lighting test on the semi-finished module. After overhauling for the next step. Mainly test the following aspects:
After the module test is completed, the module is assembled with the bottom case and the mask. Secure the bottom case and PCB with screws. It is worth noting that the outdoor led module needs to be covered with a mask after glue filling.
(4) Glue Filling (Only Outdoor LED Module)
For outdoor led modules, glue potting is required for waterproofing. Therefore, the module with the bottom case needs to be filled with glue.
After the glue is filled, it needs to be placed on a drying rack to wait for the surface glue to dry. Then fix the mask with screws.
When assembling the module, it is necessary to ensure the verticality of the led lamp. At the same time, when assembling, be careful not to damage the module bottom case and mask.
Pouring glue on the surface of the outdoor SMD led display module can play a waterproof role. This step is essential in the production of the GOB LED module. The GOB led module has high waterproof, dustproof, impact, and scratch resistance capabilities. One reason is the special glue-filling process.
Electronic potting glue is generally used now, and there are two types of A/B. When pouring glue, pay attention to:
(5) LED Module Aging
Put the modules that have been installed in the kit together after glue filling and light up the test, which is called the aging test.
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The purpose of aging finished modules is to make an overall evaluation of the whole screen. Main observations: the lifespan and attenuation of led lamps, the color difference of screen, white balance effect, display angle, quality of playing graphics and video, etc.
(3) Precautions for cabinet assembly
Ensure the flatness of the modules
Control the length of power and signal wires. Under the premise of meeting the needs, the cables should be as short as possible. It can reduce the voltage drop and signal attenuation on the cables, and save the wire at the same time.
Distinguish the polarity of the power cord. The cables have positive and negative poles. Improper connection or cause display failure
The input and sequence of system output and module signal cannot be reversed.
Why Does the LED Screen Need Aging?
The LED aging test is an indispensable part of led display manufacturing. Led products can improve efficiency and find existing problems after aging. It is an important link before shipment. The purpose is to guarantee the quality of the delivered product.
The led aging test takes measures according to the failure rate curve of the product to improve its reliability of the product.
LED Aging Method
There are two aging methods: constant current aging and constant pressure aging. The aging of the LED display is divided into white light aging (4 hours) and video aging (48 hours).
Constant current aging means that the current is constant at any time. If there is a frequency problem, it is not a constant current, but an alternating or pulsating current.
An AC or pulsating current source can be designed to have a constant effective value, but this power supply cannot be called a 'constant current source'. Constant current aging is in line with the characteristics of LED current and is a scientific method for LED aging.
Overcurrent impact aging is also an aging method used by the led display manufacturer. In this way, the frequency of use can be adjusted, which is convenient for judging the quality and life of the LED in a short time. This old-fashioned way can pick out many blemishes that conventional burn-in cannot pick out.
LED Display Aging Test Content
Screen white balance test
Red, green, blue monochrome, grayscale gradient, video effect, text effect;
LED display white balance test time needs to be more than 24 hours
Monochrome, grayscale gradient test not less than 24 hours
The video and text effect test shall not be less than 24 hours
After the 72-hour aging test, if any problem is found, it needs to be dealt with in time. And the damaged led lamps should be replaced or repaired. Make sure all products are working properly. After confirming that it is correct, the next step is to pack and ship.
Step 1: SMT uses solder paste to attach ICs to the PCB board. In this process, three lines are opened in total (adjust as needed based on actual conditions) to attach the ICs.
'SMT machine' refers to a Surface Mount Technology machine used for electronic component placement on PCB boards.
Step 2: Reflow soldering ' After the ICs are attached to the PCB board, it is conveyed to the machine (oven) for baking, which serves to secure the components. Finally, the PCB board is released for heat dissipation.
Step 3: Use an SMT machine to attach LED lights to the PCB board. Then, the components will go through the reflow soldering machine once again for baking and securing the LED lights. Finally, a check will be conducted to ensure the proper functioning of the LED lights.
Step 4: Install the module base and apply three-proof paint (moisture-proof, waterproof, and dust-proof). All outdoor LED modules require painting. If there are customers who request indoor LED modules to be painted, it can be done as well. Finally, the PCB board needs to be flipped over to check if the painting is in place.
Step 5: Place the LED modules into the machine and fasten the screws.
Step 6: Apply adhesive to the front surface of the module to achieve outdoor waterproofing.
Step 7: Allow the LED modules to air dry naturally for 60 meters, apply a cover to the modules, and finally secure them in the machine with screws.
(1) Apply three-proof paint.
(2) Dry.
(3) Use a blow dryer to lower the temperature of the LED modules.
(4) Cover the bottom shell.
(5) Screw the bottom shell.
(6) Test if the lights can function properly.
(7) Apply adhesive to the LED modules ' if there are any issues with the test results, they will be listed separately.
(8) Air dry.
(9) Automatically apply the cover and screw it in place.
The transparent LED display has extremely high transparency. It is significantly different from ordinary led displays.
