CN203155488U - Full-automatic fluorescent powder coating equipment - Google Patents
Full-automatic fluorescent powder coating equipment Download PDFInfo
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- CN203155488U CN203155488U CN 201320070572 CN201320070572U CN203155488U CN 203155488 U CN203155488 U CN 203155488U CN 201320070572 CN201320070572 CN 201320070572 CN 201320070572 U CN201320070572 U CN 201320070572U CN 203155488 U CN203155488 U CN 203155488U
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Abstract
The utility model relates to full-automatic fluorescent powder coating equipment. The equipment comprises a lower computer system and an upper computer system, wherein the lower computer system comprises a fluorescent powder nozzle, an xyz axis movement control platform, a full-automatic feeding/discharging device and a machine vision device, wherein the upper computer system comprises a coating control module, a movement control module and a machine vision control module. The full-automatic fluorescent powder coating equipment is characterized in that the lower computer system further comprises a nozzle constant-temperature control device, a vacuum agitating and de-foaming device and a laser thickness measuring device; the upper computer system further comprises a de-foaming control module; the coating control module is respectively connected with the fluorescent powder nozzle and the nozzle constant-temperature control device; the de-foaming control module is connected with the vacuum agitating and de-foaming device; the machine vision control module is respectively connected with the laser thickness measuring device and the machine vision device; and the movement control module is respectively connected with the xyz axis movement control platform and the full-automatic feeding/discharging device. According to the full-automatic fluorescent powder coating equipment disclosed by the utility model, the fluorescent powder coating precision on a high-power white light LED (Light Emitting Diode) chip or a chip module by the fluorescent powder coating equipment is greatly improved, so that the packaging qualities including the thermal resistance dispersibility, the chromaticity consistency, the light-emitting efficiency and the like of an white light LED package are effectively improved.
Description
Technical field
The utility model relates to fluorescent material paint-on technique field, is specifically related to a kind of full-automatic fluorescent material coating equipment.
Background technology
White light LEDs is all solid state lighting source of a kind of novel semi-conductor.Compare with the traditional lighting technology, leading superiority such as that this new type light source has is energy-efficient, long-life, small size, easy care, environmental protection, use safety, good weatherability is acknowledged as first choice of the following lighting source.
The white light LEDs encapsulation is to promote the international semiconductor illumination and show the critical process that develops rapidly, and fluorescent powder coated be to realize in the world that at present blue-ray LED is to the mainstream technology of white light LEDs conversion, core process and equipment are abroad monopolized always, directly restrict the sustainable development of the emerging strategic industry of China LED.The present uneven thickness that applies of homemade traditional fluorescent material coating equipment ubiquity, shortcoming such as production capacity is low, and adaptability is narrow.Therefore, independent development goes out a kind of production capacity height, applies the precision height, can adapt to simultaneously the fluorescent material coating equipment of large power white light LED module packaging technology development with rapid changepl. never-ending changes and improvements again, break away from external technical monopoly, become the only way of China LED encapsulation industrial chain development.This patent has proposed technology and the equipment that a kind of new LED fluorescent material applies, based on existing fluorescent material coating equipment (for example: rise and contain the online injection point gum machine of SD950, Anda TF-550B coating machine etc.), comprise fluorescent material shower nozzle, xyz axle motion control platform, full-automatic on/basis of existing structures such as blanking device and machine vision device on, increase the vacuum stirring defoaming device and be used for simplifying existing coating processes, effectively removed the micro-bubble that contains after phosphor gel is mixed; Increase the shower nozzle thermostatically-controlled equipment and be used for the fluorescent material shower nozzle is carried out thermostatic control, reached the purpose that reduces and stablize the phosphor gel viscosity in the described fluorescent material shower nozzle; Having increased the thickness measurement with laser device uses laser triangulation to be used for measuring the thickness distribution that applies phosphor powder layer; And proposed a cover fluorescent material and applied learning algorithm for improving LED fluorescent material coating precision.These utility models can effectively improve package qualities such as the thermal resistance dispersiveness, chromaticity uniformity, light extraction efficiency of white light LEDs encapsulation, CCU method for designing and detection algorithm theory are applied to the independent development of full-automatic fluorescent powder coated equipment, promote the technological innovation of China LED envelope survey industry.
The utility model content
The purpose of this utility model is to provide a kind of full-automatic fluorescent material coating equipment, at existing fluorescent material coating equipment (for example: rise and contain the online injection point gum machine of SD950, Anda TF-550B coating machine etc.) on the basis, increase the vacuum stirring defoaming device and be used for simplifying existing coating processes, effectively removed the micro-bubble that contains after phosphor gel is mixed; Increase the shower nozzle thermostatically-controlled equipment and be used for the fluorescent material shower nozzle is carried out thermostatic control, reached the purpose that reduces and stablize the phosphor gel viscosity in the described fluorescent material shower nozzle; Having increased the thickness measurement with laser device uses laser triangulation to be used for measuring the thickness distribution that applies phosphor powder layer; And proposed a cover fluorescent material and applied learning algorithm for improving LED fluorescent material coating precision.Can effectively improve the uniformity of fluorescent material coated weight and coating thickness, improve light source quality and the yield rate of white light LEDs.The purpose of this utility model is achieved through the following technical solutions.
