Flatness Sensing Device for Display Assembly
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Solution Overview
Problem
The assembly of large display screens, such as LED or LCD screens, is compromised by uneven flatness between basic units, affecting the overall display and visual effect, as existing technologies lack effective methods to ensure uniformity.
Innovation Solution
A flatness sensing device comprising a pressure sensing unit and a controller, which uses a pressure sensor to detect pressure variations and determine flatness by comparing measured pressures against a preset range, issuing an alarm if deviations occur, and allowing for real-time adjustment during assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual assembly methods are used for display screens, then assembly flexibility is maintained, but flatness uniformity between basic units deteriorates
Solution Approach 1:
The patent replaces manual mechanical assembly with an automated sensing system that uses pressure sensors to detect flatness deviations. The controller automatically processes sensor data and provides adjustment instructions, substituting human judgment and manual measurement with automated electronic detection and control systems.
Solution Approach 2:
The sensing device enables operators to perform self-checks during assembly by placing the sensing unit on basic units. The system provides immediate feedback through the controller, allowing workers to adjust flatness themselves based on quantitative data, transforming manual assembly into a self-correcting process.
2Productivity
If automated assembly lines are implemented, then assembly speed increases, but detection and adjustment capability for flatness decreases
Solution Approach 1:
The patent implements a feedback mechanism where pressure sensors continuously monitor flatness during assembly, the controller processes this data in real-time, and adjustment instructions are immediately provided to operators. This closed-loop feedback system ensures precise detection without slowing down the assembly process.
Solution Approach 2:
The sensing device performs preliminary detection of flatness deviations before final assembly is completed. By detecting issues early during the assembly process, the system allows for timely adjustments, preventing defects from propagating and reducing the need for rework.
3Measurement precision
If multiple pressure sensors are deployed across the surface, then measurement coverage improves, but device complexity and cost increase
Solution Approach 1:
The patent divides the sensing function into multiple independent pressure sensors distributed across the sensing unit. Each sensor monitors a specific location, and the controller aggregates data from all sensors to provide comprehensive flatness assessment. This segmentation allows comprehensive coverage while keeping individual sensor components simple and manageable.
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
The device ensures accurate flatness detection and adjustment during assembly, enhancing the quality and efficiency of the final display screen by allowing for precise alignment and uniform pressure distribution across the surface.
Implementation Method 1
a pressure sensor (14) arranged at an edge of the plate body (12) The pressure sensor (14) senses a pressure when the sensing surface (140) contacts an object to be tested
Data Source
AI summary
A flatness sensing device includes a pressure sensing unit and a controller. The pressure sensing unit includes a plate portion, and a pressure sensor fixed and exposed at an edge of the plate portion. A sensing surface of the pressure sensor is flush with the bottom surface of the plate portion. The pressure sensor senses a pressure or lack of pressure of an object to be tested when it touches the object to be tested. The controller receives the pressure value output from the pressure sensor and determines a flatness of the object to be tested, the controller can issue an alarm on finding non-flatness and cause the degree of flatness to be displayed to a user.