Philips HQ6640 User Manual 2

Automotive Industry Lighting

by Philips Lighting

lighting solutions that really last

The ever-growing automotive industry covers an extremely

wide range of different work conditions: from small workshops

to huge factory halls, from the fine precision work to heavy

industrial tasks. Philips offers a range of luminaires designed

to provide optimal lighting solutions for such conditions.

Lighting solutions that not only enhance efficiency but

solutions that really last.

Proper construction of a vehicle often requires careful

inspection at every step of the production process, with

each step demanding very specific lighting conditions.

production basics

There are six main phases in the production of a

vehicle: stamping, body-in-white (

paintwork, engine assembly, final assembly and car

testing and delivery.

Stamping

This is the process by which parts (bodies, doors,

bonnets, floor pans) are cut out of sheet metal.

Completely automated-machines known as

transfer presses perform all the work of cutting

and shaping the metal.

Body-in-white assembly

This is the assembly-line operation during which all

the various parts are put together and then welded

to make the “shell” either by semi- or fully-

automated machinery.

Paintwork

Here too, the lines are automated to reduce waste

and pollution. The body shell is cleaned, dipped in

BIW) assembly,

an anti-corrosion bath and dried thoroughly.

This process is known as cataphoresis. Paint spray

guns have been replaced by a sophisticated

procedure based on the principle of aerostatics

(the mechanics of elastic fluids), thanks to which

paint particles are spread in a perfectly even layer.

Water-based paint is used to reduce the release

of solvents into the air.

Engine, axle and transmission assembly

When all components are completed, the engine,

axles and transmissions are assembled and

tested together.

Final assembly

During final assembly, all the remaining parts of

the car are put together: seats, wheels, engine,

dashboard and so on. Parts are delivered directly

to the assembly lines by other production sites

(or power train plants) and by suppliers on a

just-in-time basis.

AUTOMOTIVE INDUSTRY LIGHTING

1

Car testing and delivery

At this stage, final exterior and interior inspection

are performed, cars are fully tested and repairs

are made as necessary.

The first essential for an automotive production center is good

general lighting, which is important for creating a pleasant working

environment with good conditions of visibility and comfort.

stamping

Stamping is operated by large, heavy and

sophisticated machinery in a press shop, often

producing high levels of noise, heat, dirt and

even oil. Typical heights in a press shop are 15 to

18 meters, allowing overhead gantry cranes to

move above the presses to transport the heavy

press moulds.

Each press shop has a large workshop of equal

height. In the workshop, a relatively high

illuminance is needed to allow tool repairs to be

performed properly.

continuous light lines can be utilized. Industrial

high-bay luminaires should be spaced closely to

prevent poor uniformity due to large obstructions.

Although twin mounting of industrial high-bay

luminaires is significantly cheaper than individual

mounting, the latter is preferred to ensure good

light uniformity. Where localized lighting is needed

inside the machinery, the color of the lamps should

be matched to that of the general lighting.

AUTOMOTIVE INDUSTRY LIGHTING

2

Lighting recommendations

Illuminance 200-300 lux,

in between machines

/ E

Uniformity E

Luminance Insignificant

Colour temperature Insignificant

Colour rendering R

Luminaires installed in press shops must be

vibration-proof and made of oil-resistant material

to guarantee worker safety. Tall machinery

(12 to 15m) causes shadows if luminaires are not

installed according to the layout. Deep light

penetration is needed to obtain the required

illuminance in between and under the metal

presses. To check the press process and to improve

safety, localized lighting must be installed onto the

machines. By arranging the luminaires properly and

by applying narrow beam reflectors, reasonable

uniformity and illuminance levels can be obtained.

Typical lighting installation

The great height in press shops makes the utilization

of high-bay luminaires ideal. If a fluorescent lighting

solution is preferred, extremely narrow-beam

min

≥ 60

a

ave

> 0.5

body-in-white
assembly

The body shop is a large metal processing

industrial hall with a height of 6 to 9 meters.

The pressed components from the press shop are

welded together here. This process is partly fully

automated by robots, and partly semi-automated.

Fully automated welding lines are often illuminated

at higher levels than manual spot-welding locations.

Process control can only occur successfully if high

lighting levels are available. During the production

process, complete subassemblies (doors, side

panels, bonnets) are checked and inspected.

Finally, the complete body is carefully checked

for small press errors and welding drips.

Due to the dark appearance of the material

(grey and galvanized metal) and the dirty

environment (caused by welding), the body shop

gives a very dark impression.

Lighting recommendations

Illuminance General: 500 lux

Inspection: 1,500 lux

Uniformity E

Luminance Limited

Color temperature General: insignificant

Color rendering R

min

Inspection: warm white

≥ 80

a

/ E

ave

> 0.7

or prismatic cover. Where luminaires are applied

at ceiling heights of below 2 meters (during

inspection of vertical surfaces), impact-resistant

luminaires should be specified. A separate, fully

closed room is sometimes available for detailed

and random test checks. Good results are obtained

with warm white or green fluorescent lamps,

as these offer the best viewing conditions.

Typical lighting installation

Either wide-beam high-bay industrial luminaires

or white fluorescent reflectors can be employed.

An even light distribution offers the greatest

flexibility for future expansion of the factory.

For localized lighting required during inspection,

direct discomfort caused by glare from bare

lamps and lamps in white reflectors should be

prevented by the use of louvers.

AUTOMOTIVE INDUSTRY LIGHTING

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Illuminance should be relatively high due to

poor luminance contrasts. Uniformity is heavily

influenced by ceiling-mounted obstructions,

and should be reasonably good. For inspection

of the body and its parts, direct glare should be

avoided, high illuminances are necessary and the

most comfortable light color (warm white)

should be installed.

Plastics applied in luminaires should be oil-

resistant. Self-cleaning luminaires should preferably

be used. At locations where welding smog is

continuously generated, luminaires should be

closed or screened off with an easy-to-clean opal