Fault maintenance and detection system for liquid crystal module of display screen

Abstract

The invention discloses a breakdown maintenance detection system for a liquid crystal module of a display screen, and relates to the technical field of breakdown maintenance, the breakdown maintenance detection system comprises a parameter acquisition module, the parameter acquisition module is used for acquiring a characteristic parameter set of each maintenance module, the characteristic parameter set comprises a first electrical parameter and a second process parameter, the first electrical parameter is a load peak current, and the second electrical parameter is a load peak current; the second process parameter is an identifier of a non-electrical detection process required to be executed after fault maintenance; according to the method, through a sorting strategy of combining process parameter grouping with arithmetic mean value starting and difference value comparison alternate expansion and matching with electrical parameter difference proportional constant-speed adjustment, power transition of adjacent modules is more balanced, precision loss and equipment impact caused by frequent sudden change of power in traditional detection are effectively improved, and the electrical index measurement reliability is improved.

Description

TECHNICAL FIELD

[0001] The application belongs to the technical field of fault maintenance, and particularly relates to a fault maintenance detection system for a display screen liquid crystal module. BACKGROUND

[0002] As a core component of various display terminals, the fault maintenance of the display screen liquid crystal module is a high-frequency demand in the field of electronic equipment operation and maintenance. In actual maintenance scenarios, the failure rate of functional components such as logic boards, backlight boards and power supply boards is huge, and the core maintenance method is to replace components of the same specification.

[0003] The existing mature maintenance detection process is usually as follows: fault positioning, old component disassembly, new component replacement, and finally power-on display verification. Among them, the standard for qualified determination is usually that the module can normally display pictures and has no immediate visual abnormalities. Due to its simplicity and efficiency, this process has been widely applied to batch maintenance scenarios of various liquid crystal modules such as consumer televisions, industrial displays, vehicle displays, etc.

[0004] However, there is a long-neglected problem in the traditional process: it only verifies the immediate display function of the replacement component, and completely ignores the long-term load adaptability of the entire module system after component replacement. In practice, although the replacement components of different brands and batches have consistent interface forms and nominal parameters with the original components, there are slight differences in their actual load impedance characteristics, current tolerance range and other dynamic parameters. Such differences cannot be shown in short-term verification tests, but they can cause the replacement components or original components to overheat and accelerate aging due to load mismatch in long-term operation, eventually resulting in faults such as black screen, flickering and even component burning after several months of use, leading to a high recurrence rate of faults.

[0005] In addition, in batch maintenance scenarios that pursue efficiency, the repaired modules often need to flow to different subsequent professional detection stations (such as optical detection, touch calibration, etc.). The existing technology usually adopts a simple first-come-first-served or independent scheduling strategy, which completely separates the load test from the subsequent logistics scheduling. This leads to two problems: first, the output power of the load test equipment needs to be frequently adjusted by a large margin when it faces a sequence of modules with greatly different electrical characteristics, which not only prolongs the test time but also damages the equipment life; second, the logistics scheduling system cannot predict the test sequence, resulting in chaotic module transfer, increased waiting time of stations, and limited overall throughput efficiency.

[0006] Therefore, the existing technology lacks a solution to the above problems. SUMMARY

[0007] The purpose of the present application is to provide a fault maintenance detection system for a display screen liquid crystal module to solve the problems mentioned in the background art.

[0008] A fault maintenance detection system of display screen liquid crystal module is used for load adaptability detection of a plurality of maintenance modules with completed component replacement in a batch, and has the characteristics that the system comprises: A parameter acquisition module is configured to acquire a characteristic parameter set of each maintenance module, wherein the characteristic parameter set comprises a first electrical parameter and a second process parameter, the first electrical parameter is a load peak current, and the second process parameter is an identifier of a non-electrical detection process required to be performed after fault maintenance; A cooperative optimization module is configured to execute a grouping and sequencing strategy, wherein a global constraint of the strategy is that module transfer and cross-level switching of load power are allowed only when all modules in a continuous group in a test sequence are completed; Under the constraint, the maintenance modules are divided into a plurality of continuous test groups according to the second process parameter, and are monotonously sequenced according to the values of the first electrical parameter in each group to generate a test sequence in which load power switching in the group is most smooth; A load test device is configured to receive the generated test sequence and sequentially perform load test on each maintenance module, and the load test device performs gradual adjustment of load power according to the first electrical parameter of adjacent modules when switching between modules in the group; A scheduling system is configured to transfer the modules in the whole group to a non-electrical detection station corresponding to the second process parameter of the modules after the load test device completes the test of the continuous group.

[0009] It should be understood that the first electrical parameter specifically refers to the load peak current of the maintenance module, which is a core index reflecting the current demand of the module under full load working state; The second process parameter refers to the identifier of the non-electrical detection process required to be performed on the module after fault maintenance, which is used to locate the target detection station; The maintenance module refers to the display screen liquid crystal module that has completed fault component replacement and preliminary assembly and is ready for load test and non-electrical detection; The load adaptability detection refers to a comprehensive detection process of simulating the actual working load of the module to detect the electrical performance stability and matching the corresponding detection process.

[0010] Preferably, the monotonous sequencing according to the values of the first electrical parameter in each group comprises the following steps: An arithmetic mean value of the first electrical parameter of all modules in the group is calculated; A sequencing starting point is determined, which is the module in the current group whose first electrical parameter value is closest to the arithmetic mean value; From the sequencing starting point, the sequencing sequence is alternately expanded to both sides, and each time the module with the smallest difference in electrical parameter from the current sequence end point is selected to join the sequence until the sequencing of all modules is completed.

[0011] Preferably, the specific process of expanding the sorting sequence alternately to both sides includes: Recording the left and right end point electrical parameter values of the current sequence; In the unsorted module, respectively finding the module with the smallest difference in the left end point electrical parameter and the module with the smallest difference in the right end point electrical parameter; Comparing the two difference values, selecting the module with the smaller difference value to join the corresponding end point, and updating the end point electrical parameter value; Repeating the above process until all modules are sorted.

[0012] Preferably, the process of expanding the sorting sequence alternately to both sides from the starting point of sorting further includes: At each time of adding a new module to the sequence, calculating the electrical parameter difference value between the newly added module and the current end point module; Recording the electrical parameter difference values between all adjacent modules in the sorted sequence, and calculating the average difference value and the standard deviation of the difference value; When it is detected that the electrical parameter difference values of a plurality of modules in the adjacent order in the sorting sequence continuously exceed the average difference value plus a standard deviation, it is determined that there is an abnormal fluctuation in the region; The modules in the abnormal fluctuation region are re-distributed and dispersedly inserted into the adjacent position with smaller difference value in the sequence to ensure the overall smoothness of the sequence.

[0013] Preferably, the system further includes a boundary coordination module for performing the following boundary coordination process: Identifying the overlapping region of the electrical parameters of the two adjacent continuous groups; Selecting the module with the median electrical parameter in the overlapping region as the boundary coordination point; Adjusting the module distribution step by step to both sides with the boundary coordination point as the center, so that the electrical parameter range of the adjacent groups forms a smooth transition.

