The Manufacturing Process of an LED Screen
The Manufacturing Process of an LED Screen
Before receiving your HTV LED screen, it undergoes an extensive manufacturing process. With 10 years of experience, HTV has been able to establish very strict specifications for its partners, and our office in Luxembourg ensures that they are adhered to. In this article, we will go through the typical manufacturing steps of an LED screen. If you want more information on the terms used in this article, you can refer to our article on the technical jargon of LED screens.
The main steps are as follows:
1. LED Selection:
Once the LED diodes are received, the first step is to mix them. Each diode will have a tiny variation in chroma (colors) and brightness, mixing them makes this difference invisible. After mixing, the LED diodes are transferred to a machine that prepares them for manufacturing, and each diode is tested before being placed on a roll. If it doesn't light up, it is automatically eliminated. Despite laboratory tests and the assurance of working with the best suppliers, the LED diodes are constantly checked throughout the manufacturing process.
2. Module Manufacturing:
The modules consist of LED diodes, IC drivers, connectors, etc. All these components are attached to a PCB (hard plastic card). They pass through a machine that automatically solders the elements and then goes through an oven to reach a temperature of over 260°C for soldering. Then they are visually checked by a quality control technician. Once the LEDs are placed on the PCB, they are transformed into modules, with the addition of their support frame and protective mask, making them black and protecting the PCB and LEDs.
3. LED Assembly:
A different manufacturing process is used for modules with DIP-type LEDs and those with SMD type. This seemingly simple process is the most crucial step as it brings us closer to the final product.
Outdoor DIP LED Modules: To ensure the waterproofing of DIP modules, they are coated with black glue to resist the weather. This process is only applied to DIP LEDs intended for outdoor use.
4. Module Verification or "Aging":
The modules are connected and lit continuously for 72 hours to test their proper functioning. This step is often overlooked by some manufacturers, but HTV includes it in its specifications and helps eliminate any potential defective modules. This step is, therefore, crucial.
5. Cabinet Assembly:
The final production step is assembling the modules on the cabinet structure, and then the power supplies and wiring are installed. The manufacturing is completed, and now it's time to test the final screen.
6. Real-world Setup:
After all these steps, the screen is assembled and set up in a real-world scenario. Any potential final defects are corrected, and the screen is configured to display images and check color quality. Color and brightness calibration is performed at this stage.
7. Quality Control:
Each manufacturing step is followed by rigorous quality control to ensure that any defects are addressed before leaving the factory. Quality control is regularly performed by the HTV team in the factory to ensure that the ordered products precisely meet our specifications. As the saying goes, trust does not exclude control.
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