Acupuncture type needle feeding amount displacement compensation method, device and equipment and storage medium

Abstract

The invention discloses a needling type needle feeding amount displacement compensation method, device and equipment and a storage medium, and relates to the technical field of intelligent control. According to the method, needle point target displacement data is set based on the chip transfer technology requirement, and a driving mechanism drives a needle point to move towards a target substrate; real-time displacement data of the transfer needle tip are detected in real time through the capacitance sensor assembly by utilizing capacitance value change caused by electrode surface distance change; comparing the real-time displacement with the target displacement to obtain an error value, and processing the error value through a PID control algorithm to generate an adjusting signal; the driving mechanism adopts a double-closed-loop framework, the motion state is adjusted according to an adjusting signal, dynamic compensation is achieved, the technology further integrates environmental factor compensation, multi-section control and a fault-tolerant mechanism, it is ensured that real-time displacement is consistent with target displacement, the problem of displacement deviation caused by uneven substrates, environmental interference and the like is solved, and the working efficiency is improved. And the chip transfer precision and the process stability are improved, and the mass production requirements of high-end display devices are met.

Description

Technical Field

[0001] This application relates to the field of intelligent control technology, and in particular to a method, device, equipment and storage medium for needle displacement compensation in needle-type needle insertion. Background Technology

[0002] In the field of MiniLED mass transfer, needle-type transfer technology has become the core solution for high-speed transfer of small-sized chips and large-sized substrates due to its advantages of compact equipment, high efficiency and strong adaptability. Its transfer efficiency far exceeds that of the traditional Pick & Place method and it is widely used in mass production scenarios of high-end display devices such as medical displays and automotive displays. However, this technology faces the hidden technical problem of dynamic displacement deviation accumulation in the actual mass production process. Existing solutions are difficult to solve the problem of needle precision loss caused by multi-factor coupling. Current needle-punching transfer systems mostly employ open-loop control or simple closed-loop architectures, relying solely on motor encoders for coarse positioning. They fail to consider dynamic variables such as differences in the microscopic flatness of the PCB substrate surface, fatigue deformation of elastic components, and rebound during high-speed movement. These factors cause deviations between the actual needle penetration and the target value, and these deviations are random and cumulative. Traditional fixed-parameter control cannot adapt in real time. Furthermore, changes in ambient temperature can cause drift in the capacitive sensing coefficient and thermal expansion and contraction of mechanical components, further amplifying displacement errors. The jitter interference generated during high-speed transfer can distort sensor signals. This affects the accuracy of displacement detection. In addition, the existing system lacks a flexible fault tolerance mechanism and multi-scenario adaptability. When the sensing signal is abnormal or the mechanism malfunctions, process defects such as chip crushing, leakage, and poor contact are prone to occur, which seriously restricts the mass production yield and process stability and cannot meet the stringent accuracy requirements of MiniLED chip transfer. Therefore, it is urgent to build a closed-loop compensation mechanism based on dynamic sensing feedback, which can monitor and automatically adjust the actual needle insertion amount in real time, solve the problems of dynamic displacement deviation, environmental interference and insufficient fault tolerance in needle transfer, and thus improve accuracy and process consistency. Summary of the Invention

[0003] The needle-type needle displacement compensation method, apparatus, device, and storage medium provided in this application realize the detection of real-time displacement data of the transfer needle tip by the capacitance value change caused by the change in the distance between the two electrode surfaces of the capacitive sensor, thereby improving the chip transfer accuracy and process stability.

[0004] In a first aspect, embodiments of this application provide a method for compensating for needle displacement in acupuncture-type needle insertion, applied to a needle transfer device. The needle transfer device integrates a transfer mechanism, which includes a drive mechanism, a transfer needle tip, and a sensor assembly. The method includes: Obtain the target displacement data set for controlling the transfer tip transfer, the target displacement data being determined based on the chip transfer process requirements; The drive mechanism is activated to move the transfer needle tip toward the target substrate. The sensor assembly detects the real-time displacement data of the transfer needle tip in real time, and the sensor assembly generates a sensing signal based on the position change of the transfer needle tip. The real-time displacement data is compared with the target displacement data to obtain the displacement error value; The displacement error value is calculated based on a preset control algorithm to obtain an adjustment signal; The adjustment signal controls the drive mechanism to correct the position of the transfer needle tip so that the position of the transfer needle tip is consistent with the position corresponding to the target displacement data.

[0005] Furthermore, the sensor assembly includes a capacitive sensor, which includes two opposing electrode surfaces, the two electrode surfaces being connected to the connecting rod of the drive mechanism and the elastic component of the transfer needle tip, respectively; The step of detecting the real-time displacement data of the transfer needle tip through the sensor assembly includes: When the movement of the transfer needle tip causes the elastic component to deform, resulting in a change in the distance between the two electrode surfaces, the capacitance change signal detected by the capacitive sensor is conditioned and processed, and converted into corresponding real-time displacement data.

[0006] Further, the calculation of the displacement error value based on the preset control algorithm to obtain the adjustment signal includes: The displacement error value is calculated using a PID control algorithm, and the proportional parameter, integral parameter, and derivative parameter are dynamically adjusted according to the magnitude and trend of the calculated displacement error value. The calculation result is determined based on the convergence threshold of the displacement error value, and the adjustment signal for adjusting the motion amplitude and speed of the drive mechanism is generated by dynamically adjusting the proportional parameter, integral parameter and differential parameter.

[0007] Furthermore, before comparing the real-time displacement data with the target displacement data, the method further includes: Environmental parameters are collected in real time using environmental sensing components; Based on the correlation between the environmental parameters and the displacement error value, the calculation parameters of the PID control algorithm are corrected.

[0008] Furthermore, after correcting the operational parameters of the PID control algorithm, the method further includes: The movement of the transfer needle tip is divided into multiple displacement intervals, and a corresponding control parameter group is set for each displacement interval. The displacement range of the transfer needle tip is determined in real time, and the corresponding displacement range control parameter group is called to process and adjust the displacement error value.

[0009] Furthermore, after invoking the corresponding displacement interval control parameter group to process and adjust the displacement error value, the method further includes: Real-time monitoring of the signal status of the sensor components and the operating status of the drive mechanism; When the signal status is detected as abnormal or the operating status is detected as faulty, switch to auxiliary detection mode to obtain displacement data, or control the drive mechanism to enter a safe operating state; The compensation control can continue based on the auxiliary displacement data, or a fault alarm signal can be issued.

[0010] Furthermore, the drive mechanism adopts a dual closed-loop control architecture, in which the outer loop is a position control loop and the inner loop is a current control loop; the adjustment signal is input to the driver of the drive mechanism, and the driver adjusts the output current through pulse width modulation to control the movement amplitude and speed of the drive mechanism; The step of controlling the drive mechanism to correct the position of the transfer needle tip according to the adjustment signal includes: After receiving the adjustment signal command, the drive mechanism adjusts the output force or movement speed of the drive mechanism based on the adjustment signal command, thereby driving the transfer needle tip to adjust its displacement so that the position of the transfer needle tip is consistent with the position corresponding to the target displacement data.

