Photo: Plant LED lighting Ledel in Kazan

Reporting by Alexei Nadezhina (LJ ammo1).

When I was invited to a press tour of the factory of LED lighting, I expect to see the production, gathering of pre-engineered products ordered in China, or even a company that sells Chinese oem-products under its own brand.

What I saw in Kazan, I was surprised and delighted.

Here, develop and manufacture products "from scratch", paying attention to such trifles, which other manufacturers do not even think about. In this case, working directly with giants such as Texas Instruments and Osram. A full-cycle production produces not only finished products but also the housing and board with electronics.
 
It all started in 2006 when Artem Kogdanin decided to make their own hands LED flashlight for your bike. Was a good flashlight and the idea that once led flashlight shines so well, why not make LED lighting for offices and even streets. Brother, businessman Arthur Kogdanin helped with the organization of the business. In 2007, the "production" that sits in one room, the office produced the first LED luminaire. In 2008 — the first LED street light. Now Ledel produces 250,000 lamps per year and occupies 15% of the Russian market of LED lighting. The production area in Kazan took more than 10,000 m², the company employs 220 people, with their own money building a new factory building.

The plant produces more than 70 varieties of lighting fixtures in 30 different buildings. One of the main areas — street lighting.

Artem Kogdanin shows an innovative lamp Super Street.

The main innovation — an unusual body, the outer edges of which provide cooling by convection. The luminaire uses modern LED Osram Oslon Square with luminous efficiency 103 lm / watt. Fixtures are available in four capacities — 340 W (100 LEDs), 250 W (72 LED), 160 watts (48 LEDs), 120 watts (36 LEDs). Luminous Flux 250-watt lamp — 25560 lm, which corresponds to a 400-watt street lamp with a sodium lamp or HPS 700-watt mercury with DRL.

The second innovation — the protective glass, combined with the optical system.

The driver of its own design withstands any power surges.

Aretm told amazing things. When the lamp was designed, he has been repeatedly raised in the tower on lampposts to understand how to do the installation and maintenance of the luminaire most comfortable. Most constructive fixtures requires the installation of two electricians, one holding a lamp, and the other connects the wires. Super Street installed by one person: first, he is attached to the mast, and then open the top cover, and connect the wires.

For easy installation, the luminaire has a bubble level, and the camera for the wire and cable is made as large as possible.

Luminaire housing is molded on request Ledel on one of the steel mills of Chelyabinsk, red plastic cap stamped at the Ledel.

Here are collected and solder the driver board and LED’s.

The first machine for future deals flux solder joints.

Then, the board set piece.

Now the LEDs are installed on the board.

Reels of electronic components.

Wave soldering.

Control of temperature in different areas of soldering.

The major components are installed on the board and soldered by hand.

Each card drivers tested and labeled.

Ready motherboard drivers.

Total Ledel advantage lamps seven types of driver boards. All the circuitry of its development, furthermore, circuits used Texas Instruments, which participated in the development engineers Ledel. I was pleasantly surprised that all types of drivers Ledel support dimming (brightness adjustment).

Before assembly, all the boards and LED drivers are re-testing.

Ready motherboard drivers.

Finished board with LEDs.

To prevent damage to the LEDs, the boards are sent to the assembly in wooden boxes with cells.

In addition to photographs here and there I managed to remove some videos.

Next, I will discuss what makes fixtures Ledel and show how the body fixtures are made, and how to collect ready-lights.

In the picture — I LED street lamp Super Street, which I put together with his own hands.

    Next, I will discuss what makes fixtures Ledel and show how the body fixtures are made, and how to collect ready-lights.

    In the picture — I LED street lamp Super Street, which I put together with his own hands.

    Of course, in all offices and shops Ledel LED lighting is used only its own production.

    Technical director Artem Kogdanin talked about how to create new products.

    The process of creating a new lamp from concept to pre-production party takes 14 months.

    Street lights are lit around the clock on the facade design office Ledel for several years.

    With the help of special equipment is measured as change their characteristics over time.

    In addition to several types of lamps for street lights Ledel produces other types of lamps.
    In the pendant light for supermarket L-industry 200 uses the same idea convection cooling, as in Super Street.

    Artem shows cast lamp housing.

    Fixtures L-school match in size and brightness of conventional lamps with two fluorescent lamps. L-school 24T, power 32 watts replaces 72-watt lamp with LDR and costs 2900 rubles.

    Fixtures L-office replace the standard lights for suspended ceilings.
    L-office 25T has a capacity of 33 watts is worth 2,600 rubles, and replaces the 72-watt lamp with four fluorescent lamps to 18 watts.

    Powerful spotlights L-lego got their naming purpose.

    Their body can connect several lamps together like bricks in the designer Lego.

    HCS-lights for dwelling houses Sveteco 8 have original function — to control the brightness of the sound. When the entrance quietly, lamp consumes only 2 watts and shines at 10% brightness when the lamp next to someone appears, the sensor includes a light sound at full power 10 watts. It is much more comfortable conventional fixtures, fully disabled by the motion sensor.

    Household lamps L-one costs 600 rubles and has a capacity of 5 W, slightly brighter than conventional 40-watt light bulb. With a special box L-one can be installed in pairs.

    I asked Ledel give me a test on a couple of these fixtures with a frame. I will experiment with LED light in the bathroom and toilet.

    More Ledel produces lamps for industrial buildings and warehouses, shop windows, for architectural lighting. In total more than thirty series: http://www.ledel.ru/production1.

    Let’s return to production. All metal and plastic enclosures are made in the home. Huge Injection molding machine (known as "locomotive" for the resemblance and similar size) casts housing office fixtures.

    On the back of the plastic molding plant looks like.

    Glass-cut filters of polycarbonate sheet with a special mesh structure, good light scattering.

    A simple rationalization for which coined its employee got a good bonus: before lights go well on a label with the name of the plant, now called milled polycarbonate on the same machine, which cuts it.

    Speaking of employees. On Ledel virtually no staff turnover — only a set of new workers because of the continuous expansion of production. Workers earn 20-40 thousand rubles a month.

    The application of sealant to cover street lighting.

    Milling of polycarbonate.

    Punching holes in the sheet metal.

    The machine, which gives the metal shape.

    The machine is hermetically glass laying on the lamp housing.

    Electronics-round fixtures.

    Assembly shop.

    Prepare wires.

    Assembling the housings of office fixtures.

    Installing the LED boards and drivers.

    Lamp assembly for park lights.

    At the end of the tour offered journalists a self assemble a street lamp. I think you will not be surprised that I built my first Super Street and it has earned.

    In Kazan airport I saw off a poster Ledel.

    It’s great that in our country there are people who are able to create from scratch a successful production.
    It was very interesting to meet these people and see the works they have created. I hope you, too, was interested to read my story.

    Original reporting:

    http://ammo1.livejournal.com/395856.html

    http://ammo1.livejournal.com/396839.html

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