A kind of full-automatic fluorescent material coating equipment, the fluorescent material that is used for finishing on the led chip applies operation, this equipment comprises lower computer system and master system, lower computer system comprise fluorescent material shower nozzle, xyz axle motion control platform, full-automatic on/blanking device and machine vision device; Master system comprises coating control module, motion-control module and machine vision control module; It is characterized in that lower computer system also comprises shower nozzle thermostatically-controlled equipment, vacuum stirring defoaming device and thickness measurement with laser device; Master system also comprises the de-bubble control module; Apply control module and connect fluorescent material shower nozzle and shower nozzle thermostatically-controlled equipment respectively, the de-bubble control module connects the vacuum stirring defoaming device, the machine vision control module connects thickness measurement with laser device and machine vision device respectively, motion-control module connect respectively xyz axle motion control platform and full-automatic on/blanking device.
In the above-mentioned full-automatic fluorescent material coating equipment, described fluorescent material shower nozzle can use a glue shower nozzle, atomizer or piezo jets fluorescent material shower nozzle, is used for sprayed with fluorescent powder glue;
Described shower nozzle thermostatically-controlled equipment comprises heating wire and thermistor, and heating wire and thermistor are installed in inside or the outside of described fluorescent material shower nozzle, is used for described fluorescent material shower nozzle is carried out thermostatic control;
Described vacuum stirring defoaming device comprises: the phosphor gel container is used for storage phosphor gel to be coated; Electronic stirring rod is used for stirring phosphor gel; Air door, be used for extracting out the air in the phosphor gel container, by air door the air of the phosphor gel internal tank that phosphor gel to be coated is housed is extracted out, form vacuum environment, electronic stirring rod constantly stirs under vacuum environment, and the bubble of phosphor gel is stirred to the final elimination in phosphor gel surface from the bottom of device in the handle assembly;
Described thickness measurement with laser device comprises: generating laser is used for emission measurement laser; The sensor photosensitive face is used for receiving the measurement laser that measured surface reflects; Lens are used for converging the measurement laser that generating laser emits; Described thickness measurement with laser device uses laser triangulation, is used for measuring the thickness distribution of the phosphor powder layer after applying;
Described machine vision device comprises imageing sensor, and imageing sensor adopts cmos sensor or ccd sensor; Visual processes and control module are based on FPGA, CPLD, DSP, DSP+FPFA or DSP+CPLD; Interface module adopts the mode based on bus, comprises IEEE 1394a, USB or Ethernet, is used for the machine vision location of led support and the defects detection of coating back phosphor powder layer;
Shower nozzle xyz axle motion control platform adopts stepper motor, servomotor or linear electric motors, is used for the described fluorescent material shower nozzle of control high-speed, high precision on the xyz direction of principal axis and moves;
Described full-automatic handling equipment comprises magazine, following magazine, the led support that is used for depositing led support to be coated respectively and has finished coating; Mechanical moving device, be used for realizing that magazine transports work to the support that applies the working region, in last magazine, led support is sent into zone to be coated before comprising coating, with apply the back coated led support be transported to down in the magazine mechanical moving device employing mechanical arm or conveyer belt realization.
In the above-mentioned full-automatic fluorescent material coating equipment, master system comprises:
Apply control module, realize that the phosphor gel quantity for spray is accurately controlled, the fluorescent material atomizing is controlled, the flow velocity control of the inner phosphor gel of fluorescent material shower nozzle, be to realize that the phosphor gel quantity for spray is accurately controlled and the crucial control module of fluorescent coating uniformity control, be used for control fluorescent material shower nozzle coating procedure fluorescent powder jet printing amount, the atomizing uniformity, spraying scope and control shower nozzle thermostatically-controlled equipment carry out heated constant temperature control to the fluorescent material shower nozzle, with the viscosity of reduction and the inner phosphor gel of stable shower nozzle;
The motion-control module of telling be used for control xyz axle motion control device the fluorescent material shower nozzle carried out the axial movement of xyz, be used for the coordination control to xyz axle motion control device and full-automatic handling equipment;
Control vacuum stirring defoaming device carries out de-bubble work, is used for control vacuum stirring defoaming device the phosphor gel that has just mixed is carried out the de-bubble operation;
Machine vision control module control thickness measurement with laser device and machine vision device are carried out thickness measure and the defects detection work to phosphor powder layer, being used for control thickness measurement with laser device carries out thickness measurement with laser work and control machine vision and defect detecting device to coated phosphor powder layer sprayed with fluorescent powder layer is carried out defects detection work.
