How we do it
Punching and bending machines
In the new Roxo Lighting production unit, we use two production lines that consist of punching machines, which act as basis in the processing of automated information, for the cutting of steel sheet luminary bodies. The two production lines operate independently allowing product customization and even the creation of complete product ranges.
The first step of the process consists of a central chisel to make cuts and holes in plates to obtain the desired part. This chisel has a cutting head with over 60 tools available.
Then, the semi-finished product is transferred to another production line consisting of two types of bending lines. A manual production line, with CNC bending machines, for small quantities and tailor-made products, and another line that includes two robots, for the production of large quantities, which is based on a program created so that the machine places and folds the steel sheet in the desired mode.
The technical drawing files are inserted into the machines by our specialized technicians and programmers, from our Product Development department. The CNC program machines from Finn-Power and ADIRA are a clear asset for the production, as they also allow customized solutions. Rapid reprogramming of machines, allows us flexibility and productivity, thus satisfying quickly and effectively our customers.
Roxo Lighting has a painting line equipped with high-end technology that allows the development of fast painting methods of the parts, with excellent quality and possibility of producing high quantities, being this, the way to ensure high quality products at competitive prices. The main steps of this process are: cleaning, drying, electrostatic painting and curing.
However, the main element of the process is the application of powder paint, distributed by four automatic guns for applying paint spray, in a reliable way, being the paint gripped to the luminary body part by static electricity. Then the piece passes through the oven at a temperature of 200°C, which makes the paint a full, rigid and durable layer.
The electrification robots allow the decrease of operating costs on a large scale, through the process of automation and by shortening the electrification time of the light fitting’s body, through flexible production and the capacity to apply components in order to meet high quality standards.
The design of the robot wiring head makes it possible to perform all operations necessary to connect the components to the body of the luminary, from the cutting of exact lengths, to the application of wire isolation terminals and to the inclusion of all needed wires in the body of the luminary. The programming of robots allows you to change the wiring in a simple and fast way.
Manual assembling cells
The implementation of the production principles is done through the use “U” type manual assembling cells, whose concept consists in the effective combination of multiple tasks for productive work. This type of assembling cells display has several benefits, including the following:
• Higher work efficiency;
• Improved management in the supply of material and semi-finished products;
• Reduction in handling;
• Ergonomic and accessible work environment to employees;
• Quality increase;
• More effective planning and production management;
• Better use of machines and production areas.
When working on "U" type assembling cells, we employ all means to achieve one-piece flow, contributing in this way to, eliminate waste of resources in each process, reducing the waiting time of the material from a previous task and minimizing the number of unfinished pieces within a cell.
This work place display in assembling cells, allows verifying the performance of individual production, thus, responding to the current needs and requirements of our clients in a flexible way.
The precise definition of photometric properties of lighting and light sources is increasingly important in meeting the requirements of our clients and in the development of products for the lighting industry.
Our photometric laboratory, allows us to calculate the correct lighting and define the lighting characteristics of luminary, providing relevant information for, datasheets, catalogues, simulation data, development of luminaries and light sources.
Roxo Lighting has also a laboratory to measure thermal behaviour and lighting techniques.
With the results provided by these resources, we are able to gather all the necessary photometric data of our products, such as:
• Characteristics of light emission (luminous intensity curves);
• Description of the lighting surface (brightness balance);
• Spatial characteristics of the light sources (brightness and dimensional field of light beams passing through various materials);
• Relations with energy and balance conditions (lighting efficiency, total input power and temperature related data that depend on the light).
In the case of the proximal field of the goniophotometer installed in Roxo Lighting’s laboratory, the sensor’s camera moves along a spherical surface in steps strictly monitored, around an object that’s being measured. The camera strictly records all necessary data, according to well defined steps. The data and light intensity curves can be stored in many different formats (Dialux, Relux, among others.