LCD display screen production line management and control system and method

Abstract

This invention discloses an LCD display production line control system and method, belonging to the field of intelligent production control technology for LCD displays. It addresses the problems of inaccurate defect identification, inaccurate correlation of hidden process anomalies, and untimely feedback during LCD display production. By reading the identification of the LCD display under test, image data, process data, environmental data, and operational data at the current workstation are collected to form production status data. Then, based on the detected images and multi-source production data, defect status and process anomaly status are determined. Correlation judgment is performed on gradient bright band defects at the edge of the bonding area, generating corresponding production line control actions and execution records. This solution enables collaborative control of display defect detection, anomaly cause identification, rework isolation, and process feedback adjustment.

Description

Technical Field

[0001] This invention relates to the field of intelligent production control technology for LCD displays, and more specifically, to an LCD display production line control system and method. Background Technology

[0002] LCD display production typically involves continuous processes such as cleaning, bonding, curing, inspection, and conveying. Production lines generally monitor product quality and workstation status through visual inspection, sensor detection, and equipment operation signals. Current production control methods often rely on single inspection results or whether a single process parameter exceeds preset limits as the basis for judgment. For example, image defect results determine product release, rework, or isolation, or single data points such as pressure, temperature, humidity, and vibration are used to determine whether a workstation is abnormal. While this method can handle obvious defects and significant exceedances, during LCD display bonding, uneven display defects such as gradient bright bands may appear at the edge of the bonding area. The cause of these defects may not be a single process parameter exceeding its limit, but rather the combined effect of multiple weak changes within the same time period, such as minor positioning rebound, pressure build-up deviation, temperature stagnation, short-term humidity changes, residual vibration, and displacement traction. If judgments are still made based on individual data points, such defects are easily misclassified as having no clear process abnormality, making it difficult to trace the cause and adjust the production line in a timely manner.

[0003] To address the above problems, this invention proposes a solution. Summary of the Invention

[0004] In order to overcome the above-mentioned defects of the prior art, embodiments of the present invention provide an LCD display production line control system and method to solve the problems mentioned in the background art.

[0005] To achieve the above objectives, the present invention provides the following technical solution: In a preferred embodiment, it includes: Read the display identification of the LCD screen under test, and collect the image data, process data, environmental data and operation data of the current workstation to form production status data; Defect status and process abnormality status are determined based on the production status data. The defect status includes the defect type and defect location, and the process abnormality status includes the abnormal data name and abnormal deviation direction. When the defect type is uneven display defect and the defect location is at the edge of the bonding area, bonding edge association processing is performed based on the same display screen identity, the same current workstation identity, and the image data, process data, environmental data, and operation data within the same processing time period. The gradient bright band defect is determined, and the positioning rebound amount, pressure establishment offset amount, temperature retention amount, humidity jump amount, residual vibration amount, and displacement traction change amount are correlated with the gradient bright band defect to determine the latent abnormal defect state of the bonding edge, and the edge cause chain and bonding edge adjustment amount are generated. Based on the defect status, the process anomaly status, the edge cause chain, and the bonding edge adjustment amount, production line control actions are generated, and production line control action execution records are formed based on the production line control actions.

[0006] In a preferred embodiment, the display identification of the LCD display under test is read, and the current workstation identification, arrival time, departure time and various data acquisition times are recorded simultaneously to construct the data association basis for the same display within the same current workstation.

[0007] In a preferred embodiment, after the LCD display under test is positioned, a detection image containing edge contours, positioning reference points, and image coordinate information is acquired, and the correspondence between the image pixel positions and the actual positions of the LCD display under test is established using camera calibration. In the bonding processing station, image data, process data, environmental data, and operational data related to the bonding process are constructed by acquiring alignment offset, bonding pressure, bonding duration, bonding temperature, as well as humidity, vibration status, conveying speed, positioning status, action completion status, and abnormal triggering status during the period from the current station's arrival to departure. The data is processed according to the start time of the action, the end time of the action, the instantaneous trigger time, and the image acquisition time. The detection values ​​are calibrated and converted, invalid detection values ​​are marked, and the images are brightness corrected, noise suppressed, and coordinate calibrated to form production status data that includes display screen identification, current workstation identification, image data, process data, environmental data, operation data, and data validity marking.

[0008] In a preferred embodiment, production status data constructed using the same display screen identifier, the same current workstation identifier, and the data acquisition time is used to read corresponding image data, process data, environmental data, operating data, and data validity markers. Data items that cannot participate in the judgment are excluded by invalid detection value markers. On the image side, the display area, edge area, bonding area, and positioning reference area are determined based on image coordinate information. The detection image is compared with the reference image under the same imaging conditions by pixel brightness or grayscale, and the abnormal pixel positions are marked. Furthermore, adjacent abnormal pixels are marked as connected regions. Based on the area, length, width, edge contour, center position, and brightness contrast of the connected regions, a defect state containing defect type, defect position, defect size, and defect level is constructed. The content related to the bonding edge mainly includes the identification of uneven display defects, bonding offset, or edge position offset, and the conversion of the center position, size, and positioning reference area of ​​the connected region into the actual position on the LCD screen under test through image coordinate calibration relationship. On the data side, the alignment offset, bonding pressure, bonding duration, and bonding temperature related to the bonding process are compared with the corresponding process control ranges. The humidity and vibration environmental data are compared with the environmental control ranges. The conveying speed, arrival status, positioning status, action completion status, abnormal trigger status, waiting, re-inspection, rework flow, or abnormal stop operation data are compared with the corresponding control conditions to construct a process abnormality state that includes the abnormal data name, abnormality type, abnormality occurrence time, abnormality duration, and abnormal deviation direction.

[0009] In a preferred embodiment, after the defect state and process abnormality state have been determined, for the case where the defect type is uneven display defect and the defect location is located at the edge of the bonding area, bonding edge association processing is performed. Specifically, using the same display screen identification, the same current workstation identification, and image data, process data, environmental data, and operation data within the same processing time period, the edge position of the bonding area edge in the detection image is first determined according to the image coordinate information. Then, multiple brightness change sequences are read along the direction perpendicular to the edge of the bonding area. When multiple adjacent brightness change sequences show a change state of gradually increasing or decreasing from the edge of the bonding area to the interior of the display area, and the abnormal pixel position is continuously or intermittently distributed along the edge of the bonding area, the corresponding uneven display defect is determined as a gradient bright band defect, and the edge extension direction, brightness gradient direction, and edge defect area are recorded.

[0010] In a preferred embodiment, based on the completion time of the positioning action, the start time of the bonding action, the time when the pressure stabilizes, the end time of the bonding action, and the time of the departure signal, the positioning holding period, the pressure establishment period, the bonding holding period, and the departure traction period are divided. Within the above-mentioned periods, the positioning rebound amount, the pressure establishment offset amount, the temperature retention amount, the humidity jump amount, the residual vibration amount, and the departure traction change amount are determined respectively. Then, each of the above-mentioned changes is correlated with the edge extension direction, the brightness gradient direction, and the edge defect area of ​​the gradient bright band defect, respectively, to determine the correspondence between the positioning rebound amount and the position of the gradient bright band defect, the correspondence between the pressure establishment offset amount and the pressure of the gradient bright band defect, the correspondence between the temperature retention amount and the temperature retention of the gradient bright band defect, the correspondence between the humidity jump amount and the environmental disturbance of the gradient bright band defect, and the correspondence between the departure traction change amount and the departure traction of the gradient bright band defect.

[0011] In a preferred embodiment, when the same gradient bright band defect simultaneously satisfies at least two correspondences, including one correspondence obtained from process data and one correspondence obtained from operating data or environmental data, the defect state corresponding to the gradient bright band defect is determined as a latent abnormal defect state of the bonding edge. Then, the positioning rebound amount, pressure establishment offset amount, temperature retention amount, humidity jump amount, residual vibration amount, and displacement traction change amount that have been established with the gradient bright band defect are written into the same edge cause chain according to the time of occurrence. Based on the data items in the edge cause chain, positioning holding adjustment amount, pressure establishment adjustment amount, temperature holding adjustment amount, humidity control adjustment amount, conveying stop waiting adjustment amount, and displacement speed adjustment amount are generated respectively. Finally, the latent abnormal defect state of the bonding edge is written into the defect state, and the edge cause chain and bonding edge adjustment amount are written into the process abnormal state.

[0012] In a preferred embodiment, based on the same display screen identity, the same current workstation identity, and the defect status and process abnormality status within the same processing time period, the defect type, defect location, defect size, defect level, abnormal data name, abnormality type, abnormality occurrence time, abnormality duration, and abnormality deviation direction are read, and the flow action of the LCD display screen under test is constructed based on the defect status, and the handling action of the current workstation is constructed based on the process abnormality status. Specifically, for defects related to uneven display, positional offset, or latent abnormal defects already written into the bonding edge status, which are related to the bonding edge associated processing, a rework transfer action or an isolation transfer action is generated based on the defect type, defect location, defect size, and allowable repair range, and the target transfer position and transfer trigger time are written; for bonding pressure, bonding temperature, humidity, vibration status, conveying speed, positioning status, and action completion status related to the bonding process in the process abnormal status, bonding pressure adjustment action, bonding temperature adjustment action, humidity handling action, vibration handling action, conveying handling action, repositioning action, or action pause action are generated based on the abnormal data name, abnormal deviation direction, and abnormal occurrence time, respectively; when the process abnormal status includes edge When adjusting the edge and the cause chain, read the positioning and holding adjustment, pressure establishment adjustment, temperature holding adjustment, humidity control adjustment, conveying stop waiting adjustment, or departure speed adjustment according to the corresponding data item in the edge cause chain, and use the corresponding adjustment as the action trigger basis for the current station's handling action; when the same LCD display under test corresponds to both the flow action and the current station's handling action, arrange the action execution relationship in the order of current station pause, isolation flow, rework flow, repeated inspection, process adjustment, environmental handling, operation handling, and release, and write the display identification, current station identification, action type, action trigger basis, action object, target flow position, action trigger time, and action execution order into the production line control action.

[0013] In a preferred embodiment, a corresponding control action execution record is constructed based on the action type, action triggering basis, action object, and action execution sequence in the production line control actions. Specifically, for repetitive detection actions related to edge bonding processing, re-positioning, re-matching lighting methods, or re-identifying edge contours and positioning reference points are performed if the cause cannot be determined, and the newly acquired image data is rewritten into the defect status. For rework flow actions corresponding to uneven display defects, positional offset defects, or latent abnormality defects in the bonding edge, the LCD display under test is transferred to a preset rework position according to the defect type, and a rework processing method of re-detecting the display status, repositioning, and then re-bonding or re-pressing is selected. For handling actions corresponding to bonding pressure, bonding temperature, humidity, vibration status, conveying speed, and positioning status, the bonding pressure setting value, heating setting value, humidity control direction, conveying speed, or positioning method is adjusted according to the abnormal data name and abnormal deviation direction, and the adjusted pressure detection value, temperature detection value, humidity detection value, vibration detection value, conveying speed feedback value, or position detection result after repositioning is read. When the action triggering basis includes edge cause chain and edge fit adjustment amount, the holding time, holding position, pressure establishment process, temperature holding adjustment amount, humidity control adjustment amount, conveying stop waiting adjustment amount or departure speed adjustment amount of the current station are adjusted accordingly. Then, the action execution time, action completion time, execution result, actual flow position, detection value before adjustment, detection value after adjustment, redefined defect status and updated control basis are written into the production line control action execution record.