[0014] Preferably, the boundary coordination process further includes: After completing the adjustment of module distribution, simulating the power switching amplitude between the adjacent groups; If the power switching amplitude exceeds the set threshold, the boundary coordination point is reselected and the adjustment process is repeated; Until the power switching amplitude meets the requirements or the maximum number of adjustments is reached.

[0015] Preferably, the system further includes a group transition module for processing the power switching between adjacent groups: After completing the test of the previous group, a transition test phase is inserted before starting the test of the next group; The transition test phase selects the two modules with the closest electrical parameters in the previous and next groups for transition test; The load test device gradually adjusts the power from the end value of the previous group to the start value of the next group during the transition test; The number of adjustment steps is determined according to the difference between the two groups of electrical parameters, and the more the difference, the more the adjustment steps; The power change of each adjustment step remains consistent, ensuring linear and smooth transition of power change.

[0016] Preferably, when the load test device performs gradual adjustment of load power, a proportional adjustment method based on electrical parameter difference is adopted: The first electrical parameter difference value of the current module and the next module is calculated; The power adjustment speed is determined according to the difference value, and the smaller the difference value, the slower the adjustment speed; The power adjustment process is kept at a constant speed to avoid sudden changes in speed.

[0017] Preferably, the scheduling system adopts a group connection control method when performing whole group transfer: Before the current group test is completed, the test preparation state of the next group is checked in advance; If the next group is ready, the next group test will start immediately after the current group transfer is completed; If the next group is not ready, the test process will be paused until the preparation is completed.

[0018] Preferably, the group connection control method further includes: When multiple groups are waiting for testing, the group with the smallest difference in electrical parameters from the just completed group is selected as the next test group; By minimizing the difference in electrical parameters between groups, the amplitude of power cross-level switching is reduced.

[0019] Compared with the prior art, the beneficial effects of the present application are: The beneficial effects of the present application are: first, the process parameter grouping combined with the arithmetic average value start, the difference value comparison and the alternating expansion of the sorting strategy, the electrical parameter difference proportional uniform adjustment, the power transition of adjacent modules is more balanced, which effectively improves the precision loss and equipment impact caused by frequent power mutation in traditional detection, improves the electrical index measurement reliability; second, the scheduling logic of whole group transfer avoids the waiting and idle running of workstations caused by the dispersion of single module, realizes the efficient connection of load test and non-electrical detection process, and helps to compress the overall cycle of batch detection; third, the global constraint and dynamic adaptation design reduces the equipment start-stop loss, fault probability and transportation system energy consumption maintenance cost, while it can flexibly adapt to different types of liquid crystal module detection requirements, reduce the debugging difficulty and process switching time cost, ensure the quality of the repaired products, improve the detection line operation stability and economy, and adapt to various batch repair and detection scenes. BRIEF DESCRIPTION OF DRAWINGS

[0020] Figure 1 The system framework structure of the present application is shown in the figure. DETAILED DESCRIPTION

[0021] The technical solutions of the present application will be described clearly and completely in combination with the embodiments. Obviously, the described embodiments are only a part of the embodiments of the present application, but not all the embodiments. Based on the embodiments in the present application, all the other embodiments obtained by those skilled in the art without creative labor are within the protection scope of the present application.

[0022] Please refer to Figure 1 The present application provides a fault maintenance detection system for display screen liquid crystal module, which is used for load adaptability detection of a plurality of maintenance modules with completed component replacement in a batch, comprising: The cooperative optimization module of the system serves as a master node, and communicates and interacts with the parameter acquisition module, the embedded master controller in the load test device and the scheduling system. The embedded master controller in the load test device receives the test sequence from the cooperative optimization module, and controls the internal electronic load module to perform power adjustment; The parameter acquisition module is used for acquiring the characteristic parameter set of each maintenance module, and the characteristic parameter set comprises a first electrical parameter and a second process parameter. The first electrical parameter is a load peak current, and the second process parameter is an identifier of a non-electrical detection process to be performed after fault maintenance. It should be noted that the acquisition scenario of the characteristic parameter set is set after the maintenance module completes component replacement and preliminary assembly. The parameter acquisition module completes data acquisition at the entrance end of the detection line of the module, and the acquisition opportunity is earlier than the preparation stage before load testing, so as to ensure that the test sequence has sufficient time to generate.

[0023] The first electrical parameter is collected by a high-precision current sensor, which has a measurement range of 0-5A and an accuracy of ±0.01A. The current sensor is connected with the power interface of the module, and loads rated voltage in the simulated full load working state of the module, runs the standard test program, continuously collects current data for 3 seconds, takes the maximum value as the load peak current, and synchronously records the data timestamp during the collection process, so as to ensure the binding with the unique identifier of the module.

[0024] The second process parameter is acquired by scanning the maintenance trace two-dimensional code on the surface of the module, and reading the built-in process code. The code corresponds to the non-electrical detection station one by one, the recognition distance of the two-dimensional code reading device is 5-10cm, and the recognition success rate is not less than 99.5%, so as to avoid process matching error.

[0025] The feature parameter set after collection is stored in a system database, the database storage technology is a mature existing technology, and details are not described here. The parameter acquisition module is connected with the collaborative optimization module through an industrial communication bus (such as an Ethernet or CAN bus) for transmitting the feature parameter set and ensuring the real-time performance of grouping and sequencing.

[0026] The collaborative optimization module is used for executing a grouping and sequencing strategy, and a global constraint of the strategy is that only when all modules in a continuous group in a test sequence are completed, is the module transfer and the cross-level switching of load power allowed to be performed; Under the constraint, the maintenance modules are divided into a plurality of continuous test groups according to the second process parameters, and are monotonously sequenced according to the values of the first electrical parameters in each group to generate a test sequence that makes the switching of load power in the group most smooth; It should be noted that the global constraint is realized by setting a group completion trigger signal. When the load test device sends a signal that the last module in a group is completed, the collaborative optimization module sends a transfer instruction to the scheduling system, and the load test device is allowed to perform cross-level power switching. The cross-level switching refers to a power adjustment amplitude that exceeds 50% of the maximum adjustment amplitude in the current group. If there are still modules in the group that have not completed the test, the scheduling system prohibits the start of the transfer operation, and the load test device is only allowed to fine-tune within the power adjustment range in the group.

[0027] The division logic of the continuous test group is to traverse all the second process parameters of the maintenance modules in the batch, and automatically group the modules with the same code into a group. The number of modules in the group can be dynamically adjusted according to the size of the batch, with a minimum of 3 and a maximum of 20, so as to avoid frequent scheduling due to too small group size or too long test waiting time due to too large group size. If the number of modules corresponding to a process parameter is 1, a group is formed separately, and the whole-group transfer rule is still followed.

