CN110849902A - Novel display panel surface defect detection system - Google Patents
Novel display panel surface defect detection system Download PDFInfo
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Abstract
The invention provides a novel display panel surface defect detection system.A poor identification subsystem comprises image acquisition equipment, a main optical unit, an auxiliary optical unit and an image processing unit; the image acquisition equipment is connected with the image processing unit; the device also comprises a reversible double-sided adsorption device and a light source brightness self-adaptive adjusting system. Has the advantages that: (1) in the defect identification subsystem, the image processing unit can simply and quickly distinguish real defect and surface foreign matter in the picture, and has the advantages of simple image processing process, high speed and high efficiency. (2) In the reversible double-sided adsorption device, the panel is adsorbed from the bottom surface, so that the adsorption is stable and reliable and the machine vision photographing is not influenced; the double-sided adsorption structure can rotate the panel by 180 degrees and stably adsorb the panel again. (3) The light source brightness self-adaptive adjusting system can greatly prolong the service life of a light source, improve the grafting rate of equipment and effectively reduce the maintenance cost of the equipment.
Description
Technical Field
The invention belongs to the technical field of display panel defect detection, and particularly relates to a novel display panel surface defect detection system.
Background
Most of the existing middle-small-sized display panels are Liquid Crystal Displays (LCDs), Organic Light Emitting Diodes (OLEDs) and the like, and some visual defects are inevitable in the manufacturing process of the middle-small-sized display panels due to the complexity of product structures and production processes. For example, in the manufacturing process of a display panel, the transportation is a basic technical link, but with the requirements of ultra-thinness, Touch and the like being higher and higher, the following problems are increasingly exposed in the existing transportation technology: when the suction cup type conveying device is used for conveying, the surface of the display panel is often scratched by scraps and the like attached to the suction cup, and the supporting structure of the pixel display area is easily damaged by the pressure of the suction cup, so that poor display of the display panel is caused. When the belt-type or roller-type conveyance is used, the surface of the display panel is frequently scratched, and the surface of the display panel is damaged. Moreover, when the display panel is thinned from 1T to 0.4T or less, the above-described situation is further deteriorated. Therefore, it is very important to perform the surface defect detection of the display panel before shipment before performing the display panel modularization process.
In the prior art, the surface defects of the display panel are mainly detected by adopting a human eye observation mode, but the problems of high misjudgment rate and low detection efficiency exist.
In addition, a display panel surface defect detection system based on machine vision appears in the prior art, and comprises an image acquisition unit and an image processing unit; the working principle is as follows: acquiring a picture of a display panel to be detected through an image acquisition unit; then, the image processing unit preprocesses the panel picture acquired by the image acquisition unit, and then performs characteristic analysis on the preprocessed panel picture to finally obtain the condition of the surface defect of the display panel.
The display panel surface defect detection system based on machine vision mainly has the following defects: when the image processing unit analyzes and processes the panel picture collected by the image collecting unit, because the panel picture often includes not only real bad defects such as surface scratches, pits, damages and the like, but also erasable surface foreign matters such as surface dust, dirt and the like, the image processing unit often needs to adopt a very complex algorithm to distinguish the real bad defects and the surface foreign matters, and has the problems of complex image processing process and long consumed time. How to effectively solve the problems is a problem which needs to be solved urgently at present.
Disclosure of Invention
Aiming at the defects in the prior art, the invention provides a novel display panel surface defect detection system which can effectively solve the problems.
The technical scheme adopted by the invention is as follows:
the invention provides a novel display panel surface defect detection system, which comprises a bad recognition subsystem; the defect identification subsystem comprises image acquisition equipment, a main optical unit, an auxiliary optical unit and an image processing unit; the image acquisition equipment is connected with the image processing unit;
the image acquisition equipment is arranged above the detected display panel;
the main optical unit comprises a plurality of main light source components, each main light source component is arranged around a lens of the image acquisition equipment, and each main light source component and the lens form a certain included angle in the vertical direction and is used for irradiating light to the surface of the detected display panel at a certain angle, so that the real defect of the detected display panel and the surface erasable foreign matter are simultaneously illuminated;
the auxiliary optical unit comprises a plurality of auxiliary light source assemblies, each auxiliary light source assembly is arranged at the periphery of the detected display panel and is used for emitting light parallel or approximately parallel to the surface of the detected display panel, so that the surface of the detected display panel is illuminated to remove foreign matters;
the image acquisition device is configured to: only opening the main optical unit, and when the auxiliary optical unit is not opened, acquiring an image of a detected display panel by the image acquisition equipment, and recording the image as a 1 st original detection image; only opening the auxiliary optical unit, and when the main optical unit is not opened, acquiring an image of a detected display panel by the image acquisition equipment, and recording the image as a 2 nd original detection image; the image acquisition equipment uploads the 1 st original detection image and the 2 nd original detection image to the image processing unit;
the image processing unit contrasts and analyzes the 1 st original detection image and the 2 nd original detection image, based on the 2 nd original detection image, surface erasable foreign matters are removed from the 1 st original detection image, and then real bad defects are extracted from the 1 st original detection image to obtain a detected display panel defect detection result;
or:
the image acquisition device is configured to: simultaneously opening the main optical unit and the auxiliary optical unit in different colors, and acquiring an image of a detected display panel by the image acquisition equipment, wherein the image is recorded as a 3 rd original detection image; uploading the 3 rd original detection image to the image processing unit;
and the image processing unit analyzes the 3 rd original detection image according to the color characteristics, eliminates the surface erasable foreign matters, and then extracts real bad defects to obtain a defect detection result of the detected display panel.