[0011] In a second aspect, embodiments of this application provide a needle-type transfer compensation device applied to a needle-type transfer device. The needle-type transfer device integrates a transfer mechanism, which includes a drive mechanism, a transfer needle tip, and a sensor assembly, comprising: The acquisition module is used to acquire the target displacement data set for controlling the transfer tip transfer, wherein the target displacement data is determined based on the chip transfer process requirements. The drive module is used to activate the drive mechanism to drive the transfer needle tip to move toward the target substrate. The detection module is used to detect the real-time displacement data of the transfer needle tip through the sensor component, and the sensor component generates a sensing signal based on the position change of the transfer needle tip. The comparison module is used to compare the real-time displacement data with the target displacement data to obtain the displacement error value; The calculation module is used to calculate the displacement error value based on a preset control algorithm to obtain an adjustment signal; The correction module is used to control the drive mechanism to correct the position of the transfer needle tip according to the adjustment signal, so that the position of the transfer needle tip is consistent with the position corresponding to the target displacement data.

[0012] In a third aspect, embodiments of this application provide an electronic device, including: a memory and one or more processors; the memory is used to store one or more programs; When the one or more programs are executed by the one or more processors, the one or more processors implement the needle displacement compensation method as described in the first aspect.

[0013] In a fourth aspect, embodiments of this application provide a storage medium for storing computer-executable instructions, which, when executed by a computer processor, are used to perform the needle displacement compensation method as described in the first aspect.

[0014] This embodiment employs a capacitive sensor assembly, connecting two electrode surfaces to the drive mechanism connecting rod and the transfer needle tip elastic component, respectively. When the transfer needle tip moves, causing deformation of the elastic component, the change in electrode surface spacing alters the capacitance value. After signal conditioning, this is accurately converted into real-time displacement data, with measurement errors controlled within ±1μm. Combined with a PID control algorithm, real-time comparison of real-time displacement and target displacement is performed, dynamically adjusting proportional, integral, and derivative parameters. The drive mechanism uses a dual closed-loop architecture (outer loop position control, inner loop current control) and PWM pulse width modulation to adjust the current, achieving micron-level dynamic compensation. This solves the problems of inconsistent needle depth caused by PCB substrate unevenness, elasticity errors, and mechanism rebound, reducing process defects such as puncture deviation, pressure damage, and missed bonding, thus improving chip transfer accuracy and mass production yield. An environmental factor compensation step is added, which collects parameters through environmental sensing components and corrects PID calculation parameters or displacement error values ​​to offset the interference of temperature drift and humidity changes on sensing accuracy. At the same time, multi-segment compensation control calls the corresponding parameter group according to the displacement range to adapt to the accuracy requirements of different movement stages of the transfer needle tip, further enhancing process stability and consistency. Due to the integration of a fault-tolerant control mechanism, the sensing signals and drive mechanism status are monitored in real time. In case of abnormality, the auxiliary detection mode is switched or the safe state is entered to avoid workpiece damage caused by the expansion of the fault. The modular design allows for flexible replacement of capacitive sensors, control algorithms, and drive structures, which can not only adapt to the transfer requirements of different types and sizes of chips, but also facilitate integration into intelligent production lines and reserve space for automation upgrades. It comprehensively realizes the technical advantages of high precision, high stability, and high adaptability. Attached Figure Description

[0015] Figure 1 This is a flowchart of the needle insertion displacement compensation method provided in the embodiments of this application; Figure 2This is a schematic diagram of the needle-type transfer method provided in the embodiments of this application; Figure 3 This is a schematic diagram of the sensor assembly structure provided in an embodiment of this application; Figure 4 This is a schematic diagram of the sensor assembly provided in the embodiments of this application completing closed-loop control; Figure 5 This is a structural diagram of the needle-type transfer compensation device provided in the embodiments of this application; Figure 6 This is a structural diagram of an electronic device provided in an embodiment of this application.

[0016] Among them, 201 is the driving mechanism; 202 is the transfer needle tip; 203 is the MiniLED chip; 204 is the PCB substrate; 301 is the connecting rod; 302 is the circuit board; 303 is the lower electrode surface of the connecting rod; 304 is the upper electrode surface of the elastic component; 305 is the piercing needle; 306 is the elastic component; and 307 is the toolbit. Detailed Implementation

[0017] To make the objectives, technical solutions, and advantages of this application clearer, specific embodiments of this application will be described in further detail below with reference to the accompanying drawings. It should be understood that the specific embodiments described herein are merely for explaining this application and not for limiting it. It should also be noted that, for ease of description, only the parts relevant to this application are shown in the drawings, not all of them. Before discussing exemplary embodiments in more detail, it should be mentioned that some exemplary embodiments are described as processes or methods depicted as flowcharts. Although the flowcharts describe operations (or steps) as sequential processes, many of these operations can be performed in parallel, concurrently, or simultaneously. Furthermore, the order of the operations can be rearranged. The process can be terminated when its operation is completed, but additional steps not included in the drawings may also be present. The above processes can correspond to methods, functions, procedures, subroutines, subroutines, etc.

[0018] The terms "first," "second," etc., used in the specification and claims of this application are used to distinguish similar objects and not to describe a specific order or sequence. It should be understood that such use of data can be interchanged where appropriate so that embodiments of this application can be implemented in orders other than those illustrated or described herein, and the objects distinguished by "first," "second," etc., are generally of the same class and the number of objects is not limited; for example, a first object can be one or more. Furthermore, in the specification and claims, "and / or" indicates at least one of the connected objects, and the character " / " generally indicates that the preceding and following objects are in an "or" relationship. In the field of MiniLED mass transfer, needle-punch transfer technology has become the core solution for high-speed transfer of small-sized chips to large-sized substrates due to its advantages of compact equipment, high efficiency, and strong adaptability. Its transfer efficiency far exceeds that of the traditional pick and place method. However, this technology faces many hidden technical problems in actual mass production: existing systems mostly adopt open-loop control or simple closed-loop architecture, relying only on motor encoders for coarse positioning, without considering dynamic variables such as the microscopic flatness difference of the PCB substrate surface, fatigue deformation of elastic components, and high-speed rebound of the mechanism. This leads to random and cumulative deviations between the actual needle penetration and the target value. Changes in ambient temperature can cause drift in the capacitance sensing coefficient and thermal expansion and contraction of mechanical components, further amplifying displacement errors. Jitter interference during high-speed transfer can distort sensor signals, affecting displacement detection accuracy. In addition, existing systems lack flexible fault-tolerance mechanisms. When the sensing signal is abnormal or the mechanism malfunctions, process defects such as chip damage, leakage, and poor contact can easily occur, severely restricting mass production yield and process stability, and failing to meet the stringent accuracy requirements of MiniLED chip transfer. Therefore, it is urgent to build a closed-loop compensation mechanism based on dynamic sensing feedback to achieve real-time monitoring and automatic adjustment of the actual needle insertion amount. Figure 1 This is a flowchart of the needle displacement compensation method provided in the embodiments of this application. Please refer to [link / reference]. Figure 1 This method achieves dynamic compensation of the needle tip transfer volume through closed-loop control of target setting, motion initiation, real-time detection, error calculation, and adjustment correction. The specific steps are as follows: Step 101: Obtain the target displacement data set for controlling the transfer tip transfer. The target displacement data is determined based on the chip transfer process requirements.

[0019] In one embodiment, target displacement data for controlling the transfer tip 202 is acquired. This target displacement data is determined based on the requirements of the chip transfer process. For example, for MiniLED chips 203 of different sizes, such as 0.1mm×0.1mm and 0.2mm×0.2mm, different types of PCB substrates 204, and different pad spacings, the pin depth is preset through the process parameter configuration interface, such as 50μm, 80μm, and 100μm. This data is stored in the system memory and supports real-time modification and retrieval. The target displacement data is stored in 32-bit floating-point format to ensure that the micron-level transfer requirements are met. Step 102: Start the drive mechanism to move the transfer needle tip toward the target substrate.

