A method and system for precisely controlling the amount of fluorescent glue coated on a high-consistency patch LED

Abstract

The present application belongs to the technical field of dispensing monitoring and control, and particularly relates to a high-consistency patch type LED fluorescent adhesive coating amount precise control method and system. The present application directly converts the control target from the traditional dispensing amount to the real-time spreading rate of the fluorescent adhesive in the support bowl cup. The laser displacement sensor is used to obtain the fluorescent adhesive free surface height change rate of the center area of the support bowl cup in real time. The theoretical spreading rate established by fusing the support bowl cup geometric size, the chip volume and the solid-liquid interface contact angle parameters is introduced as a dynamic reference. The coating filling process is changed from the fixed parameter open loop to the three-dimensional dynamic closed loop. The consistency and control precision of the coating amount are significantly improved. By comparing the rate deviation value with the preset rate deviation tolerance interval, only when the deviation exceeds the tolerance interval, the dispensing compensation amount matched with the deviation direction and the deviation degree is generated, the frequent oscillation of the control system near the target value is avoided, and the stability of the adjustment process is improved.

Description

Technical Field

[0001] This invention belongs to the field of dispensing monitoring and control technology, specifically relating to a method and system for precise control of the coating amount of highly consistent patch LED fluorescent adhesive. Background Technology

[0002] In the phosphor coating process of surface mount LEDs, the consistency of the coating amount directly affects the color temperature, brightness uniformity and product yield. Existing coating control methods mainly adopt time-pressure dispensing systems, which open-loop control the coating amount of phosphor by setting a fixed dispensing air pressure and a fixed dispensing time.

[0003] However, in actual continuous production, the viscosity, thixotropy, and other rheological properties of fluorescent adhesive drift with batch, temperature, humidity, and resting time. This causes fluctuations in the actual volume of fluorescent adhesive extruded from the dispensing needle per unit time under the same dispensing pressure. These fluctuations are significantly amplified within the tiny support cup structure, making it difficult for fixed parameter control methods to ensure that the amount of fluorescent adhesive filled for each surface-mount LED reaches the target value. This results in either an excessive coating amount causing fluorescent adhesive to overflow from the support cup or an insufficient coating amount causing the chip to be not fully covered, ultimately affecting the consistency of light output. Although some solutions introduce a visual inspection system to perform two-dimensional image analysis on the coated support cup, such methods are post-processing inspections and cannot intervene in the three-dimensional filling process of the adhesive in real time during the coating process.

[0004] To address the aforementioned issues, this application presents a method and system for precise control of the coating amount of highly consistent patch-type LED fluorescent adhesive. Summary of the Invention

[0005] To address the shortcomings of the prior art mentioned in the background section, this application proposes a method and system for precise control of the coating amount of highly consistent patch LED fluorescent adhesive. By sensing the three-dimensional filling dynamics of the fluorescent adhesive within the support cup in real time during the coating process, and performing feedforward correction and closed-loop control accordingly, the problems in the background section can be solved.

[0006] Firstly, to achieve the above objectives, this application provides a method for precisely controlling the coating amount of highly consistent surface-mount LED phosphor, which includes the following specific steps:

[0007] Step S1: Real-time acquisition of the real-time spreading rate of fluorescent adhesive in the cup of the support during the dispensing process, and acquisition of the theoretical spreading rate of fluorescent adhesive under the corresponding working conditions based on the current dispensing parameters.

[0008] Step S2: Compare the real-time spreading rate with the theoretical spreading rate, and calculate the rate deviation value of the real-time spreading rate relative to the theoretical spreading rate. The rate deviation value is an algebraic value with positive and negative directions.

[0009] Step S3: Determine the direction and degree of deviation of the current coating amount from the target coating amount based on the rate deviation value, and generate the dispensing compensation amount accordingly;

[0010] Step S4: Adjust the current dispensing air pressure value according to the dispensing compensation amount so that the real-time spreading rate after compensation is close to the theoretical spreading rate.

[0011] Step S5: After compensation adjustment, monitor the convergence trend of the real-time spreading rate. The effectiveness of the compensation adjustment is judged by comparing the absolute value change of the rate deviation before and after compensation. If the compensation adjustment is determined to be ineffective, the current coating process is stopped.

[0012] Step S6: Record the spreading rate change curve and corresponding compensation adjustment data for the entire coating process. Link and store the spreading rate change curve and compensation adjustment data in the historical database to correct the calculation model of the theoretical spreading rate used in subsequent batch coatings.

[0013] Based on the above-mentioned preferred scheme, step S1 includes the following steps:

[0014] Step S11: Align the measuring spot of the laser displacement sensor with the center area of ​​the support cup, and continuously collect the height value of the free surface of the fluorescent adhesive inside the support cup at a set sampling frequency;

[0015] Step S12: Record the initial height value at the start of coating, and subtract the initial height value from the real-time height value collected at each sampling time to obtain the colloid spreading height at each sampling time;

[0016] Step S13: Divide the difference between the colloid spreading height at the current sampling time and the colloid spreading height at the previous sampling time by the sampling time interval to obtain the instantaneous spreading rate at the current sampling time, and perform a moving average processing on the instantaneous spreading rates at multiple consecutive sampling times to obtain the real-time spreading rate.

