Process Standard

Basic inspection standards for metal billets
(1) Stamping parts and spinning parts:
    1. Material: South Korea plate is preferred, to ensure that there are no sand holes after polishing, and the surface is smooth after electroplating.
    2. Material: No pinholes, bumps, scratches,
3. Thickness: subject to the requirements of engineering data (①light cup 0.6 material; ② round chassis below 400 material 0.8, 400~800 above 1.0, 800~1000 material 1.2, more than 1200 (block) 1.5 material; ③ hanging bell 0.8 above).
4. Surface: No spin embossing, punch marks and break marks. (If there is this phenomenon, it can be removed after polishing and it is acceptable)
5. Surface: no sharp edges; burrs, burrs.
6. Size: The tolerance of general workpieces does not exceed ±1.5MM; except for special workpieces.
7. Hole position: It cannot be deformed, and the tooth holes must be smooth; if the hanging bell needs to test the boom and the welding at the head, all the head teeth must be tested.
    8. Other specific specifications; size; aperture; hole spacing;
(2) Square box:
    1. Material: Authentic South Korean board is preferred, to ensure that there are no sand holes after polishing, and the surface is smooth after electroplating.
    2. Thickness: subject to engineering data requirements (0.8 material below 400, 1.0 material above 400~800, 1.2 material for 800~1000, 1.5 material for over 1200 (block))
3. Surface: no sharp edges, burrs; no pinholes, bumps, scratches (no more than 1 bump and scratch within 1 square decimeter L=2MM, no obvious places; no more than 3 pinholes/1 square decimeter ).
4. Solder joints: Weld firmly; the welding marks on the front of the plate should not be too obvious.
5. Size: The specific size is strictly in accordance with the engineering data, and the general tolerance is ±2MM (except for special workpieces).
6. Hole position: hole diameter; hole spacing is strictly in accordance with the engineering data, with a general tolerance of ±1MM (except for special workpieces).
(3) Pipes:
    1. Material: white material (South Korea material is preferred, Taiwan; Japan); no sand holes after polishing, and the surface is smooth after electroplating.
    2. Thickness: 0.9-1.0MM (depending on usage); even thickness.
3. Surface: no welds, pull patterns; no sand holes, scratches. (If there is polishing, it must be removable)
4. Blanking: The incision section must be flat and perpendicular to the straight edge of the iron pipe, and the drape must be small.
5. Chamfering: The chamfering angle is determined according to actual needs, and there can be no reverse drape.
6. Drilling: The hole must be round, and there must be no draping inside and outside; the hole diameter and hole spacing are strictly in accordance with the engineering data; the general tolerance is ±1MM (except for special workpieces).
7. Reaming: The hole must be correct; ensure the concentricity of the inner and outer circles; there must be no drape.
    8. Tapping: Before tapping, it is generally required to be smooth and chamfered; the tooth diameter is as required; the tooth pattern should be better; the surface of the inner tooth tube should not have tooth pattern marks; be sure to test the teeth.
    9. Elbow: The radian is natural; the elbow must be full and not flattened; no pits or inflection points, deformation defects are allowed; the tolerance of the radian compared with the engineering drawings is generally ±1MM (except for special workpieces); electroplating, pay attention before baking paint Tooth guard.
(4) Stainless steel parts:
    1. Material: non-strictly pressed material (Taiwan material is preferred, Wuhan Iron and Steel; Shanggang); indoors are generally 202#, outdoor and perishable locations are 304#.
    2. Thickness: 0.8-2.0MM (according to the application and acceptance according to the drawings); the thickness is uniform, and the caliper is used for acceptance.
3. Surface: The film is complete, and there are no obvious scratches; tear the film to check, the coloring is uniform, and there is no color difference; there can be no pull pattern, sand holes, and scratches;
4. Welding edge: operate according to the inspection standard of welding parts.
5. Edges and corners: The cutting edges and corners should be chamfered and abrasive, and there should be no anti-shattering and scraping.
6. Drilling: The hole must be round, and there must be no draping inside and outside; the aperture and hole spacing are strictly in accordance with the engineering data; the general tolerance is ±1MM (except for special workpieces).
(5) Welding parts:
    1. General: silver welding for copper; copper welding for iron; argon arc welding for thin stainless steel; carbon dioxide welding for thick iron.
