Work lighting design for automobile manufacturing workshop

Automotive Industry Lighting Overview

For the automotive industry, it is first necessary to provide good general lighting to ensure visual visibility and comfort and create a pleasant working environment. Secondly, for different work environment and good processes, special work lighting is required.

The production process of a car is usually divided into six steps: stamping, shell assembly, surface coating, power assembly, final assembly, and vehicle testing and transportation. Every step has to undergo rigorous testing, which has special requirements for lighting. Good lighting ensures the comfort and safety of the working environment, reduces work errors and improves production efficiency. This paper discusses the lighting design problems of a well-known brand automobile production assembly shop in Zhengzhou, using DIALux lighting software simulation to explore and apply the actual.

design content

【Pressing and Forming Workshop】

In the on-site observation of existing stamping shops, the stamping process is usually done by tall, bulky, and complex machines that produce noisy noise and large amounts of hot air, dust, and even oil. Usually the height of the workshop is 15-18 meters, and heavy stamping dies can be transported in the air by crane hangers. The height of each press shop is roughly the same, and the required illumination is slightly higher, which has been met according to the correct maintenance needs. The selected lamps must meet the above complex environmental requirements while ensuring illumination.

Design basic lighting requirements

The space of the workshop in the new stamping workshop is: length 38 × width 20 × height 15 (m). To ensure safety, the lamps in the stamping workshop must be shockproof, corrosion resistant, dustproof, and made of oil resistant materials. The arrangement of the lamps should be consistent with the machine layout to prevent the machine from 12-15 meters high from generating shadows. The lamps need to have strong light penetration to ensure sufficient illumination in the press shop and underneath. The top of the press should be loaded locally. Illumination, which provides the illumination required for inspection and safety during the stamping process, correctly aligns the luminaires, and selects a narrow beam of luminaires to achieve the desired illuminance and illuminance uniformity.

The ceiling of the stamping workshop is relatively high. It is ideal to use high ceiling industrial lamps. The average illumination of the working surface is 398lx by DIALux software. This calculation meets the requirements of relevant national industrial plants. If you prefer to use fluorescent lamps, look at fluorescent strips with very narrow beams. High ceiling industrial lamps are generally arranged in close proximity to achieve high illumination uniformity and are usually individually mounted. Although the installation cost is lower in pairs, the lighting effect of the single dry installation is good. When loading local illumination on the press, the color temperature of the light source should match the general illumination, not to be much different.

【Surface Spray】

The general spraying process consists of the following steps: cleaning and pre-coating, initial pre-coating, sealing (the body is flexibly sealed to ensure water resistance), wet or dry sanding preparation, first spray, second and final Spray color, final inspection. The entire process is continuous, partially automated, and randomly produces cars in multiple colors.

In addition to process control, there are many manual operations: loading seals, spraying in spray booths, sanding and small body repair work, inspection spraying and final spray repair. Many visual tasks are more difficult: it is often necessary to check for small defects on a large, uneven surface. The high reflectivity of the metal surface is relatively low in contrast to the surrounding brightness. In theory, especially for black, white and metallic colors and the body, the optimum value of the brightness ratio cannot be given.

Basic lighting requirements:

Lighting designers should ensure high illumination and uniformity of illumination for each horizontal, vertical and corresponding bevel: use luminaires with white grilles or other optical accessories to reduce glare and optimize the visual environment; Sexual requirements are also relatively high to ensure that errors in the production process can be identified in the first time.

Lighting design distribution