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MANUFACTURING PROCESS

Lighting Bracket production

WHAT IS A LIGHTING BRACKET?

A lighting bracket is an device that is used for holding an electric bulb, or a tube light, and reflect the light according to the requirement. Examples include : Wall lamps tube light holders, table lamps, street lights, front and rear lights in automobiles,, etc.

Can also be used as ornamental objects for fashion and decoration.

COMPONENTS
Bulb/tube light holder Light reflector Wall clamper Electric components

MATERIALS USED IN THE MANUFACTURING


Materials used depend upon the purpose, buyer, and the use to which the bracket is to be put. In olden periods, china clay and paper were used to make lighting brackets, and instead of electric bulbs, candles, fire lamps etc. were used Nowadays, chiefly metals, fiber plastics and glass are used.

METAL LIGHTING BRACKET

PHYSICAL DESCRIPTION

Main body
A hollow shaped lightning bracket, closed at either one of the ends. Bulb or tube holder, bulb or tube and light reflector. Wiring and other electrical component.

Wall clamper

Used to fix the main body to a wall. Generally made of aluminum or steel.

Connectors

Connect the main body to the wall clampers. Provided with hinges at the joint, so that the main body could be oriented as per the requirement. Generally made of aluminum or steel.

MANUFACTURING PROCESS

MAIN BODY
A cylindrical body, with a long groove along the length , from where the light from the bulb comes out. Made using thin metal sheets, which are generally bought from an outside supplier. The material used is highly heat resistant. Plate Bending Rolls are used to convert thin metallic sheets into a cylinder of desired diameter. Outer part is polished to give an aesthetic look.

The

ends of the bent plate are welded together.

Plate Bending process

Hydraulic plate bending machine

The ends of the cylinder are closed by welding circular metallic pieces to it.

REFLECTIVE COATING

Reflective coating on the inside of the main body is done through:


Powder Coating Painting Polishing

Out of these, powder coating is mostly used.

POWDER COATING

Advanced technology for industrial application of paints on metal.


Gives More attractive finish. Process

Surface pre-treatment Coating with dry powder Heating for 10 minutes at around 2000 C

50-200 micron coating is obtained.

Powder coatings can produce much thicker coatings than conventional liquid coatings without running or sagging.

Materials used

Pre-treatment chemicals
Alkali decreasing chemicals Nitric acid Phosphate Chemicals

White coating

Dry powder

ADVANTAGES OF POWDER COATING OVER OTHER COATINGS.


High Impact Resistance Eliminates chipping or scratching Longer life than paint Flexibility - can bend without cracking Uniform control of finish Eliminates sags and runs Mil thickness of 1 to 3 Powder finishes are more durable than wet paint Environmentally Friendly Resistant to heat, corrosion, impact, and abrasion

CONNECTORS

Cylindrical tubes of small radius, bent to from a circular arc, through Tube bending process. Joined to the main body and the wall clamper through hinges or by welding or through screws.

Flexible connecter(made of plastic or spring wires) generally used in table lamp.

WALL CLAMPER
The design is chosen according to the weight of the complete assembly(including the bulb). Thin metal sheets are used. Sheets are given the desired shape using plate bending machine. Contains all the important electric components(like. Electric wires, fuse, etc.).

FLOW- CHART
MAIN BODY CONNECTER CLAMPER

METAL SHEET ROLLED

TUBE BENDING

SHEET METAL

WELDING

PLASTIC OR BENDING WIRE

POWDER COATING FINISHING

ASSEMBLY

QUESTIONS??

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