CN111229636A - Adjusting method, adjusting system, conveying device and adjusted equipment - Google Patents
Adjusting method, adjusting system, conveying device and adjusted equipment Download PDFInfo
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- CN111229636A CN111229636A CN201911137462.7A CN201911137462A CN111229636A CN 111229636 A CN111229636 A CN 111229636A CN 201911137462 A CN201911137462 A CN 201911137462A CN 111229636 A CN111229636 A CN 111229636A
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B07—SEPARATING SOLIDS FROM SOLIDS; SORTING
- B07C—POSTAL SORTING; SORTING INDIVIDUAL ARTICLES, OR BULK MATERIAL FIT TO BE SORTED PIECE-MEAL, e.g. BY PICKING
- B07C5/00—Sorting according to a characteristic or feature of the articles or material being sorted, e.g. by control effected by devices which detect or measure such characteristic or feature; Sorting by manually actuated devices, e.g. switches
- B07C5/34—Sorting according to other particular properties
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B07—SEPARATING SOLIDS FROM SOLIDS; SORTING
- B07C—POSTAL SORTING; SORTING INDIVIDUAL ARTICLES, OR BULK MATERIAL FIT TO BE SORTED PIECE-MEAL, e.g. BY PICKING
- B07C5/00—Sorting according to a characteristic or feature of the articles or material being sorted, e.g. by control effected by devices which detect or measure such characteristic or feature; Sorting by manually actuated devices, e.g. switches
- B07C5/34—Sorting according to other particular properties
- B07C5/3412—Sorting according to other particular properties according to a code applied to the object which indicates a property of the object, e.g. quality class, contents or incorrect indication
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B07—SEPARATING SOLIDS FROM SOLIDS; SORTING
- B07C—POSTAL SORTING; SORTING INDIVIDUAL ARTICLES, OR BULK MATERIAL FIT TO BE SORTED PIECE-MEAL, e.g. BY PICKING
- B07C5/00—Sorting according to a characteristic or feature of the articles or material being sorted, e.g. by control effected by devices which detect or measure such characteristic or feature; Sorting by manually actuated devices, e.g. switches
- B07C5/36—Sorting apparatus characterised by the means used for distribution
- B07C5/361—Processing or control devices therefor, e.g. escort memory
- B07C5/362—Separating or distributor mechanisms
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65C—LABELLING OR TAGGING MACHINES, APPARATUS, OR PROCESSES
- B65C9/00—Details of labelling machines or apparatus
- B65C9/02—Devices for moving articles, e.g. containers, past labelling station
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- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06K—GRAPHICAL DATA READING; PRESENTATION OF DATA; RECORD CARRIERS; HANDLING RECORD CARRIERS
- G06K17/00—Methods or arrangements for effecting co-operative working between equipments covered by two or more of main groups G06K1/00 - G06K15/00, e.g. automatic card files incorporating conveying and reading operations
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65C—LABELLING OR TAGGING MACHINES, APPARATUS, OR PROCESSES
- B65C9/00—Details of labelling machines or apparatus
- B65C2009/0003—Use of RFID labels
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- Testing Of Optical Devices Or Fibers (AREA)
- Control Of Indicators Other Than Cathode Ray Tubes (AREA)
- Investigating Materials By The Use Of Optical Means Adapted For Particular Applications (AREA)
Abstract
The invention provides an adjustment method, an adjustment system, a conveying device and an adjusted device, wherein the system performs adjustment processing such as uneven correction processing with higher precision than before, and the conveying device is used for improving the productivity of the adjustment processing. An adjustment method for obtaining consistency of a plurality of control objects of a device, having the steps of: (1) an adjustment step of detecting operation states of a plurality of control objects and generating data for obtaining consistency of the plurality of control objects based on a detection result of the operation states; (2) an accumulation step of generating accumulated data obtained by accumulating the data; (3) a feedback step of performing the adjustment step using the accumulated data; (4) a determination step of determining whether or not to continue the feedback step.
Description
Technical Field
The present invention relates to an adjustment method, an adjustment system, a conveyor, and the like for making uniform and consistent output fluctuations from a plurality of elements and components, such as unevenness of a display panel, in a device such as a display panel.
Background
For example, as described in patent document 1, as a process of correcting unevenness of a display panel or the like, there is known a technique of displaying a test pattern on the display panel, photographing the test pattern with a camera, and calculating a correction amount from the photographed data to generate unevenness correction data.
As described in patent document 2, as the unevenness correction processing of the display panel or the like, there is also known a technique that can perform correction closer to visual inspection by, for example, setting the weight of the central portion of the screen to be large and the weight of the peripheral portion to be small to change the weight of each region.
Documents of the prior art
Patent document
Patent document 1: japanese patent laid-open publication No. 2017-9891
Patent document 2: japanese laid-open patent publication No. 2005-43174
Disclosure of Invention
Technical problem to be solved by the invention
However, the conventional unevenness correction processing of the display panel or the like has the following problems: since the process of displaying the test pattern on the display panel and photographing with the camera, calculating the correction amount from the photographing data, and generating the unevenness correction data is performed only once, satisfactory unevenness correction processing cannot be performed.
In addition, since the target value of the unevenness correction processing is not set, it is unclear whether the execution result of the unevenness correction processing is satisfactory or not, and it is sometimes different depending on the situation.
In addition, an apparatus for efficiently performing the unevenness correction processing for improving the productivity has not been proposed.