[0014] In a preferred embodiment, it includes: a production status data generation module, a defect and process abnormality status determination module, a fitting edge association processing module, a production line control action execution record generation module, and signal connections between the modules; The production status data generation module is used to read the display identification of the LCD display under test and collect image data, process data, environmental data and operation data of the current workstation to form production status data; The defect and process anomaly determination module is used to determine the defect status and process anomaly status based on the production status data. The defect status includes the defect type and defect location, and the process anomaly status includes the anomaly data name and anomaly deviation direction. The edge-fitting association processing module is used to perform edge-fitting association processing based on the same display screen identifier, the same current workstation identifier, and image data, process data, environmental data, and operating data within the same processing time period when the defect type is uneven display defect and the defect location is located at the edge of the bonding area. This process determines the gradient bright band defect and correlates the positioning rebound amount, pressure establishment offset amount, temperature retention amount, humidity jump amount, residual vibration amount, and displacement traction change amount with the gradient bright band defect to determine the latent abnormal defect state of the bonding edge and generate the edge cause chain and bonding edge adjustment amount. The production line control action execution record generation module is used to generate production line control actions based on the defect status, the process abnormality status, the edge cause chain, and the bonding edge adjustment amount, and to generate production line control action execution records based on the production line control actions.

[0015] The technical effects and advantages of the LCD display production line control system and method of this invention are as follows: This invention identifies defects in LCD displays such as scratches, foreign objects, stains, edge chipping, uneven display, and positional misalignment. It also analyzes the correlation between defect findings and process, environmental, and operational data from the same workstation, product, and processing time period. Particularly for defects with gradually brightening bands at the edge of the bonding area, this solution can further determine whether they are latent anomalies caused by multiple factors that do not individually exceed limits, and generates an edge cause chain and bonding edge adjustment amount, thereby improving the accuracy of anomaly source identification. Through the coordinated actions of release, repeated inspection, rework transfer, isolation transfer, process adjustment, environmental treatment, operational treatment, and workstation suspension, the efficiency of the production line can be improved, the risk of misjudgment and omission can be reduced, and the basis for subsequent process optimization can be enhanced. Attached Figure Description

[0016] Figure 1 This is a schematic diagram of multi-source data acquisition at the current workstation in the LCD display production line control system and method of the present invention.

[0017] Figure 2 This is a schematic diagram illustrating the defect identification of the gradient bright band at the edge of the bonding area in the LCD display production line control system and method of the present invention.

[0018] Figure 3 This is a timing diagram showing the correlation between the latent anomaly at the bonding edge in the LCD display production line control system and method of the present invention. Detailed Implementation

[0019] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0020] In this embodiment, the present invention discloses a method for controlling an LCD display production line, comprising: Step 1: Read the display identification of the LCD screen under test, and collect the image data, process data, environmental data and operation data of the current workstation to form production status data; Step 2: Determine the defect status and process anomaly status based on the production status data. The defect status includes the defect type and defect location, and the process anomaly status includes the anomaly data name and anomaly deviation direction. Step 3: When the defect type is uneven display defect and the defect location is at the edge of the bonding area, perform bonding edge association processing based on the same display screen identifier, the same current workstation identifier, and the image data, process data, environmental data, and operation data within the same processing time period to determine the gradient bright band defect. Then, match the positioning rebound amount, pressure establishment offset amount, temperature retention amount, humidity jump amount, residual vibration amount, and displacement traction change amount with the gradient bright band defect to determine the latent abnormal defect state of the bonding edge and generate the edge cause chain and bonding edge adjustment amount. Step 4: Generate production line control actions based on the defect status, the process abnormality status, the edge cause chain, and the bonding edge adjustment amount, and form a production line control action execution record based on the production line control actions.

[0021] In step one, when the LCD screen under test enters the preset testing position of the current workstation along the conveyor line, the display identification identifier corresponding to the LCD screen under test is read. The display identification identifier is obtained by reading a barcode, QR code, or RFID tag set on the LCD screen under test, the carrier fixture, or the transfer device. If the LCD screen under test has already formed a batch number and a piece number in the previous process, the batch number and piece number are combined to form the display identification identifier. When reading the display identification identifier, the reading time and the current workstation identifier are recorded simultaneously, and the read display identification identifier, reading time, and current workstation identifier are written into the production status data of the LCD screen under test.

[0022] When the LCD screen under test triggers the arrival signal at the current workstation, image data of the LCD screen under test at the current workstation is acquired. During image data acquisition, the LCD screen under test is first positioned at a preset imaging position using positioning stops, adsorption positioning, or visual positioning. Positioning stops restrict the transport position of the LCD screen under test using a stop mechanism; adsorption positioning uses negative pressure to adhere the LCD screen under test to the support surface; visual positioning determines its actual position by identifying the edge contours or positioning reference points on the LCD screen under test. After the LCD screen under test is positioned, corresponding lighting is triggered according to the current inspection object, and inspection images are acquired. When the inspection object has surface scratches, foreign objects, stains, or chipped edges, reflected lighting or oblique lighting is used to acquire inspection images; when the inspection object has uneven brightness, uneven light transmission, or display abnormalities, transmitted lighting or imaging after the display is lit is used to acquire inspection images; when the inspection object has a bonding offset or edge position offset, inspection images including edge contours and positioning reference points are acquired. The image data includes the original detection image, image acquisition time, imaging position, illumination method, and image coordinate information; wherein, the image coordinate information is obtained by camera calibration, and the camera calibration establishes the correspondence between the image pixel position and the actual position of the LCD screen under test by using a calibration plate or a positioning reference point on the LCD screen under test.

[0023] During the same processing stage as the image data acquisition station, process data corresponding to the LCD display under test is acquired. If the current station is performing cleaning, the cleaning fluid flow rate, spray pressure, cleaning duration, and drying status are acquired. The cleaning fluid flow rate is obtained from the flow rate detection value, the spray pressure from the pressure detection value, the cleaning duration from the time difference between the cleaning start signal and the cleaning end signal, and the drying status from the drying completion signal or the surface inspection result after drying. If the current station is performing bonding, the alignment offset, bonding pressure, bonding duration, and bonding temperature are acquired. The alignment offset is obtained from the position difference between the positioning reference point of the LCD display under test and the bonding reference point, the bonding pressure from the pressure detection value, the bonding duration from the time difference between the bonding start signal and the bonding end signal, and the bonding temperature from the temperature detection value. If the current station is performing curing, the curing temperature, curing duration, and light intensity are acquired. The curing temperature is obtained from the temperature detection value, the curing duration from the time difference between the curing start signal and the curing end signal, and the light intensity from the light intensity detection value. The process data, along with the display screen's identity identifier, current workstation identifier, and data acquisition time, are written into the same production status data.

[0024] While the LCD screen under test is in its current workstation, environmental data corresponding to that workstation is collected. This environmental data includes temperature, humidity, particulate matter concentration, and vibration status. Temperature and humidity are obtained from temperature and humidity sensors located near the current workstation; particulate matter concentration is obtained from particulate matter sensors located within the clean area of ​​the current workstation; and vibration status is obtained from vibration sensors located near the conveying, positioning, or processing positions. The start point for data collection is the moment the LCD screen under test triggers a signal indicating the current workstation is in position, and the end point is the moment it triggers a signal indicating the current workstation is out of position. When the environmental data is continuously collected, the data segment between the start and end points is extracted; when the environmental data is collected intermittently, data collected between the start and end points is selected. The extracted or selected environmental data, along with the screen's identification, the current workstation identification, and the environmental data collection time, is written into the same production status data.

[0025] During the passage of the LCD display under test through the current workstation, operational data is collected. This operational data includes conveying speed, arrival status, positioning status, action completion status, and abnormal trigger status. Conveying speed is obtained from the speed feedback value of the conveying mechanism; arrival status is obtained from the arrival detection signal; positioning status is obtained from the positioning action completion signal or the position detection result after positioning; action completion status is obtained from the completion signal of the current workstation's processing action; and abnormal trigger status is obtained from the alarm signal generated at the current workstation during conveying, positioning, or processing. When the LCD display under test experiences waiting, re-inspection, rework, or abnormal stoppage at the current workstation, the start time of waiting, the end time of waiting, and the operational signal triggering the waiting are recorded. The start time of waiting is obtained from the conveying stop signal or workstation occupancy signal; the end time of waiting is obtained from the conveying resumption signal or workstation release signal; and the operational signal triggering the waiting is obtained from the alarm signal, re-inspection trigger signal, or rework signal of the current workstation. This operational data, along with the display's identification, the current workstation identification, and the operational data collection time, is written into the same production status data.

[0026] After acquiring image data, process data, environmental data, and operational data, the production status data is processed chronologically. For data with a continuous process, the time period corresponding to the data is determined by the start and end times of the action; for data triggered instantaneously, the time point corresponding to the data is determined by the trigger time; for detected images, the time point corresponding to the detected image is determined by the image acquisition time. If the same LCD display under test experiences multiple image acquisitions, multiple process actions, or multiple abnormal triggers at the same current workstation, the same production status data is written in chronological order, and the acquisition time or trigger time corresponding to each data point is retained separately.

[0027] The validity of the detected values ​​in the production status data is processed. For temperature, humidity, pressure, flow rate, light intensity, particulate matter concentration, vibration state, and conveying speed obtained by the detection devices, the original output value of the corresponding detection device is first read, and then converted into the actual detection value according to the calibration relationship formed during the calibration of the detection device. The calibration relationship is obtained by the detection device before it is put into use or during periodic calibration using standard measuring instruments, standard samples, or standard environmental conditions. When the output value of the detection device exceeds its detection range, the detection device does not generate an output value, or the output value cannot complete the calibration conversion, the corresponding detection value is marked as an invalid detection value. For image data, the original detection image is retained, and the detection images involved in the identification are subjected to brightness correction, noise suppression, and coordinate calibration. Brightness correction is completed based on the background image acquired when there is no LCD screen under test and the reference image acquired under standard brightness conditions. Noise suppression is achieved by filtering to reduce random noise. Coordinate calibration is performed by determining the conversion relationship between the image coordinates and the actual position of the LCD screen under test through a calibration board or positioning reference point.

[0028] After completing the above processing, the production status data of the LCD display under test at the current workstation is generated, such as... Figure 1 As shown. The production status data includes display screen identification, current workstation identification, arrival time, departure time, image data, process data, environmental data, operational data, and data validity markers.

[0029] In step two, based on the production status data generated in step one, image data, process data, environmental data, operational data, and data validity markers under the same display screen identifier and the same current workstation identifier are read. The data validity markers indicate whether the corresponding data can participate in the judgment of this step. When a data item is marked as an invalid detection value, this data item is not used to determine the defect status or process anomaly status, and the data name, acquisition time, and current workstation identifier corresponding to the invalid detection value are recorded. When image data is marked as an invalid detection value, the image judgment result of the LCD display screen under test at the current workstation is recorded as undeterminable. When process data, environmental data, or operational data is marked as an invalid detection value, the process anomaly judgment result of the corresponding data item is recorded as undeterminable.

[0030] Defect features are extracted from the image data. These defect features refer to identifiable image features formed by abnormal changes in brightness, grayscale, contour, color, or positional relationships within the detected image. During defect feature extraction, the detection area is first determined based on image coordinate information. The detection area refers to the image region in the detected image corresponding to the display area, edge area, bonding area, or positioning reference area of ​​the LCD screen under test. The image coordinate information is obtained from the camera calibration in step one. After determining the detection area, the grayscale value or brightness value of each pixel is read within the detection area and compared with the grayscale value or brightness value at the same position in a reference image. The reference image is an image acquired from a qualified LCD screen under test or a standard calibration component under the same imaging position, illumination method, and camera parameters. If the grayscale difference or brightness difference between a pixel position in the detected image and the corresponding pixel position in the reference image exceeds a corresponding difference threshold, the pixel position is marked as an abnormal pixel position. The difference threshold is determined by the grayscale fluctuation range or brightness fluctuation range of sample images acquired from qualified LCD screens of the same model under test under the same imaging conditions.

