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Building A1, Runteng Industrial Park, No. 4 Xishan Road, Longteng Community, Shiyan Subdistrict, Bao'an District, Shenzhen 518000, China
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Sunday: closed
SMT Lens Feeder Case Study: TV Backlight in Xiamen
Xiamen TV backlight maker cut its lens-feeding bottleneck with a JHIMS DPS-2 feeder on Hanwha lines: throughput +67% (6,000 to 10,000 CPH), jams -87%, 99% lens alignment.
Case Study
SMT Lens Feeder Case Study: TV Backlight in Xiamen
Xiamen TV backlight maker removed its lens-feeding bottleneck with a JHIMS DPS-2 feeder on Hanwha SM482 and SLM120S lines.
Direct answer: The JHIMS SMT lens feeder helped a Xiamen TV panel manufacturer optimize backlight lens assembly: throughput rose from 6,000 to 10,000 CPH (+67%), jam rates fell from 15% to 2% (-87%), and alignment accuracy reached 99% — while supporting 7–20mm lenses across multiple variants.
Key Takeaways
- 1+67% Throughput (6K→10K CPH)
- 2-87% Jam Rate (15%→2%)
- 399% Alignment Accuracy
- 47-20mm Lens Support
Customer & Industry
At a glance: who the customer is, where the machine was delivered, and what drove the investment.
CustomerXiamen TV panel manufacturer (name confidential)
IndustryTV panel / LED backlight manufacturing
Project LocationXiamen, China
Project TypeSMT lens feeder integration
ApplicationTV backlight lens feeding
Driving RequirementOvercome feeder bottlenecks for thinner-bezel TV backlight designs
Customer Background: TV Backlight Bottleneck
A Xiamen TV-panel and backlight maker was still running lens feeders specified for an earlier lens generation. As designs moved to thinner bezels, complex pin geometries caused orientation errors, lenses rotated under vibration and high-speed runs jammed — cutting throughput and raising cost.
Project Challenges
- Orientation Errors Complex pin designs caused orientation errors during feeding.
- Lens Rotation Lenses rotated during vibration, breaking alignment.
- Recurrent Jamming Frequent jams in high-speed runs disrupted production flow.
- Low Throughput Feeding rates stayed below 8,000 CPH — below line requirements.
- Variant Adaptability Poor adaptability across different lens variants.
The five reported problems were symptoms of how a lens behaves in a vibrating bowl — not of machine speed. Fixing only one leaves the other four in place, so they were treated as a single problem.
A backlight lens is light and carries orientation features, so it is easy to move but hard to orient — the throughput limit usually appears at the orientation step, not at the transport step.
Each reported challenge, the mechanism behind it in the feeding path, and the design response that followed.
| Reported challenge | Mechanism in the feeding path | Design response |
|---|---|---|
| Orientation errors on complex pin designs | Pins give the lens a preferred attitude that a single-frequency drive cannot correct at the exit | Direct-vibration stage settles each lens into the correct attitude before pickup |
| Lens rotation during vibration | The same motion that conveys parts also spins them once amplitude is raised for speed | Circular and direct vibration controlled separately, so the bulk rate no longer disturbs alignment |
| Recurrent jamming in high-speed runs | Parts bridge at channel entries and stack at gates when the track is pushed past its conveying window | Narrowed bowl channels sized for 7-20 mm lenses, with frequency tuned per lens family |
| Feeding rate below 8,000 CPH | Lost feed time, recovery time and re-orientation of disturbed lenses after every jam | 10,000+ CPH achieved at 0.2 s per lens with jam rate reduced to 2 percent |
| Poor adaptability across lens variants | Each lens generation needs its own track geometry and drive settings | Customizable routes plus independent channels and stored profiles |
| Alignment accuracy of 85 percent | Lenses fed correctly but arrived turned, so the nozzle picked them off-position | Alignment accuracy raised to 99 percent with a plus or minus 1 mm pickup window |
| Defects discovered downstream | Lens supply faults were only visible after placement and later optical test | Rejection held below 0.5 percent, typically 0.2-0.4 percent, measured at the feeder |
Customer Requirements
Before selecting the JHIMS SMT lens feeder, the customer verified three non-negotiable requirements:
- High-Speed Feeding The SMT lens feeder provides reliable high-speed feeding for 7–20mm lenses across multiple variants.
- Seamless Integration Compatibility with the existing Hanwha pick-and-place infrastructure (SM482, SLM120S).
- Quick Adaptation Fast changeover as product designs evolve.
The three requirements were written as measurable acceptance conditions: hold the line rate on every 7–20 mm lens variant, work with the Hanwha SM482 and SLM120S machines already on the floor, and make a lens change a recalled setup instead of an engineering project.
