Production Process of LED Modules
LED modules are used in various led display applications, such as ad billboards, live sports events, and traffic information notifications, etc., and the production of our led modules is a multi-step process:
1. Design of LED Unit Board:
This is critical as it sets the stage for the entire production process. This stage includes selecting the appropriate led chip (generally we use HS/RS/Nationstar), driver IC (generally select DP/FM/ICN/MBI), design circuit board, capacitor resistor, CAD design of PCB and bottom case. The design process should consider factors such as the size, resolution, brightness, and viewing angle of the module.
2. LED Tile Sample Prototyping:
Fabricate sample led modules and test their performance and functionality; prototypes must undergo rigorous testing for brightness, color consistency, and viewing angles, also make reasonable corrections to ensure they meet required specifications.
3. Mass Manufacturing Stage:
This includes fabrication of PCBs, assembly of LED chips and other components, and testing for defects. The PCB uses a reflow soldering process to assemble the SMD, fix the LED, IC, capacitor and resistor on the PCB, and the final product is tested for function and performance to verify whether each LED is working properly.
4. Quality Control Series of Tests:
To ensure that the led display module meets the required specifications and quality standards; this includes testing color consistency, brightness, viewing angle and temperature resistance; mandatory 72-hour test aging before dispatch, white balance aging 48 hours, video aging 24 hours.
5. Packaging and Shipping:
LED modules are fragile electronic devices, our QC personnel strictly check whether there are defective products, everything is normal, and choose reasonable foam, plastic bags, cartons for packaging to avoid damage during transportation.
Purchase Notes about LED Modules
1. Please purchase enough led modules and spare parts (3-5%) to build the overall led screen, as the same batch of led modules will use the same batch leds, ICs, and capacitors to ensure the same brightness, color temperature, angles and software settings;
2. The conventional configuration (HS/RS LED+ICN2037) usually have in stock and can be shipped within 2-3 days; customized items (Nationstar/ICN2153) can be shipped within 10-15 days, and require MOQ=500Pcs;
3. Our led modules can be matched with mainstream led control systems such as Novastar, Linsn, and Colorlight, you can ask our sales staff for relevant settings files;
4. Our led modules are provided with the necessary data ribbon cables and power cables for free, if you need special cables, additional charges will be required;
5. Our modules are tested for 72 hours of aging before dispatch, white balance aging for 48 hours and video aging for 24 hours;
6. The led modules price not include charge; if you want to via DHL(5-7 days) need add 6-10USD/Pcs, shipping by sea(20-25 days) need add 2-5USD/Pcs, please contact our sales to get specific charge.
7. Try to buy from the whole carton (40Pcs/20Kg), carton meas: 500*350*350mm;
8. Our led module has a 3-year free warranty, and it needs to be returned to the factory for repair, and the sender pays the freight.
Outdoor Custom LED Module Series Technical Parameters
| 1. Basic Parameters | ||||||
| Pixel Pitch | 2.5 | 3 | 4 | 5 | 6 | 8 |
| Module Size | 160*160mm | 192*192mm | 256*128mm | 160*160mm | 192*192mm | 256*128mm |
| Resolution/Pixels | 64*64 | 64*64 | 64*32 | 32*32 | 32*32 | 32*16 |
| LED (HS/RS/NA) | SMD1415 | SMD1415 | SMD1921 | SMD1921 | SMD2727 | SMD3535 |
| Driver IC | ICN2037/ICN2153 | ICN2037/ICN2153 | ICN2037/ICN2153 | ICN2037/ICN2153 | ICN2037/ICN2153 | ICN2037/ICN2153 |
| Driver Mode | 1/16 | 1/16 | 1/8 | 1/8 | 1/4 | 1/4 |
| 2. Electricity Parameters | ||||||
| Brightness(Nits) | ≥5500 | ≥5500 | ≥6500 | ≥5000 | ≥6000 | ≥5500 |
| Gray Scale | 8bits input, correction with 16bits | |||||
| Display Color | 16.7M | |||||
| View Angle | 140 degree ( horizontal) 140degree(vertical) | |||||
| View Distance | 1m-30m | |||||
| 3. Driver Power Supply | ||||||
| Operation Power | AC100-240V 50-60HZ Switch-able | |||||
| Maxim Power Consumption | 1000 W/m2 | |||||
| Average Power Consumption | 350 W/m2 | |||||
| 4. Control System | ||||||
| Refresh Frequency | 1920-3840Hz | |||||
| Correction Scale Level | 16bits | |||||
| Frame Update Frequency | 60Hz | |||||
| Gamma Correction | -5.0—5.0 | |||||
| Color Temperature | 5000-9300 adjustable | |||||
| Support Input | Composite Video, S-Video, DVI, HDMI., SDI, HD_SDI | |||||
| Control Distance | Ethernet cable 100m, optical fiber 5km | |||||
| Support VGA Mode | 800×600,1024×768,1280×1024,1600×1200 | |||||
| 5. Reliability | ||||||
| Operating Temp | -20-60 Celsius Degrees | |||||
| Operating Humidity | 10-95% RH | |||||
| Operating Life | 100,000 hours | |||||
| MTBF | 5000 hours | |||||
| Protection Level | IP65 | |||||
| Out of Control Rate | 0.01% | |||||
| Continuous Time | ≥48 hours | |||||
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