[0031] After obtaining the locations of abnormal pixels, adjacent abnormal pixel locations are marked as connected regions. A connected region refers to a set of pixels in the detection image that are adjacent to each other and whose grayscale or brightness difference both meet the abnormality criteria. For each connected region, its area, maximum length, maximum width, edge contour, center position, and brightness contrast in the detection image are calculated. The area is obtained by converting the number of abnormal pixels within the connected region into image coordinates; the maximum length and maximum width are obtained by converting the pixel span of the connected region in different directions into image coordinates; the center position is determined by the geometric center of each abnormal pixel location within the connected region; and the brightness contrast is obtained by the difference between the average brightness value within the connected region and the average brightness value of its surrounding normal regions. The surrounding normal regions refer to detection image regions located outside the connected region, at a distance satisfying a preset neighborhood range, and not marked as abnormal pixel locations. The preset neighborhood range is determined by the image resolution and the minimum identifiable size of the detected object.

[0032] The defect status of the LCD display under test is determined based on the area, maximum length, maximum width, edge contour, center position, and brightness contrast of the connected region. The defect status includes defect type, defect location, defect size, and defect level. If the connected region is elongated and its maximum length is significantly greater than its maximum width, and the connected region exhibits continuous brightness variations under reflected or oblique illumination, the corresponding defect type is determined to be a scratch defect. If the connected region is dot-shaped or block-shaped, and its brightness value abruptly changes compared to the brightness value of the surrounding normal area, the corresponding defect type is determined to be a foreign object defect or a stain defect; specifically, a foreign object defect is defined when the edge of the connected region is clear and the brightness contrast is stable, while a stain defect is defined when the edge of the connected region transitions slowly and the brightness contrast gradually changes. If the connected region is located in the edge area of ​​the LCD display under test, and the edge contour is missing, broken, or abruptly changed in shape relative to the edge contour in the reference image, the corresponding defect type is determined to be an edge chipping defect. If the connected region is located within the display area, and appears as locally high brightness, locally low brightness, or uneven brightness distribution in the detection image after being lit up, then the corresponding defect type is determined to be an uneven display defect.

[0033] When determining the defect location, the center position of the connected region is converted to its actual position on the LCD screen under test using image coordinate calibration relationships. When determining the defect size, the area, maximum length, and maximum width of the connected region are converted to their actual size on the LCD screen under test using image coordinate calibration relationships. When determining the defect level, the defect size, defect location, and brightness contrast are compared with the defect tolerance conditions for this model of LCD screen under test; the defect tolerance conditions refer to the allowable size range, quantity range, and brightness difference range for different defect types in different display areas, edge areas, or bonding areas as specified in the production inspection documents. If the defect size, quantity, or brightness contrast does not exceed the corresponding defect tolerance conditions, the defect level is determined to be a permissible defect; if the defect size, quantity, or brightness contrast exceeds the corresponding defect tolerance conditions, the defect level is determined to be a non-permissible defect.

[0034] For bonding misalignment or edge position misalignment, the actual reference position of the LCD display under test is determined based on the positioning reference area in the image data, and the actual reference position is compared with the reference reference position. The positioning reference area refers to the image area in the detection image that contains the edge contour, positioning holes, marker points, or bonding boundary of the LCD display under test; the reference reference position is determined by the reference image acquired after the qualified LCD display under test of the same model has been positioned in the same current station. If the lateral position difference, longitudinal position difference, or angular position difference between the actual reference position and the reference reference position exceeds the allowable offset range of the current station, the defect type is determined as a positional misalignment defect; the allowable offset range is determined by the process control range specified for the LCD display under test in the bonding, pressing, or inspection process. The process control range refers to the upper limit, lower limit, or allowable positional deviation range of the process parameters specified in the production process document.

[0035] Process anomalies are determined based on process data. A process anomaly refers to a state where the process data, environmental data, or operational data of the LCD display under test deviate from the corresponding process control range during processing, inspection, or transfer at the current workstation. When judging process data, valid detection values ​​are read from cleaning fluid flow rate, spray pressure, cleaning duration, drying status, alignment offset, bonding pressure, bonding duration, bonding temperature, curing temperature, curing duration, and light intensity. Each valid detection value is compared with its corresponding process control range. If the valid detection value is lower than the lower limit of the corresponding process control range, the process anomaly is determined as a low-value anomaly; if the valid detection value is higher than the upper limit of the corresponding process control range, the process anomaly is determined as a high-value anomaly; if the valid detection value is within the corresponding process control range, the process anomaly is determined as normal. For the duration determined by the action start signal and action end signal, the time difference between the action end time and the action start time is first calculated, and then this time difference is compared with the corresponding process control range.

[0036] An abnormal environmental state is determined based on environmental data and recorded as a process anomaly. When judging environmental data, valid detection values ​​for temperature, humidity, particulate matter concentration, and vibration are read, and each valid detection value is compared with the environmental control range corresponding to the current workstation. The environmental control range refers to the allowable temperature range, allowable humidity range, allowable particulate matter concentration range, and allowable vibration range specified in the production process documentation for the current workstation. If any valid detection value for temperature, humidity, particulate matter concentration, or vibration exceeds the corresponding environmental control range, the process anomaly is determined as an environmental anomaly, and the anomaly data name, anomaly occurrence time, anomaly duration, and anomaly deviation direction are recorded. The anomaly occurrence time is determined by the time the data first exceeds the environmental control range; the anomaly duration is determined by the time difference between the time the data first exceeds the environmental control range and the time the data returns to the environmental control range; and the anomaly deviation direction is determined based on whether the valid detection value is higher than the upper limit or lower than the lower limit.

[0037] An abnormal operating state is determined based on the operating data and written into the process abnormal state. When judging the operating data, the conveying speed, arrival status, positioning status, action completion status, and abnormal trigger status are read. If the conveying speed exceeds the speed control range corresponding to the current workstation, the process abnormal state is determined as a conveying abnormality; the speed control range is determined by the production cycle requirements of the current workstation and the allowable speed range of the conveying mechanism. If the arrival detection signal is not generated after the LCD screen under test enters the current workstation, the process abnormal state is determined as an arrival abnormality. If the positioning action completion signal is not generated, or the position detection result after positioning exceeds the allowable offset range, the process abnormal state is determined as a positioning abnormality. If the completion signal of the processing action at the current workstation is not generated, or an alarm signal exists in the abnormal trigger status, the process abnormal state is determined as an action abnormality. If the LCD screen under test experiences waiting, re-inspection, rework, or abnormal stoppage, the stoppage abnormality, re-inspection abnormality, or rework abnormality is determined based on the waiting start time, waiting end time, and the operating signal that triggered the waiting.

[0038] It should be noted that in the current workstation of the LCD display production line, after the LCD display under test is positioned, it enters the bonding process, and then leaves the current workstation after the bonding process is completed. During this process, the edge of the bonding area of ​​the LCD display under test may sometimes form a gradient bright band defect in the image data. The edge of the bonding area refers to the location near the boundary of the display area where the bonding process has been completed in the LCD display under test; the gradient bright band defect refers to a display unevenness defect in the image data that extends along the edge of the bonding area and whose brightness gradually changes from the edge inward.

[0039] Gradient bright band defects typically do not appear as isolated dots, blocks, or straight scratches, but rather as continuous or discontinuous distributions along the edge of the bonding area. Furthermore, there is a positional correspondence between the defect location and the positioning reference area, the bonding pressure area, or the displacement direction. The positioning reference area refers to the area in the image data where the edge contour, positioning holes, marker points, or bonding boundary of the LCD display under test are located; the bonding pressure area refers to the area of ​​the LCD display under test subjected to bonding pressure during the bonding process; and the displacement direction refers to the conveying direction of the LCD display under test when it leaves the current workstation.

[0040] When the aforementioned gradient bright band defect occurs, any single data point among bonding pressure, bonding temperature, alignment offset, humidity, vibration status, and positioning status may not be identified as a high-value or low-value anomaly. In other words, by comparing individual process data, environmental data, or operational data with their corresponding control ranges, the current workstation may not necessarily exhibit a clear single-item anomaly. However, during the process from positioning to bonding completion, the LCD display under test may simultaneously experience slight positioning rebound, uneven bonding pressure establishment, localized temperature stagnation in bonding, short-term humidity changes, and residual vibration after transport stops. Individually, these changes may not constitute a process anomaly, but their combined effect occurs near the edge of the bonding area.

[0041] The term "positioning micro-rebound" refers to the slight restorative change in the actual position of the LCD display under test after positioning is completed, relative to its initial position. The term "uneven bonding pressure" refers to the inconsistent time it takes for the pressure at different locations to reach a stable state during the process of bonding pressure application. The term "localized bonding temperature stagnation" refers to the slower temperature change near the edge of the bonding area compared to the surrounding area after the bonding process is completed. The term "residual vibration" refers to the short-term vibration changes that still exist in the LCD display under test or the supporting fixture after the conveyor line stops.

[0042] The formation location of the gradient bright band defect does not correspond to only one data item exceeding the control range, but rather to a common change process formed by multiple data items that do not individually exceed the limit within the same display screen identifier, the same current workstation identifier, and the same processing time period. If the defect state is still only classified according to whether there is a single process abnormality within the same processing time period, the gradient bright band defect is easily identified as a defect state without accompanying process abnormality, thus making it impossible to distinguish whether it is caused by the state of the LCD display screen under test itself or by multiple weak changes in the bonding process of the current workstation.

[0043] Therefore, in this embodiment, after determining the defect state and process abnormality state, when the defect type in the defect state is a display unevenness defect and the defect location is located at the edge of the bonding area, bonding edge association processing is performed on the defect state. The edge of the bonding area refers to the location near the boundary of the display area where bonding processing has been completed in the LCD display under test. The bonding edge association processing refers to determining whether the display unevenness defect belongs to the edge-related defect formed during the bonding process based on the same display identification, the same current workstation identification, and image data, process data, environmental data, and operating data within the same processing time period.

[0044] When performing edge association processing, the process first determines whether the uneven display defect is a gradient bright band defect based on the image data. A gradient bright band defect refers to an uneven display defect that extends along the edge of the bonding area and whose brightness gradually changes from the edge of the bonding area towards the interior of the display area. To determine a gradient bright band defect, the edge position of the bonding area in the detection image is determined based on image coordinate information. Then, multiple brightness change sequences are read along a direction perpendicular to the edge of the bonding area. These brightness change sequences are arrangements of pixel brightness values ​​obtained sequentially from the edge of the bonding area towards the interior of the display area. If multiple adjacent brightness change sequences all exhibit a gradual increase or decrease from the edge of the bonding area towards the interior of the display area, and the abnormal pixel positions corresponding to adjacent brightness change sequences are continuously or intermittently distributed along the edge of the bonding area, then the uneven display defect is determined to be a gradient bright band defect, and the edge extension direction, brightness gradient direction, and edge defect area of ​​the gradient bright band defect are recorded. Figure 2 As shown.

[0045] Furthermore, to ensure the feasibility of determining the gradient bright band defect, when reading the brightness change sequence, multiple edge sampling positions on the edge of the bonding area are used as starting points. Pixel brightness values ​​are read into the display area along a direction perpendicular to the edge of the bonding area, and the difference between adjacent pixel brightness values ​​in each brightness change sequence is calculated. If, in the same brightness change sequence, the brightness values ​​of multiple pixels arranged from the edge of the bonding area into the display area show a continuous increasing or decreasing trend, and the brightness difference between the first and last brightness values ​​in the sequence is greater than the corresponding difference threshold, then the brightness change sequence is determined to be a valid brightness change sequence.

