Automated Panel-Bonding Inspection Line with Double-Plus Chain Conveyor
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Solution Overview
Problem
The liquid crystal display manufacturing industry faces inefficiencies in the inspection and testing of semi-finished panel-bonding products, including long test times, lack of synchronization between operations, and increased operator difficulty, leading to low throughput and yield rates, with issues like panel breaking and electro-static discharge during handling.
Innovation Solution
A method utilizing a conveyance mechanism with a double-plus chain conveyor system to automate the inspection line, integrating barcode pasting and automatic packaging machines, allowing for synchronized operation of test stations and reducing operator interaction through software-based automatic inspection and voltage adjustment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual inspection and testing methods are used with operators handling panels, then flexibility in operation is maintained, but productivity is low and panel damage risk increases
Solution Approach 1:
The patent replaces manual mechanical handling with an automated conveyance mechanism that includes a conveyor belt system and robotic positioning devices. This substitution eliminates operator contact with panels during inspection, preventing ESD damage and mechanical breakage while significantly increasing inspection throughput through continuous automated operation.
Solution Approach 2:
The inspection system performs self-testing through integrated test stations that automatically conduct P-gamma chip testing, voltage adjustment, and display verification without operator intervention. The system self-regulates the inspection process, maintaining consistent quality standards while improving productivity through uninterrupted automated operation.
2Measurement precision
If P-gamma chip testing is performed manually with long test times, then testing accuracy is maintained, but loss of time increases and productivity decreases
Solution Approach 1:
The patent implements continuous automated P-gamma chip testing where panels move through the inspection line without interruption. The automated test stations perform voltage adjustment, gamma calibration, and display verification in a continuous sequence, eliminating the idle time between manual testing operations while maintaining measurement precision through standardized automated test procedures.
3Productivity
If operators perform multiple inspection tasks manually, then operational flexibility is maintained, but device complexity increases and productivity decreases
Solution Approach 1:
The inspection line is segmented into distinct functional stations including conveyance, P-gamma chip testing, voltage adjustment, display verification, and packaging. Each station performs a specific function with dedicated equipment, reducing overall system complexity through modular design while increasing productivity by enabling parallel processing of multiple panels simultaneously across different stations.
Data Source
AI summary
The present invention provides a method for inspecting a panel-bonding semi-finished product, which includes (1) placing a panel-bonding semi-finished product on a tray in a feeding station; (2) using a conveyance mechanism to convey the tray and the panel-bonding semi-finished product to a final display test station; (3) proceeding with a final display test on the panel-bonding semi-finished product and ending the test if the result fails and proceeding to the next step if the result passes; (4) conveying the tray and the panel-bonding semi-finished product to a final visual check station; (5) proceeding with final visual check for the panel-bonding semi-finished product that passes the final display test and if the result fails, ending the inspection and if the result passes, then proceeding to the next step; (6) conveying the tray and the panel-bonding semi-finished product to a quality inspection station; (7) proceeding with quality inspection on the panel-bonding semi-finished product; (8) conveying the tray and the panel-bonding semi-finished product to a packaging station; and (9) proceeding with packaging of the panel-bonding semi-finished product.