Preferably, the image acquisition device is an area-array camera; and/or
Each main light source component is a near-parallel light source component or a parallel light source component; and/or
The included angle range of the incident light of each main light source assembly and the vertical direction of the lens of the image acquisition equipment is 0-90 degrees; preferably 3 to 60 degrees, more preferably 3 to 30 degrees; and/or
Each main light source component and each auxiliary light source component are parallel surface light sources or annular surface light sources; and/or
Each main light source assembly is a light source which is symmetrically arranged around the lens of the image acquisition equipment; and/or
The number of the main light source assemblies arranged on the main optical unit is 4; and/or
The light spot center of each main light source assembly of the main optical unit covers the whole surface of the detected display panel.
Preferably, each main light source assembly has a certain distance with a lens of the image acquisition device in the horizontal direction, and the distance is at least greater than the length of the detected display panel in the corresponding direction, so that mirror imaging of the main light source assembly on the detected display panel is avoided;
in addition, each main light source component has a certain distance with the lens of the image acquisition equipment in the vertical direction, and each main light source component is lower than the lens of the image acquisition equipment, so that the image acquisition equipment and various mechanical structures above the image acquisition equipment are prevented from being imaged on the mirror surface of the detected display panel.
Preferably, the main optical unit adopts a layered light source structure, that is: and a plurality of circles are configured in the direction from inside to outside by taking the lens of the image acquisition equipment as the center, and a plurality of main light source assemblies are arranged on each circle.
Preferably, the included angle between the light source incidence angle of each auxiliary light source assembly of the auxiliary optical unit and the surface of the detected display panel is-30 degrees to-30 degrees; preferably-15 to 15 degrees; more preferably-5 to 5 degrees; and/or
Each auxiliary light source component is a parallel surface light source; and/or
Each auxiliary light source assembly is an auxiliary light source assembly symmetrically arranged around the detected display panel; and/or
The auxiliary optical unit comprises 4 auxiliary light source assemblies which are respectively arranged at the four corners of the detected display panel.
Preferably, the device further comprises a reversible double-sided adsorption device; the reversible double-sided adsorption device is used for overturning the detected display panel, so that the defects of the front side and the back side of the detected display panel are detected;
the reversible double-sided adsorption device comprises a horizontal frame (10), wherein the horizontal frame (10) comprises a left side (11) and a right side (12) which are arranged in parallel; a 1 st left guide rail (13) and a 1 st right guide rail (14) are arranged between the bottom of the left side (11) and the bottom of the right side (12); a 1 st adsorption table (15) is slidably mounted between the 1 st left guide rail (13) and the 1 st right guide rail (14), and the 1 st adsorption table (15) can slide along the 1 st left guide rail (13) and the 1 st right guide rail (14) under the driving action of a 1 st driving device (16);
the top of the left side (11) and the top of the right side (12) are fixedly provided with a 2 nd left guide rail (17) and a 2 nd right guide rail (18); a 2 nd adsorption table (19) is slidably mounted between the 2 nd left guide rail (17) and the 2 nd right guide rail (18), and the 2 nd adsorption table (19) can slide along the 2 nd left guide rail (17) and the 2 nd right guide rail (18) under the driving action of a 2 nd driving device (20) and further can slide right above the 1 st adsorption table (15) to completely cover the 1 st adsorption table (15) in the vertical direction; or slide to the side surface of the 1 st adsorption table (15) and do not intersect with the 1 st adsorption table (15) in the vertical direction completely;
also comprises a 3 rd driving device (21); the 2 nd driving device (21) is used for horizontally overturning the horizontal frame (10).
Preferably, the distance between two opposite side surfaces of the 1 st adsorption platform (15) and the 2 nd adsorption platform (19) in the vertical direction is larger than the thickness of the display panel to be detected;
and/or
The 1 st adsorption platform (15) and the 2 nd adsorption platform (19) are respectively distributed with a plurality of adsorption holes with the diameter of 0.1 mm-0.5 mm;
the device also comprises a clamping device (22); the clamping device (22) is used for buffering the overturning motion of the horizontal frame during overturning.
