Display Unit Manufacturing System for Defective Panel Re-processing
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Solution Overview
Problem
Existing display unit manufacturing systems face inefficiencies and space wastage due to the need for separate facilities and manual processes when managing defective panels with attached optical films, as they require separate unloading and re-attachment of optical films, disrupting continuous production.
Innovation Solution
A display unit manufacturing system that includes a panel conveyance route with inspection and storage units, allowing defective panels to be identified and stored for re-processing within the continuous system, utilizing a control unit to manage panel flow and separate optical films as needed, enabling continuous optical film attachment without manual intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate unloading lines and separate attachment devices are established for defective panels, then defective panels can be managed and re-processed, but facility space is wasted and process speed efficiency deteriorates
Solution Approach 1:
The patent merges the defective panel management function into the existing continuous process line by integrating a separation unit and panel storing unit within the same conveyance system. Instead of creating separate facilities, the system combines defect detection, optical film separation, panel storage, and re-attachment capabilities into the existing production line, allowing defective panels to be managed without leaving the continuous process flow.
Solution Approach 2:
The panel storing unit serves multiple functions: it temporarily holds panels awaiting optical film attachment, stores panels that need re-processing, and interfaces with both the inspection unit and the optical film attaching unit. The separation unit can separate optical films from panels at different stages, and the system can handle both newly introduced panels and returned defective panels through the same conveyance route, demonstrating multi-functionality.
2Reliability
If manual separation and re-attachment of optical films is performed for defective panels, then defective panels can be re-processed, but process efficiency deteriorates due to manual intervention
Solution Approach 1:
The system enables automated self-service for defective panel re-processing. The separation unit automatically separates optical films from panels based on inspection results, the panel storing unit automatically manages panel storage and retrieval, and the optical film attaching unit automatically re-attaches optical films to panels that need re-processing. The control unit coordinates these operations without manual intervention, allowing the system to handle defective panels autonomously while maintaining continuous operation.
3Reliability
If separate facilities are established for managing defective panels, then defective panel management is enabled, but facility space is wasted
Solution Approach 1:
The patent merges the defective panel management function into the existing continuous process line by integrating a separation unit and panel storing unit within the same conveyance system. Instead of creating separate facilities, the system combines defect detection, optical film separation, panel storage, and re-attachment capabilities into the existing production line, allowing defective panels to be managed without leaving the continuous process flow.
Solution Approach 2:
The system utilizes the temporal dimension by implementing a panel storing unit that temporarily holds panels, allowing the system to process panels at different rates without creating separate physical facilities. The storing unit acts as a buffer in time, enabling flexible management of defective panels within the existing spatial footprint of the production line.
Data Source
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AI summary
Exemplary embodiments of the present invention provide a display unit manufacturing system including: a panel conveyance route which includes an optical film attaching unit configured to attach an optical film to a panel; an inspection unit which inspects whether the panel having the optical film attached thereto is defective; a panel storing unit which stores the panel from which the optical film is separated, based on an inspection result of the inspection unit; and a control unit which controls whether to input the panel stored in the panel storing unit to the panel conveyance route.