[0028] The specific implementation steps of the monotonous sequencing in the group are as follows: The arithmetic mean of the first electrical parameters of all modules in the group is calculated. Specifically, the arithmetic mean is obtained by traversing the first electrical parameter values of all maintenance modules in the current group, summing and then dividing by the number of modules, and the calculation precision is retained to two decimal places to ensure the accuracy of the sequencing reference; The starting point of sequencing is determined. The module with the smallest difference between the first electrical parameter value and the arithmetic mean is selected from all modules in the group, and is used as the starting point of sequencing; Specifically, if there are multiple modules with the same difference (the absolute value of the difference is less than or equal to 0.01A) from the arithmetic mean, the first module is selected as the starting point according to the order in which the modules enter the detection line. If the group contains only one module, the module is directly used as the only test sequence; The sequencing sequence is alternately expanded to both sides with the starting point as the core, and the specific process includes: First, record the first electrical parameter value corresponding to the left and right endpoints of the current sorting sequence, and the starting point is the left and right endpoint at the initial state; From all unsorted modules, find the candidate module with the smallest difference in electrical parameters with the current left endpoint and the candidate module with the smallest difference in electrical parameters with the current right endpoint, and the difference value is calculated using absolute value subtraction method, and the calculation result is kept to two decimal places; Compare the difference values of the above two candidate modules, and select the candidate module with smaller difference value to join the sorting sequence: If the difference with the left endpoint is smaller, add the module to the left side of the sequence, and update the left endpoint to the first electrical parameter value of the module; If the difference with the right endpoint is smaller, add the module to the right side of the sequence, and update the right endpoint to the first electrical parameter value of the module; If the two difference values are equal (absolute value of difference ≤0.01A), add to the left side of the sequence first; Repeat the above operations of recording endpoint parameters, finding candidate modules, comparing difference values, adding modules and updating endpoints until all unsorted modules are included in the sequence, and the sorting process is terminated.

[0029] The above sorting strategy is executed by the power regulation unit of the load test device in real time, and its output directly controls the voltage / current ramp change of the power module, which is a pure mathematical operation without manual or hardware.

[0030] For easy understanding, for example, the first electrical parameter of a certain group of modules is 2.1A, 1.8A, 2.5A, 1.8A, 2.3A, the arithmetic mean is 2.1A; Select the module with the first electrical parameter of 2.1A as the sorting starting point, and the initial left and right endpoints are both 2.1A; The first expansion, the difference values of unsorted modules with the left endpoint are 0.3A, 0.4A, 0.3A, 0.2A, and the difference values with the right endpoint are the same; Select the 2.3A module with the smallest difference value to add to the right side of the sequence, and update the right endpoint to 2.3A; Next time, the difference values of unsorted modules with the left endpoint 2.1A are 0.3A, 0.4A, 0.3A, and the difference values with the right endpoint 2.3A are 0.5A, 0.2A, 0.5A. After comparison, select the 1.8A module with the smallest difference on the left side to add to the left side, and update the left endpoint to 1.8A; Continue to repeat the operation, and finally generate the sorting sequence as 1.8A, 2.1A, 2.3A, 2.5A, 1.8A or other equivalent sequences that meet the rules.

[0031] After the sorting is completed, the collaborative optimization module outputs the test sequence containing the module identification, test order, first electrical parameter, and second process parameter to the load testing device and scheduling system in table form. The table output format and data compatibility technology are existing mature technologies, and thus will not be described in detail here to ensure data compatibility between devices.

[0032] The load testing device is configured to receive the generated test sequence and sequentially perform load testing on each maintenance module. When switching between modules within a group, the load testing device performs gradual adjustment of the load power based on the first electrical parameter of the adjacent modules. It should be noted that the load testing device (1, hereinafter also referred to as "load testing device" or "electronic load module" for short, all referring to the same hardware) includes a programmable power module, a current sampling circuit based on the Hall effect, an electronic load module (i.e., load adjustment unit, used interchangeably with "load testing device" to refer to the same device) composed of MOSFET, and an embedded main controller. The embedded main controller is electrically connected to the programmable power module, the current sampling circuit, and the electronic load module, and is configured to perform a gradual power adjustment strategy.

[0033] The power module is configured to provide stable voltage required for module testing, the current and voltage acquisition unit is configured to acquire electrical data in real time during testing, the load adjustment unit is configured to achieve precise adjustment of power, and the control unit is configured to interact with the collaborative optimization module and the scheduling system to coordinate the orderly work of various components. The basic working principles of the above components and the connection of conventional selection are existing mature technologies, and thus will not be described in detail here. The device is configured to receive the generated test sequence and sequentially perform load testing on each maintenance module. When switching between modules within a group, the load testing device performs gradual adjustment of the load power based on the first electrical parameter of the adjacent modules. The gradual adjustment adopts a proportional adjustment method based on the difference in electrical parameters, which is implemented as follows: Before switching to the next module, the first electrical parameter values of the current test completion module and the next test module are read, the difference between the two is calculated by absolute value subtraction, and the calculation result is retained to two decimal places. The basic range of the preset power adjustment speed is 0.2 W / ms to 1.0 W / ms. The adjustment speed is positively correlated with the difference in electrical parameters. The smaller the difference, the slower the adjustment speed, and the larger the difference, the closer the adjustment speed to the upper limit. The specific corresponding relationship is as follows: when the difference is ≤0.2 A, the adjustment speed is set to 0.2 W / ms; when the difference is between 0.2 A and 0.5 A, the adjustment speed is set to 0.5 W / ms; and when the difference is >0.5 A, the adjustment speed is set to 1.0 W / ms. The above corresponding relationship can be fine-tuned through the system parameter configuration interface according to the detection requirements of different types of liquid crystal modules. According to the relationship that power is equal to voltage multiplied by current (the default test voltage is the module rated voltage, which is stably output by the power module), the difference between the target power and the current power is calculated; Combined with the determined adjustment speed, the required adjustment time is obtained by dividing the target power difference by the adjustment speed; within the adjustment time, the load adjustment unit uniformly completes the transition of the power from the current value to the target value, and the control unit ensures the stability of the adjustment speed throughout the adjustment by real-time sampling of the power output value and feedback adjustment, thereby avoiding power fluctuations caused by sudden changes in the adjustment speed.

[0034] After the load test device receives the test sequence, the first module is moved to the test station through the conveying line; the power supply interface and the signal acquisition interface are automatically clamped and fixed and connected; The actual working environment of the module is simulated, and the standard working conditions are 25°C and 45% to 65% humidity; The electrical indicators such as voltage stability, current output consistency, and power consumption are detected; The single-module test duration is 15 to 30 seconds, and the test results are uploaded to the system in real time.

[0035] For example, the first electrical parameter of the previous module is 2.0A, corresponding to a power of 10W, the next module is 2.1A, the electrical parameter difference value is 0.1A, the adjustment speed is determined to be 0.2W / ms, the target power is 10.5W, and the power is uniformly increased from 10W to 10.5W at a rate of 0.2W / ms, and the adjustment time is 2.5ms; If the next module is 2.6A, the difference value is 0.6A, the adjustment speed is set to 1.0W / ms, the target power is 13W, and the power is uniformly increased from 10W to 13W, which takes 3ms, avoiding sudden changes in power.

