All over the world digital display using LEDs is a very fast growing business. The static colorful display is not the only attraction. It is the moving display in the form of videos that have given it a big plus. Advertisements have become more flexible. More meaningful, detailed and impressive communication with the public has become so easy.
Business promotion and rapidly changing information spreading have become so swift. This all has become possible with technology based on the use of simple semiconductor namely LED. Do you know that LED can generate different colors? So a lot of LED working somewhat like pixels can be placed together to form text and graphics. More and denser combinations of LEDs can make excellent images. Bright colors and excellent quality image formation are such a great characteristic of LED display that the traditional billboards have become an old story. People now prefer LED billboard for various logical reasons and numerous advantages. We see all around us LED display boards. Inside cities on roads, out there on high ways, subways, in open areas like stadiums, stations, airports, and all such public places. Indoor advertisement with comparatively smaller billboards is also visible everywhere.With so much utilization of LED display boards, someone may like to know as to how the billboards building and installation takes place.
Light emitting diodes or LED are a special type of semiconductors. A lot of research and development work could help us produce LED emitting three basic colors, red, green and blue. With different combinations of these LEDs can make different shades of colors. Generally, semiconductors are inexpensive. Accordingly, LEDs are also not costly. Therefore the basic component used in building LED billboard is cost effective. Availability or production of LEDs is also not a demanding and difficult issue.
The next question that how these diodes can work together, concern their assembling. The assembling of so many LEDs to illuminate billboard in the desired form is a stepwise process as explained in the following phases.
Either for indoor or outdoor digital Signage the assembling process phases are the same. It includes a lot of mechanical as well as electrical work. Teams of specialists perform different initial tasks. Once the basic block structure building process gets complete then quality assurance and performance checks give assurance to users and digital display manufacturer.
Strength of the digital billboard to withstand stresses is the main feature of outdoor digital display boards. One basic reason is that the frame and inner blocks are all steel structures. Designing an LED billboard is not an easy job because one has to start from scratch and construct first the frame in exact sizes. It involves cutting metal pieces and fixing them into desired shapes in perfect exactness. A robust frame is like a skeleton. Therefore the strength of billboard kept in mind, thickness and rest of dimension calculations remain critical in this step. During dimension checks, frames laid out undergo ‘square-ness or straightness’ examination critically.
After completion of metalwork a full inspection guarantees insertion of other parts. The smallest defect in the shape of the frame structure can affect the overall quality of the LED display. This step takes considerable time. So a lot of due care and caution is essential. For the construction of very large frames, high-level craftsmanship is essential. To avoid the smallest designing or framing defects in large frames, digital display manufacturer do not prefer drilling and welding. In such large size frames, combinations of bolts, as well as the acrylic adhesive between the plates, remain helpful. Many jigs and clamps are also there to achieve the best and exact shape of frames. For accurate cutting of edges and corners CNC saw is helpful in terms of exactness and speed.
Digital display manufacturer working on a large scale make use of custom extrusion frames. The extrusion process can help create complex designs which are uniform throughout larger frames.
Once the main frame construction completion finishes inner structure building starts. First, we do faceplates and powder coating.
Faceplates. Faceplates made up of plastic or usually made of metal hold the other components. Normally, digital display manufacturer has faceplates readily available in their stores. In this case, production speed increases considerably. However, some time faceplates in special dimensions are required.
Faceplates after cutting and finishing gets aligned and riveted into extrusion frame. Faceplates hold modules and some other auxiliaries. Users may prefer metals such as Aluminum for making faceplates. However good plastic is also in use for faceplates fabrication. For precise fitness of faceplates riveting play an important role.
Coating. Digital display manufacturers apply white powder coating on metallic frames. In this way, metallic parts remain cool to the best extent. This process mainly takes care of vents and temperature considerations.
After preparing the basic frame structure and its necessary inspection now it is ready for installations of electronic components. Installation team mounts the screen on a moveable system of brackets. This way Modules (which are small assemblies of number of LEDs), installation become convenient.