[0046] When the number of effective brightness change sequences distributed adjacent to each other along the edge of the bonding area reaches a preset number, or the cumulative length of effective brightness change sequences along the edge of the bonding area reaches a preset length, the location of abnormal pixels is determined to be either continuously distributed or discontinuously continuously distributed along the edge of the bonding area. Discontinuously continuously distributed means that there are brightness change sequences that do not meet the difference threshold between two adjacent effective brightness change sequences, but the number of brightness change sequences that do not meet the difference threshold does not exceed a preset number of discontinuities. The preset number, preset length, and preset number of discontinuities are determined based on sample images acquired from qualified LCD displays of the same model under the same imaging conditions.

[0047] When the effective brightness change sequence consistently shows a gradual increase from the edge of the bonding area towards the interior of the display area, the brightness gradient direction is defined as increasing from the edge of the bonding area towards the interior of the display area; conversely, when the effective brightness change sequence consistently shows a gradual decrease from the edge of the bonding area towards the interior of the display area, the brightness gradient direction is defined as decreasing from the edge of the bonding area towards the interior of the display area. The distribution direction of the effective brightness change sequence satisfying the above conditions along the edge direction of the bonding area is defined as the edge extension direction, and the area formed by the abnormal pixel positions corresponding to the effective brightness change sequence after image coordinate calibration is defined as the edge defect area.

[0048] The edge extension direction refers to the direction in which the gradient bright band defect spreads along the edge of the bonding area. The brightness gradient direction refers to the direction in which the brightness of the gradient bright band defect changes from the edge of the bonding area to the interior of the display area. The edge defect area refers to the actual area on the LCD screen under test that corresponds to the image area in the detection image that is identified as a gradient bright band defect after image coordinate calibration.

[0049] After identifying the gradient bright band defect, the bonding edge-related time period for the current workstation where the bonding process is located is determined based on the operational data. This bonding edge-related time period includes a positioning holding period, a pressure building-up period, a bonding holding period, and a departure traction period. The positioning holding period is determined from the completion time of the positioning action to the start time of the bonding action. The completion time of the positioning action is obtained from the positioning action completion signal in the positioning state, and the start time of the bonding action is obtained from the bonding action start signal. The pressure building-up period is determined from the start time of the bonding action to the moment when the bonding pressure enters a stable state. The stable state refers to a state where the bonding pressure is within the corresponding process control range, and the continuously collected bonding pressure variation is less than the pressure stability judgment value. The pressure stability judgment value is determined by the bonding pressure fluctuation range when the same type of qualified LCD display under test completes bonding processing at the same current workstation. The bonding holding period is determined from the moment the bonding pressure enters a stable state to the end time of the bonding action. The end time of the bonding action is obtained from the bonding action end signal. The departure traction period is determined from the end time of the bonding action to the moment when the LCD display under test triggers the departure signal at the current workstation.

[0050] Within the time period associated with the bonding edge, the positioning springback amount is determined based on image data and operational data. The positioning springback amount refers to the amount of positional recovery change that occurs in the LCD display under test from the completion of the positioning action to the start of the bonding action. To determine the positioning springback amount, the position of the positioning reference area corresponding to the completion of the positioning action is read, and the position of the positioning reference area corresponding to the start of the bonding action is also read. The position difference between the two positioning reference area positions is determined as the positioning springback amount. The positioning reference area position is obtained by calibrating the edge contour, positioning hole, marker point, or bonding boundary in the image data using image coordinates. If the current station obtains its positioning status through position detection, the position detection results at the completion of the positioning action and the start of the bonding action are read simultaneously, and the consistency of the position detection results with the image coordinate calibration results is checked. When the corresponding movement directions are consistent, this movement direction is determined as the positioning springback direction. The positioning springback direction refers to the movement direction relative to the edge of the bonding area when the LCD display under test undergoes a positional recovery change.

[0051] Furthermore, when determining the positioning springback amount, the positioning reference area position corresponding to the completion of the positioning action is recorded as the first positioning reference area position, and the positioning reference area position corresponding to the start of the fitting action is recorded as the second positioning reference area position. The positioning springback amount is determined based on the positional difference between the first and second positioning reference area positions. If both the first and second positioning reference area positions include lateral and longitudinal positions, the lateral and longitudinal positional differences are calculated separately, and the positioning springback amount and direction are determined based on these differences. If both the first and second positioning reference area positions also include angular positions, the angular positional difference is calculated simultaneously and written into the data item corresponding to the positioning springback amount.

[0052] When the positioning springback is less than the positioning fluctuation range formed by qualified LCD displays of the same model at the same current workstation, the positioning springback is recorded as normal positioning fluctuation. When the positioning springback does not exceed the allowable offset range but is greater than the positioning fluctuation range, the positioning springback is recorded as a data item that can participate in the bonding edge association processing. When the positioning springback exceeds the allowable offset range, the positioning status is determined to be abnormal, and the positioning springback is simultaneously written into the process abnormal status.

[0053] During the pressure build-up period, the pressure build-up offset is determined based on process data. The pressure build-up offset refers to the deviation of the pressure change process from the start of the bonding action to the point of reaching a stable pressure state relative to a qualified bonding process. To determine the pressure build-up offset, the bonding pressure detection values ​​during the pressure build-up period are read, along with the qualified pressure build-up process formed by a qualified LCD display of the same model at the same current workstation. The qualified pressure build-up process is obtained by arranging the bonding pressure detection values ​​of the qualified LCD display at the time of bonding processing according to the acquisition time. The bonding pressure detection value of the LCD display under test is compared with the pressure value of the qualified pressure build-up process at the corresponding acquisition time, and the pressure build-up offset, pressure build-up offset direction, and pressure stabilization arrival time are determined based on the comparison result. The pressure build-up offset direction is determined based on whether the bonding pressure detection value of the LCD display under test is higher or lower than the qualified pressure build-up process, and the pressure stabilization arrival time is determined by the first acquisition time when the bonding pressure enters a stable pressure state.

[0054] Furthermore, when determining the pressure establishment offset, the contact pressure detection values ​​at each acquisition time during the pressure establishment period are compared with the pressure values ​​at the corresponding acquisition times during the qualified pressure establishment process to obtain multiple pressure differences. The pressure establishment offset is determined based on the maximum pressure difference, average pressure difference, or cumulative pressure difference among these multiple pressure differences. If the contact pressure detection values ​​are generally higher than the pressure values ​​during the qualified pressure establishment process, the pressure establishment offset direction is determined to be too high; if the contact pressure detection values ​​are generally lower than the pressure values ​​during the qualified pressure establishment process, the pressure establishment offset direction is determined to be too low.

[0055] When the pressure set-off offset is less than the pressure set-off fluctuation range formed by qualified LCD displays of the same model at the same current workstation, the pressure set-off offset is recorded as normal pressure set-off fluctuation. When the pressure set-off offset does not exceed the process control range but exceeds the pressure set-off fluctuation range, the pressure set-off offset is recorded as a data item that can participate in the bonding edge association processing. When the bonding pressure detection value corresponding to the pressure set-off offset exceeds the process control range, the bonding pressure is determined to be a high value abnormality or a low value abnormality, and the pressure set-off offset is simultaneously written into the process abnormality status.

[0056] During the bonding holding period and the departure traction period, the temperature retention is determined based on process data. The temperature retention refers to the delayed change in bonding temperature relative to the qualified temperature change process after the bonding action ends, as the bonding temperature changes from the bonding processing state to the departure transport state. To determine the temperature retention, the bonding temperature detection values ​​during the bonding holding period and the departure traction period are read, along with the qualified temperature change process formed by a qualified LCD display of the same model at the same current workstation. The qualified temperature change process is obtained by arranging the bonding temperature detection values ​​collected by the qualified LCD display before and after the bonding action ends, according to the collection time. If the bonding temperature detection value of the LCD display remains close to the upper or lower limit of the process control range after the bonding action ends, and the time it recovers to the range corresponding to the qualified temperature change process is later than the qualified temperature change process itself, then the temperature retention is determined based on the length of the later time and the direction of temperature deviation.

[0057] Furthermore, when determining the temperature retention, the bonding temperature detection value after the bonding action ends is compared with the temperature value at the corresponding acquisition time during the qualified temperature change process, resulting in multiple temperature difference values. The temperature retention is determined based on the maximum temperature difference among these multiple temperature differences, the cumulative temperature difference result, and the time difference for recovery to the corresponding range of the qualified temperature change process. If the bonding temperature detection value is higher than the temperature value during the qualified temperature change process, the temperature deviation direction is determined to be too high; if the bonding temperature detection value is lower than the temperature value during the qualified temperature change process, the temperature deviation direction is determined to be too low.

[0058] When the temperature retention is less than the temperature fluctuation range formed by qualified LCD displays of the same model at the same current workstation, the temperature retention is recorded as a normal temperature change. When the temperature retention does not exceed the process control range but exceeds the temperature fluctuation range, the temperature retention is recorded as a data item that can participate in the bonding edge association processing. When the bonding temperature detection value corresponding to the temperature retention exceeds the process control range, the bonding temperature is determined as a high value abnormality or a low value abnormality, and the temperature retention is simultaneously written into the process abnormality status.

[0059] Within the time period associated with the bonding edge, the humidity jump and residual vibration are determined based on environmental data. The humidity jump refers to the short-term change in humidity near the current workstation relative to the humidity at the moment of arrival during the time period associated with the bonding edge. To determine the humidity jump, the humidity detection value is read when the LCD screen under test triggers the current workstation arrival signal, and the humidity detection values ​​are read during the time period associated with the bonding edge. The maximum difference between the two is determined as the humidity jump, and the direction of the humidity jump is determined based on whether the humidity detection value increases or decreases. The residual vibration refers to the change in vibration that still exists after the conveyor line stops until the bonding pressure reaches a stable state. To determine the residual vibration, the vibration detection value is read after the conveyor line stops and before the pressure stabilizes. The residual vibration is determined based on the peak value, duration, and attenuation changes of the vibration detection values ​​during this time period. The conveyor line stopping time is obtained from the conveyor stop signal in the operating data, and the vibration detection values ​​are obtained from vibration detection devices near the current workstation.

[0060] Furthermore, when determining the humidity jump variable, the humidity detection value at the time the LCD screen under test triggers the current station arrival signal is taken as the arrival humidity value. The humidity detection values ​​at each acquisition time within the bonding edge association time period are compared with the arrival humidity value to obtain multiple humidity change differences. The humidity jump variable is determined based on the largest humidity change difference among these multiple differences, and the direction of the humidity jump is determined based on whether the corresponding humidity detection value increases or decreases relative to the arrival humidity value. If the humidity jump variable is less than the humidity change fluctuation range formed by qualified LCD screens of the same model at the same current station, the humidity jump variable is recorded as a normal humidity change. When the humidity jump variable does not exceed the environmental control range but exceeds the humidity change fluctuation range, the humidity jump variable is used as a data item that can participate in the bonding edge association processing. When the humidity detection value corresponding to the humidity jump variable exceeds the environmental control range, the humidity is determined as an environmental anomaly, and the humidity jump variable is simultaneously written into the process anomaly status.

[0061] Furthermore, when determining the residual vibration, the vibration detection values ​​after the conveyor line stops are arranged according to the acquisition time. The residual vibration is determined based on the peak value of the vibration detection value, the duration during which the vibration detection value is continuously greater than the range corresponding to the qualified vibration change process, and the recovery time when the vibration detection value decays to the range corresponding to the qualified vibration change process. If the residual vibration is less than the vibration change fluctuation range formed by the same model of qualified LCD display screen under test at the same current workstation, the residual vibration is recorded as a normal vibration change. When the residual vibration does not exceed the environmental control range but exceeds the vibration change fluctuation range, the residual vibration is recorded as a data item that can participate in the bonding edge association processing. When the vibration detection value corresponding to the residual vibration exceeds the environmental control range, the vibration state is determined as an environmental anomaly, and the residual vibration is simultaneously written into the process anomaly status.