Based on the light strip screen, it innovates in the chip manufacturing process, lamp bead packaging, control system, and structural design.
The unique manufacturing process and hollow structure reduce the occlusion of the line of sight, thus achieving the perspective effect.
(1) Put the PCB board into the machine, then brush the board with a layer of solder paste
(2) Sticking LED lamps in SMT machine production line
(3) After the reflow soldering is finished, the worker will check whether the transparent led module is working properly.
(4) Assemble the transparent led screen
(5) Aging test
UNIT LED has served many projects around the world for decades in the LED industry. Customers all over the world, many successful cases let you show our strength.
What's more, we have established close cooperation with many raw material suppliers. High-standard raw materials fully guarantee the quality of led display products.
A strong team behind UNIT LED helps you to get a satisfactory led display board.
A professional technical team will solve customers' technical problems. At the same time, we promise to provide customers with a 3-year warranty and 5% free spare parts to ensure user experience and customer satisfaction.
LED displays dominate today's modern work, from simple screens to gigantic 3D cornered walls. They are highly varied and it will leave you wondering how the LED display works in the first place that they can function differently using similar operations.
Some may find it too technical and complicated to learn about the actual process but if you're one of the curious persons who love exploring the 'hows', you're in the right place.
An LED display is a type of device that uses LEDs to produce light and images on the screen. These LED displays are energy-efficient screens that can come in different sizes and shapes. The most common types are standard, curved, and flexible LED displays. And despite the differences between these screens, they all operate and function similarly. So, how does an LED screen work?
Learning how LED display works start with understanding the terms and components that are involved in the process. The fascinating LED technology uses elements that you might just be hearing for the first time so it's important to establish them first. Here are some components and definitions that are working taking note of.
In exploring how the LED display works, you need to take note that they are developed in different sizes and shapes and are integrated with different features. But there is a basic process that all LED screens follow in one way or another. Let's start with the basic components of a LED display.
An LED display is comprised of three components, including the main LED display, the controller, and the content source. The main LED display refers to the panels that can be connected together to form an entire screen. The controller and content source may widely vary depending on the LED display. In knowing the basic knowledge of how LED display works, the panels pretty much work the same way.
The working principle of LED displays starts with a flat panel and the LEDs installed in them. These panels are composed of unmovable solid parts molded into the board and these light-emitting diodes are molded into it.
LEDs or light-emitting diodes are semiconductor materials (usually silicon-coated) that allow electricity to transform into light energy. They are one of the most important components of learning how the LED display works. These diodes can come in red, green, or blue, each with its own brightness levels and intensity. The intensity and brightness levels of LEDs vary greatly by changing the pixel pitch, pixel density, and LED scan rate. And they are able to create new colors that make it possible to produce vibrant images.
Despite their variations, there is a basic concept of how an LED screen works that can be applicable to all types of displays. But one of the factors that can set them apart is their backlighting. This gives birth to the different types of LED displays based on their backlighting.
To further understand how the LED display works in relation to the type of backlight used, here are the most common selections you can look into.
Considered the most affordable option, direct-lit LED displays can be classified under lower to mid-range LED screens. They usually come in a bigger structure but less complicated images.
How LED display works in this type of screen is that it has lower pixel density since among all of the other types of LED screens, it has the least number of diodes installed in them and does not have a local dimming feature. It's similar to a full-array LED display in a way that the diodes are directly installed behind the screen.
Recognized as the most common type of LED display, edge-lit screens are named as such because the diodes are installed at the edge of the screens. How LED display works in this case relies on how the diodes are arranged along the edges. They can be placed all around the screen, top and bottom, or left and right.
While the screens appear to be slimmer, they have fewer diodes too compared and so may have dynamic lighting issues. There might be bright spots on the edges compared to the center of the screen, leading to dimming zones.
When learning about how LED display works, going through full-array LED displays is a necessity. It has the most effective backlighting compared to edge lighting and direct lighting. Since the LED diodes are evenly distributed all over the screen (at the back and even along the edges), it produces consistent lighting with dynamic colors.
Full-array LED displays are installed with colored LEDs, which helps the device generate a wider range of colors. And since the LED diodes are evenly distributed, the display can dim and turn off specific zones on the screen.
Exploring how LED display works also means learning about the visual aspects of these screens. Besides the lighting, the semiconductor materials can also affect the colors generated from the screen. The intensity and depth of colors would rely heavily on these compounds. Here are some of the most popular compounds used for these diodes.
In exploring how the LED display works, it's important to stick with the basics. The process may include some technical terms but the process of how LED screen works are pretty standard. Light-emitting diodes are installed in the screen and when hit with electricity, they produce light responsible for producing a wide range of colors. These colors are then used to produce vibrant images and videos on the screen.
Some LED displays are brighter and some are more colorful than others, and this can be due to two factors. They have different semiconductor materials and different backlighting types. So if you're looking for a display perfect for you, make sure to look into these aspects too.
For more information, please visit transparent led screen manufacturer.