Curved LED Screen Module Assembly for Flatness and Accurate Fit
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Solution Overview
Problem
Current methods for manufacturing large curved LED display screens face challenges such as poor surface flatness, high costs, and accuracy issues, leading to a suboptimal display effect due to the use of equal-sized LED modules and complex segmentation processes.
Innovation Solution
A method involving the creation of a curved display screen with a flat panel structure, where virtual display modules are segmented and proportionally enlarged or reduced to form materialized modules with adjustment protrusions, and assembled using a double-curved surface framework to ensure accurate installation and minimize cumulative errors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If equal-sized LED modules are used for assembling large curved LED display screens, then the assembly process is simplified, but the surface flatness deteriorates and gaps between modules increase
Solution Approach 1:
The curved display screen is segmented into multiple LED module strips with different specifications rather than using equal-sized modules. Each strip is divided into a specific number of modules based on the curvature requirements, allowing the assembly process to accommodate the curved surface geometry while maintaining surface flatness and minimizing gaps between modules.
2Manufacturing precision
If complex segmentation methods are used to improve accuracy of curved display screen modules, then the radian matching improves, but the processing difficulty and cost increase
Solution Approach 1:
Different LED module strips are assigned different specifications (widths and heights) according to their local position on the curved surface. The first, second, and third strips have progressively different dimensions to match the varying curvature requirements at different locations, achieving accurate radian matching without requiring complex processing of individual modules.
3Ease of manufacture
If fixed radian segmentation is used to divide LED screen module strips, then the segmentation process is standardized, but the accumulated error increases leading to corrugated impressions
Solution Approach 1:
The number of LED modules in each strip is dynamically determined based on the strip's width and the curvature requirements, rather than using a fixed segmentation pattern. This allows the assembly to adapt to the specific geometric constraints of the curved surface, minimizing accumulated errors and preventing corrugated impressions while maintaining standardized assembly procedures.
Data Source
AI summary
A curved display screen forming method includes: modeling to obtain a virtual display layer, and segmenting the display layer to obtain a size of a virtual display module; mapping the size of the virtual display module to obtain a size of a materialized display module; reducing edges of the materialized display module, and arranging an adjustment protrusion on each edge of the materialized display module; modeling to obtain a virtual adjustment layer, wherein a virtual plate of the virtual adjustment layer corresponds to the plurality of virtual display modules, obtaining a size of the virtual plate; converting the size of the virtual plate from a curved surface to a plane to obtain a planar size of the materialized plate; and assembling the materialized display module and the materialized plate to form a curved display screen.