Use the above-mentioned coating processes of stating full-automatic fluorescent material coating equipment, it may further comprise the steps:
4.1 use the bubble of the phosphor gel inside that has just mixed in the vacuum stirring defoaming device cancellation element, meanwhile, by the shower nozzle thermostatically-controlled equipment fluorescent material shower nozzle be heated to operating temperature;
4.2 after treating that step 4.1 is finished, by full-automatic handling equipment led support to be coated is transported to above the coating working region;
4.3 after treating that step 4.2 is finished, by machine vision module control machine vision device location led support to be coated, obtain the position coordinates on workbench of led support to be coated;
4.4 after treating that step 4.3 is finished, by xyz axle motion control device the fluorescent material shower nozzle is moved to directly over the led support to be coated;
4.5 after treating that step 4.4 is finished, if the coating first of current led support type to be applied, the fluorescent material first that then uses the corresponding initial application control parameter of current led support type to be applied to carry out current led support to be applied applies; Coating first if not current led support type to be applied, then use measured last time of step 4.7 to apply and finish the back led support thickness of coating fluorescent dye distributed constant initial control parameter corresponding with current led support type to be applied, parameter is controlled in the coating of using fluorescent material coating Iterative Learning Control Algorithm to calculate this led support to be applied;
4.6 the current coating control parameter of using step 4.5 to calculate, control fluorescent material shower nozzle is finished the fluorescent material coating work of current led support;
4.7 after treating that step 4.6 is finished, detect the thickness distribution of the phosphor powder layer of current coated led support by the method that obtains the fluorescent coating thickness distribution based on laser triangulation, the fluorescent material that is used for step 4.5 applies the iterative computation of control learning algorithm, calculates coating precision next time;
4.8 after treating that step 4.7 is finished, detect the coat the defect information of institute's phosphor powder layer by machine vision and defect detecting device;
4.9 judge whether to finish coating, if do not finish, then forward step 4.2 to; If finish, then finish.
In the above-mentioned coating processes, described Iterative Learning Control Algorithm may further comprise the steps:
5.1 according to led support type to be applied and setting coating thickness, choose the initial control parameter of current led support type to be applied, comprising: initial control of fluorescent powder jet printing time parameter, the initial control of phosphor gel atomizing parameter, phosphor gel flow velocity are initially controlled parameter;
5.2 according to the thickness distribution of the last phosphor powder layer of measuring in the step 4.7 and the setting coating thickness in the step 5.1, calculate the coating error that last fluorescent material applies;
5.3 according to the resulting coating error of step 5.2, use Iterative Learning Control Algorithm, calculate the correction of each control parameter of current coating controller, comprising: fluorescent powder jet printing time control parameter correction, phosphor gel atomizing control parameter correction, phosphor gel flow parameters correction;
5.4 by the resulting current theoretical control parameter of step 5.1 and step 5.3 and control parameter correction, calculate the true controlled quentity controlled variable of current coating controller;
In the above-mentioned coating processes, the described method that obtains the fluorescent coating thickness distribution based on laser triangulation may further comprise the steps:
6.1 unlatching thickness measurement with laser fixture, generating laser irradiation measured surface, measured surface are respectively fluorescent material and apply preceding high-power LED chip surface and the fluorescent material coated side after the fluorescent material coating;
6.2 two width of cloth representation of laser facula that step 6.1 is gathered are carried out filtering with smoothing filter;
6.3 the light spot image that obtains after step 6.2 filtering is carried out two-value to be cut apart; Grey level histogram based on image obtains segmentation threshold by iterative computation;
6.4 ask for laser facula centroid position everywhere;
6.5 adopt laser triangulation to calculate the fluorescent coating thickness distribution.
Compared with prior art, the utlity model has following advantage and technique effect: the method that proposes of the present utility model, the fluorescent material that can be applied to large power white light LED or led chip module applies in the encapsulation process, but also can be applied in the coating of wafer level chip, coating coated weight and the coating layer thickness of glue that can accurately control various viscosity, and the uniformity of assurance coating layer thickness.The utility model is on the basis of the full-automatic fluorescent material coating equipment of tradition, integrated shower nozzle thermostatically-controlled equipment, thickness measurement with laser device and phosphor gel vacuum stirring de-bubble module apply precision thereby improved fluorescent material when simplifying fluorescent powder coating technique in coating equipment.
Description of drawings
Fig. 1 is fluorescent material coating equipment schematic diagram in the embodiment.
Fig. 2 is the system architecture diagram of fluorescent material coating equipment in the embodiment.
Fig. 3 is fluorescent material coating equipment process chart in the embodiment.
Fig. 4 is fluorescent material shower nozzle thermostatically-controlled equipment schematic diagram in the embodiment.