Therefore, the technical problem to be solved by the present invention is to perform adjustment processing such as unevenness correction processing with higher accuracy than before, and to efficiently perform adjustment processing by a conveyor for improving productivity of the adjustment processing.
Technical scheme for solving technical problem
An embodiment of the present invention provides an adjustment method for obtaining consistency of a plurality of control targets of a device, including:
an adjustment step of detecting operation states of a plurality of control objects and generating data for obtaining consistency of the plurality of control objects based on a detection result of the operation states; an accumulation step of generating accumulated data obtained by accumulating the data; a feedback step of performing the adjustment step using the accumulated data; a determination step of determining whether or not to continue the feedback step.
An embodiment of the present invention provides an adjustment system for obtaining consistency of a plurality of control targets of a plant, including:
an adjustment mechanism including a detection mechanism that detects operating states of a plurality of control objects and a data generation mechanism that generates data for obtaining consistency of the plurality of control objects based on a detection result of the detection mechanism; an accumulation mechanism that generates accumulated data by accumulating the data; a feedback mechanism that performs control of the adjustment mechanism using the accumulated data. A determination means that determines whether to continue control of the feedback means.
An embodiment of the present invention provides an unevenness correction method, including:
a correction step of photographing a display panel on which an image pattern is displayed, and generating data for correcting the unevenness based on an image obtained by the photographing; an accumulation step of generating accumulated data obtained by accumulating the data; a feedback step of performing the correction step using the accumulated data; a determination step of determining whether or not to continue the feedback step.
An embodiment of the present invention provides an unevenness correction system including:
a correction mechanism having an imaging mechanism that images a display panel on which an image pattern is displayed and a data generation mechanism that generates data for correcting the unevenness based on an image obtained by the imaging; an accumulation mechanism that generates accumulated data by accumulating the data; a feedback mechanism that performs control of the correction mechanism using the accumulated data; a determination means that determines whether to continue control of the feedback means.
An embodiment of the present invention provides a transfer apparatus for adjusting unevenness correction or the like, including:
setting at least one conveyor belt of the conveyor as a main conveyor belt, the main conveyor belt including:
the adjustment system;
a labeling mechanism and/or an RFID reader/writer that adds a label code on the device that can identify quality level information based on the quality level information from the adjustment system;
a sorting mechanism that sorts the devices on the main conveyor based on quality grade information of the labeling mechanism and/or the RFID reader/writer;
a transfer conveyor for transferring the sorted devices from the main conveyor to a sub conveyor;
a sub-conveyor belt for conveying the transferred apparatus in one direction.
Effects of the invention
According to the present invention, the following effects can be achieved: in order to make variations in outputs from a plurality of elements and components uniform and obtain uniformity, such as unevenness of a display panel, adjustment processing such as highly accurate unevenness correction can be efficiently performed more satisfactorily, and the productivity of the adjustment processing can be improved.
Drawings
Fig. 1 is a block diagram illustrating an overall configuration of an adjustment system such as an unevenness correction system according to an embodiment of the present invention.
Fig. 2 is a flowchart illustrating an adjustment method such as an unevenness correction method according to an embodiment of the present invention.
Fig. 3 is a flowchart for explaining an adjustment method such as an unevenness correction method according to an embodiment of the present invention.
Fig. 4 is a flowchart for explaining an adjustment method such as an unevenness correction method according to an embodiment of the present invention.
Fig. 5 is a block diagram illustrating the entire configuration of an adjustment system of a conventional unevenness correction method or the like.
Fig. 6 is a system diagram illustrating a configuration in which a transfer device is added to an adjustment system such as an unevenness correction system according to an embodiment of the present invention.
Fig. 7 is a system diagram illustrating a configuration in which a transfer device is added to an adjustment system such as an unevenness correction system according to an embodiment of the present invention.
Fig. 8 is a system diagram illustrating a configuration in which a transfer device is added to an adjustment system such as an unevenness correction system according to an embodiment of the present invention.
Fig. 9 is a system diagram illustrating a configuration in which a transfer device is added to an adjustment system such as an unevenness correction system according to an embodiment of the present invention.
Fig. 10 is a system diagram illustrating a configuration in which a transfer device is added to an adjustment system such as an unevenness correction system according to an embodiment of the present invention.
Detailed Description
An adjustment method, an adjustment system, a conveyor, and the like for making output variations from a plurality of elements and components uniform and obtaining uniformity according to an embodiment of the present invention will be described in detail with reference to the drawings, taking correction of unevenness of a display panel as an example.
Fig. 5 shows the entire configuration of the unevenness correcting system of the conventional display panel. Typically, the system is composed of a device (display panel or the like) 600 and an adjustment system (unevenness correction system or the like) 100, and the adjustment system 100 includes an adjustment mechanism (correction mechanism) 200 and a storage mechanism 500.
The device (display panel or the like) 600 may employ various panels such as a liquid crystal panel and an organic EL panel, or a device equipped with these display panels. As the device provided with the display panel, various devices such as a television, a monitor, a projection display, a smart phone, and an electronic dictionary can be used.
The adjustment mechanism (correction mechanism) 200 includes: a detection means (imaging means) 300 such as a CCD camera for imaging the display panel 600 on which the image pattern from the pattern generator is displayed; a data generation means 400 for calculating a correction amount for correcting unevenness from a captured image and generating correction data.
The sampling size of the captured image may be arbitrarily selected in units of pixels or in units of blocks (4 × 4, 16 × 16, and the like) made up of a plurality of pixels.
Further, the unevenness may be applied to luminance unevenness, color unevenness, and the like.
