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X-ray Machine for LED
If you are looking for a machine for your quality control and safety? UNI X-ray is well known in manufacturing high quality machines including X-ray machine for LED inspection.
- Allow to verify and improve mounting process of LED assembly
- Be able to inspect different types of LED components and plates
- Offer high quality imaging to detect inner hidden defects and voids
- Be capable to automatically and accurately verify soldering bubbles percentage
- Identify 100% defect-free of each LED component soldering for ensuring high reliability
X-ray Machine for LED Inspection
How many times have you wished for a tool to help you inspect your LED? If you love quality manufacturing, then that will be every time you produce another LED.
X-ray machines are a great tool to help you assess and identify defects in your LED PCBs. The fact that most devices have these components signifies that LED PCB will be in demand for many years to come.
If you are looking for quality x-ray machine for led pcb inspection, have a careful look at our wide range of x-ray machines below.
Why Global Clients Choose Us?
20 Years of Expertise
We have over 18 years of experience that specializes in X-ray Technology.
Excellent Image Quality
Uni X-ray produces X-ray machines that offer excellent and ultra-sharp image qualities.
High Degree of Safety
Our X-ray machine is one of the safest choices you can make because it ensures maximum safety.
Extremely User-friendly
Uni X-ray produces machines that have an easy mode of operation.
Services We Provide
Installation Guideline
We offer you free and quick installation instruction with online video tutorials. The tutorial explains detailed and important steps to get your machine started. Any questions about installation, feel free to contact us!
Customer Support
We work to provide the best customer support. We are here to help you solve any problems you may encounter. Feel free to contact us Uni X-ray team online via video chat, phone, or email anytime.
Quick Delivery
Online equipment shipped within 45 days and offline equipment within 20 days after payment confirmation. The customized machine is supposed to be deliveded in less than 90 days.
Warranty Service
Uni X-ray machine comes with a one-year warranty. In the warranty period, machine defects, repairs, and part changes are free. Unexpected damage issues due to shipment, handling, storage, abuse, or misuse will not be covered.
Installation Guideline
We offer you free and quick installation instruction with online video tutorials. The tutorial explains detailed and important steps to get your machine started. Any questions about installation, feel free to contact us!
Customer Support
We work to provide the best customer support. We are here to help you solve any problems you may encounter. Feel free to contact us Uni X-ray team online via video chat, phone, or email anytime.
Quick Delivery
Online equipment shipped within 45 days and offline equipment within 20 days after payment confirmation. The customized machine is supposed to be deliveded in less than 90 days.
Warranty Service
Uni X-ray machine comes with a one-year warranty. In the warranty period, machine defects, repairs, and part changes are free. Unexpected damage issues due to shipment, handling, storage, abuse, or misuse will not be covered.
X-Ray Machine for LED Inspection: the Complete Guide
Table of Contents
1. What is an LED PCB?
Ever seen a light bulb with the inscription that says LED LIGHT? This is because the light-producing component in the bulb is manufactured from a diode called the Light Emitting Diode or LED for short.
However, most electronic devices also make use of this LED on their Printed Circuit Boards (PCBs) for notification lighting, indicators, and alarm systems.
Though these PCBs can be made from various types of materials a lot of them are made from aluminum.
Nonetheless, LED PCB is receiving a lot of acceptance for the design and manufacture of various devices because of their numerous benefits including low energy consumption.
2. What is an X-ray Machine for LED Inspection?
Various X-ray machines have been tailored to fit a particular industry, specific material, or product. For instance, there are X-ray machines designed to inspect lithium-ion batteries and some have been manufactured to inspect automotive products like car wheels.
In the same vein there are X-ray machines specifically designed to inspect LED PCB due to its unique needs and peculiarities.
LED PCBs mostly use mounting technologies like Ball Grid Arrays (BGA) for the assembly of components on the PCB which often come out densely packed.
This arrangement makes it difficult to assess and to inspect the quality of welding and other quality parameters.
LED PCB X-ray machines are often the best tool to carry out the inspection and identification of flaws that might be present in the PCBs during manufacturing or assembling.
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3. Why do LED need to be Inspected?
The tightly packed arrangement of PCB components makes it hard to carry out soldering manually except through mounting technologies or other assembling methods.
There is the possibility of an error during the manufacturing or assembling process and going ahead with this PCB can result in the production of a lower quality. Also, a faulty device can cause harm to the user.
Hence, carrying out LED PCB inspection ensures that you get a quality product that meets standards of quality and safety.
4. LED PCB Design
In the production of LED PCB there are many processes that are involved and they begin with the design phase to the manufacturing and assembling phase.
Let’s take a look at these stages of production and how they affect the quality of the final product.