[0020] The drive mechanism 201 drives the transfer needle tip 202 to move towards the target substrate (PCB substrate 204). The drive mechanism 201 adopts a voice coil motor control module, which has the characteristics of fast response speed and high positioning accuracy. Its motion command is issued by the main controller through an industrial bus, such as RS-485, CAN bus or SPI. The control signal is a PWM (pulse width modulation) signal with a frequency range of 1kHz-10kHz. The motor speed and output force are controlled by adjusting the duty cycle. In the initial stage of motion, the drive mechanism 201 drives the transfer needle tip 202 to approach the target substrate at a preset fast feed speed, such as 1mm / s. When it approaches the preset deceleration threshold, such as 200μm away from the substrate surface, it automatically switches to a low feed speed, such as 0.1mm / s, to avoid high-speed collisions that may damage the chip or substrate.

[0021] Step 103: The sensor assembly detects the real-time displacement data of the transfer needle tip in real time, and the sensor assembly generates a sensing signal based on the position change of the transfer needle tip.

[0022] In one embodiment, the real-time displacement data of the transfer needle tip 202 is detected by a sensor component. The sensor component generates a sensing signal based on the position change of the transfer needle tip 202. The sensor component adopts a capacitive sensor, which realizes displacement detection by the change in capacitance value caused by the change in electrode surface spacing. The detection accuracy can reach ±1μm, the total measurement stroke is 1mm, and the repeatability is 3.76μm. It can accurately capture the tiny displacement changes of the needle tip. The detected capacitance value change signal is processed by the signal conditioning circuit and converted into a digital signal and transmitted to the main controller. The sampling frequency is 10kHz to ensure real-time performance.

[0023] Step 104: Compare the real-time displacement data with the target displacement data to obtain the displacement error value.

[0024] In one embodiment, the real-time displacement data is compared with the target displacement data to obtain the displacement error value. Optionally, the main controller has a built-in data comparison unit that uses a difference algorithm to calculate the error. The formula is: Error value = Target displacement data - Real-time displacement data. For example, if the target displacement is 100μm and the real-time detected displacement is 98.5μm, then the error value is 1.5μm; if the real-time detected displacement is 101.2μm, then the error value is -1.2μm. The error value is stored in 32-bit signed floating-point format, retaining three decimal places to ensure calculation accuracy.

[0025] Step 105: Calculate the displacement error value based on the preset control algorithm to obtain the adjustment signal.

[0026] In one embodiment, the displacement error value is calculated based on a preset control algorithm to obtain an adjustment signal. A PID control algorithm is used to dynamically adjust the proportional (P), integral (I), and derivative (D) parameters according to the magnitude and trend of the error value, generating an adjustment signal for adjusting the motion amplitude and speed of the drive mechanism 201. The adjustment signal is an analog voltage signal (0-5V) or a digital pulse signal, corresponding to the displacement adjustment amount and speed adjustment coefficient of the drive mechanism 201, ensuring the accuracy and smoothness of the adjustment. Step 106: Control the drive mechanism to correct the position of the transfer needle tip according to the adjustment signal, so that the position of the transfer needle tip is consistent with the position corresponding to the target displacement data.

[0027] In one embodiment, the position of the transfer needle tip 202 is corrected by the control drive mechanism 201 according to the adjustment signal so that the position of the transfer needle tip 202 is consistent with the position corresponding to the target displacement data. The drive mechanism 201 adopts a dual closed-loop control architecture. After receiving the adjustment signal, it drives the transfer needle tip 202 to perform micron-level displacement adjustment by adjusting the output force or movement speed. During the correction process, the sensor component continuously detects the real-time displacement data to form a closed-loop feedback until the error value converges to a preset threshold, such as within ±1.5μm, and completes one compensation process. As can be seen from the above, Figure 1 The corresponding specific implementation method constructs a complete control link of target, detection and correction through closed-loop control process, which solves the problem of insufficient accuracy of open-loop control. Its role in the overall scheme is to set up a logical framework for dynamic compensation, organically combine the scattered hardware components through process steps, and realize full automation from parameter setting to position correction.

[0028] By setting target displacement data, the needle depth adaptability under different process requirements is ensured; with the help of high-speed real-time detection and error calculation, micron-level error identification is achieved; through the combination of PID algorithm and dual closed-loop drive, high-precision position correction is achieved, reducing process defects such as puncture deviation and pressure damage, and providing a more stable basic framework for its functional expansion.

[0029] In one embodiment, the sensor assembly includes a capacitive sensor, which includes two opposing electrode surfaces connected to a connecting rod of the drive mechanism and an elastic component of the transfer needle tip, respectively. The sensor assembly detects the real-time displacement data of the transfer needle tip, including: When the movement of the transfer needle tip causes the elastic component to deform, resulting in a change in the distance between the two electrode surfaces, the capacitance change signal detected by the capacitive sensor is conditioned and processed, and converted into corresponding real-time displacement data.

[0030] A capacitive sensor is a device that detects displacement based on the principle of capacitance change. Its core consists of two opposing electrode surfaces. Changes in the distance between the electrode surfaces directly lead to changes in capacitance. The elastic component 306 is a miniature compression spring used to buffer and transfer the contact pressure of the needle tip 202 and transmit displacement changes.

[0031] The sensor assembly is a capacitive sensor. The two electrode surfaces are fixed to the lower end of the connecting rod of the drive mechanism 201 and the upper end of the elastic component of the transfer needle tip 202, respectively. When the transfer needle 202 moves, it will cause the elastic component 306 to deform, causing a slight change in the distance between the two electrode surfaces, which in turn causes a change in capacitance. After the capacitive sensor detects the capacitance change signal, it will transmit it to the signal conditioning module. After being amplified by the instrumentation amplifier (amplification factor 1000 times) and filtered by the low-pass filter (cutoff frequency 1kHz), it is converted into a digital signal by the 16-bit ADC analog-to-digital converter, and finally converted into the corresponding real-time displacement data to ensure that the detection accuracy reaches ±1μm.

[0032] The precise design of the capacitive sensor solves the problems of insufficient accuracy and slow response of traditional displacement detection methods. The collaborative design of the dual electrode surface and the elastic component 306 enables precise capture of micron-level displacement with a detection accuracy of ±1μm, providing a data foundation for closed-loop compensation. The optimized signal conditioning process effectively suppresses noise interference and ensures the stability of the detection signal. The overall structure is adaptable to the narrow installation space of the needle-type transfer equipment and does not affect the normal chip transfer process.

[0033] In one embodiment, the displacement error value is calculated based on a preset control algorithm to obtain an adjustment signal, including: using a PID control algorithm to calculate the displacement error value, and dynamically adjusting the proportional parameter, integral parameter, and derivative parameter according to the magnitude and trend of the calculated displacement error value; The calculation result is determined based on the convergence threshold of the displacement error value, and the adjustment signal for adjusting the motion amplitude and speed of the drive mechanism is generated by dynamically adjusting the proportional parameter, integral parameter and differential parameter.

[0034] The PID control algorithm is a combination of proportional, integral, and derivative parameters. It achieves rapid convergence of errors by dynamically adjusting these three parameters. The convergence threshold of the displacement error value is the critical value for judging whether the error meets the accuracy requirements.