The storage unit 500 may employ various storage media such as ROM, and stores the correction data generated by the data generation unit 400. The storage mechanism 500 may be provided separately from the display panel 600, or may be incorporated in the display panel 600.
Finally, a storage medium storing correction data is mounted on the apparatus (display panel or the like) 600, and by correcting the image signal of the input apparatus (display panel or the like) 600 using the correction data, the apparatus (display panel or the like) 600 having undergone unevenness correction can be obtained.
However, the conventional unevenness correction system has the following problems: since the generation of the correction data is performed only once by the adjustment mechanism (correction mechanism) 200, the device (display panel or the like) 600 after the unevenness correction by the correction data is inspected again, and as a result, it is found that the unevenness is not completely eliminated in some cases, which is not satisfactory.
(embodiment mode 1)
The present invention provides an adjustment system such as an unevenness correction system in which the above-described drawbacks are eliminated, and fig. 1 shows an overall configuration of the adjustment system such as the unevenness correction system of the present invention. Typically, the entire configuration of the adjustment system (unevenness correction system or the like) 1 is constituted by a device (display panel or the like) 9 and the adjustment system (unevenness correction system or the like) 1, and the adjustment system (unevenness correction system or the like) 1 includes a feedback mechanism 2, a determination mechanism 7, and a storage mechanism 8.
The feedback mechanism 2 includes an adjusting mechanism (correcting mechanism) 3 and an accumulating mechanism 6, and is a control mechanism for repeatedly executing the adjusting mechanism (correcting mechanism) 3 and the accumulating mechanism 6. Since the adjusting mechanism (correcting mechanism) 3 has the same configuration as the adjusting mechanism (correcting mechanism) 200 described with reference to fig. 5, the details thereof are omitted.
The accumulation means 6 accumulates the correction data generated by the adjustment means (correction means) 3, and generates accumulated data by adding the correction data of the first time and the correction data of the second time when the adjustment means (correction means) 3 is executed twice. When the adjustment mechanism (correction mechanism) 3 is executed three times, accumulated data is generated by adding the accumulated data of the previous time to the correction data of the third time. Later, when the number of executions increases, the accumulated data is likewise generated.
The determination means 7 is control means for determining whether or not to continue the repetitive control of the adjustment means (correction means) 3 and the accumulation means 6 by the feedback means 2.
Next, the operation of embodiment 1 will be described with reference to the flowchart of fig. 2.
When the control of the adjustment system (unevenness correction system or the like) 1 is started, in the adjustment mechanism (correction mechanism) 3, a device (display panel or the like) 9 on which an image pattern from a pattern generator is displayed is photographed by a detection mechanism (photographing mechanism) 4 such as a camera, a correction amount for correcting unevenness is calculated from the photographed image, and correction data is generated by the data generation mechanism 5 (adjustment step S1).
Next, the correction data generated by the data generation means 5 are added to generate accumulated data by the accumulation means 6, but when the adjustment means (correction means) 3 is executed for the first time, since there is no correction data from the adjustment means (correction means) 3 that was executed for the previous time, the correction data generated by the adjustment means (correction means) 3 that was executed for the first time is generated as accumulated data (accumulation step S2).
Next, the determination means 7 determines whether or not to continue the repetitive control of the adjustment means (correction means) 3 and the accumulation means 6 by the feedback means 2 (determination step S3).
When it is determined by the determination means 7 that the correction is continued, the second control of the adjustment means (correction means) 3 and the accumulation means 6 is executed, the image pattern from the pattern generator is corrected using the accumulated data generated by the adjustment means (correction means) 3 and the accumulation means 6 for the first time, the device (display panel or the like) 9 on which the corrected image pattern is displayed is photographed using the photographing means 4 such as a camera, a correction amount for correcting the unevenness is calculated from the photographed image, and the correction data is generated by the data generation means 5. Then, the accumulated data of the first time is added to the correction data of the second time by the accumulation mechanism 6 to generate accumulated data (feedback step S4).
In this way, when it is determined by the determination means 7 to continue, the control is repeated by the feedback means 2.
When it is determined by the determination means 7 not to continue, the accumulated data generated last is saved as final accumulated data in the storage means 8 as correction data suitable for the device (display panel or the like) 9.
The determination means 7 determines whether or not to continue the determination of the feedback means 2 by determining whether or not the set condition is satisfied. The setting condition may be a condition inherent in the adjustment system (unevenness correction system, etc.) 1, or may be a condition that can be arbitrarily set.
(embodiment mode 2)
The operation of embodiment 2 will be described with reference to the flowchart of fig. 3.
In embodiment 2, the number of times of execution of the feedback mechanism 2 is arbitrarily set, and the setting method thereof is set based on the rule of thumb and the obtained adjustment data (correction data). In other words, panels manufactured by a certain manufacturing plant and panels manufactured by a certain production lot often have a tendency to be uneven. According to this inclined unevenness, for example, in the case where it is assumed that the unevenness of a certain production lot is serious, the number of times of execution of the feedback mechanism 2 can be set to a plurality of times, and therefore the unevenness correction can be performed more efficiently.
(embodiment mode 3)
The operation of embodiment 3 will be described with reference to the flowchart of fig. 4.
In the case where the setting condition is set as the number of executions of the feedback mechanism 2 as in embodiment 2, the probability that satisfactory unevenness correction can be performed is increased by increasing the number of executions, but since there is no target value of unevenness correction, it is not clear whether the set number of executions is actually satisfactory unevenness correction can be performed.
