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Lens Vibrating Feeder Case Study: LED Lighting in Russia
Russian LED panel light bar maker added a JHIMS DPS-2 lens feeder to its Hanwha SM481 line: throughput +35%, downtime -25%.
Case Study
Lens Vibrating Feeder Case Study: LED Lighting in Russia
DPS-2 lens vibrating feeder integrated with an existing Hanwha SM481 line for a Russian LED panel light bar maker: +35% throughput, -25% downtime.
Direct answer: The JHIMS lens vibrating feeder is an automated lens placement solution that helped a Russian LED lighting manufacturer overcome a 40% efficiency bottleneck in manual lens assembly for LED panel light bars. Integrated with Hanwha SM481 pick-and-place machines, the feeder automated lens placement, boosting throughput by 35% and reducing downtime by 25%. It handles up to 5 lens types simultaneously at 50–120Hz, with dimensions of 1050×700×750mm and compatibility across Hanwha SM481, DECAN S1 and other SMT platforms.
Key Takeaways
- 1+35% Throughput
- 2-25% Downtime
- 35 Lens Types
- 450-120Hz Frequency
Customer & Industry
At a glance: who the customer is, where the machine was delivered, and what drove the investment.
CustomerRussian LED lighting manufacturer (name confidential)
IndustryLED lighting manufacturing
Project LocationRussia
Project TypeLens vibrating feeder (DPS-2) integration
ApplicationLED panel light bar lens assembly
Driving RequirementEliminate manual lens assembly bottleneck and scale output
LED panel light bar assembly is a case where the economics are visible: precise, high-volume lens placement, few variants, and a cost set by labor time and rework. Manual work sets the ceiling.
Customer Background: Automating Lens Assembly
Shenzhen Jinghe Technology Co., Ltd. (JHIMS) supplies SMT and PCB assembly equipment to clients worldwide; a project with a Russian LED lighting manufacturer used its lens vibrating feeder.
The customer makes LED panel light bars, where lens placement accuracy and volume decide quality and delivery. Lenses were oriented and placed by hand, which limited output and raised labor cost as demand grew.
The constraint was a manual lens assembly step, published as a 40% efficiency gap. The operator held the quality standard, but the pace was set by the person, not the machine, and hand handling added its own defects.
Project Challenges
- Manual Assembly Bottleneck Manual lens assembly for LED panel light bars created a 40% efficiency bottleneck and unmet demand.
- Lens Diversity Multiple lens types required flexible, simultaneous handling without changeover delays.
- Integration Risk New equipment had to integrate seamlessly with existing Hanwha SM481 machines.
- Quality Consistency Hand placement was prone to orientation errors and inconsistent quality.
- Labor Cost Each line needed multiple operators for lens feeding and placement.
Three challenges decide the outcome: the 40% efficiency gap that sets the size of the prize, several lens types to run without changeover delays, and fitting an installed Hanwha SM481 line without stopping it.
Customer Requirements
Before selecting the DPS-2, the customer verified five non-negotiable requirements:
- Proven Compatibility Seamless integration with their existing Hanwha SM481 pick-and-place machines.
- Multi-Type Flexibility Simultaneous handling of multiple lens types without retooling.
- High Throughput Automated lens placement fast enough to remove the line bottleneck.
- Consistent Quality Reliable orientation and placement to eliminate manual errors.
- Minimal Downtime Jam-free feeding and dependable 24/7 operation.
Five non-negotiable requirements were confirmed before selection: Hanwha SM481 compatibility, lens types without retooling, throughput that clears the bottleneck, consistent quality, and no disruption to production.
The five requirements the customer confirmed before selecting the DPS-2, and how each was addressed.
| Requirement | What it means in practice | How it was met |
|---|---|---|
| Proven compatibility | Must work with the machines already on the line | DPS-2 integrated with the existing Hanwha SM481 line |
| Multi-type flexibility | Several lens types without retooling delays | Up to five lens types handled with adjustable 50–120 Hz frequency |
| High throughput | Feeding must stop limiting line output | Automated presentation removes the manual pace limit |
| Consistent quality | Every panel light bar identical | Stable amplitude and orientation at the escapement |
| Plug-and-play installation | No disruption to running production | Standalone control cabinet, head-specific bracket, no machine modification |
JHIMS Solution
- Automated Feeding Lens vibrating feeder integrated with Hanwha SM481 pick-and-place machines, automating lens placement.
- 5-Type Capacity Handles up to 5 lens types simultaneously with adjustable 50–120Hz frequency.
- Consistent Quality Automated placement ensured consistent quality across every LED panel light bar.
- Plug-and-Play Integration Brand-specific interface kit matched the existing Hanwha SM481 line.
- 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: decades of automation experience, rigorous testing for reliable products, and real, transparent success stories — backed by open customer feedback shared on YouTube.
A single DPS-2 lens vibrating feeder was integrated with the customer’s existing Hanwha SM481 machines: placement was automated, the line was not replaced. It runs up to five lens types at 50–120 Hz without retooling.
Lens Vibrating Feeder Equipment Configuration: DPS-2
| Item | Model | Qty |
|---|---|---|
| Lens Vibratory Feeder | JHIMS DPS-2 | 1 |
| Pick-and-Place Integration | Hanwha SM481 (existing) | 1 |
The DPS-2 was delivered and integrated with the customer’s existing Hanwha SM481 line.