[0035] When the PID control algorithm is used to calculate the displacement error value, the magnitude and trend of the error value are monitored in real time: when the error value is large (e.g., >5μm), the proportional parameter (P) is increased to speed up the response; when the error persists (e.g., error >1μm for 5 consecutive sampling periods), the integral parameter (I) is increased to eliminate static error; when the error changes rapidly (e.g., error difference between adjacent sampling periods >2μm), the derivative parameter (D) is increased to suppress overshoot. The calculation result is judged according to the convergence threshold of the displacement error value. When the error value falls within ±1.5μm, a stable adjustment signal is generated; if it does not fall within this range, the P, I, and D parameters are continuously and dynamically adjusted until an adjustment signal that can accurately adjust the motion amplitude and speed of the drive mechanism 201 is generated.

[0036] By dynamically adjusting PID parameters, the limitations of poor adaptability of fixed parameter control are overcome. Based on real-time adaptation to the magnitude and trend of error, rapid convergence and stable control of error are achieved, avoiding overshoot and oscillation. The setting of the convergence threshold for displacement error value clarifies the compensation accuracy standard, ensuring that the final needle tip position error is controlled within ±1.5μm. The algorithm has high computational efficiency, capable of completing parameter adjustment and adjustment signal generation within milliseconds, meeting the requirements of real-time compensation.

[0037] In one embodiment, before comparing the real-time displacement data with the target displacement data, the method further includes: acquiring environmental parameters in real time through an environmental sensing component; Based on the correlation between the environmental parameters and the displacement error value, the calculation parameters of the PID control algorithm are corrected.

[0038] Environmental sensing components are devices used to collect environmental parameters such as temperature and humidity, including temperature sensors (measurement range -10℃ to 60℃, accuracy ±0.5℃) and humidity sensors (measurement range 20% to 80% RH, accuracy ±5% RH); the correlation database is a dataset of the correspondence between environmental parameters and displacement errors established through experiments.

[0039] Before comparing the real-time displacement data with the target displacement data, environmental parameters are collected in real time at a sampling frequency of 1Hz by an environmental sensing component and transmitted to the main controller via the I2C bus. The main controller queries the correlation database. For example, for every 10°C increase in temperature, the capacitance sensing coefficient drifts by 0.8%, and the corresponding displacement error increases by 0.8μm. The error correction value is calculated based on the current environmental parameters, and then the P, I, and D operation parameters of the PID control algorithm are corrected to counteract the interference of environmental factors on the detection accuracy.

[0040] The environmental factor compensation mechanism effectively offsets the sensing errors caused by temperature and humidity changes, solving the problem of accuracy drift caused by environmental interference in traditional systems. The establishment of the correlation database is based on a large amount of experimental data, ensuring the accuracy of error correction. The compensation process is carried out in real time without affecting the efficiency of the normal transfer process. By correcting the PID calculation parameters instead of directly correcting the displacement data, the continuity and stability of the control logic are guaranteed, and the process consistency of the system in complex environments is improved.

[0041] In one embodiment, after correcting the operational parameters of the PID control algorithm, the method further includes: The movement of the transfer needle tip is divided into multiple displacement intervals, and a corresponding control parameter group is set for each displacement interval. The displacement range of the transfer needle tip is determined in real time, and the corresponding displacement range control parameter group is called to process and adjust the displacement error value.

[0042] The displacement range is divided into different stages based on the movement stroke of the transfer needle tip 202. In this application, the 0-500μm stroke is divided into a rapid feed range (0-200μm), a deceleration range (200-400μm), and a precision compensation range (400-500μm). The control parameter group is a combination of PID parameters preset for each range.

[0043] After correcting the calculation parameters of the PID control algorithm, the displacement range of the transfer needle tip 202 is determined in real time: when in the rapid feed range, the parameter set P=0.8, I=0.05, D=0.1 is called to prioritize the movement speed; when in the deceleration range, the parameter set P=1.2, I=0.1, D=0.3 is called to balance speed and accuracy; when in the precision compensation range, the parameter set P=1.5, I=0.2, D=0.5 is called to prioritize accuracy. The control effect of different motion stages is improved through targeted parameter configuration.

[0044] The design of multi-segment compensation control achieves precise adaptation to different motion stages, solving the problem that traditional single-parameter control cannot balance speed and accuracy. Parameter groups are customized for the functional requirements of each interval, ensuring transfer efficiency in the rapid feed interval and improving positioning accuracy in the precise compensation interval. Interval judgment and parameter switching are completed in real time without significant delay, ensuring the smoothness of the motion process. This design enables the system to dynamically adjust the control strategy according to the needle tip motion state, further improving the overall solution's process adaptability and compensation accuracy.

[0045] In one embodiment, after invoking the corresponding displacement interval control parameter group to process and adjust the displacement error value, the method further includes: Real-time monitoring of the signal status of the sensor components and the operating status of the drive mechanism; When the signal status is detected as abnormal or the operating status is detected as faulty, switch to auxiliary detection mode to obtain displacement data, or control the drive mechanism to enter a safe operating state; The compensation control can continue based on the auxiliary displacement data, or a fault alarm signal can be issued.

[0046] Signal status includes indicators such as signal amplitude and signal stability. The normal signal amplitude range is 0.5V-4.5V, and the signal fluctuation frequency is ≤1kHz. Operating status includes parameters such as motor current and movement speed. The rated motor current is ≤5A, and the deviation between the movement speed and the command speed is ≤10%. The auxiliary detection mode refers to the backup detection method that obtains displacement data through the encoder of the drive mechanism 201.

[0047] After calling the corresponding parameter group for error processing, the signal status of the sensor components and the operating status of the drive mechanism 201 are monitored in real time: if the sensor signal amplitude exceeds the range of 0.5V-4.5V or the fluctuation frequency is >1kHz, it is determined to be a signal abnormality, and the auxiliary detection mode is switched to continue to perform compensation control by obtaining displacement data through the encoder; if the motor current is >5A or the movement speed deviation is >10%, it is determined to be an operating fault, and the drive mechanism is controlled to stop urgently or return to the initial position. At the same time, an alarm signal is issued by flashing indicator lights, sounding a buzzer alarm, and displaying a fault code on the display screen, and the fault information is stored for troubleshooting.

[0048] The fault-tolerant control mechanism enhances the system's reliability and security, resolving the issue of traditional systems being prone to downtime or workpiece damage under abnormal conditions. The auxiliary detection mode switching in case of signal abnormalities ensures the continuity of the compensation process and avoids production interruptions caused by single detection failures. The safety control strategy in case of operational failures effectively protects the transfer equipment, MiniLED chip 203, and PCB substrate 204, reducing production losses. The fault alarm and information storage functions facilitate maintenance personnel in quickly locating and troubleshooting problems, improving the system's maintainability.

[0049] In one embodiment, the drive mechanism adopts a dual closed-loop control architecture, wherein the outer loop is a position control loop and the inner loop is a current control loop; the adjustment signal is input to the driver of the drive mechanism, and the driver adjusts the output current through pulse width modulation to control the movement amplitude and speed of the drive mechanism; Controlling the drive mechanism to correct the position of the transfer needle tip according to the adjustment signal includes: After receiving the adjustment signal command, the drive mechanism adjusts the output force or movement speed of the drive mechanism based on the adjustment signal command, thereby driving the transfer needle tip to adjust its displacement so that the position of the transfer needle tip is consistent with the position corresponding to the target displacement data.

[0050] The dual-loop control architecture refers to a nested control structure consisting of an outer loop (position control loop) and an inner loop (current control loop); PWM pulse width modulation is a control method that adjusts the output current by adjusting the pulse duty cycle.

