Real-Time Manufacturing Control for Display Devices
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Solution Overview
Problem
In the manufacturing of display devices, quality-unqualified semi-finished products are difficult to remedy due to fluctuations in production line parameters, leading to key attributes exceeding specification limits, which results in subpar quality and increased costs.
Innovation Solution
An online real-time control method is implemented, establishing a nonlinear monitoring equation using production line parameters to estimate product attributes, updating calculations with feedback values, and adjusting subsequent parameters to maintain quality specifications, employing nonlinear functions determined by the least square method.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If production line parameters are monitored using conventional methods, then quality inspection can be performed, but quality-unqualified semi-finished products cannot be remedied once produced
Solution Approach 1:
The patent implements real-time feedback control by continuously monitoring production line parameters and comparing them against target values. When deviations are detected, the system automatically adjusts subsequent process parameters to compensate and keep product attributes within specifications, enabling remediation of quality issues in semi-finished products.
Solution Approach 2:
The system performs preliminary quality assessment by estimating product attributes before the manufacturing process is complete. By calculating predicted attribute values based on current production parameters and process characteristics, the system can identify potential quality issues early and adjust subsequent parameters to prevent final product defects.
2Adaptability or versatility
If production line parameters fluctuate, then manufacturing flexibility is maintained, but key attributes exceed specification limits
Solution Approach 1:
The patent employs dynamic parameter adjustment where production parameters are continuously modified based on real-time monitoring and prediction results. The system adapts subsequent process parameters dynamically to compensate for fluctuations in earlier stages, maintaining attribute compliance while preserving production flexibility.
Solution Approach 2:
The system changes production parameters in real-time based on monitored deviations. By adjusting parameters such as temperature, pressure, or processing time in subsequent stages, the system compensates for earlier parameter fluctuations and ensures final product attributes remain within specification limits.
3Manufacturing precision
If real-time monitoring and adjustment systems are implemented, then quality control improves, but system complexity increases
Solution Approach 1:
The system performs self-adjustment by automatically modifying production parameters based on real-time monitoring and prediction results without requiring external intervention. The control system serves itself by using its own monitoring data to make corrective adjustments, reducing the need for complex external control mechanisms.
Solution Approach 2:
The patent replaces complex mechanical quality control systems with computational methods. By using mathematical models to predict product attributes and algorithms to determine parameter adjustments, the system achieves precise quality control through information processing rather than mechanical means.
Data Source
AI summary
The invention provides an online real-time control method for a product manufacturing process and includes: (A) establishing a monitoring equation for estimating a product attribute in view of production line parameters corresponding to respective steps in a manufacturing process of a product; (B) when each of the steps is finished, updating the calculation result according to an online feedback value(s) of the production line parameter(s) corresponding to the finished step; (C) when the updated calculation result in the step (B) indicates that the quality of the product does not meet a required quality specification, adjusting the production line parameter(s) corresponding to the step(s) after the finished step to make the quality of the product meet the required quality specification. According to the method, a key attribute(s) of the display device can be kept within an acceptable specification by adjusting the production line parameter(s) of subsequent step(s).