JP2021021912A - Method for manufacturing projector device, projector device, and head-up display device - Google Patents

Abstract

To provide a method for manufacturing a projector device that can generate illuminance control data according to individual differences, a projector device, and a head-up display device.SOLUTION: The method for manufacturing a projector device includes: a first step of determining a driving ability of a light source driver 300; a second step of selecting the best master data of plural pieces of master data set according to driving abilities, which is the closest to the determined driving ability of the light source driver 300; a third step of acquiring output characteristics showing the relation between the output level of the light source control unit 201 and the luminance of display light; and a fourth step of generating illuminance control data Dm by correcting the best master data on the basis of the acquired output characteristics.SELECTED DRAWING: Figure 5

Description

The present disclosure relates to a method for manufacturing a projector device, a projector device, and a head-up display device.

Conventionally, for example, as described in Patent Document 1, a head-up display device that displays a virtual image by radiating display light onto a transmitting and reflecting surface such as a windshield is known.

Japanese Unexamined Patent Publication No. 2016-4121

The head-up display device has individual differences for each product, and the brightness and chromaticity of the display light may deviate from the target values due to the individual differences.

The present disclosure has been made in view of the above circumstances, and an object of the present invention is to provide a method for manufacturing a projector device, a projector device, and a head-up display device capable of generating lighting control data according to individual differences. ..

In order to achieve the above object, the method for manufacturing a projector device according to the first aspect of the present disclosure includes a plurality of light sources, a light source driver for driving the plurality of light sources, and the light source driver based on lighting control data. A method for manufacturing a DMD type projector device including a light source control unit for lighting the plurality of light sources and a DMD display element for generating display light based on the light emitted by the plurality of light sources, wherein the drive of the light source driver is provided. The first step of determining the capacity and the second step of selecting the optimum master data closest to the drive capacity of the light source driver determined in the first step from a plurality of master data set for each drive capacity. The lighting control data is obtained by correcting the optimum master data based on the third step of acquiring the output characteristic indicating the relationship between the output level of the light source control unit and the brightness of the display light and the acquired output characteristic. A fourth step of generating the above.

In order to achieve the above object, the projector device according to the second aspect of the present disclosure includes a plurality of light sources, a light source driver for driving the plurality of light sources, and the plurality of light sources via the light source driver based on lighting control data. A DMD type projector device including a light source control unit for lighting a light source and a DMD display element for generating display light based on the light emitted by the plurality of light sources, and having a drive ability for determining the drive ability of the light source driver. The determination unit, the master data selection unit that selects the optimum master data closest to the drive capability of the light source driver determined by the drive capability determination unit from among the plurality of master data set for each drive capability, and the above. The lighting control data is generated by correcting the optimum master data based on the output characteristic acquisition unit that acquires the output characteristic indicating the relationship between the output level of the light source control unit and the brightness of the display light and the acquired output characteristic. A data generation unit is provided.

In order to achieve the above object, the head-up display device according to the third aspect of the present disclosure includes the projector device and an optical relay unit that guides the display light radiated from the projector device to the projected member. ..

According to the present disclosure, lighting control data can be generated according to individual differences.

It is a schematic diagram of the vehicle which mounted the head-up display device which concerns on one Embodiment of this disclosure. It is the schematic which shows the structure of the head-up display apparatus which concerns on one Embodiment of this disclosure. It is the schematic which shows the structure of the lighting apparatus which concerns on one Embodiment of this disclosure. It is the schematic which shows the structure of the display unit which concerns on one Embodiment of this disclosure. It is a block diagram of the light source drive device which concerns on one Embodiment of this disclosure. It is a block diagram of the lighting control data adjustment system which concerns on one Embodiment of this disclosure. It is the schematic which shows the structure of the sample product data acquisition apparatus which concerns on one Embodiment of this disclosure. It is the schematic which shows the structure of the shipment product data acquisition apparatus which concerns on one Embodiment of this disclosure. It is a schematic diagram which shows the grade to which the sample projector apparatus which concerns on one Embodiment of this disclosure belongs. It is a graph which shows the RGB output characteristic which concerns on one Embodiment of this disclosure. It is a graph which shows the relationship between the control mode and brightness which concerns on one Embodiment of this disclosure. It is an enlarged view of a part of FIG. It is a flowchart of the master data generation processing which concerns on one Embodiment of this disclosure. It is a sub-flow chart of the master data generation processing which concerns on one Embodiment of this disclosure. It is a flowchart of the product data generation processing which concerns on one Embodiment of this disclosure. It is a timing chart which shows the waveform pattern of the current supplied to the light source and the operation of a switch in the high luminance mode which concerns on one Embodiment of this disclosure. It is a timing chart which shows the pulse of the current supplied to the light source in the low brightness mode which concerns on one Embodiment of this disclosure.