Fig. 5 is the light path principle figure that the laser measurement thickness distribution detects in the embodiment.
Fig. 6 is vacuum stirring defoaming device schematic diagram in the embodiment.
The specific embodiment
Above content has been done sufficient explanation to the utility model, understands for technical characterictic of the present utility model, purpose and effect being had more clearly, now contrasts accompanying drawing and describes the specific embodiment of the present utility model in detail.
Fluorescent material described in the utility model applies lower computer system as depicted in figs. 1 and 2, described lower computer system comprises: fluorescent material shower nozzle 12, shower nozzle thermostatically-controlled equipment 13, shower nozzle xyz axle motion control device 14, full-automatic handling equipment 15, vacuum stirring defoaming device 16, thickness measurement with laser device 17, machine vision and defect detecting device 18.Described fluorescent material coating equipment control module is namely: master system 11 comprises: apply control module 19, motion-control module 20, vacuum stirring de-bubble control module 21, machine vision control module 22.
Wherein, fluorescent material shower nozzle 12 can use a glue shower nozzle, atomizer or piezo jets fluorescent material shower nozzle, is used for sprayed with fluorescent powder glue;
Shower nozzle thermostatically-controlled equipment 13 comprises heating wire and thermistor, and heating wire and thermistor are installed in inside or the outside of described fluorescent material shower nozzle, is used for described fluorescent material shower nozzle is carried out thermostatic control;
Shower nozzle xyz axle motion control platform 14 can use stepper motor, servomotor or linear electric motors, is used for the described fluorescent material shower nozzle of control high-speed, high precision on the xyz direction of principal axis and moves;
Full-automatic handling equipment 15 comprises magazine, following magazine, the led support that is used for depositing led support to be coated respectively and has finished coating; Mechanical moving device is used for realizing that magazine transports work to the support that applies the working region, can use mechanical arm or conveyer belt to realize; Before be used for applying last magazine led support is sent into zone to be coated and apply the back magazine under coated led support is transported in.
Vacuum stirring defoaming device 16 comprises the phosphor gel container, is used for storage phosphor gel to be coated; Electronic stirring rod is used for stirring phosphor gel; Air door is used for extracting out the air in the phosphor gel container; By air door the air of the phosphor gel internal tank that phosphor gel to be coated is housed is extracted out, form vacuum environment, electronic stirring rod constantly stirs under vacuum environment, and the bubble of phosphor gel is stirred to the final elimination in phosphor gel surface from the bottom of device in the handle assembly;
Thickness measurement with laser device 17 comprises generating laser, is used for emission measurement laser; The sensor photosensitive face is used for receiving the measurement laser that measured surface reflects; Lens are used for converging the measurement laser that generating laser emits; Described thickness measurement with laser device uses laser triangulation, is used for measuring the thickness distribution of the phosphor powder layer after applying;
Fluorescent material described in the utility model applies master system 11 as shown in Figure 2, comprising:
Applying control module 19, realize that the phosphor gel quantity for spray is accurately controlled, the fluorescent material atomizing is controlled, the flow velocity control of the inner phosphor gel of fluorescent material shower nozzle, is to realize that the phosphor gel quantity for spray is accurately controlled and the crucial control module of fluorescent coating uniformity control.Be used for control fluorescent material shower nozzle coating procedure fluorescent powder jet printing amount, the atomizing uniformity, the accurate control of spraying scope and control shower nozzle thermostatically-controlled equipment are heated to the fluorescent material shower nozzle, to reduce the viscosity of the inner phosphor slurry of shower nozzle;
Motion-control module 20 carries out the axial high-speed, high precision of xyz for control xyz axle motion control device to the fluorescent material shower nozzle and moves.Be used for the high accuracy of xyz axle motion control device and full-automatic handling equipment is coordinated control;
Vacuum stirring de-bubble control module 21, control vacuum stirring defoaming device carries out de-bubble work.Be used for control vacuum stirring defoaming device the phosphor gel that has just mixed is carried out the de-bubble operation;
Machine vision control module 22, control thickness measurement with laser device and machine vision device are carried out thickness measure and the defects detection work to phosphor powder layer.Being used for control thickness measurement with laser device carries out thickness measurement with laser work and control machine vision and defect detecting device to coated phosphor powder layer sprayed with fluorescent powder layer is carried out defects detection work.