[0062] During the departure traction period, the departure traction change is determined based on operational data. The departure traction change refers to the traction change on the edge of the contact area caused by the change in conveyor speed when the LCD screen under test leaves the current workstation. To determine the departure traction change, the conveyor speed feedback value during the departure traction period is read, and the speed change process of the LCD screen under test before and after triggering the departure signal is also read. When the conveyor speed experiences a short-term increase, a short-term decrease, or a speed recovery delay during the departure traction period, the departure traction change is determined based on the direction of speed change, the duration of speed change, and the departure direction. The departure direction refers to the conveyor direction when the LCD screen under test leaves the current workstation, determined by the conveyor path between the current workstation and the next workstation.

[0063] Furthermore, when determining the change in displacement traction, the conveyor speed feedback value during the displacement traction period is compared with the qualified displacement speed change process formed by the same model of qualified LCD display screen at the same current workstation to obtain multiple speed differences. The displacement traction change is determined based on the maximum speed difference, the cumulative result of the speed differences, and the time difference for the speed to recover to the corresponding range of the qualified displacement speed change process. If the conveyor speed feedback value is higher than the qualified displacement speed change process, the direction of speed change is determined to be a short-term increase; if the conveyor speed feedback value is lower than the qualified displacement speed change process, the direction of speed change is determined to be a short-term decrease; if the time when the conveyor speed feedback value recovers to the corresponding range of the qualified displacement speed change process is later than the qualified displacement speed change process, the direction of speed change is determined to be a speed recovery delay.

[0064] When the displacement traction change is less than the displacement speed fluctuation range formed by qualified LCD displays of the same model at the same current workstation, the displacement traction change is recorded as a normal displacement change. When the displacement traction change does not exceed the speed control range but exceeds the displacement speed fluctuation range, the displacement traction change is recorded as a data item that can participate in the bonding edge association processing. When the conveying speed feedback value corresponding to the displacement traction change exceeds the speed control range, the conveying speed is determined to be a conveying abnormality, and the displacement traction change is simultaneously written into the process abnormality status.

[0065] After obtaining the positioning rebound amount, pressure build-up offset amount, temperature retention amount, humidity jump amount, residual vibration amount, and displacement traction change amount, these quantities are respectively mapped to the edge extension direction, brightness gradient direction, and edge defect area of ​​the gradient bright band defect. If the positioning rebound direction points to the edge defect area, or the positioning rebound direction is consistent with the brightness gradient direction, then the positioning rebound amount is determined to have a positional correspondence with the gradient bright band defect. If the pressure build-up offset occurs during the pressure build-up period, and the edge defect area of ​​the gradient bright band defect is located at the edge of the bonding pressure area, then the pressure build-up offset is determined to have a pressure correspondence with the gradient bright band defect. If the temperature retention amount occurs after the bonding action ends and before the displacement signal is generated, and the gradient bright band defect extends along the edge of the bonding area, then the temperature retention amount is determined to have a temperature retention correspondence with the gradient bright band defect. If the humidity jump occurs during the positioning holding period, pressure building-up period, or bonding holding period, and the direction of the humidity jump is inconsistent with the direction of humidity change in the corresponding time period of the qualified LCD display under test, then the humidity jump is determined to have an environmental disturbance relationship with the gradient bright band defect. If the residual vibration occurs after the conveyor line stops but before the bonding pressure reaches a stable state, and the positioning rebound or pressure building-up offset already has a relationship with the gradient bright band defect, then the residual vibration is determined to have a vibration superposition relationship with the gradient bright band defect. If the displacement traction change occurs during the displacement traction period, and the displacement direction is consistent with the edge extension direction or the brightness gradient direction, then the displacement traction change is determined to have a displacement traction relationship with the gradient bright band defect. Figure 3 As shown.

[0066] Furthermore, when determining the correspondence between each change and the gradient bright band defect, a unified judgment is made regarding consistency of direction, pointing towards the edge defect area, location at the edge of the bonding pressure area, and occurrence within the corresponding time period. Consistency of direction means that the angle between the positioning rebound direction, the displacement direction, the edge extension direction, or the brightness gradient direction is within a preset angle range; pointing towards the edge defect area means that the extension direction of the positioning rebound direction overlaps with the edge defect area, or the distance between the extension direction of the positioning rebound direction and the edge defect area is less than a preset distance; location at the edge of the bonding pressure area means that the distance between the edge defect area and the boundary of the bonding pressure area is less than a preset edge distance; occurrence within the corresponding time period means that the timing of the positioning rebound amount, pressure establishment offset amount, temperature retention amount, humidity jump amount, residual vibration amount, or displacement traction change amount occurs within the positioning holding period, pressure establishment period, bonding holding period, or displacement traction period.

[0067] When a change only satisfies the occurrence time condition but not the direction or region condition, the change is not identified as corresponding to the gradient bright band defect. When a change satisfies both the occurrence time condition and at least one of the direction or region conditions, the change is identified as corresponding to the gradient bright band defect. The preset angle range, preset distance, and preset edge distance are determined based on the image coordinate calibration relationship, allowable offset range, and defect allowable conditions of the same type of qualified LCD display under the same current workstation.

[0068] When the same gradient bright band defect simultaneously satisfies at least two correspondences, and the satisfied correspondences include at least one correspondence obtained from process data and one correspondence obtained from operational data or environmental data, the defect state corresponding to the gradient bright band defect is determined as a latent anomaly defect state at the bonding edge. The latent anomaly defect state at the bonding edge refers to a state where the defect state has manifested as a gradient bright band defect at the edge of the bonding area, but a single process data point, a single environmental data point, or a single operational data point has not been determined as a high-value anomaly or a low-value anomaly, yet multiple data items have a correspondence with the edge defect area within the bonding edge associated time period.

[0069] After determining the latent abnormal defect state at the bonding edge, an edge cause chain is generated. The edge cause chain refers to a combination of data items arranged chronologically according to their occurrence time and corresponding to the gradient bright band defect. When generating the edge cause chain, quantities that have already been correlated with the gradient bright band defect among the positioning rebound, pressure establishment offset, temperature retention, humidity jump, residual vibration, and displacement traction change are written into the same edge cause chain according to their occurrence time. Specifically, the occurrence time of the positioning rebound is determined from the completion of the positioning action to the start of the bonding action; the occurrence time of the pressure establishment offset is determined by the pressure establishment period; the occurrence time of the temperature retention is determined from the end of the bonding action to the temperature recovery time; the occurrence time of the humidity jump is determined by the acquisition time when the humidity detection value experiences its maximum change; the occurrence time of the residual vibration is determined from the time the conveyor line stops to the time when the vibration detection value recovers to the corresponding range of the qualified vibration change process; and the occurrence time of the displacement traction change is determined by the displacement traction period.

[0070] The edge-fitting adjustment amount is generated based on the edge-causing chain. This edge-fitting adjustment amount refers to the adjustment direction and magnitude corresponding to each data item in the edge-causing chain. If the edge-causing chain includes positioning springback, a positioning holding adjustment amount is generated based on the positioning springback direction and amount; this positioning holding adjustment amount indicates the direction of adjustment for the holding time and the direction of correction for the holding position after the positioning action is completed and before the fitting action begins. If the edge-causing chain includes pressure establishment offset, a pressure establishment adjustment amount is generated based on the pressure establishment offset direction and the pressure stabilization arrival time; this pressure establishment adjustment amount indicates the direction of pressure change and the direction of adjustment for the pressure stabilization arrival time during the fitting pressure establishment process. If the edge-causing chain includes temperature stagnation, a temperature holding adjustment amount is generated based on the temperature deviation direction and the temperature recovery time; this temperature holding adjustment amount indicates the direction of temperature adjustment and the direction of adjustment for temperature holding duration before and after the fitting action ends. If the edge-causing chain includes humidity jump, a humidity control adjustment amount is generated based on the humidity jump direction; this humidity control adjustment amount indicates the direction of humidity adjustment near the current workstation. If the edge causal chain includes residual vibration, a conveyor stop waiting adjustment amount is generated based on the duration of the residual vibration; this conveyor stop waiting adjustment amount indicates the direction of adjustment for the waiting time from when the conveyor line stops until the bonding pressure begins to build. If the edge causal chain includes displacement traction change, a displacement speed adjustment amount is generated based on the displacement direction, speed change direction, and speed change duration; this displacement speed adjustment amount indicates the direction of adjustment for the conveyor speed when the LCD display under test leaves the current workstation.

[0071] Furthermore, when generating the edge adjustment amount, the adjustment direction and adjustment range are determined based on the deviation direction and degree corresponding to each data item in the edge cause chain. If the edge cause chain includes positioning springback, and the positioning springback direction points towards the edge defect area, the positioning holding adjustment amount is increased according to the positioning springback amount, thereby increasing the holding time from the completion of the positioning action to the start of the bonding action, or correcting the holding position in the opposite direction to the positioning springback direction; if the positioning springback amount decreases to within the positioning fluctuation range, the positioning holding adjustment amount is reduced or canceled.

[0072] If the edge causal chain contains a pressure establishment offset, and the pressure establishment offset direction is high, a pressure establishment adjustment amount is generated to reduce the pressure variation amplitude during the pressure establishment process or extend the pressure stabilization arrival time. If the pressure establishment offset direction is low, a pressure establishment adjustment amount is generated to increase the pressure variation amplitude during the pressure establishment process or shorten the pressure stabilization arrival time. If the pressure establishment offset decreases to within the pressure establishment fluctuation range, the pressure establishment adjustment amount is reduced or canceled.

[0073] If the edge formation chain contains a temperature retention amount, and the temperature deviation direction is too high, a temperature holding adjustment amount is generated to reduce the temperature before and after the bonding action ends or to shorten the temperature holding time; if the temperature deviation direction is too low, a temperature holding adjustment amount is generated to increase the temperature before and after the bonding action ends or to extend the temperature holding time. If the temperature retention amount decreases to within the temperature change fluctuation range, the temperature holding adjustment amount is reduced or canceled.

[0074] If the edge cause chain contains a humidity jump variable, and the direction of the humidity jump is upward, a humidity control adjustment is generated to reduce the humidity near the current workstation; if the direction of the humidity jump is downward, a humidity control adjustment is generated to increase the humidity near the current workstation. If the humidity jump variable decreases to within the range of humidity change fluctuations, the humidity control adjustment is reduced or canceled.

[0075] If the edge causal chain contains residual vibration, a conveyor stop waiting adjustment amount is generated based on the duration of the residual vibration, increasing the waiting time from when the conveyor line stops until the bonding pressure begins to build up; when the residual vibration decreases to within the range of vibration variation fluctuations, the conveyor stop waiting adjustment amount is reduced or canceled.

[0076] If the edge causal chain includes a displacement traction change, and the velocity change direction is a short-term increase, then a displacement velocity adjustment amount is generated to reduce the displacement conveying velocity. If the velocity change direction is a short-term decrease or a velocity recovery delay, then a displacement velocity adjustment amount is generated to improve the stability of the displacement conveying velocity. If the displacement traction change decreases to within the displacement velocity change fluctuation range, then the displacement velocity adjustment amount is reduced or canceled.

[0077] The latent abnormality defect status of the bonding edge is written into the defect status, and the edge cause chain and bonding edge adjustment amount are written into the process abnormality status. The written defect status includes the display identification, current station identification, defect type, defect location, defect size, defect level, image acquisition time, edge extension direction, brightness gradient direction, and edge defect area. The written process abnormality status includes the display identification, current station identification, abnormal data name, abnormality type, abnormality occurrence time, abnormality duration, abnormal deviation direction, abnormal judgment result, edge cause chain, and bonding edge adjustment amount. If the uneven display defect does not meet the determination conditions of the gradient bright band defect, or the gradient bright band defect does not simultaneously meet at least two corresponding relationships, then the latent abnormality defect status of the bonding edge is not generated, and the already determined defect status and process abnormality status are retained.

