Address
Building A1, Runteng Industrial Park, No. 4 Xishan Road, Longteng Community, Shiyan Subdistrict, Bao'an District, Shenzhen 518000, China
Work Hours
Monday to Saturday: 09:00 – 23:00 (UTC+8)
Sunday: closed
Hanwha SM481 Lens Feeder Case Study: LED in Dongguan
Dongguan LED strip line automated on a legacy Hanwha SM481: cycle time -40% (6 min per strip), glue waste 30% to 5%, uptime 85% to 99%, payback in 4 to 6 months.
Case Study
Hanwha SM481 Lens Feeder Case Study: LED Assembly in Dongguan
How a Dongguan LED manufacturer automated 1.2 m LED strip lens assembly on a legacy Hanwha SM481 line: cycle time down 40%, glue waste 30% to 5%, labor cost down 50% and 99% uptime.
Direct answer: The Hanwha SM481 lens feeder is a custom vibratory solution that automates LED lens strip handling for high-volume production. JHIMS delivered a stainless-steel double-bowl feeder for a Dongguan LED manufacturer’s Hanwha SM481 line, enabling five simultaneous lens pickups with 50–60Hz vibration and ±0.03mm accuracy. The upgrade cut assembly time by 40%, reduced labor costs by 50%, lifted uptime from 85% to 99%, and paid back in 6 months — without requiring a new production line.
Key Takeaways
- 1-40% Assembly Time
- 2-50% Labor Cost
- 399% Uptime
- 46 mo ROI Payback
Customer & Industry
At a glance: who the customer is, where the machine was delivered, and what drove the investment.
CustomerDongguan LED manufacturer (name confidential)
IndustryLED lighting / LED strip assembly
Project LocationDongguan, Guangdong, China
Project TypeCustom Hanwha SM481 lens feeder (vibratory)
Application1.2m LED strip lens assembly
Driving RequirementAutomate lens assembly without full line overhaul
LED strip assembly is a different problem from LED module placement: a 1.2 m strip carries lenses along its whole length, so the work is a continuous dispense-and-place sequence over a long, flexible substrate that cannot be supported like a rigid PCB. The customer is a Dongguan LED manufacturer running a legacy Hanwha SM481 line at high volume. The published requirement: automate lens assembly without a full line overhaul — the new equipment had to fit the existing platform, floor layout and operator routines, and pay back before any wider modernization.
Customer Background: Lens Strip Bottleneck
A Dongguan LED manufacturer set lenses onto 1.2 m LED strips by hand inside a machine-paced line. Published figures: bottlenecks that slowed high-volume output, 30% material waste from inconsistent glue application, and labor cost rising with volume. Hand assembly paces the line — the strip cannot advance until the operator finishes — and in a dispense step material is committed at placement, so misalignment and rework consume glue and lenses that cannot be recovered. JHIMS supplied a bowl feeder customized for the customer’s lens types plus automated red-glue and epoxy dispensing.
Project Challenges
- Manual Assembly Bottleneck Manual lens strip assembly on a legacy SMT line created production bottlenecks and slowed high-volume LED output.
- Material Waste 30% waste from inconsistent glue application on 1.2m LED strips.
- Integration Risk Upgrading a legacy line without full overhaul — new equipment must integrate seamlessly with existing Hanwha SM481 infrastructure.
- High Labor Costs Manual feeding required multiple operators, inflating labor costs in high-volume production.
The four reported challenges each map to a measurable property of the delivered cell: manual assembly paced the line, so output was set by hand speed rather than machine capability; the 30% waste figure is glue and lens material committed at each dispense position; integration risk ruled out any solution needing a new platform, layout or control regime; and labor cost was the accumulated effect of a manual step at high volume. They point at a feeder built for this lens, this strip and this machine.