[0036] If the electrical indicators of the module do not meet the standards during the test, such as current fluctuation exceeding ±0.1A, the load test device immediately stops the test, marks the module as unqualified, and skips the subsequent power adjustment preparation related to the sorting of the module, and directly triggers the unqualified product transfer instruction to move it to the unqualified product temporary storage area, without affecting the test process of other modules in the same group.

[0037] It should be noted that the above various components and devices are existing mature technologies, and will not be described in detail here.

[0038] The scheduling system is used to move the entire group of modules to the non-electrical detection station corresponding to the second process parameter after the load test device completes the test of a continuous group.

[0039] It should be noted that the scheduling system is an automated scheduling device composed of a conveying control unit, a path planning unit, a station positioning unit, and a state monitoring unit.

[0040] Further, the conveying control unit is used to control the action of the conveying line, mechanical arm and other actuators, the path planning unit calculates the optimal transfer path according to the layout of the workstations and the real-time working conditions, the workstation positioning unit realizes the accurate positioning of the module through infrared sensors, encoders and other devices, and the state monitoring unit tracks the test progress and equipment operating state in real time. The basic working principle of the above units and the infrared sensors, encoders and other devices are existing mature technologies, which will not be described in detail here. The system is used to transfer the entire group of modules to the corresponding non-electrical detection workstations after the load test device completes a continuous group of tests.

[0041] Further, the scheduling system receives the test state signal of the load test device in real time, and when the last module in a group completes the test and the test result has been uploaded, it is determined that the group test is completed, triggering the transfer process.

[0042] If there are unqualified modules in the group, the unqualified modules and qualified modules are transferred separately, the qualified modules are transferred to the corresponding non-electrical detection workstations, and the unqualified modules are transferred to the temporary storage area.

[0043] The scheduling system has a workshop workstation layout map built-in, and the map storage and calling technology is an existing mature technology, which will not be described in detail here. According to the second process parameters of the continuous test group, the target non-electrical detection workstation is determined, and the optimal transfer path is calculated by the path planning algorithm; avoid other running conveying lines and equipment, the transfer speed can be dynamically adjusted according to the density of people flow in the workshop, the default is 0.5m / s, and the peak of people flow is reduced to 0.3m / s. The transfer adopts the mode of belt conveying line and mechanical arm cooperation; When the module test in the group is completed, the belt conveying line transfers the entire group of modules to the specified transfer location, the mechanical arm grabs the modules in sequence and places them on the tray of the target non-electrical detection workstation, and the infrared sensor is positioned during the transfer process to ensure that the module placement accuracy is not more than ±2mm, avoiding collision damage.

[0044] The beneficial effects of the present application are: first, the process parameter grouping combined with the arithmetic mean starting, the difference value comparison and the alternating expansion of the sorting strategy, matched with the electrical parameter difference proportional uniform speed adjustment, makes the adjacent module power transition more balanced, effectively improves the precision loss and equipment impact caused by frequent power mutation in traditional detection, improves the measurement reliability of electrical indicators; second, the scheduling logic of the whole group transfer, avoids the waiting and idling of the workstations caused by the dispersed circulation of the single module, realizes the efficient connection of the load test and the non-electrical detection process, and can help to compress the overall cycle of batch detection; third, the global constraint and dynamic adaptation design, reduces the equipment start-stop loss, fault probability and transportation system energy consumption maintenance cost, at the same time, can flexibly adapt to the detection needs of different types of liquid crystal modules, reduces the debugging difficulty and process switching time cost, guarantees the product quality of maintenance products, improves the operation stability and economy of the detection line, and adapts to various batch maintenance detection scenes.

[0045] As an embodiment of the present application, the process of alternatingly expanding the sorting sequence to both sides from the sorting starting point also includes: When a new module is added to the sequence each time, the electrical parameter difference value between the newly added module and the current endpoint module is calculated. In this embodiment, if the left endpoint of the current sequence is 1.9A and the parameter of the module newly added to the left is 1.8A, the difference value is calculated as the absolute value of 1.9A minus 1.8A, that is, 0.1A; if the right endpoint of the sequence is 2.3A and the parameter of the module newly added to the right is 3.0A, the difference value is 3.0A minus 2.3A, that is, 0.7A. The difference value calculation adopts the absolute value subtraction method, and the result is retained to two decimal places as the basic data for abnormal monitoring.

[0046] The electrical parameter difference values between all adjacent modules in the sorted sequence are recorded, and the average difference value and the standard deviation of the difference value are calculated. When a new module is added to the sequence each time, the electrical parameter difference value between the newly added module and the current endpoint module is calculated. In this embodiment, if the left endpoint of the current sequence is 1.9A and the parameter of the module newly added to the left is 1.8A, the difference value is calculated as the absolute value of 1.9A minus 1.8A, that is, 0.1A; if the right endpoint of the sequence is 2.3A and the parameter of the module newly added to the right is 3.0A, the difference value is 3.0A minus 2.3A, that is, 0.7A. The difference value calculation adopts the absolute value subtraction method, and the result is retained to two decimal places as the basic data for abnormal monitoring.

[0047] (Statistical basis: all sorted modules in the group participate, sample size n≥3) When it is detected that the electrical parameter difference values of multiple modules in sequence according to the sorted sequence are all greater than the average difference value plus one standard deviation, it is determined that there is abnormal fluctuation in this area.

[0048] In this embodiment, the average difference value is 0.23A, the standard deviation is 0.23A, and the superposition value of the two is 0.46A. The determination threshold of the continuous number is determined based on the group size of 3 to 20 modules commonly found in batch detection. The default setting is continuous 3 or more, and when the group size is less than or equal to 5, it can be fine-tuned to continuous 2. This setting avoids misjudgment as an anomaly due to a single difference value surge, and can also capture real local fluctuations in time; After updating the difference value list each time, the adjacent difference values are traversed in order to check if there is a continuous region that meets the above conditions. Among the differences of 0.7A between 2.3A and 3.0A, 0.1A between 3.0A and 3.1A, and 0.1A between 3.1A and 3.2A, although the last two difference values do not exceed the superposition value, since 0.7A has exceeded the threshold and is the start of a continuous region, it is still determined that the regions corresponding to 3.0A, 3.1A, and 3.2A are abnormal fluctuation regions. At the same time, the module identifiers and corresponding electrical parameter values contained in the region are recorded.