[0078] After completing the above processing, the defect status and process abnormality status of the LCD display under test at the current workstation are generated. The defect status includes the display identification, current workstation identification, defect type, defect location, defect size, defect level, and image acquisition time. The process abnormality status includes the display identification, current workstation identification, abnormal data name, abnormality type, abnormality occurrence time, abnormality duration, abnormal deviation direction, and abnormality judgment result.

[0079] In step three, based on the defect status and process anomaly status formed in step two, the system reads the same display screen identification, the same current workstation identification, and the defect type, defect location, defect size, defect level, anomaly data name, anomaly type, anomaly occurrence time, anomaly duration, anomaly deviation direction, and anomaly judgment result within the same processing time period. The production line control actions refer to the actions of conveying, stopping, repeating inspections, rework transfers, and isolating transfers of the LCD display screen under test on the production line, as well as adjusting the processing conditions of the current workstation. When generating production line control actions, the defect status is used as the basis for handling the LCD display screen under test, the process anomaly status is used as the basis for handling the current workstation, and the defect status and process anomaly status within the same processing time period are used together to determine the action content.

[0080] When the defect level in the defect status is a permissible defect, and there are no process anomalies within the same processing time period, a release action is generated. The release action refers to releasing the LCD display under test from its current station and allowing it to proceed to the next station according to the current transport direction. When generating a release action, the display's identification, current station identification, release time, defect type, defect location, defect size, and defect level are written into the production line control actions; the release time is determined by the time the current station completes the defect status assessment. If the defect level in the defect status is a permissible defect, but there is a process anomaly within the same processing time period, a release action with status recording is generated; this release action refers to the LCD display under test continuing to the next station, while simultaneously recording the corresponding anomaly data name, anomaly type, anomaly occurrence time, and anomaly duration in the production line control actions.

[0081] When the image judgment result in the defect status is "unable to determine", a repeat detection action is generated. The repeat detection action refers to the action of re-acquiring image data and re-determining the defect status of the same LCD display under test. When generating a repeat detection action, if the current workstation has the conditions for re-imaging, the LCD display under test is kept at the preset imaging position of the current workstation, and the same lighting and image acquisition methods as the original test object are triggered again; if the current workstation does not have the conditions for re-imaging, the LCD display under test is transported to the preset repeat detection position, and image data is re-acquired at the preset repeat detection position according to the original test object. The preset repeat detection position refers to the position on the production line used to re-acquire images of the LCD display under test, and its imaging position, lighting method, and image acquisition method correspond to the original test object. When generating a repeat detection action, the display identification, current workstation identification, original image acquisition time, reason for inability to determine, and repeat detection trigger time are written into the production line control action; wherein, the reason for inability to determine is determined by the data validity mark corresponding to the image data in step two, the detection area identification result, or the image clarity judgment result.

[0082] When the defect level in the defect status is an unacceptable defect, an isolation transfer action or a rework transfer action is generated based on the defect type, defect location, and defect size. The isolation transfer action refers to the action of transferring the LCD display under test from the normal transport path to a preset isolation position. The preset isolation position is a location on the production line used to temporarily store LCD displays under test that are not allowed to continue flowing along the normal path. The rework transfer action refers to the action of transferring the LCD display under test from the normal transport path to a preset rework position. The preset rework position is a location on the production line used to perform cleaning, re-lamination, re-pressing, or other repair treatments on the LCD display under test. When the defect type is an edge chipping defect, the defect location is in the edge area, and the defect size exceeds the allowable defect conditions, an isolation transfer action is generated. When the defect type is a scratch defect, foreign object defect, stain defect, uneven display defect, or positional offset defect, and the production inspection document corresponding to this defect type allows for repair treatment, a rework transfer action is generated. When generating isolation or rework actions, the display screen identifier, current workstation identifier, defect type, defect location, defect size, defect level, target transfer location, and transfer trigger time are written into the production line control action; among them, the target transfer location is determined based on the correspondence between the defect type and the preset isolation location or preset rework location.

[0083] When the anomaly judgment result in the process anomaly status is a low-value anomaly or a high-value anomaly, a process adjustment action is generated based on the anomaly data name and the direction of anomaly deviation. The process adjustment action refers to the action of adjusting the processing conditions corresponding to the anomaly data name at the current workstation. If the anomaly data name is cleaning fluid flow rate, and the anomaly deviation direction is below the lower limit of the process control range, a process adjustment action to increase the cleaning fluid supply is generated; if the anomaly deviation direction is above the upper limit of the process control range, a process adjustment action to decrease the cleaning fluid supply is generated. If the anomaly data name is spray pressure, and the anomaly deviation direction is below the lower limit of the process control range, a process adjustment action to increase the spray pressure is generated; if the anomaly deviation direction is above the upper limit of the process control range, a process adjustment action to decrease the spray pressure is generated. If the anomaly data name is bonding pressure, and the anomaly deviation direction is below the lower limit of the process control range, a process adjustment action to increase the bonding pressure is generated; if the anomaly deviation direction is above the upper limit of the process control range, a process adjustment action to decrease the bonding pressure is generated. If the abnormal data name is bonding temperature, curing temperature, or light intensity, then a process adjustment action is generated to increase or decrease the corresponding processing conditions according to the direction of the abnormal deviation. When generating the process adjustment action, the abnormal data name, abnormal type, abnormal deviation direction, adjustment object, and adjustment trigger time are written into the production line control action; where the adjustment object refers to the processing conditions that generate the corresponding process data in the current workstation.

[0084] When the process anomaly is an environmental anomaly, an environmental handling action is generated for the current workstation based on the anomaly data name. This current workstation environmental handling action refers to actions taken to address the temperature, humidity, particulate matter concentration, or vibration status of the current workstation. If the anomaly data name is temperature, a heating or cooling action is generated based on the direction of the anomaly deviation; if the anomaly data name is humidity, a humidification or dehumidification action is generated based on the direction of the anomaly deviation; if the anomaly data name is particulate matter concentration, a cleaning action is generated, and the LCD screen under test is held at the current workstation or moved to a preset temporary storage location until the particulate matter concentration returns to the corresponding environmental control range; if the anomaly data name is vibration status, a conveyor deceleration action or a pause action for the current workstation is generated. The preset temporary storage location refers to a location on the production line used to temporarily place the LCD screen under test without performing any processing actions. When generating the current workstation environmental handling action, the anomaly data name, anomaly occurrence time, anomaly duration, anomaly deviation direction, and handling trigger time are written into the production line control actions.

[0085] When the process anomaly is an operational anomaly, a conveying handling action, a positioning handling action, or an action pause action is generated based on the operational anomaly status. The conveying handling action refers to adjusting the conveying speed of the LCD screen under test on the production line, stopping the conveying, or resuming the conveying. The positioning handling action refers to re-performing positioning, suction positioning, or visual positioning on the LCD screen under test. The action pause action refers to stopping the processing action currently being performed at the workstation and maintaining the current position of the LCD screen under test. If the anomaly type is a conveying anomaly, a conveying deceleration action, a conveying acceleration action, or a conveying stop action is generated based on the direction of deviation of the conveying speed from the speed control range. If the anomaly type is a positioning anomaly, a conveying stop action is generated, and the time when no positioning detection signal was generated is recorded. If the anomaly type is a positioning anomaly, a repositioning action is generated, and the actual position of the LCD screen under test is re-acquired according to the positioning, suction positioning, or visual positioning method corresponding to step one. If the anomaly type is an action anomaly, an action pause action is generated, and the name of the operating data that generated the alarm signal and the time when the alarm signal was generated are recorded.

[0086] When the same display screen identifier simultaneously exhibits both an unacceptable defect and a process anomaly within the same processing time period, an isolation or rework flow action is first generated for the LCD screen under test. Then, a process adjustment action, a current workstation environment handling action, or an operational handling action is generated for the current workstation. If the unacceptable defect is an edge chipping defect, or if the defect size exceeds the repair allowable range corresponding to that defect type, an isolation flow action is generated. The repair allowable range refers to the range of defect size, location, and quantity specified in the production inspection document that can be restored through cleaning, re-lamination, re-pressing, or other repair processes. If the unacceptable defect belongs to a defect type that is repairable according to the production inspection document, and the defect size, location, and quantity are within the repair allowable range, a rework flow action is generated. After generating the flow action corresponding to the LCD screen under test, the handling action corresponding to the current workstation is generated based on the anomaly data name, anomaly type, and anomaly deviation direction in the process anomaly status.

[0087] When the same abnormal data name and abnormal type appear at the same current workstation within multiple consecutive processing time periods, a pause action is generated for the current workstation. The multiple consecutive processing time periods refer to the consecutive time periods formed when multiple LCD displays under test pass through the same current workstation, and there is no record of the abnormal data name returning to normal between two adjacent processing time periods. The pause action for the current workstation means stopping the current workstation from receiving new LCD displays under test and maintaining the position state of the existing LCD displays under test at the current workstation. When generating the pause action for the current workstation, the current workstation identifier, abnormal data name, abnormal type, the time of the first abnormal occurrence, the time of the most recent abnormal occurrence, and the pause trigger time are written into the production line control action; wherein, the time of the first abnormal occurrence is determined by the time when the abnormal data name and abnormal type first appear in the multiple consecutive processing time periods, and the time of the most recent abnormal occurrence is determined by the time when the abnormal data name and abnormal type appear in the most recent processing time period.

[0088] When the same LCD display under test corresponds to multiple production line control actions, the final production line control action is determined according to the order of action execution. The order of action execution refers to the rules for determining the sequential execution relationship when multiple production line control actions exist simultaneously. If a current workstation pause action exists among the multiple production line control actions, the current workstation pause action is executed first; if there is no current workstation pause action but there is an isolation flow action, the isolation flow action is executed first; if there is no isolation flow action but there is a rework flow action, the rework flow action is executed first; if there is no rework flow action but there is a repeat inspection action, the repeat inspection action is executed first; if only process adjustment actions, current workstation environment handling actions, or operation handling actions exist, they are executed in the order of when the abnormality occurred; if there are no defect states or process abnormal states, or only permissible defects that do not require repeat inspection, a release action is executed.

[0089] After completing the above processing, the production line control actions for the LCD display under test at the current workstation are generated. These production line control actions include the display screen's identification, the current workstation identification, the action type, the action triggering basis, the action object, the target flow position, the action trigger time, and the action execution sequence. The action types include release actions, repetitive inspection actions, isolation flow actions, rework flow actions, process adjustment actions, current workstation environment handling actions, operational handling actions, and current workstation pause actions. The action triggering basis is determined by the corresponding defect status or process anomaly status. The action object is the LCD display under test or the current workstation. The target flow position is determined by the position corresponding to the isolation flow action, rework flow action, or temporary storage action.

[0090] In step four, based on the production line control actions generated in step three, the display screen's identity identifier, current workstation identifier, action type, action triggering basis, action object, target flow position, action triggering time, and action execution sequence are read. The execution result refers to the detectable result generated after the production line control actions are executed, including the actual flow position of the LCD display screen under test, the action completion signal of the current workstation, adjusted process data, adjusted environmental data, adjusted operating data, re-acquired image data, and redefined defect status. The control basis refers to the defect allowable conditions, process control range, environmental control range, speed control range, allowable offset range, repair allowable range, the correspondence between defect type and target flow position, and the action execution sequence used in steps two and three to judge and generate actions.