Thus, for example, it is conceivable to set a level for the size of unevenness (difference in luminance value in each region) and set a specific level as a target level. For example, according to the magnitude of the difference between the minimum value and the maximum value of the luminance values in each region, the range in which the difference is small is set as level 1, the range in which the difference is medium is set as level 2, and the range in which the difference is large is set as level 3. If the level 1 is set as unevenness that can be tolerated by human visual inspection, the target level is set to the level 1 as a setting condition.
On the other hand, the adjusting step (correcting step) S21 includes a quality evaluation value step S21a and a quality rank determining step S21b in addition to embodiment 1. The quality evaluation value step S21a calculates the difference between the minimum value and the maximum value of the luminance values in each region as a quality evaluation value from an image obtained by imaging the device (display panel or the like) 9 on which the image pattern is displayed. The quality rank determination step S21b determines to which rank among rank 1, rank 2, or rank 3 the calculated quality evaluation value belongs, and determines the quality rank of the captured image.
In the determination step S34, the quality rank determined in the quality rank determination step S21b is compared with a target rank set as a setting condition, and it is determined whether or not the quality rank meets the target rank. In case the target level is not met, the control of the feedback mechanism 2 is continued until the target level is reached. Thus, correction data satisfying the targeted unevenness correction quality can be obtained.
Further, it is also conceivable that the target quality cannot be obtained regardless of the repetition of the control of the feedback mechanism 2 several times because the quality of the device (display panel or the like) 9 is poor. In this case, the number of executions of the feedback mechanism 2 of embodiment 2 is also set as the set condition, and when the set number of executions is reached, the control of the feedback mechanism 2 is terminated even if the target level is not reached yet, and it is considered that a refresh reject of satisfactory quality cannot be obtained even if corrected.
In addition, various weights similar to those used for visual inspection by humans may also be used to determine the target level and quality level. For example, if the weight of the center portion of the screen of the device (display panel or the like) 9 is set to be large and the weight of the peripheral portion is set to be small, and the target level and the quality level are specified, correction data having a quality closer to that of visual inspection by a human can be obtained.
(embodiment mode 4)
The configuration of embodiment 4 is an example of a conveying apparatus, and an adjustment method for obtaining the uniformity of a control target in the present invention is applied to correction of luminance unevenness and the like of a display panel, and is used for performing the correction control and production efficiently.
First, the present embodiment aims to reuse a display panel that has been rejected as defective until now by renewing a display panel regarded as defective to a non-defective product of a predetermined level by an adjustment method (non-uniformity correction method in the case of the present embodiment) which is a main object of the present invention. In addition to this, in order to reuse the display panel, an uneven quality level improvement of the uneven correction system and an efficient production system are provided.
In addition, in order to achieve the above object, a business model may be established through steps to be described later. First, a case will be described in which a user of a display panel requests a correction service for a defective panel to refresh the panel, as an example.
First, a request for renewing a defective product to a non-defective product is received from a user of a display panel, and the supply of the defective display panel is received from the user after the request contract is established.
Next, after the contract is made, the supply of the unqualified display panel is received from the user, and the display panel is conveyed to the conveying apparatus of the present embodiment, and during the conveyance, unevenness correction and recognition of the quality grade of unevenness are performed.
Then, based on the recognition result of the quality grade of the display panel, the display panel after the renovation desired by the user is classified, selected and collected by the classification mechanism.
And then, the collected display panels are taken out of the warehouse or stored.
As an example of the uneven quality levels as described above, a case that will be described later can be considered, and the quality levels used in the present invention are premised on the case that will be described later.
Grade A:
the display panel is applied to a high-quality display panel which is used for televisions, large-sized displays and PC monitors and is almost invisible from unevenness. The category of class a is the category of small-sized displays, but when high quality image quality is required or when the user desires. In this embodiment, the display panel of quality class a is panel a.
Grade B:
the present invention is applied to small-sized displays such as smart phones, electronic dictionaries, and small-sized displays (for car navigation) and is directed to devices that do not require high-quality video viewing. In this embodiment, the display panel of quality class B is panel B.
Grade C:
the display device is applied to equipment with less strict requirements on image quality, such as a toy display. In this embodiment, the display panel of quality class C is panel C.
Unqualified products:
display panels that do not meet the above description are shown as rejects in the figures.
Next, a conveyor for consistency adjustment according to embodiment 4 will be described with reference to the system diagram of fig. 6.
In the explanation of the transfer device, the conventional term "above" is not used for the aforementioned and described devices and mechanisms in order to avoid the complexity of the expression.
The main conveyor a700 of fig. 6 mainly performs the correction of unevenness thereof and/or the identification of quality grade thereof while conveying the display panel in one direction. As a mechanism for this, for example, at least the next device/mechanism is disposed around the main conveyor a 700.
① feedback mechanism 2 composed of adjusting mechanism (correcting mechanism) 3 and accumulating mechanism 6
② determination means 7 for determining whether or not to execute control of the feedback means 2 in response to a set condition
③ transfer the display panel 9 provided with the RFID reader/writer (labeling mechanism 702) and the suction tray 704 to the sorting mechanism 701 of the transfer conveyor and the sub-conveyor
④ transfer conveyor 705 for placing or transferring the display panels 9 sorted by the sorting mechanism 701
⑤, and a sub-conveyor 706 for conveying the display panels 9 distributed by the main conveyor a700 or the transfer conveyor 705
The conveyor belts used in the description of the present invention are composed of a cured resin or rubber belt and a plurality of rollers for rotating the belt, and the main conveyor belt a700, the transfer conveyor belt 705, and the sub-conveyor belt 706 have the same structure as the conveyor belt.