[0017] Step S14: Calculate the volume of the support bowl cup based on the cup rim radius, cup bottom radius and cup depth, and subtract the volume occupied by the chip inside the support bowl cup to obtain the theoretical filling volume of the fluorescent adhesive.

[0018] Step S15: Based on the current dispensing air pressure value, query the corresponding theoretical dispensing volume per unit time from the pre-calibrated dispensing parameter mapping model, divide the theoretical filling volume by the theoretical dispensing volume per unit time, and obtain the theoretical total spreading time required for the fluorescent adhesive to fill the support cup.

[0019] Step S16: Based on the theoretical total spreading time and theoretical filling volume, and combined with the pre-obtained solid-liquid interface contact angle parameters between the fluorescent adhesive and the inner wall of the support cup, establish a theoretical spreading curve of the height of the free surface of the fluorescent adhesive changing with time. Differentiate the theoretical spreading curve to obtain the theoretical spreading rate corresponding to each coating moment.

[0020] Based on the above-mentioned preferred scheme, step S3 specifically includes the following steps:

[0021] Step S31: Compare the rate deviation value with the preset rate deviation tolerance range;

[0022] Step S32: If the rate deviation value falls within the rate deviation tolerance range, no dispensing compensation amount is generated.

[0023] Step S33: If the rate deviation value is less than the lower limit of the rate deviation, it is determined that the current coating amount is too small, and the positive dispensing compensation amount is generated by multiplying the difference between the lower limit of the rate deviation and the rate deviation value by the negative proportional compensation coefficient.

[0024] Step S34: If the rate deviation value is greater than the upper limit of the rate deviation value, it is determined that the current coating amount is too large, and a negative dispensing compensation amount is generated by multiplying the difference between the rate deviation value and the upper limit of the rate deviation value by a positive proportional compensation coefficient.

[0025] Based on the above scheme, in step S4, the current dispensing air pressure value is adjusted according to the dispensing compensation amount, specifically as follows:

[0026] When it is determined that the current coating amount is too small, the current dispensing air pressure value is added to the dispensing compensation amount to obtain the compensated dispensing air pressure value.

[0027] When it is determined that the current coating amount is too large, the absolute value of the dispensing compensation amount is subtracted from the current dispensing air pressure value to obtain the compensated dispensing air pressure value.

[0028] The compensated dispensing air pressure value is sent to the controller of the dispensing actuator in real time, and the dispensing actuator continues to perform coating according to the compensated dispensing air pressure value.

[0029] Based on the above-mentioned preferred scheme, step S5 specifically includes the following steps:

[0030] Step S51: After applying compensation adjustment, continue to collect the real-time spreading rate at each subsequent sampling time and calculate the rate deviation value at each sampling time.

[0031] Step S52: If the absolute value of the rate deviation at three consecutive sampling times is less than the absolute value of the rate deviation before compensation, then the compensation adjustment is deemed effective, and the coating is continued while maintaining the current compensated dispensing air pressure value.

[0032] Step S53: If the absolute value of the rate deviation at three consecutive sampling times is greater than the absolute value of the rate deviation before compensation, or if the absolute value of the rate deviation shows a non-convergent oscillation state of alternating increase and decrease, then the compensation adjustment is determined to be invalid, the coating is immediately stopped, and an alarm signal is issued.

[0033] Based on the above-mentioned preferred scheme, step S6 specifically includes the following steps:

[0034] Step S61: Record the real-time spreading rate, theoretical spreading rate, rate deviation value, dispensing compensation amount, and dispensing air pressure value at each sampling moment during the entire coating process to form the spreading rate change curve and compensation adjustment data.

[0035] Step S62: The spreading rate change curve and compensation adjustment data are associated and stored in the historical database using the chip batch number and coating time as a combined index;

[0036] Step S63: Before the coating of subsequent batches begins, retrieve the historical data of the support cups of the same batch from the historical database, calculate the average rate deviation trend at each same coating time, and make a forward-looking correction to the theoretical total spreading time in the theoretical spreading rate calculation model of the current batch based on the average rate deviation trend.

[0037] Secondly, this application provides a high-consistency surface-mount LED phosphor coating amount precision control system, which specifically includes:

[0038] The spreading rate acquisition module is used to execute step S1 to acquire the real-time spreading rate of the fluorescent adhesive in the cup of the support during the dispensing process, and to acquire the theoretical spreading rate of the fluorescent adhesive under the corresponding working conditions based on the current dispensing parameters.