[0051] After receiving the adjustment signal command, the drive mechanism 201 compares the target displacement with the real-time feedback value and outputs a speed control signal; the inner current control loop detects the motor coil current and adjusts the output current through PWM to ensure that the motor output force matches the control quantity. According to the adjustment signal, the output force of the drive mechanism (adjustment range 0.5N-50N) or the movement speed (adjustment range 0.01mm / s-1mm / s) is adjusted to drive the transfer needle tip 202 to adjust the displacement until the needle tip position is consistent with the target displacement data.

[0052] By designing a dual-closed-loop control architecture, the problems of insufficient precision and lag in traditional single-loop control are solved. The outer loop position control loop ensures the accuracy of the needle tip position, while the inner loop current control loop optimizes the dynamic response and output stability of the motor, avoiding phenomena such as motor stall and overshoot. The application of PWM pulse width modulation enables fine adjustment of output force and speed, adapting to different displacement adjustment requirements. The parameter adjustment range of the drive mechanism 201 is wide, which can meet the transfer requirements of chips of different sizes and substrate types.

[0053] Figure 2 This is a schematic diagram of the needle-type transfer method provided in the embodiments of this application. Please refer to [link / reference]. Figure 2 It includes a driving mechanism 201, a transfer tip 202, a MiniLED chip 203, and a PCB substrate 204. These components work together to pick up and transfer the chip, specifically including: The drive mechanism 201 is a voice coil motor control module used to control the vertical movement and positioning accuracy of the transfer needle tip 202. The stator of the voice coil motor is fixed to the equipment frame, and the rotor is connected to the Toolbit 307 (including the elastic component 306 and the needle 305) through the connecting rod 301. It adopts linear guide rail guidance to ensure the straightness and stability of the movement. The motor's drive current range is 0-5A, and the maximum output force is 50N, which can meet the compression requirements of different elastic components. The movement stroke range is 0-5mm, and the positioning accuracy can reach ±2μm. It supports fast response and micro displacement adjustment.

[0054] The transfer tip 202 is made of tungsten carbide with a tip diameter of 50μm-100μm. The surface is polished to reduce friction damage with the chip. The transfer tip 202 has a built-in elastic component 306, such as a miniature spring, with an elastic coefficient of 1N / mm-5N / mm. When picking up the chip, it generates appropriate pressure through elastic deformation, such as 0.5N-2N, to ensure reliable contact between the chip and the transfer tip 202, while avoiding damage to the chip. The transfer tip 202 and Toolbit 307 are detachably connected, which makes it easy to replace the tip with different specifications according to the chip size. MiniLED chips 203 are the transfer targets, arranged in an array on the wafer. The chip size ranges from 0.05mm×0.05mm to 0.3mm×0.3mm, and the thickness is 20μm-50μm. Metal electrodes are provided on the chip surface to form electrical connections with the pads of the PCB substrate 204. During the transfer process, it is necessary to ensure the precise alignment of the chip electrodes and the pads, with an alignment accuracy requirement of ≤±5μm. PCB substrate 204 is the target substrate for mounting. Its surface includes structures such as pads and circuit vias. The pad size matches the electrode size of MiniLED chip 203. The pad spacing is determined according to the chip array layout. PCB substrate 204 is fixed on the worktable by a vacuum adsorption device. The worktable has a horizontal adjustment function to initially calibrate the macro flatness of the substrate, but it cannot eliminate the micro surface height difference (usually ±10μm-±50μm). This is also the problem that needs to be solved by dynamic compensation in this application. Transfer process: The drive mechanism 201 drives the transfer tip 202 downward. After the transfer tip 202 contacts the MiniLED chip 203, the elastic component 306 compresses to generate pressure, causing the chip to separate from the wafer. Subsequently, the drive mechanism 201 drives the transfer tip 202 and the chip to move towards the PCB substrate 204. When it approaches the surface of the PCB substrate 204, the system starts the dynamic compensation process, which uses sensor components to detect the displacement of the transfer tip 202 in real time and corrects the insertion depth. Finally, the transfer tip 202 precisely presses the chip onto the target pad of the PCB substrate, completing the transfer.

[0055] As can be seen from the above, Figure 2 The corresponding structural implementation provides hardware support for the overall solution, clarifies the selection, parameters and collaborative logic of core components, and its role in the overall solution is to transform abstract compensation requirements into specific hardware implementations, and ensure the feasibility of the compensation function through precise matching of each component.

[0056] The voice coil motor selection of the drive mechanism 201 ensures rapid response and micro-displacement adjustment capabilities, providing power for real-time compensation; the material and elastic design of the transfer tip 202 balances contact reliability and chip protection, reducing the risk of crushing; the fixation and preliminary calibration of the PCB substrate reduce macroscopic errors, laying the foundation for microscopic dynamic compensation; the collaborative work of each component upgrades chip transfer from rough placement to precise bonding, improving the stability and reliability of the transfer process.

[0057] Figure 3 This is a schematic diagram of the sensor assembly structure provided in an embodiment of this application. Please refer to it. Figure 3 The detailed structure of the sensor assembly includes a connecting rod 301, a circuit board 302, a lower electrode surface 303 of the connecting rod, a toolbit 307, an upper electrode surface 304 of the elastic component, an elastic component 306, and a needle 305. This assembly achieves displacement detection based on the capacitive sensing principle, specifically including: The connecting rod 301 is connected to the rotor of the drive mechanism 201. It is made of aluminum alloy, which is lightweight and high-strength. Its length is 50mm-100mm, ensuring the flexibility and stability of the movement. Circuit board 302 integrates a capacitance detection circuit and a signal conditioning circuit, and is fixed in the middle of the connecting rod 301. It communicates with the main controller through wires and is used to convert the capacitance value change signal into a digital displacement signal.

[0058] The lower electrode surface 303 of the connecting rod is a circular metal electrode, fixed to the lower end surface of the connecting rod 301. It is made of copper and has a gold-plated surface to reduce the impact of oxidation and ensure the stability of capacitance detection. Toolbit 307 is a tiny mechanical structure made of stainless steel. It has an internal mounting cavity to accommodate the elastic component 306 and the needle 305. Its upper end is fixedly connected to the upper end of the elastic component 306.

[0059] The upper electrode surface 304 of the elastic component and the lower electrode surface 303 of the connecting rod are arranged opposite to each other. They are also circular metal electrodes, fixed to the upper surface of the Toolbit 307. The initial distance between them and the lower electrode surface 303 of the connecting rod is 1mm, forming two plates of the capacitive sensor.

[0060] The elastic component 306 is a miniature compression spring with an elastic coefficient of 2N / mm and a stroke range of 0-1mm. It is sleeved on the upper part of the needle 305 to buffer the contact pressure between the needle 305 and the chip and substrate. At the same time, its deformation will drive the upper electrode surface 304 of the elastic component to move, changing the distance between it and the lower electrode surface 303 of the connecting rod. The needle 305, which is the tip of the transfer needle 202, is made of tungsten steel and is fixed to the lower end of the toolbit 307. The tip is used to pick up and transfer the MiniLED chip 203. Sensing principle: When the needle 305 moves and causes the elastic component 306 to deform, the distance between the upper electrode surface 304 of the elastic component and the lower electrode surface 303 of the connecting rod changes, resulting in a change in the capacitance value of the capacitor formed by the two electrode surfaces. The capacitance value is inversely proportional to the electrode distance, and the relationship formula is as follows: (Where C is the capacitance value, ε is the dielectric constant, S is the electrode area, and d is the electrode spacing). By detecting the change in capacitance value, the change in electrode spacing can be calculated in reverse, thereby obtaining the real-time displacement data of the needle 305.

