1, National Standards and Grading System
The "Industrial Lighting Design Standards" in our country clearly stipulate that the illumination of industrial sites should be graded according to 0.1-3000Lx, and divided into three levels: high, medium, and low according to the type of operation. For example:
The precision machining area (such as semiconductor chip manufacturing and precision instrument assembly) needs to reach 1500-3000Lx, with a color rendering index Ra ≥ 90, to ensure the recognition accuracy of micrometer level components;
The illumination standard for ordinary assembly lines (such as automotive parts assembly) is 750-1500Lx, Ra ≥ 85;
The illumination requirement for the warehousing and logistics area (such as automated three-dimensional warehouses) is 300-500Lx, which needs to take into account both vertical illumination and shelf shadow control;
The illumination of passages and auxiliary areas (such as stairs and equipment rooms) should be 150-300Lx and meet emergency evacuation requirements.
The standard emphasizes that the uniformity of illumination (minimum illumination/average illumination) should be ≥ 0.7 to avoid visual fatigue caused by frequent adjustment of the pupils by workers. For example, after adopting LED mining lights in a certain machining plant, the uniformity of illumination on the working surface was improved from 0.62 to 0.78 by optimizing the layout of the lighting fixtures, resulting in a 15% reduction in worker error rate.
2, Homework scenarios and lighting requirements
There is a significant difference in the demand for illumination in different industrial scenarios, and customized design needs to be carried out in conjunction with the visual task level (VDT classification):
High precision tasks (such as circuit board inspection): require the use of a high color temperature light source above 5000K, with an illuminance of ≥ 2000Lx, and equipped with local lighting to eliminate shadows. For example, a certain electronics factory increased its product defect detection rate by 22% after adding anti glare LED strip lights at the AOI testing station.
Continuous work area (such as assembly line): The illumination should be stable at 1000-1500Lx to avoid visual fatigue caused by light fluctuations. A certain automobile assembly workshop has reduced the complaint rate of workers' eye fatigue by 40% by using flicker free LED lights.
Dangerous work area (such as chemical operation room): In addition to meeting the basic illumination, an emergency lighting system should also be configured. After power failure, the illumination should be restored to ≥ 50Lx within 30 seconds, and IP65 protection level lamps should be used.
Special environments (such as food processing workshops): must comply with HACCP certification requirements, with a surface temperature of ≤ 60 ℃ for lighting fixtures to avoid the growth of bacteria in condensed water. After a certain dairy factory adopted moisture-proof LED flat panel lights, the qualified rate of microbiological testing in the workshop increased to 99.8%.
3, Lamp parameters and system design
The core parameters of LED lighting directly affect the illumination effect, and it is important to consider:
Luminous flux and efficiency: Modern LED mining lights can achieve an efficiency of 150-200Lm/W, saving more than 60% energy compared to traditional metal halide lamps. For example, a certain steel plant replaced 250W high-pressure sodium lamps with 120W LED lamps, resulting in an annual energy savings of 120000 kWh.
Light distribution curve: Narrow beam (15 ° -30 °) or wide beam (60 ° -120 °) lenses should be selected according to the height of the factory building (usually 8-15 meters). After adopting bat wing light distribution lamps, the uniformity of ground illumination in a certain heavy machinery factory has been improved by 30%.
Intelligent control: Through the DALI dimming system, time-sharing and zoning control is achieved. A logistics center reduces the illumination to 50% during non peak hours, saving 280000 yuan in electricity costs annually.
Maintenance factor: Due to the low light attenuation of LED lamps, the maintenance factor can be taken as 0.8-0.85, which is 10% -15% higher than traditional lamps. A precision instrument factory's lighting fixtures have a 5-year light decay rate of only 5%, far below industry standards.
4, Environmental factors and dynamic adjustments
Industrial lighting needs to dynamically adapt to environmental changes:
Natural light coupling: In factories with skylights, light sensors can be installed to automatically adjust LED brightness. A certain photovoltaic workshop has reduced daytime LED energy consumption by 40% through this technology.
Temperature impact: In high-temperature environments (such as metallurgical workshops), lighting fixtures with a temperature resistance of 80 ℃ or above should be selected, and heat dissipation space should be reserved. After a certain aluminum company expanded the spacing between lamps from 3 meters to 4 meters, the failure rate decreased by 60%.
Explosion proof requirements: In flammable and explosive areas, Ex d Ⅱ CT4 grade explosion-proof LED lights should be selected, and intrinsic safety circuit design should be adopted. After the renovation of a certain petrochemical plant, the lighting system achieved zero accidents for three consecutive years.
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