[0039] The rate deviation calculation module is used to perform step S2 by comparing the real-time spreading rate with the theoretical spreading rate and calculating the rate deviation value.

[0040] The compensation amount generation module is used to perform step S3, which determines the direction and degree of coating amount deviation based on the rate deviation value and generates the dispensing compensation amount.

[0041] The compensation adjustment module is used to perform the function of step S4 to compensate and adjust the current dispensing air pressure value according to the dispensing compensation amount.

[0042] The compensation effectiveness judgment module is used to execute step S5 to judge the effectiveness of compensation adjustment by comparing the absolute value change of the rate deviation value after compensation adjustment, and to stop the coating function when it is invalid.

[0043] The data recording and feedback module is used to execute step S6 to record the spreading rate change curve and compensation adjustment data throughout the coating process, and to associate and store the data in the historical database to correct the theoretical spreading rate calculation model for subsequent batches.

[0044] Thirdly, this application provides an electronic device, including: a processor and a memory, wherein the memory stores a computer program that can be called by the processor;

[0045] The processor executes the above-described method for precise control of the coating amount of highly consistent surface-mount LED fluorescent adhesive by calling the computer program stored in the memory.

[0046] Fourthly, this application provides a computer-readable storage medium storing instructions that, when executed on a computer, cause the computer to perform the above-described method for precise control of the coating amount of highly consistent patch LED fluorescent adhesive.

[0047] Compared with the prior art, the beneficial effects of the present invention are:

[0048] First, this solution transforms the control target from the traditional dispensing amount to the real-time spreading rate of the fluorescent adhesive within the support cup. By using a laser displacement sensor to obtain the real-time height change rate of the free surface of the fluorescent adhesive in the central area of ​​the support cup, and by introducing a theoretical spreading rate established by integrating the geometric dimensions of the support cup, chip volume, and solid-liquid interface contact angle parameters as a dynamic benchmark, the coating and filling process is transformed from a fixed parameter open-loop to a three-dimensional dynamic closed-loop, significantly improving the consistency of coating amount and control accuracy.

[0049] Secondly, when generating the dispensing compensation amount, this solution compares the rate deviation value with the preset rate deviation tolerance range, and only generates a dispensing compensation amount that matches the deviation direction and degree when the deviation exceeds the tolerance range. This avoids frequent oscillations of the control system near the target value and improves the stability of the adjustment process.

[0050] Third, after applying compensation adjustment, this solution judges the effectiveness of the compensation adjustment by continuously comparing the absolute value change of the rate deviation value at each sampling time before and after compensation, rather than simply relying on the deviation direction. It can stop coating and issue an alarm signal in time when the compensation is ineffective or the system exhibits non-convergent oscillations, which can effectively suppress the risk of continuous scrap caused by erroneous compensation and effectively ensure production yield.

[0051] Fourth, this solution records the spread rate change curve and compensation adjustment data of each coating process and stores them in the historical database using the chip batch number and coating time as indexes. This allows the theoretical total spread time in the theoretical spread rate calculation model of the current batch to be proactively corrected based on the historical average rate deviation trend of the same batch of support cups before the coating of subsequent batches begins. This endows the system with the ability to learn and adapt from historical production data, which can continuously improve the coating consistency of long-term continuous production. Attached Figure Description

[0052] The accompanying drawings are provided to further illustrate the invention and form part of the specification. They are used in conjunction with embodiments of the invention to explain the invention and do not constitute a limitation thereof. In the drawings:

[0053] Figure 1 This is a schematic diagram of the overall process of a method for precise control of the coating amount of highly consistent patch LED fluorescent adhesive according to the present invention;

[0054] Figure 2 This is a flowchart illustrating step S3 in the method for precise control of the coating amount of highly consistent patch LED fluorescent adhesive according to the present invention.

[0055] Figure 3 This is a schematic diagram of the framework of a high-consistency patch LED fluorescent adhesive coating precision control system according to the present invention. Detailed Implementation

[0056] 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 of ordinary skill in the art without creative effort are within the scope of protection of the present invention.

[0057] Example 1

[0058] To address the technical problems raised in the background art, this application provides a preferred embodiment: such as Figures 1-3 As shown, a method for precisely controlling the coating amount of highly consistent surface-mount LED phosphor includes the following specific steps:

[0059] Step S1: Real-time acquisition of the real-time spreading rate of fluorescent adhesive in the cup of the support during the dispensing process, and acquisition of the theoretical spreading rate of fluorescent adhesive under the corresponding working conditions based on the current dispensing parameters.

[0060] It should be noted that the theoretical spreading rate is determined based on the theoretical spreading curve established by the geometric dimensions of the support cup, the chip volume, and the solid-liquid interface contact angle parameters between the fluorescent adhesive and the inner wall of the support cup.

[0061] The solid-liquid interface contact angle parameter was obtained by conducting a contact angle measurement experiment on the same batch of support cups in advance. When establishing the theoretical spreading curve, the contact angle parameter was used to correct the theoretical spreading height value at each moment to compensate for the height deviation caused by the meniscus effect of the free liquid surface of the fluorescent adhesive.