[0091] When the production line control action is a release action, the dwell restriction of the LCD screen under test at the current workstation is lifted, and the conveyor line is driven to transport the LCD screen under test to the next workstation. When executing a release action, the release trigger time of the current workstation is first read, and then the conveyor line is controlled to switch from a stopped or waiting state to a conveying state. When the LCD screen under test triggers the departure signal of the current workstation, the departure time is recorded; when the LCD screen under test triggers the arrival signal of the next workstation, the arrival time of the next workstation is recorded. If the current workstation generates a departure signal, and the next workstation generates an arrival signal within the corresponding conveying time range, the execution result of the release action is determined as release complete. If the current workstation does not generate a departure signal, or the next workstation does not generate an arrival signal within the corresponding conveying time range, the execution result of the release action is determined as a release anomaly, and the anomaly type is written into the operation data. The corresponding conveying time range is determined by the conveying distance and conveying speed between the current workstation and the next workstation.

[0092] When the production line control action is a repetitive inspection action, the image data of the LCD screen under test is re-acquired based on the reasons for the inability to determine the cause recorded in step three. If the reason for the inability to determine the cause is that the image clarity does not meet the inspection requirements, the positioning action is re-executed, and the inspection image is re-acquired after positioning is completed. If the reason for the inability to determine the cause is that the lighting method does not match the inspection object, the LCD screen under test is kept in the preset imaging position, and the imaging method of reflected lighting, oblique lighting, transmitted lighting, or lighting after the display is lit is re-triggered according to the inspection object. If the reason for the inability to determine the cause is that the inspection area recognition fails, the edge contour or positioning reference point of the LCD screen under test is re-identified, and the inspection area is re-determined. The re-acquired image data is used to re-determine the defect status according to the method in step two, and the re-determined defect status is used as the repetitive inspection result. The repetitive inspection result includes the display screen identification, the current workstation identification, the time of re-acquiring the image, the defect type, the defect location, the defect size, and the defect level. If the repeated inspection result is still indeterminate, an isolation transfer action is generated; if the repeated inspection result is an acceptable defect, a release action is performed; if the repeated inspection result is an unacceptable defect, an isolation transfer action or a rework transfer action is performed based on the defect type, defect location, and defect size.

[0093] When the production line control action is an isolation transfer action, the LCD display under test is transferred from the normal transport path to a preset isolation position in the target transfer location. The normal transport path refers to the transport path through which the LCD display under test passes through each workstation in the production process sequence. When executing the isolation transfer action, the LCD display under test is first stopped at the current workstation from continuing to the next normal workstation, and then the transport direction of the LCD display under test is changed by a diversion mechanism; the diversion mechanism refers to a mechanical actuator set at the fork of the transport path that enables the LCD display under test to enter different transport paths. After the LCD display under test enters the preset isolation position, the arrival signal and display identification of that position are read; when the read display identification matches the display identification in the isolation transfer action, and the preset isolation position generates an arrival signal, the execution result of the isolation transfer action is determined as isolation complete; when the display identification does not match or the preset isolation position does not generate an arrival signal, the execution result of the isolation transfer action is determined as isolation abnormal, and the time of the abnormality, the actual transfer position, and the current workstation identification are recorded.

[0094] When the production line control action is a rework flow action, the LCD display under test is transferred from the normal transport path to the preset rework position in the target flow location. When executing the rework flow action, the rework processing method is first determined according to the defect type. When the defect type is a foreign object defect or a stain defect, the rework processing method is cleaning. When the defect type is a positional misalignment defect, the rework processing method is repositioning and re-laminating or re-pressing. When the defect type is an uneven display defect, the rework processing method is re-inspecting the display status or re-executing the process corresponding to that display status. After the LCD display under test enters the preset rework position, the arrival signal and display identification of the preset rework position are read. When the read display identification matches the display identification in the rework flow action, and the preset rework position generates an arrival signal, the corresponding rework processing method is executed. After the rework processing is completed, image data is re-acquired, and the defect status is re-determined according to the method in step two. If the redefined defect level is a permissible defect, then a release action is performed; if the redefined defect level is still a non-permissible defect, and the defect status is still within the repairable range, then a rework process is performed again; if the redefined defect level is still a non-permissible defect, and the defect status exceeds the repairable range, then an isolation process is performed.

[0095] When the production line control action is a process adjustment action, the processing conditions corresponding to the current workstation are adjusted according to the abnormal data name and the direction of the abnormal deviation. If the abnormal data name is cleaning fluid flow rate, the cleaning fluid flow rate is adjusted by changing the cleaning fluid supply opening, and the adjusted flow rate detection value is read; if the abnormal data name is spray pressure, the spray pressure is adjusted by changing the spray pressure setting value, and the adjusted pressure detection value is read; if the abnormal data name is bonding pressure, the bonding pressure is adjusted by changing the bonding pressure setting value, and the adjusted pressure detection value is read; if the abnormal data name is bonding temperature or curing temperature, the temperature is adjusted by changing the heating setting value, and the adjusted temperature detection value is read; if the abnormal data name is light intensity, the light intensity is adjusted by changing the light source output setting value, and the adjusted light intensity detection value is read. The adjusted detection value is compared with the corresponding process control range. If the adjusted detection value is within the corresponding process control range, the result of the process adjustment action is determined as the adjustment is complete, and the detection value before adjustment, the detection value after adjustment, the adjustment trigger time, and the adjustment completion time are recorded. If the adjusted detection value still exceeds the corresponding process control range, the result of the process adjustment action is determined as the adjustment is incomplete, and a pause action is generated for the current workstation.

[0096] When the production line control action is an environmental handling action for the current workstation, the corresponding handling is performed according to the name of the abnormal data. If the abnormal data name is temperature, a heating or cooling action is performed according to the direction of the abnormal deviation, and the temperature detection value after handling is read. If the abnormal data name is humidity, a humidification or dehumidification action is performed according to the direction of the abnormal deviation, and the humidity detection value after handling is read. If the abnormal data name is particulate matter concentration, a cleaning action is performed, and the particulate matter concentration detection value after handling is read. If the abnormal data name is vibration status, a conveyor deceleration action or a pause action for the current workstation is performed, and the vibration detection value after handling is read. The environmental data after handling is compared with the corresponding environmental control range. If the environmental data after handling is within the corresponding environmental control range, the execution result of the environmental handling action for the current workstation is determined as environmental handling completed. If the environmental data after handling still exceeds the corresponding environmental control range, the execution result of the environmental handling action for the current workstation is determined as environmental handling incomplete, and the current workstation remains paused.

[0097] When the production line control action is an operational handling action, a conveying handling action, a positioning handling action, or an action pause action is executed according to the anomaly type. If the anomaly type is a conveying anomaly, the conveying speed is adjusted according to the direction of deviation of the conveying speed from the speed control range, and the adjusted conveying speed feedback value is read. If the anomaly type is a positioning anomaly, the conveyor line is stopped, and the positioning detection signal is reread. If the anomaly type is a positioning anomaly, positioning stop, adsorption positioning, or visual positioning is re-executed, and the position detection result after repositioning is read. If the anomaly type is an action anomaly, the processing action being performed at the current workstation is stopped, and alarm signals and action completion signals are read. If the operational data after handling is within the corresponding speed control range, allowable offset range, or action completion condition, the execution result of the operational handling action is determined as operational handling completed. If the operational data after handling still does not meet the corresponding conditions, the execution result of the operational handling action is determined as operational handling incomplete, and a pause action is generated for the current workstation.

[0098] When the production line control action is to pause the current workstation, the current workstation stops receiving new LCD displays under test, and the LCD displays already at the current workstation remain in their current positions. When the current workstation pauses, the current workstation identifier, pause trigger time, name of the abnormal data triggering the pause, abnormal type, and display identification of the LCD display under test within the current workstation are recorded. After the current workstation pauses, process data, environmental data, and operational data for the current workstation continue to be collected. When the detection value corresponding to the abnormal data name triggering the pause returns to the corresponding process control range, environmental control range, speed control range, or allowable offset range, and the alarm signal for the current workstation is cleared, the pause release time is recorded, and a release action or a repeat detection action is performed. If the detection value corresponding to the abnormal data name does not return to the corresponding range, or the alarm signal is not cleared, the current workstation pause action is maintained.

[0099] After each production line control action is completed, the control criteria are updated based on the execution results. If the repeated detection result is consistent with the original defect status, the original defect type, defect location, defect size, and defect level are retained. If the repeated detection result is inconsistent with the original defect status, the original defect status is replaced with the defect status corresponding to the time of re-acquiring the image, and the difference between the original defect status and the repeated detection result is recorded. If the defect level is redefined after rework and changes from an unacceptable defect to an acceptable defect, the defect type, defect location, defect size, rework method, and rework result are written into the record corresponding to the acceptable repair range. If the defect level is still unacceptable after rework and the redefined defect level is still unacceptable, the defect type, defect location, defect size, and rework result are written into the record corresponding to the isolation transfer action. If the adjusted detection value is within the corresponding process control range after the process adjustment action is executed, the detection value before adjustment, the detection value after adjustment, and the time of adjustment completion are written into the process control record corresponding to the abnormal data name. If the adjusted detection value still exceeds the corresponding process control range after the process adjustment action is executed, a correspondence is established between the abnormal data name and the current workstation pause action. If the current workstation environment does not return to normal after the handling or operation handling actions are performed, a corresponding relationship will be established between the abnormal data name, the abnormal type, and the current workstation pause action.

[0100] After executing the current station's handling action based on the edge adjustment amount, the image data, process data, environmental data, and operational data of the current station are re-collected, and the defect status and process anomaly status are re-determined in the manner described above. If the re-determined defect status no longer includes the latent abnormal defect status of the edge, or if the defect size, brightness contrast, or defect level of the edge defect area decreases, then the execution result of the corresponding current station's handling action is determined to be valid. If the re-determined defect status still includes the latent abnormal defect status of the edge, and the defect size, brightness contrast, or defect level of the edge defect area does not decrease, then the execution result of the corresponding current station's handling action is determined to be invalid, and the updated defect status, process anomaly status, edge cause chain, and edge adjustment amount continue to be used as the basis for control.

[0101] After completing the above processing, a production line control action execution record is generated. This record includes the display screen identifier, current workstation identifier, action type, action triggering basis, action execution time, action completion time, execution result, actual flow position, pre-adjustment detection value, post-adjustment detection value, redefined defect status, and updated control basis. The updated control basis further includes defect tolerance conditions, process control range, environmental control range, speed control range, allowable offset range, allowable repair range, the correspondence between defect types and target flow positions, and the action execution sequence.

[0102] The present invention also proposes an LCD display production line control system, including: a production status data generation module, a defect and process abnormality status determination module, a bonding edge association processing module, a production line control action execution record generation module, and signal connections between the modules; The production status data generation module is used to read the display identification of the LCD display under test and collect image data, process data, environmental data and operation data of the current workstation to form production status data; The defect and process anomaly determination module is used to determine the defect status and process anomaly status based on the production status data. The defect status includes the defect type and defect location, and the process anomaly status includes the anomaly data name and anomaly deviation direction. The edge-fitting association processing module is used to perform edge-fitting association processing based on the same display screen identifier, the same current workstation identifier, and image data, process data, environmental data, and operating data within the same processing time period when the defect type is uneven display defect and the defect location is located at the edge of the bonding area. This process determines the gradient bright band defect and correlates the positioning rebound amount, pressure establishment offset amount, temperature retention amount, humidity jump amount, residual vibration amount, and displacement traction change amount with the gradient bright band defect to determine the latent abnormal defect state of the bonding edge and generate the edge cause chain and bonding edge adjustment amount. The production line control action execution record generation module is used to generate production line control actions based on the defect status, the process abnormality status, the edge cause chain, and the bonding edge adjustment amount, and to generate production line control action execution records based on the production line control actions.

[0103] The above formulas are all dimensionless calculations. The formulas are derived from software simulations based on a large amount of collected data to obtain the most recent real-world results. The preset parameters in the formulas are set by those skilled in the art according to the actual situation.

[0104] The above embodiments can be implemented, in whole or in part, by software, hardware, firmware, or any other combination thereof. When implemented using software, the above embodiments can be implemented, in whole or in part, in the form of a computer program product.