As shown in Figure 3, full-automatic fluorescent powder coating technique may further comprise the steps:
Step 34, treat that step 33 is finished after, by machine vision module control machine vision device location led support to be coated, obtain the position coordinates on workbench of led support to be coated;
Above-mentioned Iterative Learning Control Algorithm may further comprise the steps:
(1) according to led support type to be applied and setting coating thickness, choose the initial control parameter of current led support type to be applied, comprising: initial control of fluorescent powder jet printing time parameter, the initial control of phosphor gel atomizing parameter, phosphor gel flow velocity are initially controlled parameter;
(2) according to the fluorescent coating thickness distribution of the last time coating that obtains based on laser triangulation and the setting coating thickness in the step (1), calculate the coating error that last fluorescent material applies;
(3) according to the resulting coating error of step (2), use Iterative Learning Control Algorithm, calculate the correction of each control parameter of current coating controller, comprising: fluorescent powder jet printing time control parameter correction, phosphor gel atomizing control parameter correction, phosphor gel flow parameters correction;
(4) by the resulting current theoretical control parameter of step (1) and step (3) and control parameter correction, calculate the true controlled quentity controlled variable of current coating controller;
The above-mentioned method that obtains the fluorescent coating thickness distribution based on laser triangulation may further comprise the steps:
(1) unlatching laser range sensor, irradiation measured surface, measured surface are respectively fluorescent material and apply preceding high-power LED chip surface and the fluorescent material coated side after the fluorescent material coating;
(2) two width of cloth representation of laser facula that step (1) is gathered are carried out filtering with smoothing filter;
(3) light spot image that obtains after step (2) filtering being carried out two-value cuts apart; Grey level histogram based on image obtains segmentation threshold by iterative computation;
(4) ask for laser facula centroid position everywhere;
(5) adopt laser triangulation to calculate the fluorescent coating thickness distribution.
The above-mentioned laser range sensor of stating is used for the laser beam that the emission measurement thickness of coating fluorescent dye distributes.
As an example, a kind of full-automatic fluorescent powder coating technique as shown in Figure 3, may further comprise the steps:
The implementation method of operation 31 is as follows: earlier epoxide-resin glue is mixed with fluorescent material, mixed colloid proportion is 1.60-1.80g/cm3, and viscosity is 4000-5500 Pas; As shown in Figure 6, mixed phosphor gel is fed in the phosphor gel entrance 51, open valve V-3, make phosphor gel enter into vacuum stirring defoaming device 16, open valve V-1 and use gas passage 53 to extract air in the phosphor gel container 54 out the formation vacuum, open stirring motor 56 and make stirring rod 55 rotate, carrying out froth in vacuum handles, after band de-bubble operation is finished, open the valve V-2 of phosphor gel then, the phosphor gel after the de-bubble flows into 12 li in fluorescent material shower nozzle from exit passageway 52.
See also Fig. 3, the implementation method of operation 32 is as follows: as shown in Figure 4, describedly by thermostatically-controlled equipment 13 fluorescent material shower nozzle 12 is heated to operating temperature, after in the phosphor gel passage of phosphor gel inflow fluorescent material shower nozzle 12 the insides after mixing de-bubble, use PID control (PID control) methods control shower nozzle thermostatically-controlled equipments 13 heating fluorescent material shower nozzles 12 by the coating control module 19 in the fluorescent material coating equipment control module, wait for that the fluorescent material shower nozzle is stabilized in to set work temperature and get final product when neighbouring.Operating temperature generally can be set according to different viscosity phosphor gel, here the viscosity of phosphor gel and operating temperature inversely proportional relation roughly.
See also Fig. 3, the implementation method of operation 33 is as follows: the led chip groups of holders to be coated that full-automatic upper and lower materials device 15 will be gone up in the hopper 9 moves and is fixed on the workbench of motion control device 14; In master system 11, configure the coordinate at zero point.Described full-automatic upper and lower materials device can adopt mechanical arm to grasp or the conveyer belt conveyer transports led support, finishes material loading work.
See also Fig. 3, the implementation method of operation 34 is as follows: the led support to be coated that 18 pairs of machine vision and defect detecting devices are fixed on the workbench carries out the work of machine vision location, by the gray scale of image is calculated, orient the exact position of current led chip to be coated.
See also Fig. 3, the implementation method of operation 35 is as follows: describedly by xyz axle motion control device 14 shower nozzle 12 is accurately moved to coating zone in various sizes information and the various motion control coating parameters of master system 11 input led support to be coated, comprise the distribution of led chip array, distance between the led chip, shower nozzle applies route, shower nozzle translational speed; Treat the led chip groups of holders, put well and be fixed on the workbench of motion control device after, master system 11 is according to the parameter information of input, the led chip top that moving to of fluorescent material shower nozzle 12 high-speed, high precisions is to be coated.The vertical range of shower nozzle and led chip is decided according to the size of led chip.