◆ LED PCB Layout
The production always begins with the layout showing the schematics of the LED arrangement on the PCB.
Also, the wiring arrangement is part of the layout and should be shown in the general arrangement drawings.
Lastly, labelling the components and wiring appropriately gives you an idea of what you’ll achieve immediately.
◆ LED PCB Core Material
The different applications of LED PCBs provide different environments for their operation. These environments vary in properties and characteristics, and they determine the types of core materials that are suitable for the manufacture of LED PCB. Here are the three main core materials highlighted below.
- FR-4
This core material is a compound consisting of epoxy and glass in specific proportions and it is by far the most common type of LED PCB core material.
However, the FR-4 lacks the ability to transfer heat effectively away from the device even though it is fireproof.
- CEM-1
This is used simply based on its cheap cost rather than on its thermal conductivity. This factor due to its epoxy-based material
- Metal Core
The composition of this core material is a combination of laminated copper and aluminum that’s why it is called metal core.
The effectiveness at transferring heat away from the device is high and that’s why it enjoys varied application.
Its high efficiency as a thermal conductor and insulation against electrical current makes it suitable for various applications.
◆ LED PCB Assembly
There are basically three types of LED PCB assembly, and they are explained below.
- Through-hole
For the through-hole assembly, it involves the punching of holes into the board with the leads inserted and then soldering by the applier holds the leads firmly in place. This assembling ensures a firm set of on-board components.
This assembling process is well-suited for equipment or devices that require sturdy PCB components due to extreme handling of the devices.
Inspection and testing are often carried out to ensure the components are well placed.
- Surface Mount
Surface mount technologies are a recent innovation that allows an automated system to mount PCB components directly onto the PCB with the solders already in place.
Melting the solders is done by heating them to bond the components to the PCB. Carrying out integrity tests and inspection of the soldering is often a critical part of the process.
- COB (Chip-On-Board)
Lastly, the COB or chip-on-board assembly utilizes diodes and metal core connection to form arrays of diodes.
This simplicity in connection and its low cost makes COB a preferred LED PCB assembly type for many applications. It also has high thermal conductivity and heat transfer.
5. Aluminum PCB for LED
Aluminum is a very useful metal in the production of LED PCB due its many advantages over other types of PCB.
One of these advantages is its ability to dissipate heat away from its host device keeping it cool and functional.
This advantage alone makes the aluminum LED PCB a favorite for device manufacturers who use LED PCBs in their manufacture.
◆ Types of Aluminum LED PCBs
Aluminum LED PCB exists in three forms including universal, high-frequency, and high thermal-conductive aluminum PCB.
For the high thermal-conductive form, there is a layer of epoxy resin which should have high thermal conductivity.
The universal form has a mix of fiberglass and epoxy for its dielectric layer while the high frequency form uses a polyimide resin and fiber glass for its dielectric layer.
◆ Layers of Aluminum LED PCBs
Aluminum LED PCB is composed of three core layers including the copper foil layer, the dielectric layer, and the aluminum base layer which are all highlighted below.
- Copper Foil Layer
The copper foil layer serves as the current carrying component with a thickness of between 1-10 ounces. The thicker the copper foil layer the more the current it will carry.
- Dielectric Layer
This layer is the heat carrying part of the Aluminum LED PCB with a thickness of between 50 – 200 micrometers.
- Aluminum Base Layer
The aluminum base layer serves as the protective layer to save the PCB from external poking that might cause scratches or dents on the aluminum face.
◆ Manufacturing Difficulties
In the manufacture of aluminum PCB, there are typical challenges that you must consider if you must get the manufacture of aluminum PCB right. Here are the difficulties highlighted below.
- Copper Etching
Etching is one difficulty that you need to consider very well in relation to width-thickness ratio as the thickness of the copper foil is often very thick.
You will need to increase the width of the copper foil accordingly when the thickness exceeds three ounces
- Solder Mask Printing
Solder mask is often printed twice because of the thickness of the trace copper as the thickness usually produces a substantial difference between the board and the surface on which the image will be etched.
- Mechanical Manufacturing
When manufacturing low quantities of aluminum PCBs, you should engage professional milling as unprofessional drilling or milling often causes low electrical strength.
It is also best to avoid burning as this often affects the mechanical properties of the board.
6. How can an X-ray Machine be Applied in an LED?
Majority of the lighting you will see these days are made of LEDs because they offer an efficient and cost-effective illumination.
This is the reason why LEDs enjoy various uses, and you’ll find some X-ray machine applications for LED PCB below.