[0105] Those skilled in the art will recognize that the modules and algorithm steps of the various examples described in conjunction with the embodiments disclosed herein can be implemented in electronic hardware, or a combination of computer software and electronic hardware. Whether these functions are implemented in hardware or software depends on the specific application and inventive constraints of the technical solution. Those skilled in the art can use different methods to implement the described functions for each specific application, but such implementation should not be considered beyond the scope of this application.

[0106] In addition, the functional modules in the various embodiments of this application can be integrated into one processing module, or each module can exist physically separately, or two or more modules can be integrated into one module.

[0107] The above description is merely a specific embodiment of this application, but the scope of protection of this application is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the scope of the technology disclosed in this application should be included within the scope of protection of this application. Therefore, the scope of protection of this application should be determined by the scope of the claims.

[0108] In conclusion, the above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A method for controlling an LCD display production line, characterized in that, include: Read the display identification of the LCD screen under test, and collect the image data, process data, environmental data and operation data of the current workstation to form production status data; Defect status and process abnormality status are determined based on the production status data. The defect status includes the defect type and defect location, and the process abnormality status includes the abnormal data name and abnormal deviation direction. When the defect type is uneven display defect and the defect location is at the edge of the bonding area, bonding edge association processing is performed based on the same display screen identity, the same current workstation identity, and the image data, process data, environmental data, and operation data within the same processing time period. The gradient bright band defect is determined, and the positioning rebound amount, pressure establishment offset amount, temperature retention amount, humidity jump amount, residual vibration amount, and displacement traction change amount are correlated with the gradient bright band defect to determine the latent abnormal defect state of the bonding edge, and the edge cause chain and bonding edge adjustment amount are generated. Based on the defect status, the process anomaly status, the edge cause chain, and the bonding edge adjustment amount, production line control actions are generated, and production line control action execution records are formed based on the production line control actions.

2. The LCD display production line control method according to claim 1, characterized in that: Read the display identification of the LCD display under test, and simultaneously record the current workstation identification, arrival time, departure time and various data acquisition times to construct the data association basis for the same display within the same current workstation.

3. The LCD display production line control method according to claim 2, characterized in that: After the LCD screen under test is positioned, a detection image containing edge contours, positioning reference points, and image coordinate information is acquired, and the correspondence between the image pixel positions and the actual positions of the LCD screen under test is established using camera calibration. In the bonding process station, image data, process data, environmental data, and operational data related to the bonding process are constructed by acquiring alignment offset, bonding pressure, bonding duration, bonding temperature, as well as humidity, vibration status, conveying speed, positioning status, action completion status, and abnormal triggering status during the period from the current station's arrival to departure. The data is processed according to the start time of the action, the end time of the action, the instantaneous trigger time, and the image acquisition time. The detection values ​​are calibrated and converted, invalid detection values ​​are marked, and the images are brightness corrected, noise suppressed, and coordinate calibrated to form production status data that includes display screen identification, current workstation identification, image data, process data, environmental data, operation data, and data validity marking.

4. The LCD display production line control method according to claim 3, characterized in that: The production status data, constructed using the same display screen identifier, the same current workstation identifier, and the data acquisition time, reads the corresponding image data, process data, environmental data, operating data, and data validity markers. Invalid detection values ​​are used to exclude data items that cannot participate in the judgment. On the image side, the display area, edge area, bonding area, and positioning reference area are determined based on image coordinate information. The detection image is compared with the reference image under the same imaging conditions by pixel brightness or grayscale, and the abnormal pixel positions are marked. Furthermore, adjacent abnormal pixels are marked as connected regions. Based on the area, length, width, edge contour, center position, and brightness contrast of the connected regions, a defect status containing defect type, defect position, defect size, and defect level is constructed. The content related to the bonding edge mainly includes the identification of uneven display defects, bonding offset, or edge position offset, and the conversion of the center position, size, and positioning reference area of ​​the connected region into the actual position on the LCD screen under test through image coordinate calibration relationship. On the data side, the alignment offset, bonding pressure, bonding duration, and bonding temperature related to the bonding process are compared with the corresponding process control ranges. The humidity and vibration environmental data are compared with the environmental control ranges. The conveying speed, arrival status, positioning status, action completion status, abnormal trigger status, waiting, re-inspection, rework flow, or abnormal stop operation data are compared with the corresponding control conditions to construct a process abnormality state that includes the abnormal data name, abnormality type, abnormality occurrence time, abnormality duration, and abnormal deviation direction.

5. The LCD display production line control method according to claim 4, characterized in that: After determining the defect status and process anomaly status, for cases where the defect type is uneven display and the defect location is at the edge of the bonding area, bonding edge association processing is performed. Specifically, using the same display screen identifier, the same current workstation identifier, and image data, process data, environmental data, and operating data within the same processing time period, the edge position of the bonding area edge in the detection image is first determined based on the image coordinate information. Then, multiple brightness change sequences are read along the direction perpendicular to the edge of the bonding area. When multiple adjacent brightness change sequences show a gradual increase or decrease from the edge of the bonding area to the interior of the display area, and the abnormal pixel position is continuously or intermittently distributed along the edge of the bonding area, the corresponding uneven display defect is determined as a gradient bright band defect, and the edge extension direction, brightness gradient direction, and edge defect area are recorded.

6. The LCD display production line control method according to claim 5, characterized in that: Based on the completion time of the positioning action, the start time of the bonding action, the time when the pressure stabilizes, the end time of the bonding action, and the time of the departure signal, the system is divided into positioning holding period, pressure establishment period, bonding holding period, and departure traction period. Within each of these periods, the positioning rebound amount, pressure establishment offset amount, temperature retention amount, humidity jump amount, residual vibration amount, and departure traction change amount are determined. Then, each of these changes is correlated with the edge extension direction, brightness gradient direction, and edge defect area of ​​the gradient bright band defect to determine the correspondence between the positioning rebound amount and the position of the gradient bright band defect, the correspondence between the pressure establishment offset amount and the pressure of the gradient bright band defect, the correspondence between the temperature retention amount and the temperature retention of the gradient bright band defect, the correspondence between the humidity jump amount and the environmental disturbance of the gradient bright band defect, the correspondence between the residual vibration amount and the vibration superposition of the gradient bright band defect, and the correspondence between the departure traction change amount and the departure traction of the gradient bright band defect.

7. The LCD display production line control method according to claim 6, characterized in that: When the same gradient bright band defect satisfies at least two corresponding relationships, including one corresponding relationship obtained from process data and one corresponding relationship obtained from operation data or environmental data, the defect state corresponding to the gradient bright band defect is determined as the latent abnormal defect state of the bonding edge. Then, the positioning rebound amount, pressure establishment offset amount, temperature retention amount, humidity jump amount, residual vibration amount, and displacement traction change amount, which have been established with the gradient bright band defect, are written into the same edge cause chain according to the time of occurrence. Based on the data items in the edge cause chain, positioning holding adjustment amount, pressure establishment adjustment amount, temperature holding adjustment amount, humidity control adjustment amount, conveying stop waiting adjustment amount, and displacement speed adjustment amount are generated respectively. Finally, the latent abnormal defect status of the bonding edge is written into the defect status, and the edge cause chain and bonding edge adjustment amount are written into the process abnormal status.

8. The LCD display production line control method according to claim 7, characterized in that: Based on the same display screen identity, the same current workstation identity, and the same processing time period, the defect type, defect location, defect size, defect level, abnormal data name, abnormal type, abnormal occurrence time, abnormal duration, and abnormal deviation direction are read. The flow action of the LCD display screen under test is constructed based on the defect status, and the handling action of the current workstation is constructed based on the process abnormal status. Specifically, for defects related to uneven display, positional offset, or latent abnormal defects already written into the bonding edge status, which are related to the bonding edge associated processing, a rework transfer action or an isolation transfer action is generated based on the defect type, defect location, defect size, and allowable repair range, and the target transfer position and transfer trigger time are written; for bonding pressure, bonding temperature, humidity, vibration status, conveying speed, positioning status, and action completion status related to the bonding process in the process abnormal status, bonding pressure adjustment action, bonding temperature adjustment action, humidity handling action, vibration handling action, conveying handling action, repositioning action, or action pause action are generated based on the abnormal data name, abnormal deviation direction, and abnormal occurrence time, respectively; when the process abnormal status includes edge When adjusting the edge and the cause chain, read the positioning and holding adjustment, pressure establishment adjustment, temperature holding adjustment, humidity control adjustment, conveying stop waiting adjustment, or departure speed adjustment according to the corresponding data item in the edge cause chain, and use the corresponding adjustment as the action trigger basis for the current station's handling action; when the same LCD display under test corresponds to both the flow action and the current station's handling action, arrange the action execution relationship in the order of current station pause, isolation flow, rework flow, repeated inspection, process adjustment, environmental handling, operation handling, and release, and write the display identification, current station identification, action type, action trigger basis, action object, target flow position, action trigger time, and action execution order into the production line control action.

9. The LCD display production line control method according to claim 8, characterized in that: Based on the action type, triggering basis, action object, and execution sequence in the production line control actions, corresponding control action execution records are constructed. Specifically, for repetitive detection actions related to edge bonding processing, if the cause cannot be determined, re-positioning, re-matching the lighting method, or re-identifying the edge contour and positioning reference point are performed, and the newly acquired image data is rewritten into the defect status. For rework flow actions corresponding to uneven display defects, positional offset defects, or latent abnormality defects in the bonding edge, the LCD display under test is transferred to a preset rework position according to the defect type, and a rework processing method of re-detecting the display status, repositioning, and then re-bonding or re-pressing is selected. For handling actions corresponding to bonding pressure, bonding temperature, humidity, vibration status, conveying speed, and positioning status, the bonding pressure setting value, heating setting value, humidity control direction, conveying speed, or positioning method are adjusted according to the abnormal data name and abnormal deviation direction, and the adjusted pressure detection value, temperature detection value, humidity detection value, vibration detection value, conveying speed feedback value, or position detection result after repositioning is read. When the action triggering basis includes edge cause chain and edge fit adjustment amount, the holding time, holding position, pressure establishment process, temperature holding adjustment amount, humidity control adjustment amount, conveying stop waiting adjustment amount or departure speed adjustment amount of the current station are adjusted accordingly. Then, the action execution time, action completion time, execution result, actual flow position, detection value before adjustment, detection value after adjustment, redefined defect status and updated control basis are written into the production line control action execution record.

10. An LCD display production line control system, used to implement the LCD display production line control method according to any one of claims 1-9, characterized in that, include: The module includes a production status data generation module, a defect and process anomaly status determination module, an edge correlation processing module, a production line control action execution record generation module, and signal connections between the modules. The production status data generation module is used to read the display identification of the LCD display under test and collect image data, process data, environmental data and operation data of the current workstation to form production status data; The defect and process anomaly determination module is used to determine the defect status and process anomaly status based on the production status data. The defect status includes the defect type and defect location, and the process anomaly status includes the anomaly data name and anomaly deviation direction. The edge-fitting association processing module is used to perform edge-fitting association processing based on the same display screen identifier, the same current workstation identifier, and image data, process data, environmental data, and operating data within the same processing time period when the defect type is uneven display defect and the defect location is located at the edge of the bonding area. This process determines the gradient bright band defect and correlates the positioning rebound amount, pressure establishment offset amount, temperature retention amount, humidity jump amount, residual vibration amount, and displacement traction change amount with the gradient bright band defect to determine the latent abnormal defect state of the bonding edge and generate the edge cause chain and bonding edge adjustment amount. The production line control action execution record generation module is used to generate production line control actions based on the defect status, the process abnormality status, the edge cause chain, and the bonding edge adjustment amount, and to generate production line control action execution records based on the production line control actions.

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