[0061] Signal processing flow: The capacitance change signal detected by the capacitive sensor is a weak analog signal (mV level). After being amplified by the instrumentation amplifier on the circuit board 302 (amplification factor of 1000 times) and filtered by the low-pass filter (cutoff frequency of 1kHz), it is converted into a digital signal by the ADC (analog-to-digital converter with sampling accuracy of 16 bits) and then transmitted to the main controller for data processing, which converts it into corresponding real-time displacement data. The delay of the entire signal processing process is ≤100μs to ensure the real-time performance of the detection.

[0062] As can be seen from the above, Figure 3 The corresponding sensor component implementation is the carrier of the real-time detection function in the overall scheme. Its role in the overall scheme is to provide a high-precision, low-latency displacement detection method and provide data input for closed-loop compensation.

[0063] By integrating the dual electrode surface with the elastic component 306, mechanical displacement is converted into capacitance change, achieving a detection accuracy of ±1μm and meeting the micron-level compensation requirements. The integrated signal conditioning design of the circuit board 302 effectively suppresses noise interference and ensures the stability of signal transmission. The fast signal processing flow (delay ≤100μs) ensures the real-time performance of the detection, enabling the compensation adjustment to respond promptly to changes in the position of the transfer needle tip 202 and avoid error accumulation. The design of this component transforms the high-precision compensation goal of the overall scheme from theory to reality.

[0064] Figure 4 This is a schematic diagram of the sensor assembly provided in this application for completing closed-loop control. Please refer to [link / reference]. Figure 4 Its complete architecture for closed-loop control via capacitive sensors includes a drive mechanism 201, a PID control algorithm, a connecting rod 301, capacitive sensor position feedback, an elastic component 306, a transfer needle tip 202, target displacement data, a MiniLED chip 203, and a PCB substrate 204. These components work together to achieve dynamic compensation, specifically including: The closed-loop control architecture consists of three parts: actuators, detection components, and control algorithms. The actuator includes a drive mechanism 201 (voice coil motor), a connecting rod 301, an elastic component 306, and a transfer needle tip 202, which are used to perform the movement and position correction of the transfer needle tip 202; the detection component is a capacitive sensor, which detects the displacement data of the transfer needle tip 202 in real time and forms position feedback; the control algorithm adopts a PID control algorithm, which receives the displacement error value, generates an adjustment signal, and controls the actuator to correct the position. The control process includes: target input, where the system sets target displacement data, such as 100μm, according to process requirements, as the reference input for closed-loop control.

[0065] Motion drive: The main controller sends motion commands to the drive mechanism 201, and the drive mechanism 201 drives the transfer needle tip 202 to move toward the PCB substrate 204 via the connecting rod 301. Position detection: As the transfer needle tip 202 moves, the elastic component 306 is compressed, and the capacitive sensor detects the change in electrode spacing, generating a position feedback signal, which is transmitted to the main controller.

[0066] Error calculation involves the main controller comparing the real-time displacement data with the target displacement data to obtain the displacement error value.

[0067] The PID control algorithm calculates the error value and dynamically adjusts the P, I, and D parameters based on the magnitude and trend of the error. For example, it increases the P parameter when the error is large, increases the I parameter when the error persists, and increases the D parameter when the error changes rapidly, thus generating an adjustment signal.

[0068] When performing correction, the drive mechanism 201 receives the adjustment signal, adjusts the output force or movement speed, and drives the transfer needle tip 202 to perform displacement correction until the error value converges to the preset threshold, thus completing closed-loop control. The drive mechanism 201 adopts a dual closed-loop control architecture, with the outer loop being the position control loop and the inner loop being the current control loop. The position control loop takes the error between the target displacement and the real-time displacement as input and outputs a speed control signal to ensure the accuracy of the needle tip position.

[0069] The current control loop detects the motor coil current and adjusts the PWM output to ensure that the motor output force matches the control quantity, thereby improving the system's dynamic response capability and stability.

[0070] As can be seen from the above, Figure 4 The corresponding closed-loop control architecture implementation is the control logic carrier of the overall scheme. Its role in the overall scheme is to build a closed-loop link for detection, calculation and correction, so that displacement compensation is upgraded from static adjustment to dynamic adaptive control.

[0071] The dual closed-loop control architecture balances positional accuracy and motion stability. The outer loop ensures precise needle tip positioning, while the inner loop ensures stable motor output, avoiding overshoot and oscillation. The dynamic adjustment mechanism of PID parameters enables the system to adapt to different error states and achieve rapid error convergence. The entire closed-loop process is completed within milliseconds, ensuring real-time compensation and effectively offsetting the effects of dynamic interference factors such as uneven PCB substrate and elastic deformation, thus maintaining stable transfer accuracy.

[0072] Figure 5 This is a structural diagram of the needle-type transfer compensation device provided in the embodiments of this application. Please refer to it. Figure 5 It includes an acquisition module 801, a driving module 802, a detection module 803, a comparison module 804, a calculation module 805, and a correction module 806. These modules work together to achieve the displacement compensation function, as detailed below: The acquisition module 801 is used to acquire the set target displacement data. The target displacement data is determined based on the requirements of the chip transfer process. This module communicates with the process parameter configuration terminal through the industrial bus and supports two acquisition methods: manual input and preset parameter retrieval. When manually inputting, the operator inputs the target displacement value through the touch screen. When retrieving preset parameters, the module reads the preset target displacement data corresponding to the current chip model and substrate type from the memory, eliminating the need for repeated configuration and improving operational efficiency. The acquisition module also has a data verification function to judge the rationality of the input or read target displacement data, such as whether it is within the effective range of 0-500μm. If the data is invalid, an alarm signal is issued and subsequent processes are refused.

[0073] The drive module 802 is used to start the drive mechanism 201 to drive the transfer needle tip 202 to move towards the target substrate (i.e., PCB substrate 204). The module has a built-in motor drive circuit, supports PWM signal output, and can adjust parameters such as movement speed and acceleration through configuration registers. During the motion control process, the module receives instructions from the main controller in real time to realize automatic switching between fast feed and low feed. At the same time, it monitors the motor's operating current, temperature and other status parameters. If abnormalities such as overcurrent or overheating occur, it immediately stops the movement and issues an alarm signal to protect the safety of the equipment and the workpiece. The detection module 803 is used to detect the real-time displacement data of the transfer needle tip 202 through the sensor assembly. The module communicates with the circuit board 302 of the capacitive sensor, receives the digital signal output by the sensor, and converts it into standard real-time displacement data after filtering and calibration. The detection module also has a sensor calibration function, which supports periodic zero-point calibration (i.e., capacitance value calibration when the electrode spacing is the initial value) and range calibration of the capacitive sensor to eliminate errors caused by sensor drift and ensure detection accuracy. The comparison module 804 is used to compare real-time displacement data with target displacement data to obtain displacement error value. The module has a built-in difference calculation unit and uses hardware circuitry to achieve fast calculation, ensuring the real-time performance of error calculation. At the same time, the module has an error caching function, recording the most recent 100 sets of error values ​​to provide error change trend data for PID control algorithm and assist in dynamic parameter adjustment. The calculation module 805 is used to calculate the displacement error value based on a preset control algorithm to obtain the adjustment signal. The module has a built-in PID control algorithm unit, which supports dynamic adjustment and storage of P, I, and D parameters. It can automatically adjust parameters according to the magnitude of the error value, such as error > 5μm, 2μm ≤ error ≤ 5μm, error < 2μm, and the error change trend, such as error increasing, error decreasing, and error stabilizing. It also supports manual parameter configuration. For example, when the error is large and continues to increase, the P parameter is increased, such as from 1.0 to 1.5, and the D parameter is increased, such as from 0.2 to 0.5, to speed up the response speed. When the error is small but persists, the I parameter is increased, such as from 0.1 to 0.3, to eliminate static error.

