Assembled Linear Vs Raw Components

We are often asked why we supply completed “ready to install” linear systems instead of raw strip and aluminium profiles.

The number one reason is quality assurance, as we offer a 5 year “Guardian warranty” scheme for our linear products. To honour and support this warranty, we need to ensure that every step of the assembly process has been performed correctly by one of our trained technicians and tested within our QA procedures.

Another critical factor is ease of installation, and ensuring satisfactory results. Digilin linear systems are supplied to precision lengths, pre-assembled with connectors fitted. Linear systems are labelled with lengths and section numbers to match a project specific layout. This reduces installation time significantly and removes the opportunity for onsite errors.

There are many critical tasks associated with the design and manufacture of compact linear lighting:

System Design

All linear LED systems have an intended purpose and a desired result. Digilin engineers and technicians have vast experience in understanding the requirements of a linear lighting system and identifying potential problems before they occur. Digilin also provides system layouts and schematics for linear systems. These drawings assist with efficient installation and commissioning.

Profile Cutting

The linear profile needs to be cut to an exact measurement that allows for any possible tolerances including site conditions and strip module increment cuts. At Digilin we have a precise method to ensure that profiles are the correct length to suit the application.

Lens Cutting

Lenses need to be cut using much attention to cut lines and blade approach to ensure no burring occurs on the polymer. We often cut lenses at “offset” lengths to ensure a more consistent look when assembled on site.

Cable Entry

All linear lighting systems require cable entries for remote or integral driver applications. It is very important that these cable entries do not obstruct the illumination from the LED source, and that the cables are not visible when fixed into position. At Digilin, our metal shop can provide a cable entry at any position along a profile to ensure reliable connection and a good finish.

Clean Profiles

Before the inclusion of any electronic products into an aluminium profile, the profile must be thoroughly cleaned to remove any contaminants. This must occur after profile cutting, or drilling of cable entries. At Digilin we have a range of suitable solvents and processes to ensure profiles are spotless before applying any LED or driver product.

Insulation

We apply an additional layer of specialized insulation between LEDs and aluminium profiles to ensure there can be no contact between electronics, frames & enclosures.

LED Strip Cutting

Some LED strips or modules have very specific tools or methods for cutting them to required length or increment. At Digilin we have specialist tools for this purpose, plus we are trained in correct processes for cutting and modifying electronic PCBs and components.

Applying LED to Profile

There are many different types of LED strips and modules, and many different methods of applying these to a substrate. It is critical that the correct method is used for each strip/module. Some LED systems require special thermal paste for heat transfer, some require particular mounting processes. When strips are applied with double sided tape, the location and amount of pressure applied to the strip is very important as excessive pressure or pressure in the wrong location can cause severe damage to the LEDs or associated electronics.

Precise Soldering

LED strips and small electronic components have extremely tiny soldering pads as electrical contact points. It is very difficult to solder to these pads while ensuring the correct amount of solder is being applied and the electronic component is not being overheated. Digilin assembly staff are electronic technicians who have been professionally trained in electronic soldering techniques.

Connection Test

Digilin systems are tested following soldering of modules and connection leads or plugs. This ensures that the system is fully operational before any sealing or bonding occurs.

Chemical Anchoring

The solder used for electrical connections to electronic components is designed for conductivity and is not to be relied upon for mechanical anchoring. Any tension on this connection can cause the cables to dislodge or can cause severe damage to the electronics. Once tested, Digilin linear systems receive neutral cure chemical anchoring to all critical areas including connection points. This anchoring prevents damage which can occur during transit, unpacking, installation & commissioning.

Labelling

All linear products assembled by Digilin are labelled accordingly. These labels will indicate all relevant information within the system including profile type, strip type, length and output colour. These labels enable Digilin to efficiently provide additional lengths if required or to identify specific components or batches within a system. These labels also help the installer to locate the correct position for the linear LED in a particular project.

System Test

Once fully assembled as a finished product, linear systems are tested again to ensure the system is fully operational as a completed unit.

Quality Assurance

Prior to packaging, all linear systems are run through a strict QA process to confirm that the systems meet our high quality standards and will meet the expectations of the customer.

Support

Digilin offers extensive support for our products and we are available to assist via phone, email and onsite if necessary. It is very easy for us to diagnose an issue with a system that we manufactured however if a system is a built onsite from raw products, our effectiveness to support the system would be very limited.

Please don’t hesitate to contact us for further information.

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