▸ Consumer Lighting |
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Homes, offices, and other facilities need lighting to illuminate spaces and dark corners for individuals to see their way. These lighting are known as consumer lightings, and they use various forms of lighting solutions including torchlights, lamps, and light bulbs to this effect. However, due to the high cost of energy, most people have turned to LEDs for their lighting solutions. The cheap cost of purchase of LEDs and the low power consumption makes LEDs an effective cost-saving option for consumer lighting. X-ray machines can check the LED PCB for these consumer lightings to ensure their quality and weld consistency. |
▸ Consumer Electronics |
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Electronic design and innovation have produced numerous types of devices for various purposes that include entertainment and communication. One of the problems electronic designers try to overcome is the heat generated in the lighting components on the PCBs. LED PCBs have been one way to overcome this challenge as they are made from aluminum materials that don’t generate so much heat when compared to other forms of lighting. X-ray machines often serve to check the LED PCBs to ensure the material components are correct. |
▸ Automotive |
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The headlamps and rear lights of vehicles have often been made from other materials that consume a lot of battery power. This power consumption drastically reduces the amount of power available to other automotive electronics. However, the use of LEDs in automotive lighting have made more power available to other automotive utilities that use battery power. Also, the luminance value of LEDs is higher than other lighting sources making it brighter for drivers to see while driving. The Xray machine therefore ensures that the LED PCBs conform to automotive quality standards. |
▸ Medical |
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Medical lightings are another application of LED PCBs as you’ll often find LEDs as components of lighting used in emergency and surgery areas. The reason for their usage in this area is the low emission of heat from the LEDs and their long-lasting abilities. |
7. Inspection Methods for LED
Because of the peculiarity of LED PCBs and its uniqueness especially during its manufacturing and assembly, it has become expedient to seek out a suitable means for its quality assessments.
Different methods of inspection have their unique applications with significant benefits when employed in the appropriate situations.
Here are some ways that quality inspectors find errors in LED PCBs during its manufacturing phase.
◆ Manual Visual Inspection
Visual inspection method is still by far the standard method of quality inspection as it is the easiest and fastest way to identify an error.
It is especially effective for small quantities of samples with each sample having a large enough size for the eye to spot any anomalies.
Some parameters that inspectors can check using visual inspection include the thickness of the PCB, dimensions, solder overlap, and edge straightness. Other PCB parameters include surface smoothness, plating color, firmness, and bulging.
However, manual visual inspection is only as good as the level of attention and the eyes of the inspector. So, it is best to use it sparingly, usually as a final check after using other inspection methods.
◆ Automated Optical Inspection
AOI or Automatic Optical Inspection is an NDT inspection method that engages light properties and image analysis to identify defects in a LED PCB board.
Packets of light are released on the test samples of the board while capturing images of the samples from different points of view. These pictures are compared to standard PCB assembly pictures to identify various defects like missing components, scratches, and low solders.
While AOI can be a faster way than the visual inspection method it still is not effective to identify defects in PCBs especially for surface mounted components that are densely packed.
◆ Automatic Laser Test Measurement
This automatic non-destructive method of testing involves the use of lasers to test and to measure defects in LED PCBs.
It operates by reflecting laser on the PCBs, while measuring parameters like height, light intensity, and solder joints.
After the measurements, a standard specification of PCB is compared to the measurements taken to identify faults embedded in the PCB.
Nonetheless, the laser method poses unique advantages in finding defects like misaligned solders, volume of solder, and cleanliness of solders.
However, errors in measurements can occur due to reflection interference and shielding.
◆ X-ray Inspection
By far the most accurate method of inspection for LED PCBs, X-ray inspection offers so many other benefits for inspection than many other methods of inspection.
Most PCBs use surface mounting technologies like BGAs (Ball Grid Arrays) that make it very difficult for methods like visual inspection to be effective.
This is because the arrangement of components on the PCB is so densely packed leaving little spaces between them.
However, using X-rays to carry out the inspection allows for proper analysis of the components as the components only need to be exposed to the X-ray radiation.
The rate of absorption of this radiation is dependent on the PCB’s thickness and determines how the image appears on the screen.
A further analysis of this image will reveal the presence or absence of any defect.
8. What are the Benefits of Inspecting LED with X-ray Machine over Other Inspection Methods?
The benefits of X-ray machines over other inspection methods like optical inspection and visual inspection are numerous.
First of all, X-ray inspection is a non-destructive testing method which means samples can be used after testing unlike destructive methods where samples can no longer be used after testing.
Also, X-ray in section allows the testing of multiple samples in a short period which is an advantage over methods like visual inspection which takes a lot of time and only tests samples one at a time.
For densely packed components on PCBs using mounting technologies, X-ray offers an easy and accurate way to assess the connections of the components for defects without any contact with the samples.