See also Fig. 3, the implementation method of operation 36 is as follows: calculate 12 control parameter of current fluorescent material shower nozzle by the coating control module 19 in the master system 11, carry out this coating.Its specific algorithm is as follows:
A kind of fluorescent material applies control learning algorithm, comprises following content:
Coating thickness according to target, by applying controller, calculate current control parameter to coating control device module, comprising: the parameter vector of fluorescent powder jet printing time theory control parameter, the theoretical control of phosphor gel atomizing parameter, phosphor gel flow velocity theory control parameter.Wherein, spray time control parameter can be obtained by flow velocity, these calculation of parameter of nozzle diameter of phosphor gel in the quantity for spray of each phosphor slurry, the fluorescent material shower nozzle; Fluorescent material atomization air pressure control parameter can be by the led chip size, the flow velocity of phosphor gel in the fluorescent material shower nozzle, nozzle and led chip surface apart from these calculation of parameter acquisitions; Phosphor gel flow velocity control parameter will be controlled parameter according to spray time and control parametric synthesis with the fluorescent material atomization air pressure and calculate.
According to thickness and the target coating thickness of measured phosphor powder layer of last time, calculate last coating error; According to the resulting coating error of previous step, use Iterative Learning Control Algorithm, calculate the correction of the control parameter of current coating control device module, comprising: spray time control parameter correction, fluorescent material atomizing control parameter correction, phosphor gel flow velocity control parameter correction;
Above-mentioned iterative learning algorithm can use different study operators, and target is exactly to make the thickness and precision of fluorescent coating improve.For example, use " PID type " iterative learning algorithm as follows:
Wherein,
Be the time,
Be theory control parameter vector, comprise: spray time control theory control parameter, fluorescent material atomizing control theory control parameter and phosphor gel flow velocity control theory control parameter;
True control parameter vector for current coating controller;
Thickness error vector for last fluorescent coating;
,
,
Be the constant gain matrix.
By the resulting current theoretical control parameter of above-mentioned steps and control parameter correction, calculate the true control parameter vector of current coating controller; True controlled quentity controlled variable is controlled the fluorescent material shower nozzle and is carried out this coating work thus.
See also Fig. 3, the implementation method of operation 37 is as follows: the thickness that detects institute's phosphor powder layer by thickness measurement with laser device 17, thickness measurement with laser device 17 is followed the fluorescent material shower nozzle by motion control device 14 and is moved to led chip top, at this moment measures the distance of laser detector 17 and led chip to be coated before applying earlier carrying out fluorescent material; Finish etc. to be coated, after coating is finished, measure the distance of laser detector 17 and phosphor powder layer upper surface again, two distances that obtain are subtracted each other, can obtain the precise thickness of phosphor powder layer.
See also Fig. 3, the implementation method of operation 38 is as follows: the blemish that checks out the phosphor powder layer of current coating by machine vision and defect detecting device 18, follow the fluorescent material shower nozzle by machine vision and defect detecting device 18 by motion control device 14 and move to the led chip top, obtain the high-definition image of current fluorescent coating, fluorescent coating in the image partly is divided into several zones, the intensity profile figure that each zone is obtained compares with the phosphor powder layer that corresponding standard evenly applies then, whether has defective thereby judge current fluorescent coating.
Above-mentioned machine vision control module algorithm is as follows:
As shown in Figure 5, the incident chief ray that sends from laser instrument 1 becomes the θ angle through convergent lens 42 with tested object plane normal, and the imaging chief ray becomes the φ angle with normal, and the focal length of imaging len 43 is
, the incident chief ray incided on the A point on high-power LED chip surface 46 before fluorescent material was uncoated, dropped on the C point of sensor photosensitive face 44 through lens imaging 43 after image points.The coating thickness of fluorescent material is H, the incidence point of incident chief ray on fluorescent material coated side 45 after the B point is finished for fluorescent material applies, and the D point is the picture point of B point on the sensor photosensitive face, the distance that the C point is ordered to D is
Derive and can get by triangle relation:
Above principle analysis be certain any thickness measure principle on the laser beam, the thickness measure of other points can get its thickness equally according to present principles, and then can obtain the thickness distribution figure of fluorescent coating.
The ROF model can be removed picture noise preferably and keep image edge information, specifically describes as follows:
Wherein,
Be original image,
Be noisy image,
Be
BV half model, C is real number field, parameter
Be regularization parameter.
To gather be coated with tomographic image and adopt above-mentioned ROF model to carry out the denoising preliminary treatment after, carry out rim detection again.
Rim detection is to be a kind of detection method of feature with the local operation, comprises method that edge detection operator cuts apart in conjunction with threshold value, based on rim detection of region growing etc.The main boundary matrix that adopts the region growing method to ask element in the patent algorithm, and based on the grey level histogram of image, obtain nearest segmentation threshold by iterative computation.