    2. The welding is firm, the appearance is full, and the welding marks are uniform; no leakage welding, false welding, trachoma, etc. are allowed.
3. There can be no deformation, rotten teeth phenomenon; no phenomenon of welding through the workpiece.
4. Welds should be ground or sanded flat.
5. General requirements: welding on the surface should be fully welded; including corners, hand grinding is required after welding to facilitate polishing;
(6) Polished parts:
    1. General workpiece requirements: three sands and one hemp: 240#; 260#; 280# (except for special workpieces); if welding is required, one sand and one hemp must be thrown first.
    2. Surface: After cleaning the surface with cotton cloth, check that there are no obvious sand patterns, sand holes, bumps, and scratches; the edges and corners are distinct; the holes cannot be deformed.
3. Slag removal: Polishing residues are not allowed around the joints of all polishing parts, and the holes must be through-holes if the small holes are blocked by wax.
4. Polished parts must be packaged and protected separately after polishing, and easily deformed parts must be packaged separately or delivered separately. Note: The effect after surface treatment must be guaranteed.
(7) Copper pieces:
    1. Surface: smooth surface; no obvious knife marks, no pinholes (limitation: polishing can be removed).
    2. Surface: no drape; edge of knife edge; bruise; scratch.
3. Silk teeth: The use of enlarged size prevents the difficulty of matching the silk teeth after electroplating or painting; there should be no rotten teeth or bad teeth.
4. Shape and position: pay attention to flatness; parallelism; concentricity; taper; perpendicularity.
5. Size: strictly in accordance with the requirements of engineering data.
6. Tolerance: Under normal circumstances, it is ±0.3MM (mainly controlled flexibly according to the usage).
(8) Universal joint (shaking his head):
    1. Basic structure: head; body; tail; gasket; spring; steel ball;
    2. Surface: smooth and clean; standard packaging; body and tail must not be skewed, and the gap between the two must be uniform and not dislocated.
3. Requirements: The head and the body must be rotated flexibly, not too tight or too loose, and must withstand a certain rotational force, not 360-degree rotation.
4. Silk teeth: The teeth are unobstructed; a ring must be worn on the teeth.
(9) Sand turning parts:
    1. Surface: no sand pits (1 square decimeter can allow no more than 1 ￠0.5MM) actual requirements for special workpieces; no burrs; smooth surface.
    2. Weight/hole position: according to the requirements of engineering data; hole spacing and hole diameter according to the requirements of engineering data
3. Tolerance: generally ±1MM (except for special cases).
(10) Zinc alloy parts:
1. Surface: ensure smooth and smooth after polishing and electroplating; no pinholes or burrs.
    2. Dimensions: according to engineering data requirements.
3. Hole position: Aperture diameter, hole spacing according to engineering data requirements.
4. Silk teeth: The diameter of the teeth is according to the requirements of the engineering data; the tooth path is unobstructed, and the teeth need to be protected before electroplating and painting for special teeth.
5. Tolerance: The general tolerance is ±0.5MM (except for special cases).
 
Basic inspection standard for glass/crystal/acrylic
(1) Glass sheet and lampshade:
    1. Thickness: According to the requirements of engineering drawings, it is generally between T2.5-T6MM.
    2. Surface: smooth and uniform; no bubbles; no scratches on the surface.
3. Hole edge: no nicks, cracks, chipping cracks. The general allowable range is within 1MM (it can be adjusted appropriately according to the actual force).
4. Tempering treatment: The required strength is that a small piece of glass falls at about 1M. When broken, the fragments are crystalline, and the edges are blunt and will not hurt the human body. Generally, glass with a high temperature light source and the actual temperature exceeds 75 degrees needs to be tempered.
5. Tolerance: Size specifications under normal circumstances: small pieces of glass ± 1MM; large pieces of glass ± 2MM; hole tolerance ± 0.2MM (except for special cases).
6. Processing methods: full sandblasting; partial sandblasting; biting acid; baking paint, electroplating and other processing methods.
(2) Glass tubes:
1. Thickness: in strict accordance with the requirements of engineering drawings; the general situation is between: T2.5-T6.0MM; the general tolerance is ±0.2MM (except for special cases).