[0074] The correction module 806 is used to control the drive mechanism 201 to correct the position of the transfer needle tip 202 according to the adjustment signal. The module converts the adjustment signal generated by the calculation module into control commands that the drive mechanism 201 can recognize, such as PWM duty cycle adjustment commands and current adjustment commands, and sends them to the drive mechanism 201 through the industrial bus. During the correction process, the module receives real-time displacement data fed back by the detection module in real time and monitors the correction effect. If the error still does not converge to the threshold after correction, the adjustment signal is repeatedly generated until the accuracy requirements are met. As can be seen from the above, Figure 5 The corresponding functional module implementation method is the modular implementation carrier of the overall scheme. Its role in the overall scheme is to decompose the complex compensation function into independent and collaborative functional units, thereby improving the feasibility, maintainability and scalability of the scheme.

[0075] The clear division of functions among the modules reduces the difficulty of development and debugging, and facilitates later maintenance and upgrades; the parameter configuration and verification functions of the acquisition module 801 improve the usability and security of the system; the calibration function of the detection module 803 ensures the stability of detection accuracy during long-term use; the hardware operation design of the comparison module 804 and the calculation module 805 ensures the real-time performance of data processing; the closed-loop monitoring mechanism of the correction module 806 ensures the compensation effect. This modular design enables the overall solution to flexibly adapt to different application scenarios and supports functional expansion and hardware replacement.

[0076] Figure 6 This is a structural diagram of an electronic device provided in an embodiment of this application. Please refer to it. Figure 6The electronic device can integrate the needle-type transfer compensation device provided in the embodiments of this application, and is used to perform a needle-type needle displacement compensation method, specifically including: The electronic device includes a processor 401, a memory 402, an input device 403, and an output device 404. There may be one or more processors 401; the figure shows one processor 401 as an example. The processor 401, memory 402, input device 403, and output device 404 can be connected via a bus or other means; the figure shows a bus connection as an example.

[0077] Memory 402, as a computer-readable storage medium, can be used to store software programs, computer-executable programs, and modules, such as the program instructions / modules corresponding to the needle displacement compensation method in the embodiments of this application. Memory 402 may mainly include a program storage area and a data storage area. Stored program area: Stores the operating system, such as Linux or Windows Embedded, and at least one application required for a function, such as compensation control program, sensor driver, and motor driver; Stored data area: Stores data created based on the use of electronic equipment, such as target displacement parameters, real-time displacement data, error value records, PID parameter configuration, environmental parameter data, etc.

[0078] Memory 402 may include high-speed random access memory, and may also include non-volatile memory, such as at least one disk storage device, flash memory device, or other non-volatile solid-state storage device. In some instances, memory 402 may further include memory remotely located relative to processor 401, which can be connected to electronic devices via a network, including but not limited to the Internet, intranets, local area networks, mobile communication networks, and combinations thereof. The processor 401 executes various functional applications and data processing of the electronic device by running software programs, instructions and modules stored in the memory 402, that is, to realize the above-mentioned needle-type needle displacement compensation method. The processor 401 can be a central processing unit (CPU), digital signal processor (DSP), application-specific integrated circuit (ASIC), field-programmable gate array (FPGA) and other programmable logic devices, which have high-speed computing capabilities and can meet the real-time requirements of closed-loop control (computation delay ≤1ms).

[0079] The input device 403 can be used to receive input digital or character information, and to generate key signal inputs related to user settings and function control of electronic devices. For example, the input device 403 can be a touch screen, keyboard, mouse, knob, external interface such as RS-232 interface, Ethernet interface, etc., for inputting target displacement data, PID parameters, process parameters, etc., and can also receive detection data from external sensors such as environmental sensors. Output device 404 can be used to send or display key signal outputs related to user settings and function control of electronic devices. For example, output device 404 can be a display screen, such as an LCD touch screen, indicator lights, a buzzer, or an external interface, such as an RS-485 interface or a CAN bus interface. The display screen is used to display target displacement data, real-time displacement data, error values, and equipment operating status. Indicator lights are used to indicate normal operation and alarm status of the equipment. The buzzer is used to emit alarm sounds. The external interface is used to send control commands to the drive mechanism and transmit operating data to external terminals, such as MES systems. As can be seen from the above, Figure 6 The corresponding electronic device implementation is the hardware platform of the overall solution. Its role in the overall solution is to provide computing, storage and interaction capabilities to ensure that the compensation method and device can operate stably.

[0080] The selection of the high-performance processor 401 ensures the real-time performance of closed-loop control and data processing, with a computational latency of ≤1ms, meeting the millisecond-level compensation response requirements; the large-capacity memory 402 supports the storage of multiple sets of parameters and data recording, facilitating process traceability and parameter optimization; the diverse input / output devices enhance the system's usability, supporting manual configuration and remote monitoring; the bus connection method ensures high-speed data transmission between various hardware components. The construction of this hardware platform provides the overall solution with the foundation for industrial applications, enabling it to stably adapt to the continuous operation requirements of mass production scenarios.

[0081] Before comparing the real-time displacement data with the target displacement data, an environmental factor compensation step is also included: Environmental parameters are collected in real time by an environmental sensing component, including temperature (measurement range -10℃ to 60℃, accuracy ±0.5℃) and humidity (measurement range 20% to 80%RH, accuracy ±5%RH). The environmental sensing component communicates with the main controller via an I2C bus, with a sampling frequency of 1Hz, and transmits environmental parameter data in real time. The main controller has a built-in database of the correlation between environmental parameters and displacement error. This database was established through a large amount of experimental data. For example, for every 10℃ increase in temperature, the capacitive sensing coefficient drifts by 0.8%, corresponding to an increase in displacement error of 0.8μm. Based on the currently collected environmental parameters, the correlation database is queried to obtain the error correction value, which is used to correct the calculation parameters of the PID control algorithm, such as P, I, and D parameters, or to directly correct the displacement error value, thus offsetting the interference of environmental factors on the detection accuracy.