The four reported challenges, the mechanism behind each one, and the response built into the delivered cell.
| Reported challenge | Mechanism on a 1.2 m strip line | Response in the delivered configuration |
|---|---|---|
| Manual assembly bottleneck | The hand lens step paces the line instead of following it | Five-head pickup and machine sequencing at 15+ lenses per minute |
| 30 percent material waste | Glue is dispensed per position, so a misplacement spends material that cannot be recovered | Integrated dispensing reduced waste to 5 percent |
| Integration risk on a legacy line | New equipment that needs a new platform carries cost the project cannot carry | Feeder built for the existing Hanwha SM481 line, validated on site |
| High labor cost at volume | Each additional strip adds operator time rather than machine time | Reported 50 percent labor cost reduction with payback in 4 to 6 months |
| Continuous lens consumption | A long strip draws lenses in long runs, so refilling interrupts the cycle | Stainless steel double-bowl system keeps the pickup positions supplied |
| Positional accuracy along the strip | Length makes any accumulated error visible at the far end of the strip | Plus or minus 0.03 mm accuracy for lens placement on the strip |
| Line availability during upgrade | A rebuild stops production and puts the schedule at risk | Zero downtime during transition, with 99 percent uptime after handover |
Customer Requirements
Before selecting the JHIMS Hanwha SM481 lens feeder, the customer verified four non-negotiable requirements:
- Seamless Integration Compatibility with the existing Hanwha SM481 pick-and-place line.
- High-Volume Handling Reliable feeding for 1.2m LED strips at scale.
- Multi-Lens Pickup Simultaneous pickup to accelerate assembly cycles.
- Precision Dispensing Automated glue application for red glue and epoxy on LED strips.
All four requirements were testable at the machine: compatible with the existing Hanwha SM481 line — mounts, programs and runs without a rebuild; reliable feeding for 1.2 m LED strips at volume (length and volume, not a rate figure alone); simultaneous multi-lens pickup, which turns a hand sequence into a machine cycle and produces most of the published time saving; and automated red-glue and epoxy dispensing, the requirement that answers the 30% waste figure. Together they describe one integrated cell, validated on site with zero downtime.
JHIMS Solution: Hanwha SM481 Lens Feeder
- Custom Double-Bowl Feeder The Hanwha SM481 lens feeder uses a stable stainless-steel double-bowl system engineered for reliable lens feeding into the Hanwha SM481, customized for diverse lens types.
- 5-Head Pickup Optimized pickup nozzles enable multi-lens handling — 15+ lenses per minute with 5 simultaneous pickups.
- Integrated Dispensing Paired with online automatic dispensing machines for precise red-glue and epoxy coating on LED strips.
- On-Site Validation Validated on-site with zero downtime during transition, achieving 99% uptime.
- No Line Overhaul Full compatibility with chips, ICs, and sockets — no new production line required.
- After-Sales Support End-to-end service from design to deployment, with video tutorials and remote assistance.
Why JHIMS: 10+ years in custom SMT solutions for LED assembly, tailored integrations like multi-lens pickups for Hanwha machines, and cost-effective upgrades with proven 50% savings.
A custom double-bowl vibratory feeder with stainless steel bowls feeds lenses into the Hanwha SM481, paired with an online dispensing machine for red glue and epoxy. Two bowls matter on a 1.2 m strip, where lenses are drawn continuously and a single small bowl would mean frequent refills. A five-head pickup turns the step into a machine cycle: published 15+ lenses per minute against 2 to 3 by hand. Dispensing is sequenced by the same cell, with published accuracy of plus or minus 0.03 mm.
Hanwha SM481 Lens Feeder Equipment Configuration
| Feature | Details |
|---|---|
| Compatibility | Hanwha SM481/SM482 pick-and-place machines; supports 1.2m LED strips |
| Capacity | 5 simultaneous lens pickups; vibration frequency 50–60Hz |
| Materials | Stainless steel double-bowl design |
| Accuracy | ±0.03mm |
| Dispensing Integration | Integrates with online automatic dispensing machines |
| Feeding Speed | 15+ lenses per minute (5× pickup) |
| Uptime | 99% |
The published configuration shows how narrowly this was scoped: compatibility with Hanwha SM481 and SM482 machines and support for 1.2 m LED strips — which is what allowed the feeder to be added to an existing line. Vibration frequency is a narrow 50 to 60 Hz band, tuned for these lens bodies. Capacity: five simultaneous pickups above 15 lenses per minute, held over a full shift by stainless steel double-bowl construction. Dispensing pairs with online automatic machines for red glue and epoxy, making the cell a combined dispense-and-place unit.
