CN103128041A - Full automatic fluorescent powder coating process and device - Google Patents
Full automatic fluorescent powder coating process and device Download PDFInfo
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- CN103128041A CN103128041A CN2013100485972A CN201310048597A CN103128041A CN 103128041 A CN103128041 A CN 103128041A CN 2013100485972 A CN2013100485972 A CN 2013100485972A CN 201310048597 A CN201310048597 A CN 201310048597A CN 103128041 A CN103128041 A CN 103128041A
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Abstract
The invention relates to a full automatic fluorescent powder coating process and device. A vacuum stirring defoaming device is added on the basis of the existing fluorescent powder coating device to simplify the existing coating process and effectively remove small air bubbles contained in mixed fluorescent powder glue. A nozzle constant temperature control device is added to conduct constant temperature control on a fluorescent powder nozzle and achieve the aim of reducing and stabilizing fluorescent powder glue adhesiveness in the fluorescent powder glue. A laser thickness measuring device is added to measure thickness distribution of a coating fluorescent layer in a laser triangle measurement method. The vacuum stirring defoaming device of the fluorescent powder glue is integrated in the coating device, and the fluorescent powder coating process is simplified and integrated. The process and the device greatly improve fluorescent powder coating accuracy of the fluorescent coating device on large-power white light light-emitting diode (LED) chips or chip modules, and effectively improve package quality of white light LED package such as heat resistance dispersibility, chromaticity consistency and light outlet efficiency accordingly.
Description
Technical field
The present invention relates to fluorescent material paint-on technique field, be specifically related to a kind of full-automatic fluorescent powder coating technique and 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, the 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 following lighting source.
White-light LED encapsulation is 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 domestic traditional fluorescent material coating equipment ubiquity, the shortcoming such as production capacity is low, and adaptability is narrow.Therefore, independent development goes out that a kind of production capacity is high, to apply precision high, can adapt to again simultaneously the fluorescent material coating equipment of large power white light LED module packaging technical development with rapid changepl. never-ending changes and improvements, break away from external technical monopoly, become the only way of China LED encapsulation industrial chain development.This patent has proposed technique and the equipment that a kind of novel 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 on the basis of the existing structures such as fluorescent material shower nozzle, xyz axle Motion Control Platform, full-automatic up/down materials device and machine vision device, 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 described fluorescent material shower nozzle; Having increased laser thickness measuring apparatus 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 inventions can effectively improve the package qualities such as the thermal resistance dispersiveness, chromaticity uniformity, light extraction efficiency of white-light LED 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.
Summary of the invention
The object of the present invention is to provide a kind of full-automatic fluorescent powder coating technique and 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 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 described fluorescent material shower nozzle; Having increased laser thickness measuring apparatus 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.Purpose of the present invention is achieved through the following technical solutions.
A kind of full-automatic fluorescent material coating equipment, the fluorescent material that is used for completing on LED chip applies operation, this equipment comprises lower computer system and master system, and lower computer system comprises fluorescent material shower nozzle, xyz axle Motion Control Platform, full-automatic up/down materials 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 laser thickness measuring apparatus; Master system also comprises the de-bubble control module; Apply control module and connect respectively fluorescent material shower nozzle and shower nozzle thermostatically-controlled equipment, the de-bubble control module connects the vacuum stirring defoaming device, the machine vision control module connects respectively laser thickness measuring apparatus and machine vision device, and motion-control module connects respectively xyz axle Motion Control Platform and full-automatic up/down materials device.
In 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 arranged on 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 storing phosphor gel to be coated; Driven 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, driven stirring rod constantly stirs under vacuum environment, and in handle assembly, the bubble of phosphor gel is stirred to final elimination the in phosphor gel surface from the bottom of device;
Described laser thickness measuring apparatus 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 laser thickness measuring apparatus 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 the rear phosphor powder layer of coating;
Shower nozzle xyz axle Motion Control Platform adopts stepper motor, servomotor or linear electric motors, is used for controlling described fluorescent material shower nozzle high-speed, high precision on the xyz direction of principal axis and moves;
Described full-automatic handling equipment comprises magazine, blanking box, the LED support that is used for depositing respectively LED support to be coated and has completed coating; Mechanical moving device, be used for realizing that magazine transports work to the support that applies the working region, in upper magazine, LED support is sent into zone to be coated before comprising coating, with apply after coated LED support is transported in blanking box, mechanical moving device adopts mechanical arm or conveyer belt realization.