[0062] Step S2: Compare the real-time spreading rate with the theoretical spreading rate, and calculate the rate deviation value of the real-time spreading rate relative to the theoretical spreading rate. The rate deviation value is an algebraic value with positive and negative directions.

[0063] Step S3: Determine the direction and degree of deviation of the current coating amount from the target coating amount based on the rate deviation value, and generate the dispensing compensation amount accordingly;

[0064] Step S4: Adjust the current dispensing air pressure value according to the dispensing compensation amount so that the real-time spreading rate after compensation is close to the theoretical spreading rate.

[0065] Step S5: After compensation adjustment, monitor the convergence trend of the real-time spreading rate. The effectiveness of the compensation adjustment is judged by comparing the absolute value change of the rate deviation before and after compensation. If the compensation adjustment is determined to be ineffective, the current coating process is stopped.

[0066] Step S6: Record the spreading rate change curve and corresponding compensation adjustment data for the entire coating process. Link and store the spreading rate change curve and compensation adjustment data in the historical database to correct the calculation model of the theoretical spreading rate used in subsequent batch coatings.

[0067] Furthermore:

[0068] In an optional embodiment, step S1 includes the following steps:

[0069] Step S11: Align the measuring spot of the laser displacement sensor with the center area of ​​the support cup, and continuously collect the height value of the free surface of the fluorescent adhesive inside the support cup at a set sampling frequency;

[0070] Step S12: Record the initial height value at the start of coating, and subtract the initial height value from the real-time height value collected at each sampling time to obtain the colloid spreading height at each sampling time;

[0071] Step S13: Divide the difference between the colloid spreading height at the current sampling time and the colloid spreading height at the previous sampling time by the sampling time interval to obtain the instantaneous spreading rate at the current sampling time, and perform a moving average processing on the instantaneous spreading rates at multiple consecutive sampling times to obtain the real-time spreading rate.

[0072] Step S14: Calculate the volume of the support bowl cup based on the cup rim radius, cup bottom radius and cup depth, and subtract the volume occupied by the chip inside the support bowl cup to obtain the theoretical filling volume of the fluorescent adhesive.

[0073] Step S15: Based on the current dispensing air pressure value, query the corresponding theoretical dispensing volume per unit time from the pre-calibrated dispensing parameter mapping model, divide the theoretical filling volume by the theoretical dispensing volume per unit time, and obtain the theoretical total spreading time required for the fluorescent adhesive to fill the support cup.

[0074] Step S16: Based on the theoretical total spreading time and theoretical filling volume, and combined with the pre-obtained solid-liquid interface contact angle parameters between the fluorescent adhesive and the inner wall of the support cup, establish a theoretical spreading curve of the height of the free surface of the fluorescent adhesive changing with time. Differentiate the theoretical spreading curve to obtain the theoretical spreading rate corresponding to each coating moment.

[0075] In an optional embodiment, step S3 specifically includes the following steps:

[0076] Step S31: Compare the rate deviation value with the preset rate deviation tolerance range;

[0077] It should be noted that the rate deviation tolerance range consists of a lower limit and an upper limit of rate deviation.

[0078] Step S32: If the rate deviation value falls within the rate deviation tolerance range, no dispensing compensation amount is generated.

[0079] Step S33: If the rate deviation value is less than the lower limit of the rate deviation, it is determined that the current coating amount is too small, and the positive dispensing compensation amount is generated by multiplying the difference between the lower limit of the rate deviation and the rate deviation value by the negative proportional compensation coefficient.

[0080] Step S34: If the rate deviation value is greater than the upper limit of the rate deviation value, it is determined that the current coating amount is too large, and a negative dispensing compensation amount is generated by multiplying the difference between the rate deviation value and the upper limit of the rate deviation value by a positive proportional compensation coefficient.

[0081] In an optional embodiment, step S4 involves adjusting the current dispensing air pressure value based on the dispensing compensation amount, specifically as follows:

[0082] When it is determined that the current coating amount is too small, the current dispensing air pressure value is added to the dispensing compensation amount to obtain the compensated dispensing air pressure value.

[0083] When it is determined that the current coating amount is too large, the absolute value of the dispensing compensation amount is subtracted from the current dispensing air pressure value to obtain the compensated dispensing air pressure value.

[0084] The compensated dispensing air pressure value is sent to the controller of the dispensing actuator in real time, and the dispensing actuator continues to perform coating according to the compensated dispensing air pressure value.

[0085] In an optional embodiment, step S5 specifically includes the following steps:

[0086] Step S51: After applying compensation adjustment, continue to collect the real-time spreading rate at each subsequent sampling time and calculate the rate deviation value at each sampling time.