An embodiment of a head-up display device (hereinafter referred to as a HUD device) according to the present disclosure will be described with reference to the drawings.
As shown in FIG. 1, the HUD device 1 is mounted on the dashboard of the vehicle 2, generates a display light L representing an image, and radiates the generated display light L toward the windshield 3. The display light L reaches the viewer 4 (for example, the driver of the vehicle 2) after being reflected by the windshield 3. As a result, the viewer 4 can visually recognize the virtual image V displayed in front of the windshield 3. Various vehicle information such as engine speed and vehicle speed is displayed on the virtual image V, for example.

As shown in FIG. 2, the HUD device 1 includes a projector device 18, a transmissive screen 50, a light source drive device 5, plane mirrors 55 and 61, a concave mirror 62, a concave mirror drive unit 65, a housing 70, and the like. It is provided with a translucent unit 71. The projector device 18 includes a lighting device 10 that emits illumination light C, and a display unit 19 that receives illumination light C and emits display light L.

The housing 70 is formed in a box shape, for example, by a light-shielding material. A plane mirror 61, a concave mirror 62, and a concave mirror driving unit 65 are housed in the housing 70. The housing 70 is formed with an opening 70a through which the display light L passes.
The translucent portion 71 is formed in the shape of a curved plate made of a translucent resin such as acrylic, and is provided so as to close the opening 70a of the housing 70.

The lighting device 10 generates illumination light C and radiates the generated illumination light C toward the display unit 19. Specifically, as shown in FIG. 3, the lighting device 10 includes a light source group 11, a photosynthesis unit 13, and a light source temperature detection unit 600.

The light source group 11 is composed of, for example, three light sources 11r, 11g, and 11b each composed of an LED (Light Emitting Diode). The light source 11r is a red light source, and emits red light R when lit. The light source 11g is a green light source, and emits green light G when lit. The light source 11b is a blue light source, and emits blue light B when lit. Each of the light sources 11r, 11g, and 11b is driven by the light source driving device 5 and emits light at a predetermined light intensity and timing.

The photosynthesis unit 13 generates illumination light C by aligning the optical axes of red light R, green light G, and blue light B sequentially emitted from the light sources 11r, 11g, and 11b, and displays the generated illumination light C as a display unit. Radiate towards 19. Specifically, the photosynthesis unit 13 includes a reflection mirror 13a and dichroic mirrors 13b and 13c that reflect light of a specific wavelength and transmit light of other wavelengths other than the specific wavelength. The reflection mirror 13a reflects the incident blue light B toward the dichroic mirror 13b. The dichroic mirror 13b reflects the incident green light G toward the dichroic mirror 13c and transmits the blue light B from the reflection mirror 13a as it is. The dichroic mirror 13c transmits the green light G and the blue light B from the dichroic mirror 13b while reflecting the incident red light R toward the display unit 19. As a result, the dichroic mirror 13c radiates the illumination light C, which is a combination of the red light R, the green light G, and the blue light B, toward the display unit 19.
The light source temperature detection unit 600 detects the temperatures of the light sources 11r, 11g, and 11b, and outputs the detection result as the light source temperature signal ST to the light source driving device 5 as shown in FIG.