In 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 control of the inner phosphor gel of fluorescent material shower nozzle, it is the crucial control module that realizes that the phosphor gel quantity for spray is accurately controlled and the fluorescent coating uniformity is controlled, be used for controlling 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 to the fluorescent material shower nozzle to be controlled, with the viscosity of reduction and the inner phosphor gel of stable shower nozzle;
The motion-control module of telling be used for to control xyz axle motion control device the fluorescent material shower nozzle carried out the axial movement of xyz, be used for the coordination of xyz axle motion control device and full-automatic handling equipment is controlled;
Control the vacuum stirring defoaming device and carry out de-bubble work, be used for controlling the vacuum stirring defoaming device phosphor gel that has just mixed is carried out the de-bubble operation;
Machine vision control module control laser thickness measuring apparatus and machine vision device are carried out thickness measure and the defects detection work to phosphor powder layer, be used for to control laser thickness measuring apparatus coated phosphor powder layer is carried out thickness measurement with laser work, and control machine vision and defect detecting device 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 comprises the following steps:
4.1 use the bubble of the phosphor gel inside that has just mixed in vacuum stirring defoaming device cancellation element, meanwhile, by the shower nozzle thermostatically-controlled equipment, the fluorescent material shower nozzle be heated to operating temperature;
4.2 after step 4.1 is completed, by full-automatic handling equipment, LED support to be coated is transported to and applies above the working region;
4.3 after step 4.2 is completed, control machine vision device location LED support to be coated by machine vision module, obtain the position coordinates on workbench of LED support to be coated;
4.4 after step 4.3 is completed, by xyz axle motion control device, the fluorescent material shower nozzle is moved to directly over LED support to be coated;
4.5 after step 4.4 is completed, if the coating first of current LED support type to be applied uses the corresponding initial application of current LED support type to be applied to control the coating of fluorescent material first that parameter is carried out current LED support to be applied; Coating first if not current LED support type to be applied, the LED support thickness of coating fluorescent dye distributed constant initial control parameter corresponding with current LED support type to be applied after using measured last time of step 4.7 to apply to complete uses fluorescent material to apply the coating control parameter that Iterative Learning Control Algorithm calculates this LED support to be applied;
4.6 use the current coating that step 4.5 calculates to control parameter, control the fluorescent material coating work that the fluorescent material shower nozzle is completed current LED support;
4.7 after step 4.6 is completed, 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 step 4.7 is completed, detect the coat the defect information of institute's phosphor powder layer by machine vision and defect detecting device;
4.9 judge whether to complete coating, if do not complete, forward step 4.2 to; If complete, finish.
In above-mentioned coating processes, described Iterative Learning Control Algorithm comprises the following 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 step 4.7 and the setting coating thickness in step 5.1, calculate the coating error that last fluorescent material applies;
5.3 coating error resulting according to step 5.2, use Iterative Learning Control Algorithm, calculate each control modification of the parameters amount of current coating controller, comprising: parameter correction, phosphor gel flow parameters correction are controlled in fluorescent powder jet printing time control parameter correction, phosphor gel atomizing;
5.4 by resulting current theoretical parameter and the control parameter correction controlled of step 5.1 and step 5.3, calculate the true controlled quentity controlled variable of current coating controller;
In above-mentioned coating processes, the described method that obtains the fluorescent coating thickness distribution based on laser triangulation comprises the following steps:
6.1 unlatching laser thickness measuring apparatus device, generating laser irradiation measured surface, measured surface are respectively fluorescent material and apply front high-power LED chip surface and the fluorescent material coated side after the fluorescent material coating;
6.2 the two width representation of laser facula that step 6.1 gathers are carried out filtering with smoothing filter;
6.3 the light spot image that obtains after step 6.2 filtering is carried out binary segmentation; The image-based grey level histogram 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 present invention has following advantage and technique effect: the method that proposes of the present invention, the fluorescent material that can be applied to large power white light LED or LED chip module applies in 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 present invention is on the basis of the full-automatic fluorescent material coating equipment of tradition, integrated shower nozzle thermostatically-controlled equipment, laser thickness measuring apparatus 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 embodiment.