JHIMS Solution: SMT Lens Feeder for TV Backlight
- Adaptive Dual-Vibration The SMT lens feeder corrects misalignment and rotation, accelerating feed rates to 10,000+ CPH.
- Compact Bowl Optimization Narrower channels ensure straight-path movement for 7–20mm lenses.
- Precision Controllers Fine-tuned vibration frequencies deliver jam-free operation.
- Customizable Routes Adaptable to diverse lens types, compatible with Hanwha SM482 and SLM120S.
- 48-Hour Burn-In Machine verified with the customer’s own lens samples before shipment.
- After-Sales Support Video tutorials, remote assistance, and on-site services worldwide.
Why JHIMS: patented technology with a 20-year design lifespan, 10+ years of SMT automation expertise, a 1-year warranty with 24/7 support. Alignment is corrected continuously, not inspected afterwards: dual-vibration splits bulk conveying (50–120 Hz) from fine settling (100–200 Hz), so raising the rate does not disturb alignment, and the 48-hour burn-in runs on the customer’s own lens samples.
SMT Lens Feeder Equipment Configuration
| Item | Model | Qty |
|---|---|---|
| SMT lens feeder | JHIMS DPS-2 | 1 |
| Pick-and-Place Integration | Hanwha SM482 / SLM120S (existing) | 1 |
The SMT lens feeder was delivered and integrated with the customer’s existing Hanwha pick-and-place infrastructure.
SMT Lens Feeder Key Specifications
| Feature | Details |
|---|---|
| Channels | 1–10 |
| Lens Size | 7–20mm |
| Feeding Speed | 0.2s per lens (10,000+ CPH achieved) |
| Vibration Frequency | Circular 50–120 Hz; direct 100–200 Hz |
| Rejection Rate | Under 0.5% (typically 0.2–0.4%) |
| Alignment Tolerance | ±1 mm |
| Power Supply | 220V, 0.5 kW |
| Compatibility | Hanwha SM482, SLM120S, and other major SMT brands |
| Design Lifespan | 20 years (patented vibration technology) |
Two details matter on a mixed line: 1–10 independent channels let several lens types run without tooling swaps, and the rejection figure (under 0.5%, typically 0.2–0.4%) is measured at the feeder — before placement.
The published specification of the feeder delivered to this project, and what each figure governs on the line.
| Parameter | Published figure | What it governs in production |
|---|---|---|
| Feeder model | JHIMS DPS-2 lens vibratory feeder | Delivered as a drop-in unit for the existing Hanwha line |
| Lens size range | 7-20 mm | Covers the TV backlight lens families in the production schedule |
| Channels | 1-10, independently driven | How many lens types a shift can run without tooling changes |
| Feeding speed | 0.2 s per lens, 10,000+ CPH achieved | Line rate ceiling set by the feeder rather than by the mounter |
| Vibration frequency | Circular 50-120 Hz; direct 100-200 Hz | Bulk conveying separated from the final alignment stage |
| Alignment tolerance | Plus or minus 1 mm at the pickup window | How much nozzle teaching a new lens variant requires |
| Rejection rate | Under 0.5 percent, typically 0.2-0.4 percent | Rework and material waste generated upstream of placement |
| Power supply | 220V, 0.5 kW | Integration onto standard factory services |
| Compatible platforms | Hanwha SM482, SLM120S and other major SMT brands | Whether the feeder can be moved to another line later |
| Pre-shipment testing | 48-hour burn-in on the customer’s own lens samples | Confidence that the rate holds after installation |
| Design lifespan | 20 years, patented vibration technology | Replacement and maintenance planning for the line |
Implementation: SMT Lens Feeder Integration & Results
Within the first production week, the Xiamen facility confirmed the SMT lens feeder’s stable vibrations and reliable high-speed performance. The dual-vibration system eliminated lens rotation, while the optimized bowl channels kept every 7–20mm lens on a straight path to the pickup point.
Scope was deliberately narrow: the feeder went onto the existing Hanwha line, and tuning ran on the customer’s own lens samples before shipment, so on-site work was pickup position and rate confirmation. The first production week — lenses from several moulds, full shift temperature drift — delivered the numbers below: 6,000 → 10,000 CPH, jams 15% → 2%, alignment 85% → 99%.
Video: SMT Lens Feeder in Production
Watch the SMT lens feeder streamline TV backlight lens feeding on a Hanwha line. Watch the full feeder video on YouTube.
Watch the bowl-track exit: lenses should arrive one at a time, already correctly rotated, with no queue behind a turned part. Watch a starved channel refill — it should return to rate gradually, not in a burst. The 48-hour burn-in exists to expose settling, wear and thermal drift before shipment.