9. How Much Does It Cost to Buy an X-ray Machine for LED Inspection?
In your bid to get a suitable X-ray machine for your LED PCB inspection you will have to consider various critical factors that may affect the price of the machine.
Firstly, the choice of a brand-new X-ray machine will attract a significant cost when compared to a refurbished one.
Also, picking a highly automated X-ray solution will cost you more than a semi-automatic or an analog version of the same X-ray machine.
The choice of manufacturer is yet another essential consideration. Chinese brands are the most affordable manufacturers in the X-ray inspection industry.
Where European and American manufacturers all have high price tags on their brands of X-ray machines, Chinese manufacturers give affordable, tailor-made solutions for the same quality.
Lastly, choosing a foreign manufacturer as opposed to a local one can significantly increase the cost of purchasing an X-ray machine as freight cost can greatly add to the overall cost.
So, depending on these factors, the cost of an LED PCB X-ray machine can cost between $45,000 for a basic model and $600,000 for a highly advanced and automated LED PCB X-ray machine.
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10. How do I Choose the Best X-ray Machine for LED?
Even if it is not your first time purchasing an X-ray machine, choosing the best X-ray machine for your LED PCB inspection might seem like a huge mountain to climb. But this shouldn’t be the case.
A recurring problem is often the decision to choose between an automated one or an analog X-ray machine. But that is just one of the many dilemmas that you might face.
However, one good way to start out making your decision is to consider your inspection needs and to find a tailor-made X-ray solution that suits this need.
Among the questions you should answer when deciding your choice of LED PCB X-ray machine should include the defects that you plan to inspect. If your choice of X-ray machine cannot effectively detect these defects, then you may have to consider other X-ray choices.
Some other considerations include the type of PCB material, the thickness of your LED PCB, your planned inspection rate, and the expected level of accuracy.
Answering these essential questions should start you on the right path to getting a suitable LED PCB X-ray machine for your inspection.
11. The Best LED X-ray Machine Supplier in China – Uni X-ray
One excellent Chinese manufacturer that can effectively serve your LED PCB inspection needs is Uni X-ray. They have consistently served the X-ray inspection industry for close to two decades both locally in China, and internationally in the US and Europe.
Their successful track record for close to twenty years have earned them recommendations and quality partnership from multinational brands like BMW, PHILIPS, and BYD.
Their trademarks of excellent quality, competitive pricing, and exceptional after-sales support has made them stand out in the LED PCB industry and across various other industries for many years.
★ High Quality
Uni X-ray is the go-to X-ray manufacturing company with high quality X-ray solutions that has been reliable for almost two decades.
With many years of research and development, Uni X-ray constantly produces suitable solutions that meet various international standards of quality.
★ Affordable Price
With the strategic location of its facility in Shenzhen often also known as China’s Silicon Valley, Uni X-ray has positioned itself to harness the large pool of X-ray professionals available in this part of the world.
This access to so many industry experts has made manufacturing cost very affordable which has in turn translated to highly affordable X-ray machines when compared to their US and European counterparts.
★ Excellent After-sale Service
Customers of Uni X-ray enjoy unrivalled after sales support and service as Uni X-ray offers innovative ways of proffering solutions to the needs of its customers.
What’s more is that there is no location barrier to this offering as their online communication centers are available 24 hours to answer client’s questions.
12. How to Import an X-ray Machine for LED from China?
Once you’ve chosen a Chinese supplier and decided to import your LED PCB X-ray machine from China, the process should be seamless if you follow these following steps.
For starters, ensure that you have read and understand the manufacturer’s offering before ordering so that you don’t initiate the manufacturing then realize you’ve made a mistake. Such mistakes can be very costly.
Again, ask questions and let the manufacturer satisfactorily answer all your questions before proceeding to the manufacturing.
Ensure that you get the expected date of completion and arrival so that you can make plans for a credible freight and logistics company to take care of shipping.
Also, engage a competent clearing agent to take care of the complicated part of customs processes including related fees.
Lastly, confirm that your chosen manufacturer has great after sales support as this is essential to forestall any occurrence of downtime once you start operating your LED PCB X-ray machine.
Conclusion
To wrap up, LED PCBs have various applications across various industries that makes them very important to everyday life.
Their numerous benefits like low power consumption, brilliant luminance, and low heat emission makes them suitable for things like electronics, consumer lightings, and automotive lightings.
However, their unique mounting technologies makes it difficult for many inspection methods to assess them for errors and defects.
X-ray method of inspection is preferable for inspecting LED PCB as it uses X-ray radiation which produces an image of the sample for analysis and defects.
It is best to choose a Chinese manufacturer like Uni X-ray seeing that they offer competitive pricing, high quality standards, and a great after sales service.
So, what are you waiting for?