Next, the respective devices and mechanisms will be described in detail below.
A sorting mechanism 701:
RF tags 703 are attached to the display panel 9 sorted by the sorting mechanism 701. While the display panel 9 passes over the main conveyor a700, the information of the RF tag 703 is read, and the destination is determined and transferred to the appropriate transfer mechanism 705 and sub conveyor 706. As an example of the panel transfer mechanism 705 of the present invention, a device using the suction tray 704 is described, and the device includes a panel grip portion configured by the suction tray 704 gripping the display panel and a moving mechanism for moving the panel grip portion, and the panel grip portion includes a panel suction portion 703 sucking the display panel. The panel suction unit 703 sucks the display panel 9 so that the thickness direction of the display panel 9 and the vertical direction are aligned, and moves the display panel while determining the moving direction with respect to the transfer mechanism 705 and the sub-conveyor 706, which are suitable for transfer after the suction. Then, the suction of the suction tray 703 is released while maintaining the horizontality of the panel on a desired transfer mechanism or sub-conveyor.
Labeling mechanism 702:
the conveying apparatus according to the present invention is an unevenness correction system capable of processing various signals, and therefore, an Identification signal for classifying products may be generated in the unevenness correction system, and classification may be performed by controlling a classification mechanism based on the signal.
On a production line, as identification tags for classifying products, there are RF tags, QR codes, IC chips, bar codes, and the like, which are technologies widely used in the field of inventory management and the like.
First, an RF tag 703 in which IDs for specifying a user, a producer, and an unevenness quality level are recorded is attached to a display panel to be corrected which is placed on a conveyor belt and sequentially moved, information of the user and the producer is read by an RFID reader/writer at a passing position of the conveyor belt, or corrected accumulated data and quality level data are written to the RF tag 703, and the display panel 9 conveyed on the conveyor belt is classified. Therefore, quality level management, shipment management, inventory management, and the like can be easily performed by using the conveyor.
The RF tag 703 is not shown in detail, but is formed to include an internal antenna, an IC chip, and the like. By this antenna, an electric wave can be transmitted and received between the RFID readers/writers. The IC chip includes: a power supply circuit for generating electric power from the received electric wave; a memory circuit for writing a tag code; a wireless processing circuit for generating a response electric wave; and a control circuit for information and quality level management of a user or a producer, and the like.
In embodiment 4, for convenience of explanation, the labeling mechanism 702 is described separately from the adjustment mechanism and the determination mechanism for uneven correction of the present invention, but the labeling mechanism 102 may be incorporated in the RFID reader/writer portion or may be disposed in the uneven correction system 1 having the adjustment mechanism 3 and the determination mechanism 7.
Transfer carousel 705:
the transfer conveyor 705 is used to transfer the display panels 9 sorted by the sorting mechanism 701 for each uneven quality grade to the sub conveyor 706 after being discharged from the main conveyor a700 (so-called off-line).
The display panel 9 discharged from the main conveyor a700 is a display panel 9 that cannot be corrected regardless of the unevenness correction performed several times, and for example, a panel in which bright lines or bright spots are generated due to pixel defects. Since these display panels 9 cannot improve the non-uniform quality level, only the discarding process can be performed.
On the other hand, the display panels 9 transferred to the sub-conveyer 706 are classified for each quality level of unevenness and/or each user or manufacturing factory. In principle, a display panel having a poor quality level but a margin for unevenness correction or a display panel of a specific quality level is transported.
Secondary conveyor belt 706:
the display panel 9 transferred by the transfer conveyor 705 is conveyed in a constant direction, and in some cases, correction control for raising the quality level is performed for each uneven quality level during the conveyance, or the display panel is conveyed separately only for the quality level on a plurality of conveyors. The method of using the sub-conveyor 706 is various, and therefore, the following drawings will explain the method.
(embodiment 5)
Fig. 7 shows a configuration in which display panels of various quality levels supplied by a user are transported and received by a main conveyor a700, and display panels 9 of different quality levels are transferred to a sub conveyor B706, a sub conveyor C706, and a sub conveyor D706 via a transfer conveyor 705 during the transportation.
In addition, the structure of simultaneously producing display panels of quality grade A, B, C is a system that classifies panels A, B, C and rejects by quality grade A, B, C only, as will be described later.
① only panel a of quality class a is obtained by the main conveyor a 700.
② only panel B of quality class B is obtained by sub-conveyor B706.
③ only panel C of quality class C is obtained by sub-conveyor C706.
④ discharge only the rejected panel via sub-conveyor D706.
Therefore, the embodiment of fig. 7 is provided with the unevenness correction system of the present invention only on the main conveyor a700, and performs correction control of the display panels of various quality ranks conveyed by the main conveyor a700 in sequence, and identifies and classifies the quality ranks of the display panels obtained as a result. The sheet is transferred to the sub-conveyer 706 via the transfer conveyer 705. The present embodiment is a configuration that is suitable for various kinds of production of various quality grades for various users.
(embodiment mode 6)
Fig. 8 shows that the unevenness correction system 1 is also provided on the sub-conveyer B706 to collectively upgrade the panel to a desired one of quality levels such as level a.