Fig. 2 is the system architecture diagram of fluorescent material coating equipment in embodiment.
Fig. 3 is fluorescent material coating equipment process chart in embodiment.
Fig. 4 is fluorescent material shower nozzle thermostatically-controlled equipment schematic diagram in embodiment.
Fig. 5 is the light path principle figure that in embodiment, the laser measurement thickness distribution detects.
Fig. 6 is vacuum stirring defoaming device schematic diagram in embodiment.
The specific embodiment
Above content has been done sufficient explanation to the present invention, understands for technical characterictic of the present invention, purpose and effect being had more clearly, now contrasts accompanying drawing and describes the specific embodiment of the present invention in detail.
Fluorescent material of the present invention 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, laser thickness measuring apparatus 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 arranged on 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 controlling described fluorescent material shower nozzle high-speed, high precision on the xyz direction of principal axis and moves;
Full-automatic handling equipment 15 comprises magazine, blanking box, the LED support that is used for depositing respectively LED support to be coated and has completed 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; At upper magazine, LED support is sent into zone to be coated before be used for applying, and apply afterwards coated LED support is transported in blanking box.
Vacuum stirring defoaming device 16 comprises the phosphor gel container, is used for storing phosphor gel to be coated; Driven 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, driven stirring rod constantly stirs under vacuum environment, and in handle assembly, the bubble of phosphor gel is stirred to final elimination the in phosphor gel surface from the bottom of device;
Laser thickness measuring apparatus 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 laser thickness measuring apparatus uses laser triangulation, is used for measuring the thickness distribution of the phosphor powder layer after applying;
Fluorescent material of the present invention 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 control of the inner phosphor gel of fluorescent material shower nozzle, is the crucial control module that realizes that the phosphor gel quantity for spray is accurately controlled and the fluorescent coating uniformity is controlled.Be used for controlling fluorescent material shower nozzle coating procedure fluorescent powder jet printing amount, the atomizing uniformity, the accurate control of spraying scope, and control the shower nozzle thermostatically-controlled equipment fluorescent material shower nozzle is heated, 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 to control;
Vacuum stirring de-bubble control module 21 is controlled the vacuum stirring defoaming device and is carried out de-bubble work.Be used for controlling the vacuum stirring defoaming device phosphor gel that has just mixed is carried out the de-bubble operation;
Machine vision control module 22, control laser thickness measuring apparatus and machine vision device are carried out thickness measure and the defects detection work to phosphor powder layer.Be used for to control laser thickness measuring apparatus coated phosphor powder layer is carried out thickness measurement with laser work, and control machine vision and defect detecting device sprayed with fluorescent powder layer is carried out defects detection work.