2. Surface: natural arc transition, no inflection point, no indentation, no more than 2 1MM defect points within 10 square decimeters are qualified.
3. Dimensions: Strictly follow the engineering drawings, with a tolerance of ±0.2MM (except for special cases).
4. Hole position: Bake after drilling, the hole position may be deformed; the hole position tolerance is ±0.2MM (except for special cases).
5. Processing methods: edging; edge polishing; sandblasting; baking paint, electroplating, etc.; can not be strengthened again.
6. Full inspection: After punching or fire roasting, after cooling for 48 hours, test for cold explosion, and the cracks are visually inspected by light transmission, which does not exceed 1MM;
(3) Crystals:
    1. Grading: The material is divided into crystal material (K9, transparent color, heavier, cold to the touch, and water vapor) and glass frit (K5, dark color, lighter, not cool to the touch, no water vapor); grinding surface Separate machine grinding (good surface, neat water chestnut and edge), semi-manual (machine-grinded defective product, after manual repair), full manual, sanding (grinding with sand); the crystal grade division also corresponds to the material and grinding process, The more advanced the better.
    2. Sunlight inspection: Protect the crystal from sunlight. The first step is to observe the color refracted by the crystal. The quality of the colorful distribution is good, otherwise it is poor; the second step is to prevent the crystal from sunlight for more than 8 hours. Discoloration (yellow and foggy) is a defective product;
3. Bending and drilling crystals should be tested for light transmission, and the cracks should not exceed 1MM;
4. Surface color: Crystal after electroplating or painting, according to electroplating inspection standards.
5. There are only one water pattern, bubbles and impurities in the visible surface within ￠1MM, and 2-3 within ￠0.5 (except for special cases).
(4) Acrylic type:
    1. Color: The color board shall prevail, the color is pure; do not pay attention to the white frosted acrylic, which is divided into milk white frosted sand (whiter, less light transmission) and transparent frosted sand (darker, better light transmission, materials, below The order and acceptance must be clear.
    2. Surface: single-sided processing, to ensure the integrity of the coating; smooth, no spots, impurities, no drape; no gaps in the trimmed edge; and acceptance of the holes/edges that require a bright surface as specified in the engineering data.
3. Dimensions: Strictly in accordance with the requirements of engineering data.
4. Hole diameter: According to the requirements of engineering data; the diameter of the hole is smooth.
5. Tolerance: ±0.5MM (according to actual matching needs).

 
Surface treatment basic inspection standard
(1) Painted parts:
    1. Requirements before baking paint: must go through: degreasing; rust removal; phosphating.
    2. If you use powder foundation: the silk teeth part must be protected (including some inner teeth to be screwed up with full teeth).
3. Surface: no running oil is allowed; paint is too thick; too thin; uneven thickness; rust spots; scratches; bumps; blistering; stains, etc.
4. Color: mainly according to the color palette; (flexibly control according to the actual situation, the accessories on the same lamp are not allowed to have too large color difference).
5. Adhesion test: Use a knife to draw the "H" frame on the baking paint layer that does not affect the appearance, the adhesive tape is close to it, and tear it off quickly after 1 minute, and the baking paint layer cannot fall off.
6. Material requirements for returning to the factory: must be properly packaged and data standardized
(2) Electroplating/oxidizing parts:
    1. Polishing residues before electroplating must be cleaned up on electroplating.
    2. The adhesion of the coating should be strong, and no shedding is allowed.
3. The sand-drawing parts are not allowed to leak or pull through, and the sand-drawing grains should be uniform in thickness, uniform in density, and not chaotic.
4. Silk teeth should be protected to avoid rotten teeth.
5. The surface seal oil is not allowed to have oil flow; too thick; too thin; poor adhesion; stains and other defects; no blistering; rust stains are allowed.
6. Black spots; orange peel; oil particles; dust acceptability: 2 particles per square decimeter less than Φ2 mm acceptable; 4 particles per square decimeter less than Φ1 mm2 acceptable.
7. Yin-Yang color: 0.6M away from the line of sight is acceptable, otherwise unacceptable.
    8. The coating is not allowed to fall off, and the color is subject to the color plate.
    9. Scratch marks; stretch marks; polishing marks; wave marks acceptability: less than 2 square millimeters per 1 square decimeter acceptable interval 5CM.