[0049] The modules in the abnormal fluctuation region are redistributed and inserted into adjacent positions in the sequence with smaller difference values to ensure the overall smoothness of the sequence. In this embodiment, the three modules of 3.0A, 3.1A, and 3.2A determined to be abnormal fluctuation regions are temporarily extracted, the region position in the original sequence is emptied, and the sequence is reconnected at both ends to form a temporary remaining sequence of 1.8A, 1.9A, 2.1A, and 2.3A. Subsequently, all adjacent positions in the remaining sequence are traversed, and the existing difference values of each position are calculated as 0.1A, 0.2A, and 0.2A. The three adjacent positions with difference values less than the current average difference value of 0.23A are selected as the target insertion positions. The extracted abnormal modules are sorted in ascending order of electrical parameters as 3.0A, 3.1A, and 3.2A, and are inserted into the target positions one by one. After inserting 1.9A and 2.1A, 2.1A and 2.3A, and 2.3A, the difference values adjacent to the insertion positions are recalculated. The superposition value is calculated using the real-time average difference value and standard deviation of the new sequence after insertion. It is verified whether the difference value still does not exceed the superposition value. If it exceeds, it is adjusted to other target positions, and finally a new sequence is formed.

[0050] Further, after completing the redistribution of abnormal modules, the adjacent difference value list of the entire sequence needs to be recalculated, and the average difference value and the standard deviation are updated synchronously to verify whether there is an abnormal fluctuation region in the entire sequence that has not been processed. If there is, the abnormal fluctuation detection and re-distribution step is repeatedly performed until there is no abnormal fluctuation region in the whole set of sequences. Meanwhile, the left end point and right end point electrical parameter values of the sorted sequences are updated, and if there is still an unsorted module in the group, the original alternating expansion logic (recording new end point parameters, searching for candidate modules, comparing difference values and adding modules) is continued to be executed based on the updated sequences, and the abnormal fluctuation regulation process is synchronously executed after adding a new module each time; If there is no unsorted module in the group, the sorting process is terminated. Specifically, during the above-mentioned alternating expansion process, the smoothness of the sequences is synchronously monitored: after adding a new module each time, the electrical parameter difference value between it and the adjacent module is calculated, and the average difference value and the standard deviation of the sorted sequences are updated in real time. If it is detected that the electrical parameter difference values of three consecutive adjacent modules all exceed "average difference value + 1 times standard deviation", it is determined that there is an abnormal fluctuation in the region, all the modules in the region are immediately extracted and inserted into other adjacent positions with smaller difference values in the sequence, and the average difference value and the standard deviation of the whole set of sequences are recalculated until there is no new abnormal fluctuation region, so as to ensure the overall smoothness of the final sequence.

[0051] The difference value real-time calculation, statistical operation of the average difference value and the standard deviation, and temporary storage of the module identification involved in this step are basic functions that can be realized by the control unit of the collaborative optimization module. The data processing algorithm and storage logic are existing mature technologies, which will not be described in detail here. Through the execution of this process, the sorting abnormal fluctuation caused by local parameter concentration can be effectively resolved, the electrical parameter transition of the whole set of sequences is more balanced, a reliable guarantee is provided for the smooth power adjustment of the subsequent load test, and the accuracy and efficiency of batch detection are improved.

[0052] Specifically, in the batch detection process based on the second process parameter grouping and the alternating expansion sorting in the group, although the smooth transition of the electrical parameters of the modules in the group is ensured through the sorting in the group and the abnormal fluctuation regulation, there may still be electrical parameter mutation problems between two adjacent continuous groups. This is because the sorting of each group is only optimized based on the arithmetic mean value in the group, without considering the parameter connection with the adjacent group. When there is no overlap or the overlap is small between the electrical parameter ranges of the two groups, the load test device needs to make a large power adjustment across the groups when it completes the test of the previous group and switches to the first module of the next group. Even if a proportional uniform adjustment is used, there will still be precision fluctuations and equipment impact due to the adjustment amplitude exceeding the normal range in the group, and there is also the risk of data connection discontinuity after the whole group is transferred.

[0053] As an embodiment of the present application, the system further comprises a boundary coordination module for performing the following boundary coordination process: identifying an electrical parameter overlapping area of two adjacent continuous groups; in this embodiment, assuming that the two adjacent groups are group one and group two, the first electrical parameter values of all modules of group one are 1.8A, 1.9A, 2.1A, 2.3A, 2.4A, and the parameter range is 1.8A to 2.4A; the first electrical parameter values of all modules of group two are 2.2A, 2.3A, 2.5A, 2.6A, 2.7A, and the parameter range is 2.2A to 2.7A.

[0054] We extract the intersection area of the two groups as the overlapping area by comparing the parameter ranges of the two groups, that is, 2.2A to 2.4A, which includes the 2.3A and 2.4A modules of group one and the 2.2A and 2.3A modules of group two. The determination of the parameter range is defined by the minimum and maximum values of the first electrical parameters of all modules in the group, and the calculation of the overlapping area is performed by taking the maximum value of the left boundary and the minimum value of the right boundary. If the calculation result is left boundary ≤ right boundary, there is an overlapping area, otherwise it is determined that there is no overlapping area.

[0055] Selecting a module with a central electrical parameter in the overlapping area as a boundary coordination point; in this embodiment, the overlapping area is 2.2A to 2.4A, first calculate the middle value of the electrical parameters in this area, the middle value is (2.2A+2.4A) ÷ 2 = 2.3A; Then, by filtering the first electrical parameter values of all modules in the overlapping area, that is, 2.3A and 2.4A of group one and 2.2A and 2.3A of group two, select the module with the same parameter value as the middle value 2.3A as the boundary coordination point. If there are multiple modules that meet the conditions, select the module close to the group boundary in the group. In this embodiment, the 2.3A module of group one is selected as the boundary coordination point. If there is no module in the overlapping area with the same parameter value as the middle value, select the module with the smallest difference from the middle value. The difference value is calculated using absolute value subtraction. If there are multiple modules with the same difference value, preferentially select the module of the previous group as the coordination point.

[0056] Adjusting the module allocation step by step to the left and right of the boundary coordination point to form a smooth transition of the electrical parameter range of the adjacent groups.

[0057] In this embodiment, the boundary coordination point is the 2.3A module of group one, and its parameter value is 2.3A. First, check the parameter distribution of the adjacent modules on both sides of the coordination point. The right side of the coordination point of group one is the 2.4A module, and the module close to the boundary of group two is the 2.2A module. The parameter transition at the boundary of the two groups is from 2.4A (the rightmost module of group one) to 2.2A (the leftmost module of group two), which has a reverse fluctuation of 0.2A.

[0058] In the adjustment, the 2.4A module on the right side of group one is exchanged with the 2.2A module on the left side of group two. After the exchange, the parameter range of group one is still 1.8A to 2.4A (including the 2.2A module after the exchange), and the parameter range of group two is still 2.2A to 2.7A (including the 2.4A module after the exchange); At this time, the parameter of the rightmost module of group one is 2.2A, and the parameter of the leftmost module of group two is 2.3A. The transition of the adjacent group boundary parameter is 2.2A to 2.3A, with a difference of only 0.1A, forming a smooth transition.

[0059] After the exchange, it is necessary to check again whether the second process parameter identifiers of the two groups are still consistent with the original grouping; the checking method is to read the process code in the module QRCode. If there is a cross-code mixed group, immediately undo this exchange and roll back the module list; If there is a cross-process parameter mixed group, undo this exchange, select a suboptimal coordination point (i.e. the module with the second smallest difference value from the middle value in the overlapping area) and repeat the adjustment until the process parameter consistency meets the requirements.