Be described in further detail the implementation process of thickness measurement with laser and machine vision and defects detection below:
(1) unlatching generating laser, irradiation measured surface, measured surface are respectively fluorescent material and apply preceding high-power LED chip surface and the fluorescent material coated side after the fluorescent material coating;
(2) gather two width of cloth representation of laser facula that fluorescent material applies front and back with the IMAQ terminal; Utilize two width of cloth representation of laser facula, adopt laser triangulation to calculate the thickness distribution of fluorescent coating, and according to setting thickness calibration, judge whether to exist blocked up, thin and in uneven thickness excessively defective;
(3) close generating laser, the angle of adjusting imageing sensor makes the imageing sensor receiving plane parallel with the fluorescent material coated side, the fluorescent coating image after applying with IMAQ terminal collection fluorescent material again;
(4) the fluorescent coating image of gathering in the step (3) is carried out filtering, rim detection, fluorescent coating image template with standard compares again, detects fluorescent coating according to comparative analysis at last and whether has the defective that coated side is irregular, be stained with glue and foreign matter.
In the step (2), described to obtain the method for fluorescent coating thickness distribution based on laser triangulation as follows:
1. two width of cloth representation of laser facula of gathering are carried out filtering with smoothing filter;
2. the light spot image that 1. step is obtained after the filtering carries out two-value and cuts apart; Grey level histogram based on image obtains segmentation threshold by iterative computation;
3. ask for laser facula centroid position everywhere;
4. adopt laser triangulation to calculate the fluorescent coating thickness distribution.
The detection method of the defective that in the step (4), described coated side is irregular, be stained with glue and foreign matter is as follows:
1. set up the fluorescent coating template of standard;
2. the fluorescent coating image that abovementioned steps (3) is gathered carries out denoising with the ROF model;
3. the fluorescent coating image that is 2. obtained after the denoising by step is carried out deblurring, strengthens preliminary treatment, and copy portion;
4. a copy of it fluorescent coating image of step in 3., carry out rim detection, the sealing fluorescent material coated side that obtains is filled the area of handling and calculating the fluorescent material coated side, compare with setting area standard, judge whether the defective that exists coated side excessive, too small;
5. step in 3. another part fluorescent coating image and the fluorescent coating template image of standard carry out pattern match, judge whether to exist the defective that applies irregular, foreign matter, is stained with glue.
See also Fig. 3, the implementation method of operation 39 is as follows: judge whether to finish current led support coating work by master system 11.As finish, then forward operation 41 to; If do not finish, then forward operation 40 to.
See also Fig. 3, the implementation method of operation 40 is as follows: detect the detected coat the defect information of the thickness of institute's phosphor powder layer and machine vision and defect detecting device 18 by thickness measurement with laser device 17, use as the data of learning algorithm; Master system 11 by these detection information, uses a kind of iterative learning algorithm again, calculates the control parameter that next time applies.
See also Fig. 3, the implementation method of operation 41 is as follows: full-automatic upper and lower materials device 15 has applied the led support of finishing with the workbench of motion control device 14 and has grasped and move in the blanking groove 8.
Claims (3)
1. full-automatic fluorescent material coating equipment, the fluorescent material that is used for finishing on the led chip applies operation, this equipment comprises lower computer system and master system, lower computer system comprise fluorescent material shower nozzle, xyz axle motion control platform, full-automatic on/blanking device and machine vision device; Master system comprises coating control module, motion-control module and machine vision control module; It is characterized in that lower computer system also comprises shower nozzle thermostatically-controlled equipment, vacuum stirring defoaming device and thickness measurement with laser device; Master system also comprises the de-bubble control module; Apply control module and connect fluorescent material shower nozzle and shower nozzle thermostatically-controlled equipment respectively, the de-bubble control module connects the vacuum stirring defoaming device, the machine vision control module connects thickness measurement with laser device and machine vision device respectively, motion-control module connect respectively xyz axle motion control platform and full-automatic on/blanking device.
2. full-automatic fluorescent material coating equipment according to claim 1 is characterized in that described fluorescent material shower nozzle can use a glue shower nozzle, atomizer or piezo jets fluorescent material shower nozzle, is used for sprayed with fluorescent powder glue;
Described shower nozzle thermostatically-controlled equipment comprises heating wire and thermistor, and heating wire and thermistor are installed in inside or the outside of described fluorescent material shower nozzle, is used for described fluorescent material shower nozzle is carried out thermostatic control;
Described vacuum stirring defoaming device comprises: the phosphor gel container is used for storage phosphor gel to be coated; Electronic stirring rod is used for stirring phosphor gel; Air door, be used for extracting out the air in the phosphor gel container, by air door the air of the phosphor gel internal tank that phosphor gel to be coated is housed is extracted out, form vacuum environment, electronic stirring rod constantly stirs under vacuum environment, and the bubble of phosphor gel is stirred to the final elimination in phosphor gel surface from the bottom of device in the handle assembly;
Described thickness measurement with laser device comprises: generating laser is used for emission measurement laser; The sensor photosensitive face is used for receiving the measurement laser that measured surface reflects; Lens are used for converging the measurement laser that generating laser emits; Described thickness measurement with laser device uses laser triangulation, is used for measuring the thickness distribution of the phosphor powder layer after applying;
Described machine vision device comprises imageing sensor, and imageing sensor adopts cmos sensor or ccd sensor; Visual processes and control module are based on FPGA, CPLD, DSP, DSP+FPFA or DSP+CPLD; Interface module adopts the mode based on bus, comprises IEEE 1394a, USB or Ethernet, is used for the machine vision location of led support and the defects detection of coating back phosphor powder layer;
Shower nozzle xyz axle motion control platform adopts stepper motor, servomotor or linear electric motors, is used for the described fluorescent material shower nozzle of control high-speed, high precision on the xyz direction of principal axis and moves;
Described full-automatic handling equipment comprises magazine, following magazine, the led support that is used for depositing led support to be coated respectively and has finished coating; Mechanical moving device, be used for realizing that magazine transports work to the support that applies the working region, in last magazine, led support is sent into zone to be coated before comprising coating, with apply the back coated led support be transported to down in the magazine mechanical moving device employing mechanical arm or conveyer belt realization.