Preferably, the reversible double-sided adsorption device works in the following process:
step 1: the adsorption surface of the 1 st adsorption platform (15) is arranged upwards, and the 2 nd adsorption platform (19) slides to the side surface of the 1 st adsorption platform (15) and is not intersected with the 1 st adsorption platform (15) in the vertical direction completely;
step 2: placing a detected display panel on the adsorption surface of the 1 st adsorption table (15); the front side of the detected display panel faces upwards; the suction hole of the 1 st adsorption platform (15) sucks air to generate certain negative pressure, and then the display panel to be detected is stably adsorbed;
and step 3: adopting a bad recognition subsystem to collect images on the front side of the detected display panel;
and 4, step 4: under the driving action of a 2 nd driving device (20), a 2 nd adsorption table (19) slides to the position right above a 1 st adsorption table (15) along a guide rail, so that the adsorption table completely covers the 1 st adsorption table (15) in the vertical direction;
and 5: under the driving action of a 3 rd driving device (21), the whole horizontal frame (10) is horizontally overturned, so that a 1 st adsorption platform (15) is positioned above, and a 2 nd adsorption platform (19) is positioned below;
step 6: the negative pressure is reduced for the adsorption hole of the 1 st adsorption platform (15), the detected display panel moves to the 2 nd adsorption platform (19) below under the action of gravity, the front surface of the detected display panel is contacted with the 2 nd adsorption platform (19), and the back surface of the detected display panel is not contacted with the 2 nd adsorption platform (19);
and 7: the 2 nd adsorption platform (19) is sucked to generate negative pressure, so that the display panel to be detected is stably adsorbed;
and 8: under the driving action of a 1 st driving device (16), the 1 st adsorption table (15) slides along the guide rail, so that the 1 st adsorption table (15) and the 2 nd adsorption table (19) are not intersected completely in the vertical direction; at this time, the display panel to be detected is sucked and fixed on the 2 nd suction table (19), and the back surface of the display panel to be detected faces upwards;
and step 9: and adopting a bad recognition subsystem to acquire an image of the back surface of the detected display panel.
Preferably, the system also comprises a light source brightness self-adaptive adjusting system; the light source brightness adaptive adjusting system comprises: the device comprises a light source actual brightness detection unit, a light source control card and a light source controller;
the light source actual brightness detection unit is used for detecting light source actual brightness values of all positions and transmitting the light source actual brightness values to the light source controller;
the light source controller compares the actual brightness value of the light source with a pre-stored specified brightness value of the light source, generates an adjusting instruction according to the deviation between the actual brightness value of the light source and the specified brightness value of the light source, and sends the adjusting instruction to the light source control card; the light source control card adjusts voltage or current to compensate the light source brightness to form closed-loop control of real-time compensation, and therefore the light source brightness is guaranteed to be stable at a required value.
Preferably, the light source actual brightness detection unit is implemented by the following two ways:
the first method is as follows: fixedly installing a brightness sensor at a position below a detected light source, wherein the brightness sensor detects light source brightness data in real time and transmits the light source brightness data to the light source controller;
the second method comprises the following steps: placing a standard color plate at a fixed position; shooting a standard color plate by using a camera at intervals, wherein the parameter settings of the camera and the light source are consistent; the gray scale data of the shot standard color plate picture is analyzed through an algorithm, and the actual data of the light source brightness is indirectly reflected.
The novel display panel surface defect detection system provided by the invention has the following advantages:
(1) the image processing unit of the defect identification subsystem provided by the invention can simply and quickly distinguish real defect and surface foreign matter in the picture, and has the advantages of simple image processing process, high speed and high efficiency.
(2) The reversible double-sided adsorption device provided by the invention adsorbs the panel from the bottom surface, so that the adsorption is stable and reliable, and the machine vision photographing is not influenced; the double-sided adsorption structure can rotate the panel by 180 degrees and stably adsorb the panel again.
(3) The light source brightness self-adaptive adjusting system provided by the invention can greatly prolong the service life of a light source, improve the grafting rate of equipment and effectively reduce the maintenance cost of the equipment.
Drawings
FIG. 1 is a schematic structural diagram of a fault identification subsystem provided in the present invention;
wherein, 1-image acquisition equipment; 2-a main optical unit; 3-a secondary optical unit; 4-detected display panel; 5-real bad defect points of the panel; 6-the panel surface can erase foreign object points.
FIG. 2 is a schematic diagram of a layered light source module in a failure identification subsystem according to the present invention;
FIG. 3 is a photograph of a defect in a display panel captured by an image capture device;
FIG. 4 is a schematic diagram of two sets of sucker type panel turnover devices and turnover processes in the prior art;
4, detecting the display panel; 7-an adsorption stage; 8-1-left adsorption small mechanical arm; 8-2-left sucker; 9-1-right adsorption small mechanical arm; 9-2-right sucker;
FIG. 5 is a schematic structural view of a reversible double-sided adsorption device according to the present invention;
fig. 6 is a working schematic diagram of the light source brightness adaptive adjustment system provided by the invention.
Detailed Description
In order to make the technical problems, technical solutions and advantageous effects solved by the present invention more clearly apparent, the present invention is further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the invention and are not intended to limit the invention.
Automatic appearance inspection of intermediate products or modules of a display panel such as a tft lcd is a technology that is being studied vigorously at present. In view of the low efficiency and low accuracy of the detection system which takes the linear array camera to scan the surface defects of products as the key characteristics at present, the invention discloses a novel detection system for the surface defects of a display panel, which comprises a bad recognition subsystem, a reversible double-sided adsorption device and a light source brightness self-adaptive adjustment system. The failure identification subsystem comprises an area-array camera arranged above the display panel to be detected, a main optical unit arranged around the area-array camera, an auxiliary optical unit arranged around the display panel and an image processing unit connected with the area-array camera. The reversible double-sided adsorption device adsorbs the panel from the bottom surface, so that the adsorption is stable and reliable and the machine vision photographing is not influenced; the double-sided adsorption structure can rotate the panel by 180 degrees and stably adsorb the panel again. The light source brightness self-adaptive adjusting system comprises: a method of detecting the brightness of the light source by a brightness sensor provided at a fixed position or indirectly judging the light source through a standard image photographed by a camera. And then comparing the detected result with the specified brightness of the light source, and then adjusting the voltage or the current through the light source control card to compensate the light source to form closed-loop control of real-time compensation so as to ensure that the brightness of the light source can be stable for a long time.