SMT Lens Feeder Results & Operational Benefits
Post-implementation, the Xiamen facility reported that the SMT lens feeder delivered stable vibrations, enhanced routes, and reliable high-speed performance — solving diversity and speed issues while slashing costs.
| Metric | Before | After | Improvement |
|---|---|---|---|
| Throughput (CPH) | 6,000 | 10,000 | +67% |
| Jam Rate | 15% | 2% | -87% |
| Alignment Accuracy | 85% | 99% | +17% |
Throughput rose from 6,000 to 10,000 CPH (+67%), mainly because jams fell from 15% to 2%: every jam costs feeding time, recovery time and the re-orientation of parts behind it. Alignment rising from 85% to 99% removes a different loss — lenses that fed but arrived wrong, which shows up as rework and, in a backlight, as optical defects caught at a later test station.
- Speed Stable high-speed feeding at 10,000+ CPH solved diversity and speed issues.
- Cost Reduced jamming and misalignment slashed operating and rework costs.
- Reliability Stable vibrations and enhanced routes delivered reliable performance.
- Waste Reduction Precision controllers reduced rework and material waste across TV panel lines.
- Long-Term Value Patented technology with a 20-year design lifespan and 1-year warranty.
Beyond throughput gains, the SMT lens feeder’s precision controllers reduced rework and material waste, supporting the manufacturer’s cost-reduction targets across its TV panel lines.
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How does the SMT lens feeder optimize TV backlight production?▼
The SMT lens feeder’s adaptive dual-vibration technology corrects lens rotation and misalignment, raising throughput from 6,000 to 10,000 CPH with 99% alignment accuracy and an 87% reduction in jam rate.
What is an SMT lens feeder?▼
An SMT lens feeder is an automated vibratory feeding system that aligns and feeds LED lenses into SMT pick-and-place machines at high speed, eliminating manual handling and orientation errors.
Is it compatible with Hanwha machines?▼
Yes. Customizable routes support Hanwha SM482 and SLM120S pick-and-place systems with minimal modification, plus other major SMT brands.
What are the key specifications?▼
Channels: 1–10; Lens size: 7–20mm; Feeding speed: 0.2s per lens; Power: 220V, 0.5kW; Compatibility: Hanwha SM482, SLM120S.
How does this feeder reduce costs?▼
By cutting jam rates from 15% to 2% and eliminating misalignment rework, the feeder reduces waste and operating costs by up to 20% in high-volume production.
What is the DPS-2 Lens Vibratory Feeder?▼
The DPS-2 is an automatic multi-channel SMT lens feeder — a vibratory bowl feeder for lens feeding in pick and place lines. It feeds optical lenses (3–25 mm) at 0.5–1 second per lens with under 0.5% rejection, replacing 2–3 manual operators with one.
What pick and place machines are compatible with the DPS-2?▼
As a Hanwha lens feeder, the DPS-2 integrates with Hanwha SM481, SM482, HM520 and DECAN machines, and also supports Yamaha (YSM20R, YSM10), JUKI (RS-1, RX-7), Samsung (SM series), Hitachi (G5, SIGMA) and Fuji (NXT, AIMEX). A brand-specific interface kit is supplied.
How fast is the DPS-2? What UPH does it achieve?▼
The DPS-2 lens feeder transfers 0.5–1 second per lens per channel, which equals 3,600–7,200 UPH per channel. A 4-channel configuration reaches 14,400–28,800 total UPH — 3–6 times faster than manual lens placement at 800–1,200 UPH.
What is the rejection rate with the DPS-2?▼
The DPS-2 lens feeder achieves under 0.5% rejection, typically 0.2–0.4% after optimization. For comparison, manual feeding runs 5–15% and generic vibratory feeders 2–5%. Every machine is verified during a 48-hour burn-in with your own lens samples.
What lens sizes and shapes are supported?▼
The DPS-2 handles lens diameters from 3 mm to 25 mm, including round, three-foot, four-angle and rectangular-cutout geometries, with ±1 mm bowl alignment tolerance. Custom track tooling is available for asymmetric lens designs.
How many channels can the DPS-2 support?▼
The standard configuration uses 2 disc tracks, expandable to up to 10 tracks for high-mix production. Each track is fully independent — its own drive, sensors and jog control — all managed by a single Mitsubishi FX5U PLC.
What is dual-frequency vibration technology?▼
It is a JHIMS-patented drive architecture with two independent vibration units and separate PID controllers: circular vibration (50–120 Hz) moves lenses in bulk along the bowl track, while direct vibration (100–200 Hz) delivers precision alignment.