The published before-and-after figures for this project, measured on the customer’s own 1.2 m LED strips.
| Metric | Manual / pre-upgrade | Automated cell |
|---|---|---|
| Cycle time per strip | 10 minutes | 6 minutes, a 40 percent reduction |
| Lenses placed per minute | 2 to 3 by hand | 15+ with five simultaneous pickups |
| Placement error rate | 15 to 20 percent | Under 1 percent with precision dispensing |
| Glue waste on strips | 30 percent | 5 percent, an 83 percent reduction |
| Line uptime | 85 percent | 99 percent |
| Labor cost | Multiple operators on the lens step | 50 percent reduction, payback in 4 to 6 months |
| Placement accuracy | Dependent on operator skill | Plus or minus 0.03 mm |
| Pickup configuration | One lens at a time | Five simultaneous pickups |
| Platform compatibility | Hanwha SM481 line, chips, ICs and sockets | Unchanged, with no new production line required |
The custom Hanwha SM481 lens feeder was engineered and delivered for the customer’s Hanwha SM481 line, with the double-bowl system providing stable feeding for diverse lens types.
Implementation: Hanwha SM481 Lens Feeder Integration & Validation
JHIMS engineered the Hanwha SM481 lens feeder with a stable double-bowl system for reliable feeding, optimized pickup nozzles for multi-lens handling, and seamlessly integrated dispensing technology for precise strip coating. The setup was validated on-site, ensuring zero downtime during transition.
The upgrade followed the pattern a legacy line requires: the feeder was engineered around the customer’s own lens types with a stable double-bowl system, pickup nozzles were optimized for multi-lens handling, and dispensing was integrated so coating and placement happen in one sequence. Validation ran on site with zero downtime during transition — the line was transitioned in place, not stopped and rebuilt — which depends on the feeder being prepared against the customer’s lens samples before delivery. The published 99% uptime afterwards is the durable version of that result.
Video: Hanwha SM481 Lens Feeder in Action
Watch the Hanwha SM481 lens feeder and LED light bar dispensing integration. Watch the full feeder video on YouTube.
Watch the sequence between dispense and placement: glue must be applied and the lens seated inside the adhesive’s open time, so an unstable index shows lenses not sitting down properly. Watch the bowl exit during a strip — a 1.2 m strip draws lenses in long runs, so the feeder has to hold its rate for the whole strip. Watch the pickup head: five simultaneous picks should complete without a missed nozzle. And watch the rejects, because in dispensing the measure is not only lenses per minute but how much material is wasted reaching that number.
Hanwha SM481 Lens Feeder Results & Operational Benefits
Post-implementation, the Dongguan facility reported 40% faster production cycles via the Hanwha SM481 lens feeder’s 5-head pickups, 50% reduced labor costs, and full compatibility with chips, ICs, and sockets — no new line required.
| Metric | Pre-Upgrade | Post-Upgrade | Improvement |
|---|---|---|---|
| Cycle Time | 10 min/strip | 6 min/strip | -40% |
| Waste Reduction | 30% | 5% | -83% |
| Uptime | 85% | 99% | +16% |
Manual vs. Automated Lens Feeding
| Aspect | Manual Feeding | Hanwha SM481 Lens Feeder (Automated) |
|---|---|---|
| Speed | 2–3 lenses/min | 15+ lenses/min (5× pickup) |
| Cost Savings | High labor (20% waste) | 50% reduction; ROI in 6 months |
| Error Rate | 15–20% | <1% with precision dispensing |
| Scalability | Limited to small runs | Handles high-volume LED strips |
Results match the mechanism: cycle time per strip fell from 10 minutes to 6 (down 40%) because five-head pickup replaced a hand sequence; glue waste fell from 30% to 5% (down 83%) because dispensing and placement are machine-sequenced, so material goes where a lens will be placed and rejected strips are far fewer; uptime rose from 85% to 99% by removing the hand operation and validating before handover; labor cost fell 50% with payback in four to six months. Placement errors fell from the 15 to 20% typical of manual work to under 1% with precision dispensing.