It is emphasized that the three systems can be three independent systems, and each system can be independently applied to the field of surface defect detection of the display panel. The present invention does not limit the requirement for the same set of system for detecting surface defects of the display panel, and the three systems must be used simultaneously.
These three systems are described in detail below:
(I) failure recognition subsystem
FIG. 1 is a schematic diagram of a fault identification subsystem; the failure identification subsystem comprises an image acquisition device, a main optical unit, an auxiliary optical unit and an image processing unit which are arranged above the detected display panel. Wherein, the image acquisition equipment is connected with the image processing unit. The core components of the defect identification subsystem are a primary optical element disposed around the image acquisition device and a secondary optical element disposed around the display panel.
(1) Main optical unit
The main optical unit includes nearly parallel light source subassembly or parallel light source subassembly and mechanical structure, nearly parallel light source subassembly and parallel light source subassembly use image acquisition equipment's camera lens to center and around the camera lens, set up with the certain contained angle of the vertical direction formation of camera lens, nearly parallel light source subassembly and parallel light source subassembly's incident light shines on waiting to detect the display panel, thereby illuminate the real bad defect and the surperficial erasable foreign matter that are detected display panel simultaneously, in the camera lens that makes display panel's real bad defect and surperficial erasable foreign matter reflection entering image acquisition equipment of display panel top that awaits measuring, thereby detect display panel surface defect. The certain angle means that the included angle between the incident light of the approximately parallel light source assembly and the vertical direction of the lens of the image acquisition equipment ranges from 0 degree to 90 degrees, preferably ranges from 3 degrees to 60 degrees, and more preferably ranges from 3 degrees to 30 degrees. This range of angles ensures that surface defects of the display panel, such as scratches, pits, breakage, etc., can appear in the camera image. In addition, the near-parallel light source assembly and the parallel light source assembly are a parallel surface light source and an annular surface light source. Furthermore, the parallel surface light source is a plurality of parallel surface light sources which are symmetrically arranged around the lens of the image acquisition equipment, preferably 4 parallel surface light sources which are symmetrically arranged, in a specific embodiment, four parallel surface light source components are symmetrically arranged around the lens of the area array camera from the front direction, the rear direction, the left direction and the right direction, incident light emitted by the four parallel surface light sources is incident at an angle of 3-60 degrees with the vertical direction of the lens, and the light source intensity is 300-2000 nit.
In addition, because the detected display panel has mirror surface imaging, the near parallel light source assembly or the parallel light source assembly and the lens of the image acquisition equipment have a certain distance range in the horizontal direction, and the distance range is at least larger than the size of the display panel. For example, the center of the display panel to be measured coincides with the center of the lens, the side length of the display panel is 10cm, and the horizontal distance from the light source to the lens is guaranteed to be larger than 10 cm. In this case, no mirror image of the light source is formed in the image. In addition, this nearly parallel light source subassembly or parallel light source subassembly are located the camera lens below, can not illuminate camera lens and other be located by any mechanical structure of measured display panel top to guarantee not to have the mirror surface formation of image of lens camera and all kinds of mechanical structure, promptly: the image does not have mirror imaging of a camera lens and various mechanical structures, and the subsequent image analysis processing steps are simplified.
In addition, for the main light source assembly, in order to obtain a wider angle range, and in a specific embodiment, the distribution positions of the concave point defects on the surface of the display panel are random, and the shape is different in size and depth. In order to complete the detection, the structure of the light source assembly of the present invention needs to be further improved, mainly the angle range is further expanded, so as to realize both a large angle and a small angle, and simultaneously still avoid the problem of mirror imaging of the light source in the display panel, the present invention proposes the structure of the main light source assembly in a layered layout, as shown in fig. 2, which is a schematic diagram of the light source assembly in a layered layout in a poor identification subsystem; namely: a plurality of circles are configured in the inward and outward direction by taking a lens of the image acquisition equipment as the center, and a plurality of main light source assemblies are arranged on each circle. That is, the light source at one layer is close to the lens in the vertical direction, the light source at the other layer is far away from the lens, and so on, the multilayer design can be realized. The distance is related to the accurate debugging result. The embodiment of the invention refers to a two-layer design, and refers to fig. 2, which is a schematic layout diagram of a two-layer layout main light source assembly, and the distances from the lens in the vertical direction are respectively 5cm to 200cm and 10cm to 500 cm.
In addition, the light source intensity of the parallel surface light source is 500nit-10000 nit. The incident light of the light source is visible light or infrared ultraviolet light with different frequencies such as white light, red light, green light, blue light and the like, and is particularly related to the selection of the area array camera and the sensitivity of the defect of the display panel to be detected.
In addition, any main light source in the main light source assembly is adjusted through corresponding mechanical design, so that the light spot center of the main light source assembly covers the surface of the whole display panel to be measured.
(2) Auxiliary optical unit
The auxiliary optical unit comprises auxiliary light source components arranged around the detected display panel, the auxiliary light source components are used for emitting light parallel or approximately parallel to the surface of the detected display panel, and the incident angle of the light source is parallel or approximately parallel to the surface of the display panel and has the following functions: the light source can illuminate all the surfaces of the panel, and foreign matters such as dust, dirt and the like can be erased.