As shown in FIG. 4, the display unit 19 includes a prism 15, a light intensity detection unit 500, a DMD display element 30, a projection optical system 40, and a plane mirror 54.
The heimenkyo 54 reflects the illumination light C from the illumination device 10 toward the prism 15.
The prism 15 is formed of a right-angled isosceles triangular columnar shape by a translucent material. The prism 15 includes an inclined surface 15a facing the plane mirror 54, an orthogonal surface 15b facing the DMD display element 30, and an orthogonal surface 15c facing the projection optical system 40. The illumination light C from the heimenkyo 54 reaches the inclined surface 15a of the prism 15. The inclined surface 15a causes most of the illumination light C from the plane mirror 54 to enter the prism 15, and reflects a part of the illumination light C from the plane mirror 54 toward the light intensity detection unit 500. The illumination light C incident on the prism 15 is emitted toward the DMD display element 30 via the orthogonal plane 15b of the prism 15. The display light L from the DMD display element 30 is incident on the prism 15 via the orthogonal surface 15b, and then is reflected by the inclined surface 15a toward the orthogonal surface 15c. Then, the display light L reflected by the inclined surface 15a is emitted toward the projection optical system 40 via the orthogonal surface 15c.

The DMD display element 30 includes a plurality of movable micromirrors 30a. The plurality of micromirrors 30a are arranged in a matrix so as to correspond to the pixels of the image M. The micromirror 30a is provided with an electrode (not shown), and is turned on or off by switching the voltage value applied to the electrode. When the micromirror 30a is on, the illumination light C is reflected toward the transmissive screen 50. When the micromirror 30a is off, the illumination light C is reflected in a direction different from that of the transmissive screen 50.

Each micromirror 30a expresses the color in each pixel of the image M by adjusting the on period under the control of the light source driving device 5. The plurality of micromirrors 30a display information by displaying the image M so as to have a desired gradation for each pixel.

The light intensity detecting unit 500 is composed of, for example, a light receiving element having a photodiode, and is provided at a position where it receives the illumination light C reflected by the prism 15. The light intensity detection unit 500 receives a part of the illumination light C and detects the light intensities of the lights R, G, and B constituting the illumination light C in a time-division manner. As shown in FIG. 5, the light intensity detection unit 500 outputs the detection result as a light intensity detection signal SFB to the second control unit 200 described later of the light source driving device 5.

As shown in FIG. 4, the projection optical system 40 is composed of a concave lens, a convex lens, or the like, magnifies the display light L from the DMD display element 30 through the prism 15, and magnifies the enlarged display light L into a plane mirror shown in FIG. It emits light at 55. The plane mirror 55 reflects the display light L toward the transmissive screen 50.
As shown in FIG. 2, the transmissive screen 50 is composed of a holographic diffuser, a microlens array, a diffuser, and the like, and receives the display light L from the projection optical system 40 to display the image M.

The flat mirror 61 reflects the display light L representing the image M displayed on the transmissive screen 50 toward the concave mirror 62. The concave mirror 62 reflects the display light L from the planar mirror 61 toward the windshield 3. The display light L passes through the translucent portion 71 of the housing 70 and is reflected by the windshield 3 toward the viewer 4.

The concave mirror driving unit 65 includes a motor and a gear mechanism for transmitting the driving force of the motor to the concave mirror 62, which are not shown. The concave mirror driving unit 65 rotates the concave mirror 62 around the rotation axis Ax extending in the direction perpendicular to the paper surface of FIG. By rotating the concave mirror 62 around the rotation axis Ax, the irradiation position of the display light L with respect to the viewer 4 is adjusted in the height direction.

As shown in FIG. 5, the light source driving device 5 controls a light source driver 300 that supplies a constant current to the light source group 11, an inductor L1, a light source driving unit 43 that drives the light source group 11, a DMD display element 30, and the like. A second control unit 200 for controlling the concave mirror drive unit 65 and the like, and a first control unit 100 for controlling the concave mirror drive unit 65 and the like are provided.