As shown in Figure 3, full-automatic fluorescent powder coating technique comprises the following steps:
Above-mentioned Iterative Learning Control Algorithm comprises the following 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 step (1), calculate the coating error that last fluorescent material applies;
(3) coating error resulting according to step (2), use Iterative Learning Control Algorithm, calculate each control modification of the parameters amount of current coating controller, comprising: parameter correction, phosphor gel flow parameters correction are controlled in fluorescent powder jet printing time control parameter correction, phosphor gel atomizing;
(4) by resulting current theoretical parameter and the control parameter correction controlled of step (1) and step (3), 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 comprises the following steps:
(1) unlatching laser range sensor, irradiation measured surface, measured surface are respectively fluorescent material and apply front high-power LED chip surface and the fluorescent material coated side after the fluorescent material coating;
(2) the two width representation of laser facula that step (1) gathered are carried out filtering with smoothing filter;
(3) light spot image that obtains after step (2) filtering is carried out binary segmentation; The image-based grey level histogram 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, comprises the following steps:
The implementation method of operation 31 is as follows: first 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 passed in 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 phosphor gel container 54 Airs out the formation vacuum, open stirring motor 56 and make stirring rod 55 rotate, carrying out froth in vacuum processes, after band de-bubble operation is completed, then open the valve V-2 of phosphor gel, the phosphor gel after de-bubble flows into 12 li, 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 phosphor gel after mixing de-bubble flows in the phosphor gel passage of fluorescent material shower nozzle 12 the insides, use PID to control (PID controls) methods by the coating control module 19 in fluorescent material coating equipment control module and control shower nozzle thermostatically-controlled equipments 13 heating fluorescent material shower nozzles 12, 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: full-automatic feeding, discharge device 15 moves the LED chip support group to be coated in feeding groove 9 and be fixed on the workbench of motion control device 14; Set the coordinate at zero point in master system 11.Described full-automatic feeding, discharge device can adopt mechanical arm crawl or conveyer belt conveyer to transport LED support, completes 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 workbench carries out machine vision location work, by the gray count to image, 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 supports to be coated, comprise the distribution of LED chip array, distance between LED chip, shower nozzle applies route, shower nozzle translational speed; Treat LED chip support group, after putting well and be fixed on the workbench of motion control device, 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 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: fluorescent powder jet printing time theory control parameter, the theoretical parameter vector of controlling parameter, phosphor gel flow velocity theory control parameter of phosphor gel atomizing.Wherein, spray time is controlled parameter and 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, fluorescent material shower nozzle; The fluorescent material atomization air pressure is controlled 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 control parameter will be controlled parameter and fluorescent material atomization air pressure according to spray time and control parametric synthesis and calculate.
The thickness of the phosphor powder layer measured according to the last time and target coating thickness calculate last coating error; Coating error resulting according to previous step, use Iterative Learning Control Algorithm, calculate the control modification of the parameters amount of current coating control device module, comprising: spray time is controlled the parameter correction, parameter correction, phosphor gel flow control parameter correction are controlled in the fluorescent material atomizing;
Above-mentioned Iterative 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 Algorithm as follows:
Wherein,
Be the time,
Control parameter vector for theory, comprising: the spray time control theory is controlled parameter, fluorescent material atomizing control theory is controlled parameter and the theoretical parameter of controlling of phosphor gel flow control;
True control parameter vector for current coating controller;
Thickness error vector for last fluorescent coating;
,
,
Be the constant gain matrix.
By resulting current theoretical parameter and the control parameter correction controlled of above-mentioned steps, calculate the true control parameter vector of current coating controller; True controlled quentity controlled variable, control the fluorescent material shower nozzle and carry 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 laser thickness measuring apparatus 17, laser thickness measuring apparatus 17 is followed the fluorescent material shower nozzle by motion control device 14 and is moved to LED chip top, is at this moment carrying out fluorescent material and first measure before applying the distance of laser detector 17 and LED chip to be coated; Complete etc. to be coated, apply complete after, then measure the distance of laser detector 17 and phosphor powder layer upper surface, 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 image partly is divided into several zones, then the intensity profile figure that each zone is obtained compares with the phosphor powder layer that corresponding standard evenly applies, thereby judge current fluorescent coating and whether have defective.
Above-mentioned machine vision control module algorithm is as follows:
As shown in Figure 5, into θ angle through convergent lens 42 and tested object plane normal from the incident chief ray that laser instrument 1 sends, the imaging chief ray becomes the φ angle with normal, and the focal length of imaging len 43 is
, the uncoated front incident chief ray of fluorescent material incides on the A point on high-power LED chip surface 46, drops 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 completed 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 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 preferably picture noise and keep the marginal information of image, 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 noise suppression preprocessing after, then carry out rim detection.