10. Acceptable level of bumps: 1 square millimeter is acceptable for every 20 square centimeters, (it is acceptable to not see 0.6M from the line of sight).
12. A simple salt spray test is required: after soaking in 5% salt water for 24 hours, there is no shedding, acid spitting, spotting, etc.
 
Basic inspection standards for electrical accessories
(1) Lamp holder:
    1. Certification: According to customer requirements or the area where the lamps are sold. General European regulations use VDE or CE; American regulations use CUL or UL.
    2. Test maximum temperature: B15 and B22/165 to 210 degrees Celsius with T symbol; B15 and E14/135 degrees Celsius without T symbol; B22 and E27 without T symbol, E26/165 degrees Celsius; E39 and E40/without T symbol 225 degrees Celsius.
3. Classified by material: bakelite; ceramics; insulating plastic; iron shell lamp holder (the outer ring needs to be used with a force of 3~10KG), etc. (according to engineering data and customer requirements).
4. Classified by specifications: CE: E14; E27; UL: B15; B22; E12; E26, general purpose: G4; G5.5; G9; GU10; MR11; MR16; R7S, etc.
5. Silk teeth: Generally, the American standard uses the British tooth; the European standard uses the metric tooth. Make sure your teeth are clear.
6. Other testing standards are in accordance with the standards indicated by the lamp holder itself.
(2) Wire:
    1. Certification: According to customer requirements or the area where the lamps are sold. Generally, European regulations use VDE or CE (blue-brown lines); American regulations use CUL or UL (black and white lines).
    2. The highest test temperature: general PVC insulation material / 90 degrees Celsius (the place where the force is applied, such as the clamping part is 75 degrees Celsius); Teflon 170 degrees Celsius; except for special materials. The test is mainly based on the temperature marked on the wire itself.
3. According to the insulation layer classification: single layer (generally the lamp head line and internal connection) and double layer (generally the main line), etc. (according to engineering data and customer requirements).
4. Classification and safe load according to the conductive cross-sectional area (about 12% of the load is skipped):
Divided into 0.3 (40WX1); 0.5 (40WX1); 0.75 (40WX18); 1.0 (40WX28); 1.5 (40WX42); 2.0 (40WX60); The diameter is correspondingly increased), and the wire diameter is measured and calculated using a micrometer: the square of the radius of a single piece * 3.14 * the number of pieces (unit: mm).
5. According to the classification of conductive metal materials: copper (tinned copper - white and bare copper - primary color); (according to engineering data and customer requirements).
(3) Switch:
1. Certification: According to customer requirements or lighting sales area and engineering data requirements.
2. Material: PVC ordinary insulating material; flame retardant material, etc. (according to customer requirements).
3. Specifications: dimmer switch; springboard switch; foot switch; gear switch; three-stage switch; electronic fine-tuning, etc. (according to customer requirements).
4. Generally, desk lamps use smaller specifications, such as springboards, gears, etc.; floor lamps use larger specifications such as pedals; electronic fine-tuning, etc.
5. Simple test of flame retardant material: ignite the material with a natural gas fire or an alcohol flame, and after 3 seconds of removing the flame, the material is qualified if there is no open flame on it.
6. Basic requirements of safety regulations: After connecting with the live end of the power supply, there should be enough rated value (repeated switch), and the installation should be firm to prevent rotation.
(4) Plug:
    1. Certification: According to customer requirements or lighting sales area and engineering data requirements.
    2. Specifications: two-pin flat plug; three-pin flat plug; two-pin round plug (conventional); three-pin round plug, etc. (according to customer requirements).
3. Some features: round plug points ￠4.8; ￠4.0; flat plug points: polar plugs and ordinary plugs (according to customer requirements).
4. General test temperature: 70 degrees Celsius.
(5) Terminal block; nipple; screw terminal:
    1. Certification: According to customer requirements or lighting sales area and engineering data requirements.
    2. The terminal block is classified into: 230; 500; 800, etc. (the wires at the outer skin of the wires are exposed within 1MM, and the specifications are based on the actual needs of the lamp structure).
3. Pacifiers (CE) are classified into: C1; C2; C3; C4, etc. (according to the actual needs of the lamp structure).
4. Screw terminals (UL/CCC - our company's internal cables are recommended to use) are classified into: P1; P2; P3, etc. (according to the actual needs of the lamp structure).