[0060] During the adjustment, it is necessary to ensure that the second process parameters of the two groups after the adjustment still meet the grouping requirements, i.e. the process code of the module remains unchanged, and only the modules with the same process code between adjacent groups are adjusted. If there is no module with the same code in a group that can be adjusted, the module with the parameter closest to the coordination point in the group is retained at the boundary position and is not adjusted across groups.

[0061] After completing the module allocation adjustment, the boundary coordination module first simulates the power switching amplitude between adjacent groups, and then judges whether iterative adjustment is needed according to the calculation result.

[0062] In the simulation calculation, the first electrical parameter of the last module of the previous group and the first electrical parameter of the first module of the next group after the adjustment are taken as the reference, combined with the rated voltage during the test, and the power values of the boundary modules of the two groups are calculated through the formula that power is equal to voltage multiplied by current. The difference between the two is the power switching amplitude between adjacent groups. A power switching amplitude threshold is set, which is determined based on the stable adjustment capability of the load test device. In this embodiment, the rated test voltage is 5V, and the threshold is set to 1.0W; The parameter of the last module of group one after the adjustment is 2.3A, corresponding to a power of 11.5W, and the parameter of the first module of group two is 2.5A, corresponding to a power of 12.5W. The simulated calculation obtains a power switching amplitude of 1.0W, which is exactly equal to the set threshold, meeting the requirements and not needing re-adjustment. If If the power switching amplitude exceeds the set threshold value, for example, the power of the last module of the first group is 11.5W and the power of the first module of the second group is 13.0W, the switching amplitude is 1.5W, which exceeds the threshold value 1.0W, and the threshold value can be set in the range of 0.5-2.0W according to the equipment tolerance (which has been described in the embodiment, and those skilled in the art can select as needed), then return to the step of selecting the boundary coordination point in the overlapping area, reselect the coordination point (such as preferentially selecting the module closer to the parameter range of the next group in the overlapping area) and repeat the adjustment process. At the same time, the maximum number of adjustments is set, in this embodiment, the maximum number of adjustments n, 2≤n≤5, preferably 3, if the power switching amplitude still does not meet the requirements after reaching the maximum number of adjustments, the scheme with the smallest switching amplitude in the current adjustment result is selected as the final scheme, and the adjustment log is recorded for subsequent parameter optimization reference.

[0063] Further, after the power switching amplitude meets the requirements or reaches the maximum number of adjustments, the boundary coordination module feeds back the lists of the two groups of modules and the parameter distribution after the final adjustment to the collaborative optimization module, and the collaborative optimization module re-generates the in-group sorting sequence of the two groups to ensure that the in-group sorting still meets the rules of starting from the arithmetic mean and alternating expansion, and synchronously updates to the load testing device and the scheduling system.

[0064] As a specific implementation example, the adjusted module parameters of the first group are 1.8A, 1.9A, 2.1A, 2.2A and 2.3A, and the re-ordered sequence is 2.1A, 1.9A, 1.8A, 2.2A and 2.3A; the module parameters of the second group are 2.3A, 2.4A, 2.5A, 2.6A and 2.7A, and the re-ordered sequence is 2.5A, 2.4A, 2.3A, 2.6A and 2.7A.

[0065] The load testing device performs testing according to the adjusted sequence, and switches from the last module 2.3A of the first group to the first module 2.5A of the second group when crossing the group, and the parameter difference value is 0.2A, and the corresponding power adjustment speed is 0.5W / ms, and the adjustment smoothness is improved.

[0066] It should be noted that the basic functions such as parameter range calculation, overlapping area extraction, intermediate value operation and power simulation calculation involved in the module can be realized by the microprocessor of the boundary coordination module, and the data operation logic and module information interaction mechanism are existing mature technologies, which will not be described in detail here.

[0067] The innovation of the present application lies in that, through the execution of the boundary coordination process, the electrical parameter mutation problem between adjacent groups can be effectively eliminated, the cross-group power adjustment amplitude is controlled within a reasonable range, the in-group sorting optimization and abnormal fluctuation regulation are combined, a full-process parameter smooth transition system is formed, and the accuracy and efficiency of batch testing are further improved.

[0068] It should be understood that after the adjacent group module distribution is optimized by the boundary coordination module, the electrical parameter range between adjacent groups is smoothly connected, but there may still be a problem of insufficient smoothness of power adjustment when switching between groups. This is because the boundary coordination only optimizes the intersection of the parameter ranges of the two groups through module distribution, and does not specifically design the power adjustment process for cross-group switching. When there is still a certain difference in the electrical parameters of the boundary modules of the two groups, the load test device directly switches from the power of the last module of group one to the power of the first module of group two. Even if a proportional uniform adjustment is used, a single adjustment process may still cause power fluctuations due to the accumulation of parameter differences. Especially when batch detection is continuously tested in multiple groups, the superposition of fluctuations caused by multiple cross-group switches will affect the overall detection accuracy.

[0069] As an embodiment of the present application, the system further comprises a group transition module for processing power switching between adjacent groups: After completing the test of the previous group and before starting the test of the next group, a transition test phase is inserted. In this embodiment, it is assumed that the previous group is group A and the next group is group B. After group A completes all module tests, the load test device is in the test power state of the last module of group A. At this time, the group transition module triggers a transition test phase start signal, suspends the test start process of the first module of group B, and after the transition test phase is completed, the group B test start instruction is triggered.

[0070] It should be understood that the start and termination of the transition test phase is realized through signal interaction between the group transition module and the load test device. The signal interaction uses serial communication, the communication rate is 9600bps, and the signal delay is not more than 5ms, ensuring the real-time performance of the process connection. Serial communication technology is a mature technology, and will not be described in detail here.

[0071] The two module groups with the closest electrical parameters before and after the transition test phase selection are selected for transition testing; in this embodiment, the first electrical parameters of all module groups in group A are 1.7 A, 1.9 A, 2.0 A, 2.2 A, and 2.3 A, and the first electrical parameters of all module groups in group B are 2.4 A, 2.5 A, 2.6 A, 2.8 A, and 2.9 A. First, all module parameters of group A and all module parameters of group B are extracted, two-by-two pairing combinations of the two groups of parameters are constructed, and the electrical parameter difference values of each combination are calculated, the difference value is calculated by using absolute value subtraction, and the result is retained to two decimal places. Among all combinations, the difference value between the last module 2.3 A of group A and the first module 2.4 A of group B is 0.1 A, the difference value between 2.3 A of group A and 2.5 A of group B is 0.2 A, the difference value between 2.2 A of group A and 2.4 A of group B is 0.2 A, and the difference values of the remaining combinations are all greater than 0.1 A, therefore, the 2.3 A module of group A and the 2.4 A module of group B are selected as the two transition modules for transition testing, and the two form the parameter reference for transition testing. If there are multiple combinations with the same minimum difference value, the combination of the modules close to the group boundary is preferred.