(3) Image acquisition device and image processing unit
The invention can simplify the complexity of image processing by the image processing unit through the matching of the main optical unit and the auxiliary optical unit, and can simply and quickly distinguish the real bad defects and surface foreign matters of the image. Fig. 3 is a specific diagram of the display panel captured by the image capturing device; the following is presented by way of two examples:
the first embodiment is as follows:
the main light source and the auxiliary light source are turned on in a time-sharing manner to take a picture, namely: only opening the main optical unit, and when the auxiliary optical unit is not opened, acquiring an image of the detected display panel by using image acquisition equipment, and recording the image as a 1 st original detection image; only opening the auxiliary optical unit, and when the main optical unit is not opened, acquiring an image of the detected display panel by using the image acquisition equipment, and recording the image as a 2 nd original detection image; the image acquisition equipment uploads the 1 st original detection image and the 2 nd original detection image to the image processing unit;
the image processing unit contrasts and analyzes the 1 st original detection image and the 2 nd original detection image, based on the 2 nd original detection image, the surface erasable foreign matter is removed from the 1 st original detection image, then the real bad defect is extracted from the 1 st original detection image, and the defect detection result of the detected display panel is obtained.
Example two:
the primary and secondary light sources are turned on simultaneously, but the primary and secondary light sources are selected to be of different light source colors. Preferred primary and secondary light source color combinations may be in the "blue + red" or "red + blue" mode. Then, acquiring an image of the detected display panel by using image acquisition equipment, and recording the image as a 3 rd original detection image; uploading the 3 rd original detection image to an image processing unit;
the image processing unit analyzes the 3 rd original detection image according to the color characteristics, because the auxiliary light source can illuminate the surface erasable foreign matters such as dust and the like but cannot illuminate the real defective defects, and the main light source can illuminate the real defective defects and the surface erasable foreign matters simultaneously, the image processing unit can distinguish the real defective defects from the surface erasable foreign matters according to the color characteristics, so that the surface erasable foreign matters are removed, then the real defective defects are extracted, and the defect detection result of the detected display panel is obtained.
Wherein the incidence angle of the auxiliary light source is parallel or approximately parallel to the surface of the panel, and the included angle ranges from-30 degrees to 30 degrees, preferably from-15 degrees to 15 degrees, and more preferably from-5 degrees to 5 degrees. This angular range ensures that all foreign matter such as dust, dirt, and the like on the surface of the display panel, which can be removed from the surface, can be illuminated. In addition, the auxiliary light source is a parallel surface light source. Further, the parallel surface light source is a plurality of symmetrically arranged parallel surface light sources arranged around the display panel, preferably 4 symmetrically arranged parallel surface light sources. Wherein the light source intensity of the parallel surface light source is 500nit-10000 nit. The incident light of the light source is visible light or infrared ultraviolet light with different frequencies such as white light, red light, green light, blue light and the like.
For the bad recognition subsystem, a specific embodiment is introduced:
as shown in fig. 2, four light sources, namely, the left light source, the right light source, the front light source and the rear light source, which are close to the lens in the vertical direction, in the main light source unit are first-layer light sources, and the distance from the first-layer light sources to the center of the lens is 5cm-20 cm; the four light sources which are slightly far away from the lens in the vertical direction, namely the left light source, the right light source, the front light source and the rear light source are second-layer light sources, the distance between the second-layer light sources and the lens is 10cm-30cm, and blue light emitting diode arrays are used. The distance between the lens and the LCD display panel is 50cm-200cm, and the lens is located in the center of the display panel to be measured. The focal length of the lens is 20mm-80 mm. The auxiliary light source system is provided with 4 light sources around the horizontal direction of the display panel, and red light emitting diode arrays are used. The distance from the display panel is 1cm-10 cm. And adjusting each light source in the main light source assembly to enable the central light spot to cover the display panel to be tested. And adjusting each light source in the auxiliary light source assembly to uniformly irradiate the surface of the panel. And simultaneously starting the main light source and the auxiliary light source, emitting light from the main light source to irradiate the display panel to be detected, always reflecting the light at the concave point defect, emitting light from the auxiliary light source to irradiate the display panel to be detected, and always reflecting the light at the dust. And controlling the camera to take a picture, wherein the blue pit defect and the red dust appear in the image, and finally identifying through image processing software. According to the layered light source assembly layout, the concave point defects on the surface of the display panel can be detected comprehensively, the defects do not have different results due to factors such as distribution positions, shapes, sizes and depths of the defects on the display panel, and the layered light source assembly layout is the fundamental reason for improving the detection accuracy.
Compared with the prior art, the invention adopts the area-array camera, and can detect the surface defects of the display panel by establishing the main optical system arranged around the area-array camera and the auxiliary optical system arranged around the display panel and adopting one-time imaging and combining with an image processing algorithm, the complexity of the detection system is greatly reduced, the detection efficiency is improved by more than 20 percent, and the accuracy is improved by more than 2 percent.
Therefore, through the defect identification subsystem provided by the invention, the image processing unit can simply and quickly distinguish real defect and surface foreign matter in the picture, and has the advantages of simple image processing process, high speed and high efficiency.