In this phase, the digital display manufacturer’s team have to perform technical tasks of following types:
At the same time associated necessary tasks include:
Team checks all the functions that digital displays have to perform. Connectivity with computer and internet is always an integral part of digital display screens. All needed application software runs in a real-time environment to ensure the required throughput. A full test run under all possible stresses is essential at this stage. Thorough monitoring of Videos and graphics displays, designed to execute repeatedly is part of checks in this step.
At this stage, the user may want to make some changes. If the changes are not concerning design and frame, the manufacturer should make it. In fact, during this step manufacturer test each aspect of videos and image quality. Experts of all mechanical, as well as electrical teams, ensure 100% working of each and every component. At digital display manufacturer site, this step is most critical before taking out LED display for mounting on the desired location.
Involvement of end user during functionality tests is very important and should be encouraged. Functionality testing of all accessories should be given sufficient time. ‘Sweating’ more at this step may save ‘bleeding’ later. Therefore functions of modules, working of cooling systems, continuous supply of energy, etc. are significant checks in this phase.
companies finally give what is called ‘burn-in’ session to the product before taking out for mounting at the final destination. In this process they put the LED display on lifting supports, testing for a longer time. Any weak component replacement, as well as calibration for visual quality, becomes easier. In this way, the digital display gets a quality assurance check as well.
Prior to sending LED display complete testing by many experts at different levels have to be done. Thoroughly checked LED billboard at digital display manufacturer site, it is now ready for dispatch which takes place stepwise.
The whole structure that is once assembled by production teams first of all undergo dissembling back into smaller units. Parts of LED billboard display are carefully packed and loaded on a truck. A ‘checklist’ is usually encouraging to avoid any embracement. Management of dispatch procedure which should always be there, add to efficiency and productivity.
On the installation site, finalizing angle of vision and related technicalities are considerations which are significant. Not paying due attention to this part, an excellent display product may fail to give its real impact. Other ‘on-site’ procedures are:
Assembling on the ground. On-site, first we do assembling of digital display on the ground. Again! A lot of caution remains an essential part of the procedure. After assembling all its bits and pieces now the LED Billboard is ready for lifting as a whole.
Lifting and hooking up. We can now lift the whole assembly of the LED display to an appropriate position. Quickly team of technician hooks it mechanically. Fixing point by point one is to ensure its strength and reliability.
Electrical wiring or cabling to connect LED display board to a power source is the job of electricians who do it with no error. Software engineers carry out the connectivity of display board with a computer. They may also complete essential internet integration with the help of onboard cellular modems, at this stage.
Onsite final testing and putting LED display in operation is the final step before handing over to the customer. Before finally putting billboard into operation, monitoring its working for a specific time period is good practice. A satisfactory report from the user may be a good option.
This completes the final installation of an LED billboard. A small size LED digital display are easier to install. Generally, an installation manual is helpful for the user. In that case, the user can do the installation as and when required.
Indoor digital Signage is easy. User can take help from the installation manual. Indoor digital Signage may frequently require a change of location or position. But keeping installation manual, user does not need digital display manufacturer services for installation every time.
So far we have been discussing stepwise, building and installation of the LED billboard. Elaborating almost all necessary aspects above, some side issues still need discussion. These points are significant. Therefore, we feel that a thorough understanding of these issues is essential.
Cost of Digital Signage is not fixed. The overall cost depends on various factors. These factors include size, the quality level of video or graphics display, and the material of billboard, mounting object, and cost of essential accessories. Therefore, building and installation of LED display is one thing. It is the cost of LED Signage which will determine the track to follow.
rental LED displays have come up to make it easy. One can find out there so many Digital display manufacturer in the rental display business.
How to meet this challenge? Considering it, in the beginning, is not only wise but also necessary. Apparently, maintenance cost can be a big hurdle. However, a simpler way is to go for a maintenance-free solution. For outdoor LED Signage and, medium to larger screens, rental LED display is best. In this case, the screen always remains the property of the manufacturer. Maintenance of display also remains the responsibility of the owner. In a way end user get a maintenance-free deal. Sounds good?
Outdoor LED billboard is subject to wear and tear due to weather. Environmental effects also affect the performance and quality of digital display placed in the open. Therefore maintenance cost is a bigger concern of outdoor digital display. The indoor digital displays also need maintenance. The life of the LED itself is very long. Therefore indoor digital display does not need frequent maintenance.