3. full-automatic fluorescent material coating equipment according to claim 1 is characterized in that master system comprises:
Apply control module, realize that the phosphor gel quantity for spray is accurately controlled, the fluorescent material atomizing is controlled, the flow velocity control of the inner phosphor gel of fluorescent material shower nozzle, be used for control fluorescent material shower nozzle coating procedure fluorescent powder jet printing amount, the atomizing uniformity, spraying scope and control shower nozzle thermostatically-controlled equipment carry out heated constant temperature control to the fluorescent material shower nozzle, with the viscosity of reduction and the inner phosphor gel of stable shower nozzle;
The motion-control module of telling be used for control xyz axle motion control device the fluorescent material shower nozzle carried out the axial movement of xyz, be used for the coordination control to xyz axle motion control device and full-automatic handling equipment;
Control vacuum stirring defoaming device carries out de-bubble work, is used for control vacuum stirring defoaming device the phosphor gel that has just mixed is carried out the de-bubble operation;
Machine vision control module control thickness measurement with laser device and machine vision device are carried out thickness measure and the defects detection work to phosphor powder layer, being used for control thickness measurement with laser device carries out thickness measurement with laser work and control machine vision and defect detecting device to coated phosphor powder layer sprayed with fluorescent powder layer is carried out defects detection work.
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| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN 201320070572 CN203155488U (en) | 2013-02-07 | 2013-02-07 | Full-automatic fluorescent powder coating equipment |
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| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN 201320070572 CN203155488U (en) | 2013-02-07 | 2013-02-07 | Full-automatic fluorescent powder coating equipment |
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| CN203155488U true CN203155488U (en) | 2013-08-28 |
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| Application Number | Title | Priority Date | Filing Date |
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| CN 201320070572 Withdrawn - After Issue CN203155488U (en) | 2013-02-07 | 2013-02-07 | Full-automatic fluorescent powder coating equipment |
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Cited By (7)
| Publication number | Priority date | Publication date | Assignee | Title |
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| CN103128041A (en) * | 2013-02-07 | 2013-06-05 | 华南理工大学 | Full automatic fluorescent powder coating process and device |
| CN106263296A (en) * | 2016-10-17 | 2017-01-04 | 成都卡美奇鞋业有限公司 | A kind of automatic adhesive spray device |
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| Publication number | Priority date | Publication date | Assignee | Title |
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| CN103128041A (en) * | 2013-02-07 | 2013-06-05 | 华南理工大学 | Full automatic fluorescent powder coating process and device |
| CN103128041B (en) * | 2013-02-07 | 2014-09-10 | 华南理工大学 | Full automatic fluorescent powder coating process and device |
| CN106263296A (en) * | 2016-10-17 | 2017-01-04 | 成都卡美奇鞋业有限公司 | A kind of automatic adhesive spray device |
| CN110505925A (en) * | 2017-03-30 | 2019-11-26 | 马自达汽车株式会社 | Applying device and coating method |
| US11161141B2 (en) | 2017-03-30 | 2021-11-02 | Mazda Motor Corporation | Coating device configured to apply a coating agent to an object and detect a shape of the object after the application of the coating agent to the object |
| CN108355917A (en) * | 2018-04-28 | 2018-08-03 | 湖州金辰机械有限公司 | A kind of mud-coated equipment for diesel engine filter core |
| CN108405269A (en) * | 2018-05-28 | 2018-08-17 | 河北省机电体化中试基地 | A kind of intelligent glue spreading apparatus and method for different size rubber fastening band |
| CN109465131A (en) * | 2019-01-14 | 2019-03-15 | 航天材料及工艺研究所 | A kind of body structure functional coating automation paint unit and method |
| CN115138536A (en) * | 2022-06-28 | 2022-10-04 | 上海交通大学 | Vacuum treatment method and device for glue-homogenizing bubbles of embedded chip packaging substrate |
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