[0087] Step S52: If the absolute value of the rate deviation at three consecutive sampling times is less than the absolute value of the rate deviation before compensation, then the compensation adjustment is deemed effective, and the coating is continued while maintaining the current compensated dispensing air pressure value.

[0088] Step S53: If the absolute value of the rate deviation at three consecutive sampling times is greater than the absolute value of the rate deviation before compensation, or if the absolute value of the rate deviation shows a non-convergent oscillation state of alternating increase and decrease, then the compensation adjustment is determined to be invalid, the coating is immediately stopped, and an alarm signal is issued.

[0089] In an optional embodiment, step S6 specifically includes the following steps:

[0090] Step S61: Record the real-time spreading rate, theoretical spreading rate, rate deviation value, dispensing compensation amount, and dispensing air pressure value at each sampling moment during the entire coating process to form the spreading rate change curve and compensation adjustment data.

[0091] Step S62: The spreading rate change curve and compensation adjustment data are associated and stored in the historical database using the chip batch number and coating time as a combined index;

[0092] Step S63: Before the coating of subsequent batches begins, retrieve the historical data of the support cups of the same batch from the historical database, calculate the average rate deviation trend at each same coating time, and make a forward-looking correction to the theoretical total spreading time in the theoretical spreading rate calculation model of the current batch based on the average rate deviation trend.

[0093] The advantages of the above embodiments are as follows: This solution records the spread rate change curve and compensation adjustment data of each coating process and stores them in the historical database with chip batch number and coating time as indexes. This allows the theoretical total spread time in the theoretical spread rate calculation model of the current batch to be proactively corrected based on the historical average rate deviation trend of the same batch of bracket cups before the coating of subsequent batches. This gives the system the ability to learn and adapt from historical production data, and can continuously improve the coating consistency of long-term continuous production.

[0094] Example 2

[0095] Based on the same inventive concept as in Embodiment 1, such as Figure 3 As shown, this embodiment provides a high-consistency surface-mount LED phosphor coating amount precision control system, which specifically includes:

[0096] The spreading rate acquisition module is used to execute step S1 to acquire the real-time spreading rate of the fluorescent adhesive in the cup of the support during the dispensing process, and to acquire the theoretical spreading rate of the fluorescent adhesive under the corresponding working conditions based on the current dispensing parameters.

[0097] The rate deviation calculation module is used to perform step S2 by comparing the real-time spreading rate with the theoretical spreading rate and calculating the rate deviation value.

[0098] The compensation amount generation module is used to perform step S3, which determines the direction and degree of coating amount deviation based on the rate deviation value and generates the dispensing compensation amount.

[0099] The compensation adjustment module is used to perform the function of step S4 to compensate and adjust the current dispensing air pressure value according to the dispensing compensation amount.

[0100] The compensation effectiveness judgment module is used to execute step S5 to judge the effectiveness of compensation adjustment by comparing the absolute value change of the rate deviation value after compensation adjustment, and to stop the coating function when it is invalid.

[0101] The data recording and feedback module is used to execute step S6 to record the spreading rate change curve and compensation adjustment data throughout the coating process, and to associate and store the data in the historical database to correct the theoretical spreading rate calculation model for subsequent batches.

[0102] The parameters and steps of each unit module in the high-consistency surface mount LED fluorescent adhesive coating amount precision control system of the present invention described above can be referred to the parameters and steps in the embodiments of the high-consistency surface mount LED fluorescent adhesive coating amount precision control method described above, and will not be repeated here.

[0103] Specific implementation method: When coating a surface-mount LED bracket cup with fluorescent adhesive, the spreading rate acquisition module first aligns the measurement spot of the laser displacement sensor with the center area of ​​the bracket cup and continuously collects the height value of the free surface of the fluorescent adhesive. After differential calculation and moving average processing, the real-time spreading rate is obtained. At the same time, the module calculates the theoretical filling volume based on the cup rim radius, cup bottom radius, cup depth and chip volume. Combined with the theoretical adhesive dispensing amount per unit time corresponding to the current dispensing air pressure value, the theoretical total spreading time is obtained. The theoretical spreading curve of the height of the free surface of the fluorescent adhesive changing with time is corrected by introducing the pre-acquired solid-liquid interface contact angle parameter between the fluorescent adhesive and the inner wall of the bracket cup. The theoretical spreading rate corresponding to each coating moment is obtained by differentiating the theoretical spreading curve.

[0104] Then, the rate deviation calculation module compares the real-time spreading rate with the theoretical spreading rate to calculate the rate deviation value with positive and negative directions.

[0105] Next, the rate deviation value is compared with the preset rate deviation tolerance range through the compensation amount generation module. If the rate deviation value falls within the tolerance range, no dispensing compensation amount is generated. If the rate deviation value is less than the lower limit of the rate deviation, it is determined that the coating amount is too small and a positive dispensing compensation amount is generated. If the rate deviation value is greater than the upper limit of the rate deviation, it is determined that the coating amount is too large and a negative dispensing compensation amount is generated.