DPS-2 Key Specifications
| Feature | Details |
|---|---|
| Model | JHIMS DPS-2 Lens Vibratory Feeder |
| Lens Diameter Range | 3 mm – 25 mm |
| Lens Types | Round, three-foot, four-angle, rectangular-cutout |
| Transfer Speed | 0.5–1 s per lens per channel (3,600–7,200 UPH/channel) |
| Rejection Rate | Under 0.5% (typically 0.2–0.4%) |
| Alignment Tolerance | ±1 mm |
| Tracks | 2 disc tracks standard, expandable to 10 |
| Vibration Frequency | Circular 50–120 Hz; direct 100–200 Hz |
| Dimensions | 1050 × 700 × 750 mm (approx. 130 kg) |
| Power Supply | 220V AC, 50–60 Hz, single phase, 0.55 KVA |
| PLC / HMI | Mitsubishi FX5U / 7-inch Weintek HMI (50 profiles) |
| Compatibility | Hanwha SM481/482/HM520/DECAN, Yamaha, JUKI, Samsung, Hitachi, Fuji |
The delivered configuration was one DPS-2 feeder with its own control cabinet mounted on the existing Hanwha SM481 line. Lens diameters from 3 mm to 25 mm are covered, so the placement machine is not modified.
The configuration as delivered, against the published DPS-2 specification.
| Item | Configuration |
|---|---|
| Feeder | JHIMS DPS-2 lens vibratory feeder, one unit |
| Integration | Existing Hanwha SM481 pick-and-place line |
| Lens diameter range | 3 mm – 25 mm |
| Lens types | Round, three-foot and other common LED lens outlines |
| Frequency range | Adjustable 50–120 Hz |
| Stored profiles | Up to 50, recalled in under 3 seconds |
| Changeover | Under 5 minutes per lens type |
| Burn-in | 48 hours with the customer’s own lens samples |
| Published outcome | +35% throughput, −25% downtime |
Implementation: Integration & Delivery
The DPS-2 was built, tuned and burned in for 48 hours with the customer’s own lenses at the JHIMS factory, then integrated with the Hanwha SM481 line. Changeover takes under 5 minutes, with up to 50 saved profiles.
Delivery followed the sequence used for every feeder of this class.
- 48-hour burn-in at the JHIMS factory with the customer’s own lenses
- Settings proven on the customer’s parts before shipment
- Integration with the existing Hanwha SM481 line on site
- Changeover in under 5 minutes, using up to 50 saved profiles
- On-site verification of rate and lens placement
- Handover with operator training
Video: Lens Vibrating Feeder in Action
Watch the JHIMS lens vibrating feeder feeding lenses on a pick-and-place line — the same feeder model delivered to this Russian LED lighting customer. Watch the full lens feeder video on YouTube.
The video shows the feeder feeding lenses on a pick-and-place line.
- Lenses leaving the vibrating bowl one by one with even spacing
- Each lens oriented and presented to the placement head
- The head picking a lens and placing it on the light bar
- A lane that runs without manual refilling
- Where a jam or double-feed would appear on the feeder
Results & Operational Benefits
Production efficiency rose with a 35% throughput boost and 25% less downtime after automation: the feeder removed manual lens handling and its vibration control cut jams to near zero.
JHIMS’s feeder transformed our workflow — no issues, just results. — Russian LED Lighting Customer
- Throughput 35% increase in production efficiency after automation.
- Downtime Reduced by 25% through reliable, jam-free feeding.
- Quality Consistent lens placement quality across all LED panel light bar production.
- Labor One DPS-2 replaces 2–3 manual operators per line.
- Long-Term Value The production manager highlighted fewer maintenance hours and consistent performance across production runs.
The production manager from the Russian client shared: “The lens vibrating feeder not only increased our SMT efficiency by 35%, but its reliability has saved us countless hours in maintenance. JHIMS delivered beyond expectations.”
The published result is +35% throughput and -25% downtime: manual lens handling was eliminated and jams fell to near zero. The gain came from removing the human pace limit, the downtime cut from fewer stoppages.
Automating Lens Placement on an Existing Hanwha Line
Most lens feeding projects are additions to an existing line, not new lines: the constraint is the interface with a machine the customer owns. Disruption is the main risk — platform position, triggering, lens recovery.
A feeder with its own control cabinet answers the three concerns without touching the customer’s machine.
- It runs independently of the placement machine’s control
- Changeover between lens types stays on the feeder
- The customer’s line keeps producing during installation
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SupportTechnical SupportGlobal after-sales support, remote training, spare parts and service requests.Get support →Frequently Asked Questions
How much did the lens feeder boost SMT efficiency?▼
The Russian LED lighting customer saw a 35% throughput increase and 25% downtime reduction after integrating the JHIMS lens vibrating feeder with their Hanwha SM481 machines.
What is a lens vibrating feeder?▼
An automated feeding system that uses vibration to align and feed LED lenses into pick-and-place machines, eliminating manual lens handling. It reduces labor, speeds up placement and keeps quality consistent.
How many lens types can it handle?▼
Up to 5 lens types simultaneously, with adjustable frequency from 50 to 120 Hz. The DPS-2 handles lens diameters from 3 mm to 25 mm.
Is it compatible with Hanwha machines?▼
Yes. It 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) with a brand-specific interface kit.
What are the feeder dimensions?▼
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.
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 (LED panel light bar lenses, TV backlight 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.
Ready to Automate Your Lens Assembly?
Contact JHIMS for a free consultation on lens feeder integration — we reply within 12 working hours (Mon–Sat, 09:00–23:00 China Standard Time, UTC+8).