[0072] The load testing device gradually adjusts the power from the end value of the previous group to the start value of the next group during the transition test; in this embodiment, the test rated voltage is 5 V, the power corresponding to the last module 2.3 A of group A is 11.5 W (i.e., the end power of the previous group), and the power corresponding to the first module 2.4 A of group B is 12.0 W (i.e., the start power of the next group), and the load testing device gradually adjusts the power from 11.5 W to 12.0 W during the transition test phase.

[0073] The power adjustment is completed by the electronic load module (i.e., the load adjustment unit, also referred to as the load testing device hereinafter) of the load testing device, which realizes accurate power output through pulse width modulation.

[0074] The number of adjustment steps is determined according to the size of the electrical parameter difference value of the two groups, the larger the difference value, the more adjustment steps; the power change amount of each adjustment step remains consistent to ensure linear and smooth transition of power change. In this embodiment, the electrical parameter difference value of the two transition modules is calculated first, i.e., the absolute value of 2.4 A minus 2.3 A is 0.1 A, and the corresponding power difference value is 0.5 W.

[0075] The corresponding rules between the electrical parameter difference value and the number of adjustment steps are set as follows: when the difference value is ≤0.2 A, the number of adjustment steps is 5 steps; when the difference value is between 0.2 A and 0.5 A, the number of adjustment steps is 10 steps; When the difference is greater than 0.5A, the number of adjustment steps is 15 (the value is determined by 144 groups of samples, 3 sigma orthogonal test, confidence 95%; fine adjustment is allowed in the configuration interface); specifically, the above difference-step correspondence is based on 1000 groups of liquid crystal module measured data, and is determined by orthogonal test (samples cover 5 brands, 3 sizes, confidence 95%), which can be fine adjusted in the system configuration interface.

[0076] In the embodiment, the difference is 0.1A, and the number of adjustment steps is determined to be 5. The power change of each adjustment step is the total power difference divided by the number of steps, that is, 0.5W divided by 5 equals 0.1W, and each step maintains a uniform change of 0.1W.

[0077] The transition test phase is executed according to the determined adjustment steps. The load test device starts from 11.5W, increases by 0.1W each step, and sequentially passes through 11.6W, 11.7W, 11.8W, 11.9W, and finally reaches 12.0W. The duration of each adjustment step is set to 100ms, and the next adjustment step is executed after the power is stably output. The duration can be adjusted within the range of 50ms-200ms according to the detection accuracy requirement.

[0078] If the power fluctuation of a step is greater than ±0.02W, the step is paused and re-executed, with a maximum of 3 retries (the threshold value here can be obtained from 1000 power step tests, covering 5 brands, 3 sizes of modules, with a confidence of 95%); if it is still out of tolerance, the load test device is marked for calibration and the transition test is skipped, and the next group of tests is started directly with the current power, while recording the abnormal log.

[0079] During the step execution process, the current and voltage acquisition unit of the load test device collects output power data in real time, which is fed back to the inter-group transition module for monitoring. If the power fluctuation of a step exceeds ±0.02W, the adjustment is paused and the step is re-executed until the power is stable.

[0080] When the last adjustment step reaches 12.0W and is stable, the inter-group transition module sends a transition test completion signal, and the load test device stops the transition test and starts the formal test process of the first module of group B.

[0081] The present application disassembles the cross-group power switching into uniform linear adjustment steps through the processing of the inter-group transition module, effectively avoiding the power fluctuation risk in the single adjustment process. Combined with the module allocation optimization of the boundary coordination module, a double cross-group optimization system of "parameter range connection + power linear transition" is formed, which further improves the stability and detection accuracy of the whole batch detection system, and adapts to the large-scale batch detection scene of continuous multiple groups.

[0082] As an embodiment of the present application, the inter-group connection control method further comprises: When multiple groups are waiting for testing, the group with the smallest difference in electrical parameters from the group just completed is selected as the next testing group; By minimizing the difference in electrical parameters between groups, the magnitude of power cross-tier switching is reduced.

[0083] In this embodiment, when multiple groups are waiting for testing, the group transition module first obtains the electrical parameter key information of the group just completed testing, and then collects the corresponding parameter information of all groups waiting for testing to construct a parameter comparison dataset. We refer to the group just completed testing as the completed group C, and the first electrical parameters of all modules of this group are 2.0A, 2.1A, 2.2A, 2.3A, and 2.4A. The electrical parameter core feature value of this group is the average value of the first electrical parameters of all modules in the group, which is calculated as (2.0A+2.1A+2.2A+2.3A+2.4A) ÷ 5 = 2.2A. This average value is used as the reference value for difference comparison with the waiting groups. There are three groups waiting for testing, namely, the waiting group D, the waiting group E, and the waiting group F. The average value of the first electrical parameters of the waiting group D is 2.3A, the average value of the first electrical parameters of the waiting group E is 1.8A, and the average value of the first electrical parameters of the waiting group F is 2.7A. The average values of the groups are pre-calculated and stored by the collaborative optimization module after the grouping is completed, and are read in real time by the group transition module through Ethernet.

[0084] The difference values of the electrical parameters between the completed group and each waiting testing group are calculated, and the group with the smallest difference value is selected as the next testing group. In this embodiment, the difference values are calculated based on the average value of the electrical parameters of the completed group and the average value of the electrical parameters of the waiting group, and the absolute value subtraction method is used, with the result being rounded to two decimal places.

[0085] The specific calculation process is as follows: the difference value between the completed group C and the waiting group D is the absolute value of 2.3A-2.2A = 0.1A; the difference value between the completed group C and the waiting group E is the absolute value of 2.2A-1.8A = 0.4A; The difference value between the completed group C and the waiting group F is the absolute value of 2.7A-2.2A = 0.5A. Comparing the three difference values, 0.1A is the smallest, so the waiting group D is selected as the next testing group.

[0086] If there are multiple waiting groups with the same difference value as the completed group and the difference value is the smallest (for example, the difference values of the waiting group D and the waiting group G are both 0.1A), then the second process parameters of each group are further compared, and the group with the same or similar process parameters as the completed group is selected first; If the process parameters are also consistent, then the group generated earlier is selected according to the order of group generation time.

[0087] After determining the next test group, the inter-group transition module sends a group selection confirmation signal to the collaborative optimization module, which marks the group as a to-be-started state, and then performs parameter connection optimization of the boundary coordination module and the transition test phase of the inter-group transition module according to the original process.

[0088] In this embodiment, after determining that the waiting group D is the next test group, the collaborative optimization module marks it as to-be-started, the boundary coordination module extracts the electrical parameter range of the completed group C and the waiting group D, the group C is 2.0A-2.4A, and the group D is 2.2A-2.5A, and identifies the overlapping area as 2.2A-2.4A and completes the boundary module distribution adjustment. Then, the inter-group transition module selects the module with the closest electrical parameter in the two groups (2.4A of group C and 2.2A of group D, with a difference value of 0.2A) as the transition module, determines the adjustment step number as 5 steps according to the parameter difference, and each step changes the power by 0.1W. After performing the transition test, the formal test of group D is started.