(II) reversible double-sided adsorption device
Because the front and back of the display panel to be detected need to be subjected to defect detection, equipment for turning the front and back of the panel needs to be adopted. And because the number of the display panels to be detected is large, especially the number of the TFT-LCDCell in small and medium sizes is tens of thousands, and the display panels are light, thin and fragile, a set of efficient panel front and back overturning equipment is needed, the panels can be quickly overturned, and meanwhile, the surfaces of the panels cannot be shielded.
In the prior art, a sucker type panel turnover device is mainly adopted to turn over a panel. Referring to fig. 4, a schematic diagram of two sets of sucker type panel turnover devices and turnover processes in the prior art is shown, where the turnover process is:
(1) initially, the panel is in an A-face up state;
(2) then, the panel is sucked up by the left sucker and is vertically reversed for 1 time;
(3) then the panel B surface is absorbed by the right sucker, and vertical inversion is carried out for 2 times;
(4) then the panel is placed on the adsorption platform 1 by the right sucker, and the surface B faces upwards, so that the panel is reversed.
The whole process shows that the related actions are more, the efficiency is low, and especially for tens of thousands of panel detection quantities, the efficiency of machine detection is directly influenced.
The inventor of the invention provides a novel reversible double-sided adsorption device through diligent research and structural change optimization for multiple times, and the novel reversible double-sided adsorption device can meet the requirements.
The reversible double-sided adsorption device adsorbs the panel from the bottom surface, so that the adsorption is stable and reliable, and the machine vision photographing is not influenced; the double-sided adsorption structure can rotate the panel by 180 degrees and stably adsorb the panel again; the motion speed is within 1s, while the above conventional method is at least 1.5 s.
As shown in fig. 5, a schematic structural diagram of the reversible double-sided adsorption device provided by the present invention includes a horizontal frame 10, where the horizontal frame 10 includes a left side 11 and a right side 12 which are arranged in parallel; a 1 st left guide rail 13 and a 1 st right guide rail 14 are arranged between the bottom of the left side 11 and the bottom of the right side 12; a 1 st adsorption platform 15 is slidably arranged between the 1 st left guide rail 13 and the 1 st right guide rail 14, and the 1 st adsorption platform 15 can slide along the 1 st left guide rail 13 and the 1 st right guide rail 14 under the driving action of a 1 st driving device 16;
the top of the left side 11 and the top of the right side 12 are fixedly provided with a 2 nd left guide rail 17 and a 2 nd right guide rail 18; a 2 nd adsorption table 19 is slidably mounted between the 2 nd left guide rail 17 and the 2 nd right guide rail 18, and the 2 nd adsorption table 19 can slide along the 2 nd left guide rail 17 and the 2 nd right guide rail 18 under the driving action of a 2 nd driving device 20, further can slide right above the 1 st adsorption table 15 and completely covers the 1 st adsorption table 15 in the vertical direction; or slide to the side of the 1 st adsorption platform 15 without intersecting the 1 st adsorption platform 15 in the vertical direction;
a 3 rd driving device 21 is also included; the 2 nd driving device 21 is used to horizontally turn the horizontal frame 10.
In practical application, the distance between two opposite side surfaces of the 1 st adsorption platform 15 and the 2 nd adsorption platform 19 in the vertical direction is larger than the thickness of the display panel to be detected; usually 1mm to 5 mm.
The 1 st adsorption platform 15 and the 2 nd adsorption platform 19 are respectively provided with a plurality of adsorption holes with the diameter of 0.1 mm-0.5 mm;
the device also comprises a clamping device 22; the locking device 22 is used to buffer the tilting movement of the horizontal frame during the tilting. In particular, when intermediate precise angular positions, i.e. only 0 and 180 degrees, are not required, a detent with a damping action is provided at the bearing location.
In practical application, for the left and right adsorption tables related to the present invention, materials such as aluminum, steel, and alloy can be selected, and in order to adapt to the common use of multiple panel models, the width is preferably 50 to 100mm, the length is 80 to 300mm, and the thickness is 5mm to 15mm, and in order to reduce the weight, the structure is partially hollowed, which is understandable by general mechanical designers and is not described herein again. According to the detection technical requirements of the liquid crystal display panel, the surface of the adsorption platform is oxidized (blackened) and treated with an antistatic coating. According to the inversion principle of the invention, the two adsorption tables are opposite, the surface distance is 1-5 mm, the distance is larger than the thickness of the panel (usually 0.3-0.8 mm), and after inversion, the panel moves to the other adsorption table under the action of gravity, so that the distance cannot be too large. Each adsorption platform is distributed with adsorption holes with the diameter of 0.1 mm-0.5 mm. For a plurality of absorption holes in the overall arrangement, preferably 8 ~ 12, the even atress of fully considering the panel reaches and both guarantees reliable and stable absorption, ensures not producing the damage to the panel again because of adsorbing. The slide rail adopts high-precision ball slide rail. The edge of the adsorption platform is contacted with the slide rail. The slide rail not only plays the accurate control to the direction of movement, but also plays the supporting role to adsorbing the platform. The adsorption platform is connected with a linear push rod or a cylinder. The adsorption platform, the slide rail and other integrated structures are connected with the rotary cylinder or the rotary motor, and when the rotary cylinder or the rotary motor moves, the rotation is finished. In particular, when intermediate precise angular positions, i.e. only 0 and 180 degrees, are not required, a detent with a damping action is provided at the bearing location.