Rim detection is a kind of detection method take local operation as feature, comprises that edge detection operator is in conjunction with the method for Threshold segmentation, 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 image-based grey level histogram obtain nearest segmentation threshold by iterative computation.
The below is described in further detail the implementation process of thickness measurement with laser and machine vision and defects detection:
(1) unlatching generating laser, irradiation measured surface, measured surface are respectively fluorescent material and apply front high-power LED chip surface and the fluorescent material coated side after the fluorescent material coating;
(2) gather with the IMAQ terminal the two width representation of laser facula that fluorescent material applies front and back; Utilize two width 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, excessively thin and in uneven thickness defective;
(3) close generating laser, the angle of adjusting imageing sensor makes the imageing sensor receiving plane parallel with the fluorescent material coated side, then the fluorescent coating image after applying with IMAQ terminal collection fluorescent material;
(4) the fluorescent coating image that gathers in 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 step (2), described to obtain the method for fluorescent coating thickness distribution based on laser triangulation as follows:
1. the two width representation of laser facula that gather are carried out filtering with smoothing filter;
2. the light spot image that 1. step is obtained after filtering carries out binary segmentation; The image-based grey level histogram 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 step (4), described coated side is irregular, be stained with glue and foreign matter is as follows:
1. the fluorescent coating template of Criterion;
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 denoising by step is carried out deblurring, strengthens pretreatment, and copy portion;
4. a copy of it fluorescent coating image in 3. step, carry out rim detection, the sealing fluorescent material coated side that obtains is filled the area of processing and calculate the fluorescent material coated side, compare with setting area standard, judge whether the defective that exists coated side excessive, too small;
5. another part fluorescent coating image in 3. and the fluorescent coating template image of standard carry out pattern match step, 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 complete current LED support coating work by master system 11.As complete, forward operation 41 to; If do not complete, forward operation 40 to.
See also Fig. 3, the implementation method of operation 40 is as follows: detect thickness and machine vision and the detected coat the defect information of defect detecting device 18 of institute's phosphor powder layer by laser thickness measuring apparatus 17, use as the data of learning algorithm; Master system 11 by these detection information, uses a kind of Iterative 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 feeding, discharge device 15 has applied with the workbench of motion control device 14 the LED support crawl of completing and has moved in blanking groove 8.
Claims (6)
1. full-automatic fluorescent material coating equipment, the fluorescent material that is used for completing on LED chip applies operation, this equipment comprises lower computer system and master system, and lower computer system comprises fluorescent material shower nozzle, xyz axle Motion Control Platform, full-automatic up/down materials 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 laser thickness measuring apparatus; Master system also comprises the de-bubble control module; Apply control module and connect respectively fluorescent material shower nozzle and shower nozzle thermostatically-controlled equipment, the de-bubble control module connects the vacuum stirring defoaming device, the machine vision control module connects respectively laser thickness measuring apparatus and machine vision device, and motion-control module connects respectively xyz axle Motion Control Platform and full-automatic up/down materials 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 arranged on 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 storing phosphor gel to be coated; Driven 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, driven stirring rod constantly stirs under vacuum environment, and in handle assembly, the bubble of phosphor gel is stirred to final elimination the in phosphor gel surface from the bottom of device;
Described laser thickness measuring apparatus 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 laser thickness measuring apparatus 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 the rear phosphor powder layer of coating;
Shower nozzle xyz axle Motion Control Platform adopts stepper motor, servomotor or linear electric motors, is used for controlling described fluorescent material shower nozzle high-speed, high precision on the xyz direction of principal axis and moves;
Described full-automatic handling equipment comprises magazine, blanking box, the LED support that is used for depositing respectively LED support to be coated and has completed coating; Mechanical moving device, be used for realizing that magazine transports work to the support that applies the working region, in upper magazine, LED support is sent into zone to be coated before comprising coating, with apply after coated LED support is transported in blanking box, mechanical moving device adopts 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 control of the inner phosphor gel of fluorescent material shower nozzle, be used for controlling 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 to the fluorescent material shower nozzle to be controlled, with the viscosity of reduction and the inner phosphor gel of stable shower nozzle;
The motion-control module of telling be used for to control xyz axle motion control device the fluorescent material shower nozzle carried out the axial movement of xyz, be used for the coordination of xyz axle motion control device and full-automatic handling equipment is controlled;
Control the vacuum stirring defoaming device and carry out de-bubble work, be used for controlling the vacuum stirring defoaming device phosphor gel that has just mixed is carried out the de-bubble operation;
Machine vision control module control laser thickness measuring apparatus and machine vision device are carried out thickness measure and the defects detection work to phosphor powder layer, be used for to control laser thickness measuring apparatus coated phosphor powder layer is carried out thickness measurement with laser work, and control machine vision and defect detecting device sprayed with fluorescent powder layer is carried out defects detection work.