The main conveyor a700 is set as a dedicated production line for display panels of a certain desired quality grade, for example grade a. The display panels of quality ranks other than rank a, for example, rank B, C, are transferred to sub-carousel B706 and sub-carousel C706 via transfer carousel 705. Then, the display panel is upgraded to a desired quality grade, for example, a grade B panel to a grade a panel, or a grade C panel to a grade a panel, by the unevenness correction system 1, the labeling mechanism 702 provided on the sub-conveyor 706. The panels a, B, etc. can be mass-produced by this production method.
(embodiment 7)
In fig. 9, similarly to fig. 8, the unevenness correction system 1 is provided on the sub-conveyor 706, and is assumed to be a production line for a display panel of a desired level a (or B or C). The difference from fig. 8 is that the configuration of each sub-conveyor 706 is also the same as that of the main conveyor a700, and the process of the production line is completed on a conveyor-by-conveyor basis. Of the display panels sorted by the conveyors, panels other than those of a desired grade are discharged from the main conveyor and the sub-conveyor by the respective transfer conveyors 705.
That is, the sub-conveyors B706 and C706 are also classified into desired one quality class unit. Thus, only grade a, grade B or grade C, which are desired quality grades, are produced randomly strained on a plurality of conveyor belts. In embodiment 7, for example, display panels determined to be other than the level a are discharged from the respective conveyors onto the transfer conveyor. The discharged rank display panels other than rank a are used for other correction control at a later date. This embodiment 7 is suitable for mass production of panels of a specific quality class using a plurality of conveyors.
(embodiment mode 8)
Fig. 10 is a modified embodiment 8 in which the conveyor belt is arranged in a cross shape.
The transfer conveyor 705 or the sub conveyor 706 is provided so as to be orthogonal to the longitudinal direction of the main conveyor a700, and thus the sub conveyor 706 provided in parallel with the main conveyor a700 is not required. It is advantageous to make the layout of the factory compact and to improve the workability.
The main conveyor a700 classifies only the display panels of the level a, and transfers the display panels other than the level a to the transfer conveyor 705 or the sub conveyor 706 positioned at the right angle. The unevenness correction system 1 and the labeling mechanism 702 are disposed in a part of the transfer conveyor 705 or the sub conveyor 706, and the display panels 9 other than the desired quality grade classified by the main conveyor a700 are upgraded to, for example, panels of a desired grade a. The panel of grade a and defective is simply discharged to the transfer conveyor 705 or the sub-conveyor 706, and the display panel of grade B, C is sorted to the transfer conveyor B705, the transfer conveyor D705, or the sub-conveyor 706 provided with the unevenness correction system 1, the labeling mechanism 702, and then subjected to the unevenness correction control to be upgraded to grade a.
(embodiment mode 9)
In the adjustment method and the adjustment system for obtaining uniformity by making uniform the variations in the outputs from a plurality of elements or components, such as the unevenness of the display panel described in the above embodiments 1 to 8, there is also a method of making full use of artificial intelligence for performing machine learning.
This method is particularly effective in an unevenness correction system for a display panel, the reason for which is described below.
< technical problem >
①, there is a need to improve the production efficiency of display panels that are the subject of mass production.
② especially in the case of panels with extremely low production yield, such as organic EL panels, a large number of defective products are produced.
③, it is desirable to upgrade the large quantity of rejects to at least a substantially acceptable level (retrofit panel) such as a class B (class B) or class C (class C) product.
< solving the technical problem >
The unevenness correction system of the present invention has the following configuration, which can solve the above-described problems, and has preferable factors to be applied to machine learning described later.
① has a structure in which unevenness correction data is accumulated and held, and repetitive control of unevenness correction by a feedback mechanism may also be referred to as machine learning itself.
②, although various unevenness such as color unevenness including luminance unevenness occurs in the repetitive control, various unevenness correction data corresponding to these unevenness may be accumulated and stored.
③ the various correction data are classified into large, medium, and small categories according to the shape and the position of occurrence of the unevenness, and stored as unevenness correction data.
④ the original unevenness data before correction is classified into large, medium, and small categories according to the unevenness shape and the occurrence position and stored as original unevenness data.
⑤ by comparing the stored data of each of ③ and ④ and instantaneously judging the approximation thereof, it is possible to realize an increase in the speed of the unevenness correction control.
⑥, the data of ③ and ④ may be stored by supervised learning such as approximation function, permutation, neural network, and the like of the merit function corresponding to the machine learning algorithm.
⑦, it is not necessary to set reward conditions in the machine learning, and the most approximate and optimal unevenness correction conditions can be found quickly by performing the machine learning based on the determination of the comparison result between the set conditions set in the unevenness correction system 1, the correction data obtained in the feedback step 2, and the original unevenness data obtained by the imaging means 4.
⑧ for example, when the setting condition set in the unevenness correction system 1 is "the number of times designated", if the panel of a certain user or producer is judged to have good unevenness quality (for example, level B), the number of times designated may be set to "two" relatively small and the panel of level A may be obtained.
⑨ in the conveyer of FIG. 8, information obtained during or after the completion of machine learning in the unevenness correction system 1 of the main conveyer A700 is supplied to the correction system 1 disposed on the sub-conveyer B706 and the sub-conveyer C706.
⑩ according to the supply information, the sub-conveyer belt B706 sets a specified number of times for upgrading panel B to the highest evaluation of panel a and upgrades to panel a in the shortest time.
In the above
In this case, the panel C is upgraded to the panel B and then the panel B is upgraded to the panel a in stages using two unevenness correction systems 1 or the like, but the panel C may be upgraded to the panel a using one unevenness correction system 1.
