LED Electrostatic Resistance Sorting Automation
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Solution Overview
Problem
Current methods for testing LEDs for electrostatic resistance are labor-intensive and prone to human error, leading to inaccuracies in failure rate estimation and potential damage to LEDs during the testing process.
Innovation Solution
An automated system and method that involves a transport carrier passing LEDs through an electrostatic discharging zone, a lightening evaluating zone, and a sorting zone, using an electrostatic discharging device, a lighting device, and a sorting device to assess and sort LEDs based on their electrostatic resistance, significantly increasing the sampling ratio and reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If random sampling method is used for testing LEDs, then labor cost and testing time are reduced, but the reliability of failure rate estimation decreases
Solution Approach 1:
The patent replaces the manual mechanical testing process with an automated electrostatic discharging device that systematically applies electrostatic discharge to LEDs. This automation enables 100% sampling while maintaining high testing speed, resolving the contradiction between testing efficiency and estimation reliability by eliminating the need for random sampling.
Solution Approach 2:
The system performs preliminary electrostatic discharging testing on all LEDs before they are packaged and shipped. By conducting complete testing in advance rather than relying on random sampling later, the system ensures accurate failure rate estimation while maintaining productivity through automated high-speed testing.
2Ease of operation
If staff manually test LEDs with electrostatic gun, then flexibility and adaptability are maintained, but human error and potential LED damage increase
Solution Approach 1:
The automated system performs electrostatic discharging testing without human intervention. The device automatically positions, discharges, and evaluates LEDs, eliminating human error while maintaining consistent testing protocols. This self-service approach improves reliability without sacrificing operational flexibility.
Solution Approach 2:
The patent introduces an automated electrostatic discharging device as an intermediary between the tester and the LED. This intermediary eliminates direct human contact that could cause HBM ESD damage, while the device's controlled discharge mechanism ensures consistent and accurate testing.
3Reliability
If high sampling ratio is achieved for accurate failure rate estimation, then reliability improves, but labor cost and testing time increase
Solution Approach 1:
The automated electrostatic discharging device replaces manual testing, enabling 100% sampling of LEDs without the labor cost or time penalty that would accompany manual 100% testing. The automation maintains high productivity while achieving complete sampling for reliable failure rate estimation.
4Reliability
If staff equip anti-static equipment to prevent HBM ESD damage, then LED protection improves, but cannot completely eliminate damage risk
Solution Approach 1:
The automated electrostatic discharging device serves as an intermediary that eliminates direct human contact with LEDs during testing. This removes the HBM ESD risk entirely, as the automated device uses controlled discharge mechanisms rather than human body charge transfer.
Solution Approach 2:
The system applies controlled electrostatic discharge in a controlled environment before LEDs leave the manufacturing facility. This preliminary action ensures any electrostatic vulnerabilities are identified and addressed before the LEDs are exposed to potential HBM ESD risks in the field.
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 system enables efficient detection of electrostatic resistance for large quantities of LEDs, increasing the reliability of failure rate estimation and preventing LED damage, thereby improving customer satisfaction by ensuring accurate sorting and reduced labor costs.
Implementation Method 1
in the electrostatic discharging zone, discharging an electrostatic power with a detecting voltage to the LED on the transport carrier through an electric conducting member by an electrostatic discharging device
Implementation Method 2
in the lightening evaluating zone, inputting a lightening power to the LED on the transport carrier via an electrode of the LED electrically connecting with the electric conducting member by a lighting device
Data Source
AI summary
Disclosed is a method for automatically sorting LEDs (light emitting diode) according to electrostatic resistance and a system using the same. The system includes a transport carrier for laying LEDs and passing LEDs through an electrostatic discharging zone, a lightening evaluating zone, and a sorting zone in sequence. An electrostatic discharging device discharges an electrostatic power to the LED in the electrostatic discharging zone. Furthermore, a lighting device inputs a lightening power to the LED in the lightening evaluating zone. Moreover, an evaluating device in the evaluating zone generates an evaluating signal to a sorting device in the sorting zone according to the lighting condition of the LED for allowing the sorting device to sort LEDs according to electrostatic resistance. Thereby the reliability both for the failure rate and the detection rate can be raised.