How long does a lens-type changeover take?▼
Under 5 minutes. The PLC recalls a saved profile in under 3 seconds (up to 50 profiles stored), tool-less track adjustment takes about 2 minutes, magnetic bowl inserts swap in under 1 minute, and verification takes 1–2 minutes.
What are the dimensions, weight and power requirements?▼
The DPS-2 measures 1050 × 700 × 750 mm and weighs approximately 130 kg. It runs on 220V AC, 50–60 Hz, single phase, with 0.55 KVA rated power consumption (0.35 KVA typical). Compressed air requirement is 0.4–0.6 MPa, and noise is under 65 dB(A).
What PLC and HMI does the DPS-2 use?▼
Standard: Mitsubishi FX5U-32MT/ES PLC with a 7-inch Weintek HMI, storing up to 50 profiles. Optional: Siemens S7-1200 with Pro-face HMI. The HMI supports English, Chinese, Spanish, Vietnamese, Hindi and Turkish, and communicates via Modbus TCP.
Does the DPS-2 support Industry 4.0 / MES integration?▼
Yes. Modbus TCP streams lens count, speed, rejection rate, downtime and active profile ID for OEE dashboards, quality alerts and batch traceability (IATF/FDA). Optional Ethernet/IP and OPC UA gateways are available.
What maintenance does the DPS-2 require?▼
Daily: 2-minute visual inspection. Weekly: clean tracks and check pneumatic pressure (10 minutes). Monthly: inspect vibration units and lubricate guide rails (30 minutes). Annual: comprehensive 4-hour preventive maintenance by JHIMS.
Is the DPS-2 available in anti-static / ESD-safe configuration?▼
Yes. An ESD-safe bowl coating (10⁶–10⁹ Ω per IEC 61340-5-1), static-dissipative track inserts and a dedicated grounding kit are available for lens types sensitive to electrostatic discharge. Cleanroom (ISO Class 7) configuration is also offered.
What warranty does the DPS-2 come with?▼
Every DPS-2 includes a 1-year comprehensive warranty covering parts and labor, plus lifetime technical support. Remote diagnostics reply within 12 working hours (Mon–Sat, 09:00–23:00 China Standard Time, UTC+8) and spare parts dispatch within 48 hours via DHL. An extended warranty up to 3 years is available.
How do I get technical support?▼
Contact us on phone (86-755) 86700443, WhatsApp, email ([email protected]) or Telegram (@jinghe_tech). An engineer replies within 12 working hours (Mon–Sat, 09:00–23:00 China Standard Time, UTC+8) (business days), and most issues are diagnosed remotely by video before any on-site visit is considered. Browse JHIMS machine videos on YouTube.
Can the feeder be customized for my lens type?▼
Yes. JHIMS tailors the DPS-2 to your lens geometry and pick-and-place platform. Send lens samples for a 48-hour burn-in verification before shipment — the machine ships tuned to your production conditions.
Does the feeder eliminate manual operators?▼
Yes. One DPS-2 replaces 2–3 manual lens assembly operators per line. The machine runs fully automatically under PLC control, and one operator can supervise 4 or more feeder-equipped lines.
How long does delivery take for a DPS-2?▼
Standard: 2-4 weeks (production + 48-hour burn-in with your lens samples + export packaging + freight). Express delivery available for urgent orders.
Can I visit JHIMS to see the DPS-2 running?▼
Absolutely. Visit our Shenzhen demo center to see the DPS-2 feeding lenses on a live pick-and-place line. We can also arrange a remote video demonstration.
What payment terms does JHIMS offer?▼
T/T (Telegraphic Transfer) is the primary method. Standard payment terms: 70% T/T deposit with the order, 30% T/T before shipment. Existing customers may use L/C (Letter of Credit) at sight.
What is the lens vibrating feeder used for?▼
It feeds optical lenses (TV backlight lenses, LED panel light bar lenses, etc.) into pick-and-place machines so they can be placed onto PCBs automatically — replacing slow, inconsistent manual lens assembly.
How does a vibratory bowl feeder align lenses?▼
Vibratory action moves lenses along a spiral bowl track, orienting each lens into the correct position before the pick-and-place nozzle picks it up. Dual-frequency vibration separates bulk feeding from precision alignment.
What is the expected lifespan of a JHIMS lens feeder?▼
JHIMS lens feeders use patented vibration technology designed for a 20-year lifespan, with 10+ years of SMT automation expertise backing every unit.
How many lens types can the feeder handle simultaneously?▼
Up to 5 lens types simultaneously with adjustable frequency from 50 to 120 Hz, and up to 10 independent channels on the DPS-2 for high-mix production.
Ready to Optimize Your TV Backlight Line?
Send your lens samples for a free 48-hour SMT lens feeder test — we will validate throughput and jam rate on your line.