Display Substrate Gantry Layout for Inline Transfer, Inspection, and Mending
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current display manufacturing apparatuses require separate stations for transferring, inspecting, and mending miniature light emitting diodes, leading to inefficiencies due to long conveying distances and times, resulting in delayed inspection and mending processes.
Innovation Solution
Integration of transferring, inspecting, and mending processes on a single apparatus with a working platform, conveying paths, and movable stations for efficient handling and welding of miniature light emitting diodes, including a transferring station, defect inspecting station, and mending station, which reduces conveying distance and time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If separate stations for transferring, inspecting, and mending are used, then each process can be performed independently, but the conveying distance and time increase, resulting in reduced productivity
Solution Approach 1:
The patent combines multiple independent manufacturing stations (transferring, inspecting, and mending stations) into a single integrated apparatus. The transferring gantry, inspecting gantry, and mending gantry are all disposed on the same working platform and share common conveying paths and carriers, enabling seamless integration of processes without intermediate conveying steps between separate apparatuses.
Solution Approach 2:
The working platform serves multiple functions by accommodating different types of gantries (transferring, inspecting, mending) that can operate on the same conveying paths. The carriers are universally designed to handle display substrates through all three processes, and the control system coordinates all stations to work harmoniously as a unified system.
2Productivity
If separate manufacturing apparatuses are used for transferring, inspecting, and mending, then each process can be optimized independently, but the factory space required increases
Solution Approach 1:
The patent consolidates multiple manufacturing functions into a single apparatus located on one working platform. The transferring station, defect inspecting station, and mending station all share the same physical space and infrastructure, eliminating the need for separate factory areas for each process and reducing overall facility requirements.
Solution Approach 2:
The patent utilizes vertical space by employing gantry systems that move overhead on the working platform. The transferring gantry, inspecting gantry, and mending gantry operate in the vertical dimension above the conveying paths, allowing multiple processes to occupy the same horizontal footprint without interfering with each other.
3Reliability
If display substrates are conveyed between separate stations, then each process can be performed by specialized equipment, but waiting time in line increases
Solution Approach 1:
The integrated apparatus enables continuous processing where display substrates move seamlessly from the transferring station to the inspecting station and then to the mending station without interruption or waiting. The shared conveying paths and coordinated gantry operations ensure that each process can begin immediately upon the substrate's arrival, eliminating idle time and maintaining continuous production flow.
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
Enables simultaneous performance of transferring, inspecting, and mending processes, increasing production efficiency and reducing material waiting times, thereby optimizing the display device manufacturing process.
Implementation Method 1
The transferring welding device is adapted to take a plurality of miniature light emitting diodes, and weld the taken plurality of miniature light emitting diodes on the plurality of display substrates
Data Source
AI summary
A display device manufacturing apparatus includes a working platform, a transferring station including a transferring gantry and a transferring welding device, a defect inspecting station including an inspecting gantry and a defect inspecting device, and a mending station including a mending gantry and a mending device. The working platform includes a plurality of pairs of conveying paths, and a plurality of carriers disposed on the plurality of pairs of conveying paths. The transferring gantry, inspecting gantry and mending gantry are disposed on the working platform and stride over the conveying paths. The transferring welding device, defect inspecting device and mending device are connected to the transferring gantry, inspecting gantry and mending gantry respectively, and movable along each gantry to the position opposite to each carrier to perform the corresponding manufacturing process to each display substrate carried by each carrier, thereby optimizing the manufacturing course and reducing waiting time.