[0106] Subsequently, through the compensation adjustment module, when the coating amount is too small, the current dispensing air pressure value is added to the dispensing compensation amount; when the coating amount is too large, the absolute value of the dispensing compensation amount is subtracted from the current dispensing air pressure value to obtain the compensated dispensing air pressure value, which is then sent to the controller of the dispensing actuator in real time, so that the dispensing actuator continues to coat according to the compensated dispensing air pressure value, making the real-time spreading rate approach the theoretical spreading rate.

[0107] After the compensation adjustment is applied, the compensation effectiveness judgment module continues to collect the real-time spreading rate at subsequent sampling times and calculate the rate deviation value. The absolute value change of the rate deviation value before and after compensation is compared. If the absolute value of the rate deviation value at multiple consecutive sampling times is less than the absolute value of the rate deviation value before compensation, the compensation adjustment is determined to be effective, and the coating continues to maintain the current compensated dispensing air pressure value. If the absolute value of the rate deviation value is continuously greater than the value before compensation or shows a non-convergent oscillation state, the compensation adjustment is determined to be ineffective, the coating is immediately stopped, and an alarm signal is issued.

[0108] Finally, through the data recording and feedback module, the real-time spreading rate, theoretical spreading rate, rate deviation value, dispensing compensation amount, and dispensing air pressure value at each sampling moment during the entire coating process are recorded as spreading rate change curves and compensation adjustment data. These data are then stored in the historical database using the chip batch number and coating time as a combined index. Before the coating of subsequent batches begins, historical data of the same batch of bracket cups are retrieved from the historical database to calculate the average rate deviation trend at the same coating moment. Based on this, the theoretical total spreading time in the theoretical spreading rate calculation model of the current batch is proactively corrected to achieve continuous optimization of coating consistency.

[0109] Example 3

[0110] Based on the same inventive concept as Embodiment 1, this embodiment provides an electronic device, including: a processor and a memory, wherein the memory stores a computer program that can be called by the processor;

[0111] The processor executes the above-described method for precise control of the coating amount of highly consistent surface-mount LED phosphor by calling the computer program stored in the memory.

[0112] It should be noted that all computer programs for the method of precisely controlling the coating amount of highly consistent patch LED fluorescent adhesive are implemented using the C language.

[0113] Example 4

[0114] Based on the same inventive concept as in Embodiment 1, this embodiment proposes a computer-readable storage medium having an erasable and rewritable computer program stored thereon.

[0115] When a computer program runs on a computer device, it causes the computer device to perform the aforementioned method for precise control of the coating amount of highly consistent surface-mount LED fluorescent adhesive.

[0116] For example, computer-readable storage media can be read-only memory, random access memory, read-only optical disc, magnetic tape, floppy disk, and optical data storage devices.

[0117] The various embodiments in this invention are described in a progressive manner. For the same or similar parts between the various embodiments, please refer to each other. Each embodiment focuses on describing the differences from other embodiments. In particular, for the IoT device and medium embodiments, since they are basically similar to the method embodiments, the description is relatively simple. For relevant parts, please refer to the description of the method embodiments.

[0118] The systems, media, and methods provided in the embodiments of the present invention are in one-to-one correspondence. Therefore, the systems and media also have similar beneficial technical effects as their corresponding methods. Since the beneficial technical effects of the methods have been described in detail above, the beneficial technical effects of the systems and media will not be repeated here.

[0119] Those skilled in the art will understand that embodiments of the present invention can be provided as methods, systems, or computer program products. Therefore, the present invention can take the form of a completely hardware embodiment, a completely software embodiment, or an embodiment combining software and hardware aspects. Furthermore, the present invention can take the form of a computer program product embodied on one or more computer-usable storage media (including, but not limited to, disk storage, CD-ROM, optical storage, etc.) containing computer-usable program code.

[0120] This invention is described with reference to flowchart illustrations and / or block diagrams of methods, apparatus (systems), and computer program products according to embodiments of the invention. It will be understood that each block of the flowchart illustrations and / or block diagrams, as well as combinations of blocks in the flowchart illustrations and / or block diagrams, can be implemented by computer program instructions. These computer program instructions can be provided to a processor of a general-purpose computer, special-purpose computer, embedded processor, or other programmable data processing apparatus to produce a machine, such that the instructions, which execute via the processor of the computer or other programmable data processing apparatus, generate instructions for implementing the flowchart. Figure 1 One or more processes and / or boxes Figure 1 A device that provides the functions specified in one or more boxes.

[0121] These computer program instructions may also be stored in a computer-readable storage medium that can direct a computer or other programmable data processing device to function in a particular manner, such that the instructions stored in the computer-readable storage medium produce an article of manufacture including instruction means, which are implemented in a process Figure 1 One or more processes and / or boxes Figure 1 The function specified in one or more boxes.