The reversible double-sided adsorption device has the working process that:
step 1: the suction surface of the 1 st suction table 15 is arranged upward, and the 2 nd suction table 19 is slid to the side surface of the 1 st suction table 15 without intersecting the 1 st suction table 15 in the vertical direction;
step 2: placing a display panel to be detected on the adsorption surface of the 1 st adsorption table 15; the front side of the detected display panel faces upwards; the suction hole of the 1 st adsorption platform 15 sucks air to generate certain negative pressure, and then the display panel to be detected is stably adsorbed;
and step 3: adopting a bad recognition subsystem to collect images on the front side of the detected display panel;
and 4, step 4: under the driving action of the 2 nd driving device 20, the 2 nd adsorption platform 19 slides to the position right above the 1 st adsorption platform 15 along the guide rail, so that the 1 st adsorption platform 15 is completely covered by the 2 nd adsorption platform in the vertical direction;
and 5: under the driving action of the 3 rd driving device 21, the whole horizontal frame 10 is horizontally overturned, so that the 1 st adsorption platform 15 is positioned above, and the 2 nd adsorption platform 19 is positioned below;
step 6: the negative pressure is reduced for the adsorption hole of the 1 st adsorption platform 15, the detected display panel moves to the 2 nd adsorption platform 19 below under the action of gravity, the front surface of the detected display panel is contacted with the 2 nd adsorption platform 19, and the back surface of the detected display panel is not contacted with the 2 nd adsorption platform 19;
and 7: sucking air by the 2 nd adsorption platform 19 to generate negative pressure, thereby stably adsorbing the display panel to be detected;
and 8: under the driving action of the 1 st driving device 16, the 1 st adsorption platform 15 slides along the guide rail, so that the 1 st adsorption platform 15 and the 2 nd adsorption platform 19 are not intersected completely in the vertical direction; at this time, the display panel to be detected is sucked and fixed on the 2 nd suction table 19, and the back surface of the display panel to be detected faces upward;
and step 9: and adopting a bad recognition subsystem to acquire an image of the back surface of the detected display panel.
Therefore, the reversible double-sided adsorption device adsorbs the panel from the bottom surface, so that the adsorption is stable and reliable, and the machine vision photographing is not influenced; the double-sided adsorption structure can rotate the panel by 180 degrees and stably adsorb the panel again.
(III) light source brightness self-adaptive adjusting system
Along with the long-time operation of the equipment, the brightness of a main component in the equipment, namely a light source, can be attenuated, so that the detection capability of the whole equipment is reduced, the detection equipment does not play a due role, a plurality of defective products flow to the rear end and even flow to a client, and huge loss is caused; the current common practice of factories is to replace new spare parts of the light source; but its drawback is obvious, directly leads to the cost to increase, and it is also more frequent to change the light source subassembly to it is also longer to change the required time at every turn, leads to the equipment to be transferred the rate and hardly promotes, and production efficiency is low.
Therefore, the present invention provides a light source brightness adaptive adjustment system, as shown in fig. 6, which is a working schematic diagram of the light source brightness adaptive adjustment system, and includes: the device comprises a light source actual brightness detection unit, a light source control card and a light source controller; the light source actual brightness detection unit is used for detecting light source actual brightness values of all positions and transmitting the light source actual brightness values to the light source controller; the light source controller compares the actual brightness value of the light source with a pre-stored specified brightness value of the light source, generates an adjusting instruction according to the deviation of the actual brightness value of the light source and the specified brightness value of the light source, and sends the adjusting instruction to the light source control card; the light source control card adjusts voltage or current to compensate the light source brightness to form closed-loop control of real-time compensation, and then the light source brightness is ensured to be stabilized at a required value.
The light source actual brightness detection unit is realized by adopting the following two modes:
the first method is as follows: a brightness sensor is fixedly arranged at the position below the detected light source, and the brightness sensor detects light source brightness data in real time and transmits the light source brightness data to the light source controller;
the second method comprises the following steps: placing a standard color plate at a fixed position; shooting a standard color plate by using a camera at intervals, wherein the parameter settings of the camera and the light source are consistent; the gray scale data of the shot standard color plate picture is analyzed through an algorithm, and the actual data of the light source brightness is indirectly reflected.
By adopting the light source brightness self-adaptive adjusting system, the service life of the light source can be greatly prolonged, the grafting rate of the equipment is improved, and the maintenance cost of the equipment is effectively reduced.
Therefore, the novel display panel surface defect detection system provided by the invention has the following advantages:
(1) the image processing unit of the defect identification subsystem provided by the invention can simply and quickly distinguish real defect and surface foreign matter in the picture, and has the advantages of simple image processing process, high speed and high efficiency.
(2) The reversible double-sided adsorption device provided by the invention adsorbs the panel from the bottom surface, so that the adsorption is stable and reliable, and the machine vision photographing is not influenced; the double-sided adsorption structure can rotate the panel by 180 degrees and stably adsorb the panel again.
(3) The light source brightness self-adaptive adjusting system provided by the invention can greatly prolong the service life of a light source, improve the grafting rate of equipment and effectively reduce the maintenance cost of the equipment.