5. Terminal blocks and terminals should have sufficient mechanical strength, corrosion resistance and flame retardancy, and the conductors should be clamped to prevent them from being pulled too much without causing excessive damage to the conductors.
(6) Insulating gaskets and sleeves:
    1. Temperature: The heat-resistant temperature of the sleeve should be 20 degrees Celsius higher than the temperature measured on the wire; and flame retardant.
    2. Safety regulations: Safety labels that must correspond to the requirements.
 
Basic inspection standards for other materials
(1) Carton:
    1. Material: Russian A=B, imitation Russian A=B, V coating=B, five-layer paper, generally reinforced double pits are for export or headlights, and one reinforced pit is for domestic sales.
    2. Marks: clear handwriting; no color difference; no ink sticking phenomenon.
3. Trimming: chamfering; standard trimming, within 2MM of the box and sealed.
4. Size: according to engineering data requirements (tolerance: ±0.5CM).
(2) Inner plastic bag:
1. Material: new material, transparent without fog, less small particles; T0.04MM above 30CM; T0.03MM below 30CM.
2. Size: according to the requirements of engineering data; tolerance ±0.2CM; plastic bags above 10CM need to be punched.
(3) Foaming class: a. The outer size should not exceed 0.5cm (multiple boxes should be within 0.3cm). b. The deviation of the inner hole is within 0.5cm, including the radian and the displacement.
(4) Wooden boxes: wooden boxes are inspected for the specifications of wooden strips (conventionally 1*4CM), and nails are used to reinforce iron strips; the specification should not be in error by 1CM; whether the cover is suitable; generally, it is necessary to confirm whether to use plywood according to the order or the business department for export lamps and lanterns. crate.
Basic requirements for lamp assembly
(1) European lamps and lanterns (domestic sales shall be carried out according to this standard if there is no special requirement):
    1. Classification:
CLASS0 lamps: lamps that rely on basic insulation as protection against electric shock (basically not produced).
Class I lamps and lanterns: The protection against electric shock of lamps not only relies on basic insulation, but also includes additional safety measures, that is, ground wire protection.
CLASSⅡ: The electric shock protection of lamps not only relies on basic insulation, but also has additional double insulation protection (our company's regular requirements).
CLASSⅢ: Electric shock protection relies on the power supply voltage being a safe extra-low voltage, and will not produce lamps with a voltage higher than SELV.
    2. Assembly basic requirements:
2.1 All electrical accessories must have VDE/CE certification (mark).
2.2 Class I lamps must be grounded; Class II lamps must be double-insulated; nipples and heat-shrinkable tubes are used for internal wiring to enhance insulation; ; The outlet of the lamp body is protected by rubber particles or yellow wax pipe; the lower part of the ground wire used must have internal gear slides and the surface cannot be placed upside down.
2.3 Use a parachute to strengthen the insulation protection of the plastic lamp tail; the lamp tail must be screwed to fasten the lamp head; the lower part of the wiring block used must have an insulating layer; There must be a locking device. All wire heads need to be wrapped with wire terminals (preferred) or soldered; the ground wire must be 2-3CM longer than the outlet wire; the wires used must not be damaged and must be firmly connected; lamp outlet: base to switch 30CM; Floor lamp outlet: base to switch 50CM;
2.4 Tilt test: 15 degrees for table lamps, 8 degrees for floor lamps;
2.5 Lamp body test: withstand voltage test; on-off test; grounding test, etc. (100% test); withstand voltage test: Class I lamps: 1500V; 10MA; 1 second (minimum implementation standard of our company); Class II lamps: 4000V; 10MA; 1 second
2.6 Desiccant should be placed in the inner plastic bag; labeling requirements: Watt label; place of origin label, etc.; manuals should be placed in the parts bag; wood screws; expansion screws, etc.;
(2) American standard lamps:
    1. The electrical appliances used must have UL or CUL certification.
    2. The wire head generally needs to be soldered; the wire must not be damaged; all lamps must have a locking device (US standard lamps generally require UL knots); the color of the outgoing wire should generally be consistent with the color of the lamp body; the American standard hanging chain and lamp body outlet The requirements are slightly longer (specifically according to customer requirements); the wiring of the lamp head must be 100% correct; the US standard table lamp; the floor lamp has more K/D, pay attention to the protection of the exposed wire;
3. The hanging plate screw should not be too short, it is allowed to be longer; the place where the lamp body should be tightened must be tightened.