[0089] If the next test group selected in priority cannot be started due to equipment failure, abnormal module state, or other reasons during the waiting process, the inter-group transition module automatically skips the group, recalculates the electrical parameter difference value of the just-completed group and the remaining waiting groups, selects a new group with the smallest difference value as the next test group, and records the skipping reason in the system log. In this embodiment, if the waiting group D cannot be started due to module positioning failure, the inter-group transition module recalculates the difference values of the completed group C and the remaining waiting groups E and F, which are still 0.4A and 0.5A, selects the waiting group E as the next test group, and records "waiting group D is skipped due to module positioning failure" in the system log.

[0090] The innovation of the present application lies in that, through the execution of the inter-group connection control step, the electrical parameter difference between groups is minimized from the test group selection link, the optimization effect of boundary coordination and transition test is better, not only the power cross-level switching amplitude is reduced, but also the transition test time is shortened, and the overall process efficiency and equipment operation stability in the multi-group batch detection scenario are effectively improved.

[0091] The above is only a specific embodiment of the present application, but the protection scope of the present application is not limited thereto. Any person skilled in the art can easily think of changes or replacements within the technical scope disclosed in the present application, which should be covered within the protection scope of the present application. Therefore, the protection scope of the present application should be subject to the protection scope of the claims.

Claims

1. A fault repair and detection system for LCD modules, used to perform load compatibility testing on multiple repair modules in a batch that have undergone component replacement, characterized in that, include: The parameter acquisition module is used to acquire the feature parameter set of each maintenance module. The feature parameter set includes a first electrical parameter and a second process parameter. The first electrical parameter is the load peak current, and the second process parameter is the identifier of the non-electrical testing procedures to be performed after fault repair. The collaborative optimization module is used to execute the grouping and sorting strategy. The global constraint of this strategy is that module transfer and cross-level switching of load power are only allowed after all modules in a consecutive group in the test sequence have completed testing. Under this constraint, the maintenance module is divided into several consecutive test groups according to the second process parameters, and the first electrical parameter is monotonically sorted within each group to generate the test sequence that makes the load power switching within the group the smoothest. A load testing device is used to receive the generated test sequence and perform load tests on each maintenance module in sequence; when switching between modules within a group, the load testing device performs a gradual adjustment of the load power based on the first electrical parameters of the adjacent modules. The scheduling system is used to transfer the entire group of modules to the non-electrical testing station corresponding to its second process parameter after the load testing device has completed a continuous set of tests.

2. The fault repair and detection system for a display screen LCD module according to claim 1, characterized in that, Monotonic sorting within each group according to the value of the first electrical parameter includes the following steps: Calculate the arithmetic mean of the first electrical parameters of all modules within the group; Determine the sorting starting point, which is the module in the current group whose first electrical parameter value is closest to the arithmetic mean; Starting from the sorting start point, the sorting sequence is expanded alternately to both sides. Each time, the module with the smallest difference in electrical parameters from the current sequence endpoint is selected and added to the sequence until all modules are sorted.

3. The fault repair and detection system for a display screen LCD module according to claim 2, characterized in that, The specific process of alternately expanding the sorting sequence to both sides includes: Record the electrical parameter values ​​of the left and right endpoints of the current sequence; In the unsorted modules, find the module with the smallest difference from the electrical parameters of the left endpoint and the module with the smallest difference from the electrical parameters of the right endpoint respectively; Compare the two difference values, select the module with the smaller difference value to add to the corresponding endpoint, and update the endpoint electrical parameter values; Repeat the above process until all modules are sorted.

4. The fault repair and detection system for a display screen LCD module according to claim 2, characterized in that, The process of alternately expanding the sorted sequence to both sides from the starting point also includes: Each time a new module is added to the sequence, the difference in electrical parameters between the newly added module and the current endpoint module is calculated; Record the electrical parameter differences between all adjacent modules in the sorted sequence, and calculate the average difference and the standard deviation of the difference. When the electrical parameter differences of multiple consecutive modules in a sorted sequence exceed the average difference plus one standard deviation, it is determined that there is abnormal fluctuation in the region. The modules in the abnormal fluctuation region are redistributed and inserted into adjacent positions with smaller differences in the sequence to ensure the overall smoothness of the sequence.

5. The fault repair and detection system for a display screen LCD module according to claim 1, characterized in that, The system also includes a boundary coordination module, which performs the following boundary coordination processes: Identify the overlapping area of ​​electrical parameters between two consecutive adjacent groups; Within the overlapping area, select the module with the middle electrical parameters as the boundary coordination point; Centered on the boundary coordination point, the module allocation is gradually adjusted to both sides to create a smooth transition in the electrical parameter range of adjacent groups.

6. The fault repair and detection system for a display screen LCD module according to claim 5, characterized in that, The border coordination process also includes: After completing the module allocation adjustment, the power switching amplitude between adjacent groups is simulated and calculated. If the power switching amplitude exceeds the set threshold, the boundary coordination point is reselected and the adjustment process is repeated. Until the power switching amplitude meets the requirements or the maximum number of adjustments is reached.

7. The fault repair and detection system for a display screen LCD module according to claim 1, characterized in that, The system also includes an inter-group transition module for handling power switching between adjacent groups: After completing the test for the previous group and before starting the test for the next group, insert a transition test phase. The transition test phase selects the two modules with the closest electrical parameters from the two groups to perform the transition test. During the transition test, the load testing device gradually adjusts the power from the end value of the previous set to the starting value of the next set. The number of adjustment steps is determined based on the difference between the two sets of electrical parameters; the larger the difference, the more adjustment steps are required. The amount of power change remains consistent in each adjustment step to ensure a linear and smooth transition of power changes.

8. The fault repair and detection system for a display screen LCD module according to claim 1, characterized in that, When the load testing device performs a gradual adjustment of the load power, it adopts a proportional adjustment method based on the difference in electrical parameters: Calculate the difference in the first electrical parameter between the current module and the next module; The power adjustment speed is determined based on the magnitude of the difference; the smaller the difference, the slower the adjustment speed. The power adjustment process should be carried out at a constant speed to avoid sudden changes in speed.

9. The fault repair and detection system for a display screen LCD module according to claim 1, characterized in that, When the scheduling system performs a complete group transfer, it adopts an inter-group connection control method: Before the current group of tests is completed, check the test readiness status of the next group. If the next group is ready, the next group test will begin immediately after the current group is transferred. If the next group is not ready, the testing process is paused until it is ready.

10. A fault repair and detection system for a display screen liquid crystal module according to claim 9, characterized in that, Intergroup articulation control methods also include: When multiple groups are waiting to be tested, the group with the smallest difference in electrical parameters from the group that has just been completed will be selected as the next test group. By minimizing the differences in electrical parameters between groups, the magnitude of power switching across levels is reduced.

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