Automated Tray Alignment Inspection Before Display Loading
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Display devices may not be properly seated on trays during manufacturing processes due to misalignment, potentially causing damage.
Innovation Solution
A tray alignment device with a supply module, alignment module, and inspection module to ensure trays are correctly positioned before loading display devices, using cameras to inspect alignment and determine correct positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If tray alignment is performed manually or without inspection, then the loading process is faster, but display devices may not be properly seated on trays causing damage
Solution Approach 1:
The inspection module performs alignment inspection before the display device is loaded onto the tray. The camera captures images of the tray's alignment marks, and the control unit processes these images to determine whether the tray is correctly positioned. This preliminary inspection ensures that only properly aligned trays receive display devices, preventing damage while maintaining efficient automated loading operations.
2Reliability
If alignment inspection is added to the loading process, then display device damage is prevented, but the manufacturing process time increases
Solution Approach 1:
The patent replaces manual alignment inspection with an automated optical inspection system. A camera captures images of alignment marks on the tray, and a control unit with image processing algorithms automatically determines tray position accuracy. This substitution eliminates time-consuming manual inspection while providing consistent, precise alignment verification, thus preventing display device damage without significantly increasing manufacturing process time.
3Measurement precision
If the inspection module is positioned above the tray, then alignment inspection is effective, but the device structure becomes more complex
Solution Approach 1:
The inspection module is integrated into the existing automated loading system structure. The camera and control unit share the same platform as other loading components, allowing the inspection function to be performed using the existing mechanical framework. This integration approach enables effective alignment inspection from above the tray while minimizing additional structural complexity, as the inspection module utilizes the multi-functional nature of the automated loading system's support structures.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Prevents damage to display devices by ensuring trays are aligned correctly before loading, enhancing manufacturing efficiency and reducing defects.
Implementation Method 1
an adsorption portion disposed above the stage and including an adsorption nozzle for adsorbing the tray
Data Source
AI summary
An embodiment of a tray alignment device includes a stage, a supply module, an alignment module, and an inspection module. The supply module supplies a tray to the stage. The alignment module is disposed to surround the tray supplied to the stage and align the tray by pressing at least a portion of an edge of the tray. The inspection module inspects an alignment of the tray.