The foregoing is only a preferred embodiment of the present invention, and it should be noted that, for those skilled in the art, various modifications and improvements can be made without departing from the principle of the present invention, and such modifications and improvements should also be considered within the scope of the present invention.
Claims (1)
1. A novel display panel surface defect detection system is characterized by comprising a bad recognition subsystem; the defect identification subsystem comprises image acquisition equipment, a main optical unit, an auxiliary optical unit and an image processing unit; the image acquisition equipment is connected with the image processing unit;
the image acquisition equipment is arranged above the detected display panel;
the main optical unit comprises a plurality of main light source components, each main light source component is arranged around a lens of the image acquisition equipment, and each main light source component and the lens form a certain included angle in the vertical direction and is used for irradiating light to the surface of the detected display panel at a certain angle, so that the real defect of the detected display panel and the surface erasable foreign matter are simultaneously illuminated;
the auxiliary optical unit comprises a plurality of auxiliary light source assemblies, each auxiliary light source assembly is arranged at the periphery of the detected display panel and is used for emitting light parallel or approximately parallel to the surface of the detected display panel, so that the surface of the detected display panel is illuminated to remove foreign matters;
the image acquisition device is configured to: only opening the main optical unit, and when the auxiliary optical unit is not opened, acquiring an image of a detected display panel by the image acquisition equipment, and recording the image as a 1 st original detection image; only opening the auxiliary optical unit, and when the main optical unit is not opened, acquiring an image of a detected display panel by the image acquisition equipment, and recording the image as a 2 nd original detection image; the image acquisition equipment uploads the 1 st original detection image and the 2 nd original detection image to the image processing unit;
the image processing unit contrasts and analyzes the 1 st original detection image and the 2 nd original detection image, based on the 2 nd original detection image, surface erasable foreign matters are removed from the 1 st original detection image, and then real bad defects are extracted from the 1 st original detection image to obtain a detected display panel defect detection result;
or:
the image acquisition device is configured to: simultaneously opening the main optical unit and the auxiliary optical unit in different colors, and acquiring an image of a detected display panel by the image acquisition equipment, wherein the image is recorded as a 3 rd original detection image; uploading the 3 rd original detection image to the image processing unit;
the image processing unit analyzes the 3 rd original detection image according to color characteristics, removes surface erasable foreign matters, and then extracts real bad defects to obtain a defect detection result of the detected display panel;
wherein, the device also comprises a reversible double-sided adsorption device; the reversible double-sided adsorption device is used for overturning the detected display panel, so that the defects of the front side and the back side of the detected display panel are detected;
the reversible double-sided adsorption device comprises a horizontal frame (10), wherein the horizontal frame (10) comprises a left side (11) and a right side (12) which are arranged in parallel; a 1 st left guide rail (13) and a 1 st right guide rail (14) are arranged between the bottom of the left side (11) and the bottom of the right side (12); a 1 st adsorption table (15) is slidably mounted between the 1 st left guide rail (13) and the 1 st right guide rail (14), and the 1 st adsorption table (15) can slide along the 1 st left guide rail (13) and the 1 st right guide rail (14) under the driving action of a 1 st driving device (16);
the top of the left side (11) and the top of the right side (12) are fixedly provided with a 2 nd left guide rail (17) and a 2 nd right guide rail (18); a 2 nd adsorption table (19) is slidably mounted between the 2 nd left guide rail (17) and the 2 nd right guide rail (18), and the 2 nd adsorption table (19) can slide along the 2 nd left guide rail (17) and the 2 nd right guide rail (18) under the driving action of a 2 nd driving device (20) and further can slide right above the 1 st adsorption table (15) to completely cover the 1 st adsorption table (15) in the vertical direction; or slide to the side surface of the 1 st adsorption table (15) and do not intersect with the 1 st adsorption table (15) in the vertical direction completely;
also comprises a 3 rd driving device (21); the 2 nd driving device (21) is used for horizontally overturning the horizontal frame (10);
each main light source assembly and a lens of the image acquisition equipment have a certain distance in the horizontal direction, and the distance is at least greater than the length of the detected display panel in the corresponding direction, so that mirror surface imaging of the main light source assembly on the detected display panel is avoided;
in addition, each main light source component has a certain distance with the lens of the image acquisition equipment in the vertical direction, and each main light source component is lower than the lens of the image acquisition equipment, so that the image acquisition equipment and various mechanical structures above the image acquisition equipment are prevented from being imaged on the mirror surface of the detected display panel.
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| CN201911175193.3A Withdrawn CN110849906A (en) | 2016-06-08 | 2016-06-08 | Novel display panel surface defect detection system |
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- 2016-06-08 CN CN201911175193.3A patent/CN110849906A/en not_active Withdrawn
- 2016-06-08 CN CN201911176531.5A patent/CN110849907A/en not_active Withdrawn
- 2016-06-08 CN CN201911175017.XA patent/CN110849904A/en not_active Withdrawn
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Also Published As
| Publication number | Publication date |
|---|---|
| CN110849903A (en) | 2020-02-28 |
| CN110849906A (en) | 2020-02-28 |
| CN110849907A (en) | 2020-02-28 |
| CN110849905A (en) | 2020-02-28 |
| CN110849904A (en) | 2020-02-28 |
| CN106814084A (en) | 2017-06-09 |
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Application publication date: 20200228 |