Backlight Module Assembly Fixture with Vision Alignment
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Solution Overview
Problem
The assembly process of backlight modules is challenging due to the increasing thinness of light guiding plates, leading to difficulty in alignment and reduced assembly efficiency and yield, primarily because manual operation is error-prone and inefficient.
Innovation Solution
An assembly fixture comprising a first assembling disk for optical elements, a second assembling disk for the back plate, a vision alignment system for acquiring coordinate information, and a manipulator to align and secure the optical elements with the back plate using a preset tilt angle, ensuring precise fitting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If manual operation is used for alignment and assembly, then device complexity is reduced, but manufacturing precision and assembly yield deteriorate due to increasing thinness of light guiding plates
Solution Approach 1:
The patent replaces manual mechanical alignment operations with an automated vision alignment system that uses image processing and coordinate calculation to determine precise positioning. The system captures images of the light guiding plate and back plate, calculates their relative positions and rotation angles, and guides the assembly process automatically, eliminating manual operation errors while improving alignment precision.
Solution Approach 2:
The patent introduces a vision alignment system as an intermediary between the components to be assembled and the assembly operator. This system serves as a mediator that processes visual information from both parts, calculates fitting parameters, and provides guidance for precise alignment, thereby resolving the contradiction between simple device structure and high precision requirements.
2Device complexity
If manual alignment is used, then equipment investment is reduced, but assembly efficiency and productivity deteriorate due to difficulty in aligning thin light guiding plates
Solution Approach 1:
The patent replaces inefficient manual alignment with an automated vision-based alignment system that rapidly captures images, processes coordinates, and determines precise positioning. This substitution dramatically improves assembly efficiency by eliminating the time-consuming and skill-dependent manual alignment process, even though it increases equipment complexity.
3Device complexity
If manual operation is used for assembly, then manufacturing cost is reduced, but assembly yield deteriorates due to increased difficulty in assembling thin light guiding plates
Solution Approach 1:
The patent replaces manual assembly operations with an automated system that uses vision alignment to ensure precise positioning before assembly. This substitution improves assembly yield by eliminating human error in alignment and positioning, ensuring consistent quality even though it increases process complexity and equipment investment.
Solution Approach 2:
The patent implements a feedback mechanism where the vision alignment system continuously monitors the positions of the light guiding plate and back plate, calculates their relative alignment status, and provides real-time guidance for adjustment. This closed-loop feedback ensures high assembly yield by preventing misalignment before assembly occurs.
Data Source
AI summary
The embodiments of the present disclosure provide an assembly fixture and assembly method for a backlight module, so as to improve assembly efficiency and assembly yield of the backlight module. The assembly fixture includes: a vision alignment system for acquiring a first coordinate information of the set of optical elements and a second coordinate information of the back plate, calculating a fitting location coordinate information depending on the first coordinate information and the second coordinate information, and sending the fitting location coordinate information to a manipulator; and a manipulator for aligning the set of optical elements with the back plate depending on the fitting location coordinate information, and embedding a protrusion structure of the set of optical elements into a groove structure of the back plate by a preset tilt angle, and then laying the set of optical elements on the back plate.