[0122] These computer program instructions may also be loaded onto a computer or other programmable data processing equipment to cause a series of operational steps to be performed on the computer or other programmable equipment to produce a computer-implemented process, thereby providing instructions that execute on the computer or other programmable equipment for implementing the process. Figure 1 One or more processes and / or boxes Figure 1 The steps of the function specified in one or more boxes.

[0123] In a typical configuration, a computing device includes one or more processors (CPU), input / output interfaces, network interfaces, and memory.

[0124] Memory may include non-persistent storage in computer-readable media, such as random access memory (RAM) and / or non-volatile memory, such as read-only memory (ROM) or flash RAM. Memory is an example of computer-readable media.

[0125] Computer-readable media include both permanent and non-permanent, removable and non-removable media that can store information using any method or technology. Information can be computer-readable instructions, data structures, modules of programs, or other data. Examples of computer storage media include, but are not limited to, phase-change memory (PRAM), static random access memory (SRAM), dynamic random access memory (DRAM), other types of random access memory (RAM), read-only memory (ROM), electrically erasable programmable read-only memory (EEPROM), flash memory or other memory technologies, CD-ROM, digital versatile optical disc (DVD) or other optical storage, magnetic tape, other magnetic storage devices, or any other non-transferable medium that can be used to store information accessible by a computing device. As defined herein, computer-readable media does not include transient computer-readable media, such as modulated data signals and carrier waves.

[0126] It should also be noted that the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitations, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes that element. The above are merely embodiments of the present invention and are not intended to limit the invention. Various modifications and variations can be made to the present invention by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principle of the present invention should be included within the scope of the claims of the present invention.

Claims

1. A method for precisely controlling the coating amount of highly consistent surface-mount LED phosphor adhesive, characterized in that, Includes the following steps: Step S1: Real-time acquisition of the real-time spreading rate of fluorescent adhesive in the cup of the support during the dispensing process, and acquisition of the theoretical spreading rate of fluorescent adhesive under the corresponding working conditions based on the current dispensing parameters. Step S2: Compare the real-time spreading rate with the theoretical spreading rate, calculate the rate deviation value of the real-time spreading rate relative to the theoretical spreading rate, and the rate deviation value is an algebraic value with positive and negative directions. Step S3: Determine the direction and degree of deviation of the current coating amount from the target coating amount based on the rate deviation value, and generate the dispensing compensation amount accordingly; Step S4: Adjust the current dispensing air pressure value according to the dispensing compensation amount so that the real-time spreading rate after compensation is close to the theoretical spreading rate. Step S5: After compensation adjustment, monitor the convergence trend of the real-time spreading rate. The effectiveness of the compensation adjustment is judged by comparing the absolute value change of the rate deviation before and after compensation. If the compensation adjustment is determined to be ineffective, the current coating process is stopped. Step S6: Record the spreading rate change curve and corresponding compensation adjustment data for the entire coating process. Link and store the spreading rate change curve and compensation adjustment data in the historical database to correct the calculation model of the theoretical spreading rate used in subsequent batch coatings.

2. The method for precisely controlling the coating amount of highly consistent surface-mount LED phosphor adhesive according to claim 1, characterized in that: Step S1 includes the following steps: Step S11: Align the measuring spot of the laser displacement sensor with the center area of ​​the support cup, and continuously collect the height value of the free surface of the fluorescent adhesive inside the support cup at a set sampling frequency; Step S12: Record the initial height value at the start of coating, and subtract the initial height value from the real-time height value collected at each sampling time to obtain the colloid spreading height at each sampling time; Step S13: Divide the difference between the colloid spreading height at the current sampling time and the colloid spreading height at the previous sampling time by the sampling time interval to obtain the instantaneous spreading rate at the current sampling time, and perform a moving average processing on the instantaneous spreading rates at multiple consecutive sampling times to obtain the real-time spreading rate. Step S14: Calculate the volume of the support bowl cup based on the cup rim radius, cup bottom radius and cup depth, and subtract the volume occupied by the chip inside the support bowl cup to obtain the theoretical filling volume of the fluorescent adhesive. Step S15: Based on the current dispensing air pressure value, query the corresponding theoretical dispensing volume per unit time from the pre-calibrated dispensing parameter mapping model, divide the theoretical filling volume by the theoretical dispensing volume per unit time, and obtain the theoretical total spreading time required for the fluorescent adhesive to fill the support cup. Step S16: Based on the theoretical total spreading time and theoretical filling volume, and combined with the pre-obtained solid-liquid interface contact angle parameters between the fluorescent adhesive and the inner wall of the support cup, establish a theoretical spreading curve of the height of the free surface of the fluorescent adhesive changing with time. Differentiate the theoretical spreading curve to obtain the theoretical spreading rate corresponding to each coating moment.

