Laser Surface Flatness Measurement for LCD Panels
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Solution Overview
Problem
Conventional surface flatness measurement methods for LCD panel industries, such as using thick gauges or steel rulers, suffer from low precision, manual measurement errors, and the inability to automatically record and upload data.
Innovation Solution
A non-contact laser-based surface flatness measuring device and method that uses a measuring platform with marked points, a laser head to emit and receive beams, and a computer to determine a datum plane and calculate distance values for precise surface flatness measurements, enabling high precision and automatic data recording and saving.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional thick gauge or steel ruler methods are used for surface flatness measurement, then the measurement process is simple and equipment cost is low, but measurement precision is low (about 0.1 mm) and measurement error is high
Solution Approach 1:
The patent replaces the mechanical measurement system (thick gauge or steel ruler contact methods) with a laser-based optical measurement system. The laser head emits laser beams to measure height values at multiple points on the board surface non-contactingly, eliminating mechanical contact and achieving much higher precision (0.001 mm) while removing the limitations of manual measurement error.
Solution Approach 2:
The patent creates a digital copy of the physical measurement process by capturing height measurement values at multiple points and processing them through computer algorithms to determine the datum plane and calculate surface flatness. This digital replication enables automatic data recording, multiple measurements, and eliminates manual recording errors while maintaining measurement accuracy.
2Reliability
If manual measurement methods are used, then operation simplicity is maintained, but measurement error is high and data recording capability is lacking
Solution Approach 1:
The measurement system performs self-service through automatic data acquisition and processing. The laser head automatically moves to predetermined points, captures height values, and the computer automatically processes these values to determine the datum plane and calculate surface flatness. The system self-records all measurement data, eliminating the need for manual measurement and recording operations while ensuring consistent reliability.
Solution Approach 2:
The system incorporates feedback mechanisms where the computer controls the laser head movement based on predetermined point coordinates, and the measurement results feed back into the calculation algorithm to determine surface flatness. This closed-loop approach ensures measurement reliability by systematically processing data rather than relying on manual operations.
3Productivity
If manual measurement and recording is performed, then equipment complexity is low, but productivity is low due to inability to efficiently handle large batches
Solution Approach 1:
The system performs preliminary actions by pre-defining the measurement points (eight specific locations on the board) and pre-programming the laser head movement paths. This preparation enables rapid sequential measurement of multiple points without requiring manual positioning for each measurement, significantly increasing productivity for batch processing while the computer automates the complex coordination of movements and calculations.
Solution Approach 2:
The patent merges multiple functions into an integrated system: the laser head serves as both the measurement instrument and data source, the computer combines data acquisition, processing, calculation, and recording functions, and the predetermined point system integrates positioning and measurement coordination. This consolidation enables efficient batch processing that would be impractical with separate manual operations for each measurement task.
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 solution achieves measurement precision of 0.001 mm and reduces errors to within 3 um, allowing for automatic data recording and efficient measurement of large batches, addressing the limitations of manual methods.
Implementation Method 1
at least one laser head, configured to emit laser beams to one of the points under measurement and receive reflected light
Implementation Method 2
emit laser beams to one of the points under measurement and receive reflected light
Data Source
AI summary
A surface flatness measuring device and a surface flatness measuring method are disclosed. By non-contacting laser measurement, measurement precision can reach 0.001 mm so the measurement precision is high. A repetitive measurement error thereof can be controlled to be within 3 um so the measurement error is tiny, which prevent issues of low measurement precision and great measurement errors due to manual measurement in prior art. At the same time, the present invention measurement data can be automatically recorded and saved, measurement for a large batch of boards under measurement can be implemented, which prevents the issues of the conventional measurement data requiring manual recording and lacking capability of uploading the measurement data.