4. Lamps must be tested: withstand voltage test (1500V; 0.5MA); polarity test; continuity test; grounding test, etc. (100% test).
5. Table lamp outlet: base to switch about 30CM; floor lamp outlet: base to switch about 50CM;.
6. The packaging is divided into safety packaging and test-drop packaging (test-drop requirements: one corner, three sides and six sides).
7. Desiccant should be placed in the inner plastic bag; labeling requirements: watt label; certification label; polarity label; warning label;

appendix:
General test methods for luminaires (part)
(1) Withstand voltage test (routine test):
1. According to the regional standard of the lamp, first debug the corresponding voltage and leakage current; then connect the wire at one end of the withstand voltage machine to the positive pole of the outlet of the lamp <the switch is on>, and then connect the other end of the withstand voltage machine to the conductivity gun. <Or conductance rod> turn on and hit the outer metal part of the lamp for 1 second, if the voltage tester does not make a sound, the power cord of this pole of the lamp will pass the test; otherwise, there will be leakage or breakdown.
2. Use the same method to test the negative power cord of the lamp, and pay attention to personal safety (under normal operation, there is no actual danger to human contact).
(2) On-off test (routine test):
1. Rotate the bulb to the lamp head and connect it to the power cord to start the switch test.
2. Connect one end of the voltage-resistant machine to one pole of the power cord, and the other end to contact the corresponding pole of the lamp head <generally, the metal in the middle of the lamp head is
The metal on the side of the positive electrode is the negative electrode> if the pressure machine makes a sound, it is a passage, otherwise it is an open circuit.
3. It can also be tested with a multimeter, the method is the same as B, if the pointer swings, it will be connected, otherwise it will be disconnected.
(3) Polarity test <generally used for American lamps> (routine test):
    1. Polarity distinction: single power cord: black is positive; white is negative. Two-core power cord: one with word is positive; one without word is negative. Polarity plug: small head is positive; big head is negative. Lamp head: middle The metal is the positive electrode; the side metal is the negative electrode.
    2. Use the negative end of the multimeter to contact the negative pole of the power cord or plug, and the positive end of the multimeter to contact the negative pole of the lamp head, and the needle movement is correct; otherwise, it is wrong.
(4) Grounding test (routine test):
    1. <General export>: Set the range of the grounding meter to 10A and clamp one end of the grounding meter wire to the metal part of the grounding wire; use the other end of the wire to shoot the metal part of the lamp. If the resistance is lower than 100mΩ, it is qualified <If the qualified grounding meter will make a sound> ; Otherwise, it is unqualified.
    2. <General domestic sales>: Set the grounding meter range to 25A. The method is the same as above. If the resistance is lower than 500mΩ, it is qualified; otherwise, it is unqualified.
(5) Mechanical strength test:
    1. By using the spring impact test device specified in GB/T 2423.44, or with other suitable devices that can obtain the same results, the sample is subjected to impact to check its eligibility.
    2. The same impact energy obtained by different test methods does not necessarily give the same test results.
3. The spring impact hammer makes the product of the compression (MM) and the applied force (N) equal to 1000, and the spring compression is about 20MM. The spring should be adjusted so that the impact hammer can impact according to the impact energy shown in Table 4.3 of GB7000.1-2002/IEC60598-1:1999.
4. If the sample is installed or supported on a piece of hardwood in normal use, the cable entrance is open, and the knock-out hole is also open, and the cover fixing screws and similar screws shall be three-pointed as specified in Table 4.1 of GB7000.1-2002/IEC60598-1:1999. The second torque is tightened.
5. Shock three times at the weakest point possible, paying particular attention to the insulating material and insulating bushings surrounding live parts, if any. Additional samples may be required to find the weakest point, and if in doubt retest with a new sample, with only three shocks to the new sample.
6. The sample shall be undamaged after the test and live parts shall not become accessible; the insulator effect shall not be diminished.
(6) This standard is applicable to all quality activities and quality requirements of the factory, and is coordinated with other corresponding document specifications as the quality standard of the factory;