- Speed 40% faster production cycles via Dongguan-tested 5-head pickups (15+ lenses/min).
- Cost 50% reduced labor costs with full ROI in 4–6 months.
- Compatibility Full compatibility with chips, ICs, and sockets — no new line required.
- Quality Precision dispensing cut glue waste from 30% to 5%.
- Reliability 99% uptime with on-site validation and after-sales support.
Beyond the metrics, the feeder’s design accommodates various lens shapes via adjustable vibration settings, tailored for Dongguan-scale volumes — supporting LED lighting fixtures, automotive lighting, and smart home devices.
Related Products
FeaturedDPS-2 Lens Vibratory FeederDual-frequency vibratory lens feeder — 0.5–1s per lens, 3–25mm lenses, 2 disc tracks expandable to 10.View product →
CompanionYamaha YSM10 MounterHigh-speed compact modular mounter – 46,000 CPH, 96 feeders, e-Vision + Side View.View product →
RelatedYamaha YSM20R MounterHigh-speed modular mounter – 95,000 CPH, 140 feeders, 0201 to 55×100mm components.View product →
RelatedJHIMS S630 3D SPI3D solder paste inspection – verifies print quality before reflow.View product →
RelatedJHIMS ZM500 Screw MachineAutomated screw tightening and removal for electronics assembly.View product →
RelatedJHIMS R10 Reflow OvenLead-free hot-air reflow soldering for SMT lines – 20 heating zones, up to 300°C peak.View product →Related Resources
Case StudyXiamen TV Backlight CaseLens vibrating feeder raising TV backlight throughput from 6K to 10K CPH in Xiamen.Read article →
Case StudyRussia Lens Feeder CaseLens vibrating feeder automating lens assembly for a Russian LED lighting manufacturer.Read article →
Case StudySaudi Screw Machine Case2P-LXS500 screw tightening automation for a Saudi LED display manufacturer.Read article →
ComparisonSMT Lens Feeder Comparison 2026An objective comparison of technology, component quality, price positioning, and best-fit customer profiles across global brands.Read article →
GuideSourcing SMT Equipment from ChinaA risk-managed procurement guide – sourcing, QC and delivery for SMT equipment from China.Read article →
SupportTechnical SupportGlobal after-sales support, remote training, spare parts and service requests.Get support →Frequently Asked Questions
Is the Hanwha SM481 lens feeder compatible with other SMT machines?▼
Yes, our custom vibratory bowl feeder for Hanwha SM481 can be adapted for SM471 or Samsung models with minimal modifications.
How does the lens feeder integrate with automated dispensing?▼
It pairs directly with our online dispensing machines for precise glue application on LED strips, supporting UV and epoxy resins.
What is the ROI for upgrading to this SMT lens feeder?▼
Clients like our Dongguan partner see full ROI in 4–6 months with the Hanwha SM481 lens feeder — 40% efficiency gains and reduced waste on 1.2m strips.
Can it handle custom lens types for LED production?▼
Absolutely — our design accommodates various shapes via adjustable vibration settings, tailored for Dongguan-scale volumes.
How reliable is the Hanwha SM481 integration?▼
99% uptime guaranteed, with full on-site validation and after-sales support as proven in our Dongguan deployment.
How fast is the automated lens feeding vs manual?▼
The 5-head pickup reaches 15+ lenses per minute versus 2–3 lenses per minute manually — a 5× speed gain — while cutting labor costs by 50%.
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 feeder 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 feeder 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?▼
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 feeder running?▼
Absolutely. Visit our Shenzhen demo center to see the feeder 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.
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.
Ready to Optimize Your LED SMT Line?
Contact JHIMS for a free consultation on Hanwha SM481 lens feeder integration.