[0082] After correcting the operational parameters of the PID control algorithm, multiple compensation control steps are also included: The motion stroke of the transfer needle tip 202 is divided into multiple displacement ranges. For example, the 0-500μm stroke is divided into three ranges: rapid feed range (0-200μm), deceleration range (200-400μm), and precision compensation range (400-500μm). A corresponding set of control parameters is set for each displacement range. For example: rapid feed range: P=0.8, I=0.05, D=0.1, prioritizing speed; deceleration range: P=1.2, I=0.1, D=0.3, balancing speed and precision; precision compensation range: P=1.5, I=0.2, D=0.5, prioritizing precision. The detection module 803 determines the displacement range of the transfer needle tip 202 in real time, and the comparison module 804 calls the corresponding control parameter set to process and adjust the error value, ensuring optimal control performance at different motion stages. After calling the corresponding displacement range control parameter group for error value processing and adjustment control, the system also includes a fault-tolerant control step: the main controller monitors the signal status of the sensor components in real time, such as signal amplitude, signal stability, and the operating status of the drive mechanism 201, such as motor current and movement speed; when the sensor signal amplitude is detected to be outside the normal range, such as <0.5V or >4.5V, signal fluctuation frequency >1kHz (determined as signal abnormality), or the motor current is outside the rated range, such as >5A, or the movement speed deviates from the command speed by >10% (determined as operation fault), the fault-tolerant mechanism is activated; if the signal is abnormal, the system switches to auxiliary detection mode, obtains displacement data (auxiliary displacement data) through the encoder of the drive mechanism 201, and continues to perform compensation control; if the operation fault is, the system controls the drive mechanism 201 to enter a safe operation state, such as emergency stop or return to the initial position; at the same time, the output device 404 issues a fault alarm signal, such as indicator light flashing, buzzer alarm, and display of fault code on the display screen, and stores the fault information (fault type, occurrence time, current parameters) in the memory for easy troubleshooting by maintenance personnel. The needle-punching displacement compensation method, device, equipment, and storage medium provided in this application have high transfer accuracy: ±1μm-level displacement detection is achieved through a capacitive sensor; combined with a PID control algorithm and a dual closed-loop drive architecture, micron-level dynamic compensation is realized, solving the problem of inconsistent needle-punching amounts caused by uneven PCB substrates, elastic errors, and mechanical rebound, controlling the transfer alignment accuracy within ±5μm, and reducing process defects such as needle deviation, pressure damage, and incomplete solidification; strong process stability: integrated environmental factor compensation function to offset the interference of temperature and humidity changes on sensing accuracy; and multi-segment compensation control to adapt to different motion stages. The system meets the precision requirements of each segment, ensuring parameter consistency during batch transfer and improving mass production yield. It boasts high system reliability: incorporating a fault-tolerant control mechanism, it monitors sensor signals and drive mechanism status in real time, switching to auxiliary detection mode or entering a safe state in case of abnormalities to prevent workpiece damage caused by escalating faults and ensure production continuity. It also offers strong adaptability: its modular design allows for flexible replacement of capacitive sensors, control algorithms, and drive structures, adapting to different sizes of MiniLED chips (0.05mm×0.05mm-0.3mm×0.3mm) and different types of substrates, facilitating integration into intelligent production lines and supporting increased automation levels. The above description is merely a preferred embodiment and the technical principles employed in this application. This application is not limited to the specific embodiments provided herein, and various obvious changes, readjustments, and substitutions that can be made by those skilled in the art will not depart from the scope of protection of this application. Therefore, although this application has been described in detail through the above embodiments, this application is not limited to the above embodiments, and may include many other equivalent embodiments without departing from the concept of this application, the scope of which is determined by the scope of the claims.

Claims

1. A needle displacement compensation method for needle puncture, applied to a needle puncture transfer device, wherein the needle puncture transfer device integrates a transfer device, the transfer device comprising a drive mechanism, a transfer needle tip, and a sensor assembly, characterized in that... The method includes: Obtain the target displacement data set for controlling the transfer tip transfer, the target displacement data being determined based on the chip transfer process requirements; The drive mechanism is activated to move the transfer needle tip toward the target substrate. The sensor assembly detects the real-time displacement data of the transfer needle tip in real time, and the sensor assembly generates a sensing signal based on the position change of the transfer needle tip. The real-time displacement data is compared with the target displacement data to obtain the displacement error value; The displacement error value is calculated based on a preset control algorithm to obtain an adjustment signal; The adjustment signal controls the drive mechanism to correct the position of the transfer needle tip so that the position of the transfer needle tip is consistent with the position corresponding to the target displacement data.

2. The needle displacement compensation method according to claim 1, characterized in that, The sensor assembly includes a capacitive sensor, which includes two opposing electrode surfaces, which are respectively connected to the connecting rod of the drive mechanism and the elastic component of the transfer needle tip. The step of detecting the real-time displacement data of the transfer needle tip through the sensor assembly includes: When the movement of the transfer needle tip causes the elastic component to deform, resulting in a change in the distance between the two electrode surfaces, the capacitance change signal detected by the capacitive sensor is conditioned and processed, and converted into corresponding real-time displacement data.

3. The needle displacement compensation method according to claim 1, characterized in that, The displacement error value is calculated based on a preset control algorithm to obtain an adjustment signal, including: The displacement error value is calculated using a PID control algorithm, and the proportional parameter, integral parameter, and derivative parameter are dynamically adjusted according to the magnitude and trend of the calculated displacement error value. The calculation result is determined based on the convergence threshold of the displacement error value, and the adjustment signal for adjusting the motion amplitude and speed of the drive mechanism is generated by dynamically adjusting the proportional parameter, integral parameter and differential parameter.

4. The needle displacement compensation method according to claim 3, characterized in that, Before comparing the real-time displacement data with the target displacement data, the method further includes: Environmental parameters are collected in real time using environmental sensing components; Based on the correlation between the environmental parameters and the displacement error value, the calculation parameters of the PID control algorithm are corrected.

5. The needle displacement compensation method according to claim 4, characterized in that, After correcting the operational parameters of the PID control algorithm, the method further includes: The movement of the transfer needle tip is divided into multiple displacement intervals, and a corresponding control parameter group is set for each displacement interval. The displacement range of the transfer needle tip is determined in real time, and the corresponding displacement range control parameter group is called to process and adjust the displacement error value.

6. The needle displacement compensation method according to claim 5, characterized in that, After invoking the corresponding displacement interval control parameter group to process and adjust the displacement error value, the method further includes: Real-time monitoring of the signal status of the sensor components and the operating status of the drive mechanism; When the signal status is detected as abnormal or the operating status is detected as faulty, switch to auxiliary detection mode to obtain displacement data, or control the drive mechanism to enter a safe operating state; The compensation control can continue based on the auxiliary displacement data, or a fault alarm signal can be issued.

7. The needle displacement compensation method according to claim 3, characterized in that, The drive mechanism adopts a dual closed-loop control architecture, in which the outer loop is a position control loop and the inner loop is a current control loop; the adjustment signal is input to the driver of the drive mechanism, and the driver adjusts the output current through pulse width modulation to control the movement amplitude and speed of the drive mechanism; The step of controlling the drive mechanism to correct the position of the transfer needle tip according to the adjustment signal includes: After receiving the adjustment signal command, the drive mechanism adjusts the output force or movement speed of the drive mechanism based on the adjustment signal command, thereby driving the transfer needle tip to adjust its displacement so that the position of the transfer needle tip is consistent with the position corresponding to the target displacement data.

8. A needle-type transfer compensation device, applied to a needle-type transfer equipment, wherein the needle-type transfer equipment integrates a transfer device, the transfer device comprising a drive mechanism, a transfer needle tip, and a sensor assembly, characterized in that, include: The acquisition module is used to acquire the target displacement data set for controlling the transfer tip transfer, wherein the target displacement data is determined based on the chip transfer process requirements. The drive module is used to activate the drive mechanism to drive the transfer needle tip to move toward the target substrate. The detection module is used to detect the real-time displacement data of the transfer needle tip through the sensor component, and the sensor component generates a sensing signal based on the position change of the transfer needle tip. The comparison module is used to compare the real-time displacement data with the target displacement data to obtain the displacement error value; The calculation module is used to calculate the displacement error value based on a preset control algorithm to obtain an adjustment signal; The correction module is used to control the drive mechanism to correct the position of the transfer needle tip according to the adjustment signal, so that the position of the transfer needle tip is consistent with the position corresponding to the target displacement data.

9. An electronic device, characterized in that, include: Memory and one or more processors; The memory is used to store one or more programs; When the one or more programs are executed by the one or more processors, the one or more processors implement the needle displacement compensation method as described in any one of claims 1-7.

10. A storage medium for storing computer-executable instructions, characterized in that, The computer-executable instructions, when executed by a computer processor, are used to perform the needle displacement compensation method as described in any one of claims 1-7.

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