As described above, in the unevenness correction system incorporated with reinforcement learning, machine learning is performed by exchange of the original unevenness data obtained by the photographing mechanism 4, the unevenness correction data obtained in the correction step S21, and the machine learner (incorporated in the feedback step S24 of fig. 4, not shown) as a subject to be learned.
The present invention is not limited to any specific configuration of the above embodiments. All of the constituent elements described in the present specification (including the claims, abstract and drawings) and/or all of the steps of any method or process disclosed may be combined in any combination, except combinations where mutually exclusive features are present.
The present invention has the following advantages due to the above structure: in order to obtain uniformity by making uniform output variations from a plurality of elements and components such as unevenness of a display panel, adjustment processing such as highly accurate unevenness correction is effectively performed more satisfactorily, and the productivity of the adjustment processing can be improved.
Description of the reference numerals
1 adjustment system (unevenness correction system, etc.)
2 feedback mechanism
3 adjusting mechanism (correcting mechanism)
4 detection mechanism (shooting mechanism)
5 data generating mechanism
6 accumulation mechanism
7 judging mechanism
8 storage mechanism
9 Equipment (display panel, etc.)
10 setting conditions (number of executions, target level, etc.)
700 main conveyor a
701 sorting mechanism
702 labeling mechanism (RFID reader/writer)
703 RFID tag
704 adsorption disk
705 transfer conveyor (transfer conveyor A, transfer conveyor B, transfer conveyor C, transfer conveyor D)
706 Secondary conveyer (secondary conveyer B, secondary conveyer C, secondary conveyer D)
707 antenna.
Claims (27)
1. An adjustment method for obtaining consistency of a plurality of control objects of a device, comprising:
an adjustment step of detecting operation states of the plurality of control objects, and generating data for obtaining consistency of the plurality of control objects based on a detection result of the operation states;
an accumulation step of generating accumulated data obtained by accumulating the data;
a feedback step of performing the adjustment step using the accumulated data; and
a determination step of determining whether or not to continue the feedback step.
2. The adjustment method according to claim 1,
the determining step determines whether a set condition is satisfied.
3. The adjustment method according to claim 2,
the setting condition is the number of times of execution of the feedback step.
4. The adjustment method according to claim 2,
the adjusting step further includes a quality evaluation value generating step of determining a quality evaluation value of the detection result of the operation state and a quality rank determining step of determining a quality rank based on the quality evaluation value,
the setting condition is a target level of the quality level,
the determining step determines whether the quality level determined in the quality level determining step meets the target level.
5. The adjustment method according to any one of claims 1 to 4,
if it is determined that the operation is not continued in the determining step, the accumulated data used last in the feedback step is stored as final accumulated data.
6. An apparatus conditioned by the conditioning method of any one of claims 1 to 5.
7. An adjustment system for obtaining consistency of a plurality of control objects of a plant, comprising:
an adjustment mechanism including a detection mechanism that detects an operating state of the plurality of control objects and a data generation mechanism that generates data for obtaining consistency of the plurality of control objects based on a detection result of the detection mechanism;
an accumulation mechanism that generates accumulated data by accumulating the data;
a feedback mechanism that performs control of the adjustment mechanism using the accumulated data; and
a determination means that determines whether to continue control of the feedback means.
8. The adjustment system according to claim 7,
if the determination means determines that the data is not continuous, the accumulated data used last in the feedback means is stored in storage means as final accumulated data.
9. An unevenness correction method for correcting unevenness of a display panel, comprising:
a correction step of photographing a display panel on which an image pattern is displayed, and generating data for correcting the unevenness based on an image obtained by the photographing;
an accumulation step of generating accumulated data obtained by accumulating the data;
a feedback step of performing the correction step using the accumulated data; and
a determination step of determining whether or not to continue the feedback step.
10. The unevenness correction method according to claim 9,
if it is determined that the operation is not continued in the determining step, the accumulated data used last in the feedback step is stored as final accumulated data.
11. An unevenness correction system for correcting unevenness of a display panel, comprising:
a correction mechanism having an imaging mechanism that images a display panel on which an image pattern is displayed and a data generation mechanism that generates data for correcting the unevenness based on an image obtained by the imaging;
an accumulation mechanism that generates accumulated data by accumulating the data;
a feedback mechanism that performs control of the correction mechanism using the accumulated data; and
a determination means that determines whether to continue control of the feedback means.
12. The unevenness correction system according to claim 11,
if the determination means determines that the data is not continuous, the accumulated data used last by the feedback means is stored in the storage means as final accumulated data.
13. A conveyor having a plurality of conveyors for sorting and selecting the devices using the adjustment system of claim 7,
setting at least one conveyor belt of the conveyor as a main conveyor belt, the main conveyor belt including:
the adjustment system;
a labeling mechanism and/or an RFID reader/writer that adds a label code on the device that can identify quality level information based on the quality level information from the adjustment system;
a sorting mechanism that sorts the control object on the main conveyor based on quality grade information of the labeling mechanism and/or the RFID reader/writer; and
a transfer conveyor for discharging a part of the sorted control target from the main conveyor.
14. A conveyor with a plurality of conveyors for sorting and selecting the devices, using the adjustment system of claim 7 or 8,
setting at least one conveyor belt of the conveyor as a main conveyor belt, the main conveyor belt including:
the adjustment system;
a labeling mechanism and/or an RFID reader/writer that adds a label code on the device that can identify quality level information based on the quality level information from the adjustment system;
a sorting mechanism that sorts the devices on the main conveyor based on quality grade information of the labeling mechanism and/or the RFID reader/writer;
a transfer conveyor for transferring the sorted devices from the main conveyor to a sub conveyor; and
a sub-conveyor for conveying the transferred apparatus in one direction.