4. the coating processes of right to use requirement 1 a described full-automatic fluorescent material coating equipment, is characterized in that, comprises the following steps:
4.1 use the bubble of the phosphor gel inside that has just mixed in vacuum stirring defoaming device cancellation element, meanwhile, by the shower nozzle thermostatically-controlled equipment, the fluorescent material shower nozzle be heated to operating temperature;
4.2 after step 4.1 is completed, by full-automatic handling equipment, LED support to be coated is transported to and applies above the working region;
4.3 after step 4.2 is completed, control machine vision device location LED support to be coated by machine vision module, obtain the position coordinates on workbench of LED support to be coated;
4.4 after step 4.3 is completed, by xyz axle motion control device, the fluorescent material shower nozzle is moved to directly over LED support to be coated;
4.5 after step 4.4 is completed, if the coating first of current LED support type to be applied uses the corresponding initial application of current LED support type to be applied to control the coating of fluorescent material first that parameter is carried out current LED support to be applied; Coating first if not current LED support type to be applied, the LED support thickness of coating fluorescent dye distributed constant initial control parameter corresponding with current LED support type to be applied after using measured last time of step 4.7 to apply to complete uses fluorescent material to apply the coating control parameter that Iterative Learning Control Algorithm calculates this LED support to be applied;
4.6 use the current coating that step 4.5 calculates to control parameter, control the fluorescent material coating work that the fluorescent material shower nozzle is completed current LED support;
4.7 after step 4.6 is completed, 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 step 4.7 is completed, detect the coat the defect information of institute's phosphor powder layer by machine vision and defect detecting device;
4.9 judge whether to complete coating, if do not complete, forward step 4.2 to; If complete, finish.
5. coating processes according to claim 4 is characterized in that described Iterative Learning Control Algorithm comprises the following 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 step 4.7 and the setting coating thickness in step 5.1, calculate the coating error that last fluorescent material applies;
5.3 coating error resulting according to step 5.2, use Iterative Learning Control Algorithm, calculate each control modification of the parameters amount of current coating controller, comprising: parameter correction, phosphor gel flow parameters correction are controlled in fluorescent powder jet printing time control parameter correction, phosphor gel atomizing;
5.4 by resulting current theoretical parameter and the control parameter correction controlled of step 5.1 and step 5.3, calculate the true controlled quentity controlled variable of current coating controller.
6. coating processes according to claim 5 is characterized in that the described method that obtains the fluorescent coating thickness distribution based on laser triangulation comprises the following steps:
6.1 unlatching laser thickness measuring apparatus device, generating laser irradiation measured surface, measured surface are respectively fluorescent material and apply front high-power LED chip surface and the fluorescent material coated side after the fluorescent material coating;
6.2 the two width representation of laser facula that step 6.1 gathers are carried out filtering with smoothing filter;
6.3 the light spot image that obtains after step 6.2 filtering is carried out binary segmentation; The image-based grey level histogram 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.
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