3. The method for precisely controlling the coating amount of highly consistent surface-mount LED phosphor adhesive according to claim 2, characterized in that: Step S3 specifically includes the following steps: Step S31: Compare the rate deviation value with the preset rate deviation tolerance range; Step S32: If the rate deviation value falls within the rate deviation tolerance range, no dispensing compensation amount is generated. Step S33: If the rate deviation value is less than the lower limit of the rate deviation, it is determined that the current coating amount is too small, and the positive dispensing compensation amount is generated by multiplying the difference between the lower limit of the rate deviation and the rate deviation value by the negative proportional compensation coefficient. Step S34: If the rate deviation value is greater than the upper limit of the rate deviation value, it is determined that the current coating amount is too large, and a negative dispensing compensation amount is generated by multiplying the difference between the rate deviation value and the upper limit of the rate deviation value by a positive proportional compensation coefficient.

4. The method for precisely controlling the coating amount of highly consistent surface-mount LED phosphor adhesive according to claim 3, characterized in that: In step S4, the current dispensing air pressure value is adjusted according to the dispensing compensation amount, specifically as follows: When it is determined that the current coating amount is too small, the current dispensing air pressure value is added to the dispensing compensation amount to obtain the compensated dispensing air pressure value. When it is determined that the current coating amount is too large, the absolute value of the dispensing compensation amount is subtracted from the current dispensing air pressure value to obtain the compensated dispensing air pressure value. The compensated dispensing air pressure value is sent to the controller of the dispensing actuator in real time, and the dispensing actuator continues to perform coating according to the compensated dispensing air pressure value.

5. The method for precise control of the coating amount of highly consistent surface-mount LED phosphor adhesive according to claim 4, characterized in that: Step S5 specifically includes the following steps: Step S51: After applying compensation adjustment, continue to collect the real-time spreading rate at each subsequent sampling time and calculate the rate deviation value at each sampling time. Step S52: If the absolute value of the rate deviation at three consecutive sampling times is less than the absolute value of the rate deviation before compensation, then the compensation adjustment is deemed effective, and the coating is continued while maintaining the current compensated dispensing air pressure value. Step S53: If the absolute value of the rate deviation at three consecutive sampling times is greater than the absolute value of the rate deviation before compensation, or if the absolute value of the rate deviation shows a non-convergent oscillation state of alternating increase and decrease, then the compensation adjustment is determined to be invalid, the coating is immediately stopped, and an alarm signal is issued.

6. The method for precise control of the coating amount of highly consistent surface-mount LED phosphor adhesive according to claim 5, characterized in that: Step S6 specifically includes the following steps: Step S61: Record the real-time spreading rate, theoretical spreading rate, rate deviation value, dispensing compensation amount, and dispensing air pressure value at each sampling moment during the entire coating process to form the spreading rate change curve and compensation adjustment data. Step S62: The spreading rate change curve and compensation adjustment data are associated and stored in the historical database using the chip batch number and coating time as a combined index; Step S63: Before the coating of subsequent batches begins, retrieve the historical data of the support cups of the same batch from the historical database, calculate the average rate deviation trend at each same coating time, and make a forward-looking correction to the theoretical total spreading time in the theoretical spreading rate calculation model of the current batch based on the average rate deviation trend.

7. A high-consistency surface-mount LED phosphor coating amount precision control system, which is based on the high-consistency surface-mount LED phosphor coating amount precision control method as described in any one of claims 1-6, characterized in that, include: The spreading rate acquisition module is used to execute step S1 to obtain the real-time spreading rate of the fluorescent adhesive in the cup of the support during the dispensing process, and to obtain the theoretical spreading rate of the fluorescent adhesive under the corresponding working conditions based on the current dispensing parameters. The rate deviation calculation module is used to perform step S2 by comparing the real-time spreading rate with the theoretical spreading rate and calculating the rate deviation value. The compensation amount generation module is used to perform step S3, which determines the direction and degree of coating amount deviation based on the rate deviation value and generates the dispensing compensation amount. The compensation adjustment module is used to perform the function of step S4 to compensate and adjust the current dispensing air pressure value according to the dispensing compensation amount. The compensation effectiveness judgment module is used to execute step S5 to judge the effectiveness of compensation adjustment by comparing the absolute value change of the rate deviation value after compensation adjustment, and to stop the coating function when it is invalid. The data recording and feedback module is used to execute step S6 to record the spreading rate change curve and compensation adjustment data throughout the coating process, and to associate and store the data in the historical database to correct the theoretical spreading rate calculation model for subsequent batches.

8. An electronic device, comprising: A processor and a memory, wherein the memory stores a computer program that can be called by the processor, characterized in that: the processor executes a method for precise control of the coating amount of highly consistent surface-mount LED phosphor by calling the computer program stored in the memory as described in any one of claims 1-6.

9. A computer-readable storage medium, characterized in that: The device stores instructions that, when executed on a computer, cause the computer to perform a method for precise control of the coating amount of highly consistent patch LED fluorescent adhesive as described in any one of claims 1-6.

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