15. The transfer device of claim 14,
the main conveyor is a production line of a device of a desired quality class, and other devices of quality classes are transferred to the sub conveyor via the transfer conveyor,
the adjusting system, the labeling mechanism and/or the RFID reader/writer are configured on the auxiliary conveyor belt, and equipment on the auxiliary conveyor belt is upgraded to the quality level expected by the main conveyor belt.
16. The transfer device of claim 14,
upgrading the equipment on the secondary conveyor to a level outside the desired quality level produced on the primary conveyor.
17. The transfer device of claim 14,
the transfer conveyor belt or the sub conveyor belt is provided so as to be orthogonal to the longitudinal direction of the main conveyor belt, and the adjustment system, the labeling mechanism, and/or the RFID reader/writer are disposed on the orthogonal transfer conveyor belt or sub conveyor belt,
upgrading equipment other than the desired quality level to a desired quality level to be delivered from the main conveyor to a transfer conveyor.
18. The transfer device of claim 14,
the sorting mechanism sorts the device using an identification tag including at least one of an RF tag, a QR code, an IC chip, and a barcode attached to the device.
19. The transfer device of claim 14,
the storage mechanism is a labeling mechanism and/or an RFID reader/writer, or a storage medium provided in a PC or a server.
20. A conveyor apparatus having a plurality of conveyor belts for sorting and selecting equipment using the unevenness correction system according to claim 11,
setting at least one conveyor belt of the conveyor as a main conveyor belt, the main conveyor belt including:
the unevenness correction system;
a labeling mechanism and/or an RFID reader/writer that adds a label code that can identify quality grade information on the display panel based on the quality grade information from the unevenness correction system;
a sorting mechanism that sorts the display panels on the main conveyor based on quality grade information of the labeling mechanism and/or the RFID reader/writer; and
a transfer conveyor for discharging a portion of the sorted display panels from the main conveyor.
21. A conveyor apparatus having a plurality of conveyor belts for sorting and selecting equipment using the unevenness correction system according to claim 11 or 12,
setting at least one conveyor belt of the conveyor as a main conveyor belt, the main conveyor belt including:
the unevenness correction system;
a labeling mechanism and/or an RFID reader/writer that adds a label code that can identify quality grade information on the display panel based on the quality grade information from the unevenness correction system;
a sorting mechanism that sorts the display panels on the main conveyor based on quality grade information of the labeling mechanism and/or the RFID reader/writer;
a transfer conveyor for discharging a part of the sorted display panels from the main conveyor; and
a sub conveyor belt for conveying the transferred display panel in one direction.
22. The transfer device of claim 21,
the main conveyor is a production line of display panels of a desired quality class, and the display panels of other quality classes are transferred to the sub conveyor via the transfer conveyor,
and arranging the unevenness correction system and the labeling mechanism and/or the RFID reader/writer on the auxiliary conveyor belt, and upgrading the display panel on the auxiliary conveyor belt to the desired quality grade of the main conveyor belt.
23. The transfer device of claim 21,
upgrading the display panels on the secondary conveyor to a grade other than the desired quality grade produced on the primary conveyor.
24. The transfer device of claim 21,
the transfer conveyor belt or the sub conveyor belt is provided so as to be orthogonal to the longitudinal direction of the main conveyor belt, and the feedback mechanism, the judgment mechanism, and the labeling mechanism and/or the RFID reader/writer are disposed on the orthogonal transfer conveyor belt or sub conveyor belt,
the display panels conveyed from the main conveyor to the transfer conveyor beyond a desired quality level are upgraded to a desired quality level.
25. The transfer device of claim 21,
the sorting mechanism sorts the display panel using an identification tag including at least one of an RF tag, a QR code, an IC chip, and a barcode attached to the display panel.
26. The transfer device of claim 21,
the storage mechanism is a labeling mechanism and/or an RFID reader/writer, or a storage medium provided in a PC or a server.
27. A trusted system for uneven correction traffic, characterized by,
the display panel after being refurbished and desired by a user is stored out or in custody by performing the following steps:
a step of receiving a request for an uneven correction service of a display panel by a user;
a step of signing a consignment contract of the uneven correction service with the user;
receiving a supply of the display panel from a user after the entrusting contract is signed;
a step of conveying the display panel obtained in the supplying step by a conveyor belt for unevenness correction;
a condition setting step of setting a user-desired unevenness correction condition on the conveyor belt;
a classification step of selectively acquiring the display panel that meets the desired condition setting by a classification mechanism;
an identification step of identification of the user and/or of the non-uniform quality level by means of a labelling mechanism and/or an RFID reader/writer; and
a step of collecting the display panels that meet the uneven quality level of each user based on the identification in the identifying step.
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| JP2018-234903 | 2018-11-28 | ||
| JP2018234903A JP2020086419A (en) | 2018-11-28 | 2018-11-28 | Adjustment method and adjustment system for obtaining uniformity of plural control objects and conveyer device and adjusted equipment |
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| CN111229636A true CN111229636A (en) | 2020-06-05 |
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| JP2020086419A (en) | 2020-06-04 |
| JP2023051934A (en) | 2023-04-11 |
| JP7503731B2 (en) | 2024-06-21 |
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