The light source driver 300 includes a constant current driver IC (Integrated Circuit) that generates a constant current based on electric power from an in-vehicle battery (not shown), and is controlled by a second control unit 200.
The light source driver 300 supplies a constant current to the light source group 11 based on a command signal from the second control unit 200. When the light source driver 300 receives a command signal from the second control unit 200 to turn off the light source driver 300, the light source driver 300 stops supplying a constant current. The inductor L1 is connected between the light source driver 300 and the light source group 11.

The light source drive unit 43 includes switch units Swr, Swg, Swb, Swc, Swa, a capacitor C1, and a voltage detection unit 49.
The switch units Swr, Swg, Swb, Swc, and Swa are composed of, for example, n-type channel FETs (Field Effect Transistors), and are on (closed) and off (closed) and off (closed) under the control of the second control unit 200. It switches between (open state).
The switch unit Swr is connected in series with the light source 11r. The switch unit Swg is connected in series with the light source 11g. The switch unit Swb is connected in series with the light source 11b. The switch unit Swc and the capacitor C1 are connected in series.

When the switch units Swr, Swg, and Swb are switched to the ON state, a current from the light source driver 300 is passed through the corresponding light sources 11r, 11g, and 11b, and the corresponding light sources 11r, 11g, and 11b are turned on. The switch units Swr, Swg, and Swb cut off the current from the light source driver 300 to the corresponding light sources 11r, 11g, and 11b by switching to the off state, and turn off the corresponding light sources 11r, 11g, and 11b.
The switch unit Swa has a function of controlling the inductor current flowing from the light source driver 300 to the inductor L1 to a target value by switching to the ON state.
The switch unit Swc has a function of adjusting the inclination of the rising portion of the pulse P, which will be described later, by passing a current from the light source driver 300 to the capacitor C1 by switching to the ON state.
The voltage detection unit 49 is connected between the ground and the switch units Swr, Swg, Swb, Swc, and Swa, detects the voltage detection signal SV, and then outputs the voltage detection signal SV to the second control unit 200.

As shown in FIG. 5, the first control unit 100 includes a CPU (Central Processing Unit), a microcontroller including a memory, and the like, and controls the concave mirror drive unit 65. The required luminance signal SL indicating the light intensity of the ambient light around the vehicle 2 detected through the illuminance sensor 7 is input to the first control unit 100. The first control unit 100 outputs the input requested luminance signal SL to the second control unit 200.

The second control unit 200 is an LSI (Large Scale Integration) that realizes a desired function by hardware, and is composed of, for example, an ASIC (Application Specific Integrated Circuit) or an FPGA (Field Programmable Gate Array).
The second control unit 200 includes a video signal SE for displaying the image M from the video signal input unit 700, a light source temperature signal ST detected by the light source temperature detection unit 600, and a voltage detection detected by the voltage detection unit 49. The signal SV and the light intensity detection signal SFB detected by the light intensity detection unit 500 are input.

The second control unit 200 stores a light source control unit 201 that sets the light intensity of the illumination light C according to the required brightness, a display element control unit 202 that controls the DMD display element 30, and illumination control data Dm. It includes a storage unit 203 and a product data generation processing unit 205 that corrects the lighting control data Dm. The product data generation processing unit 205 includes a drive capacity determination unit 205a, a master data selection unit 205b, an output characteristic acquisition unit 205c, and a data generation unit 205d.
The display element control unit 202 displays the image M by controlling each micromirror 30a in the DMD display element 30 on / off based on the video signal SE.

As shown in FIG. 11, the illumination control data Dm includes data indicating the brightness range Bl in each control mode Q1 to Qn (n is an arbitrary natural number). The brightness range Bl of each control mode Q1 to Qn is a brightness range for emitting a desired color, for example, white display light L from the projector device 18. The luminance range Bl of the control modes Q1 to Qn becomes smaller as the control mode Q1 approaches the control mode Qn. The control modes Q1 to Qn are the low-luminance mode or the high-luminance mode, respectively, the gain set by the gain setting unit 201a described later, the target value of the current supplied to the light sources 11r, 11g, and 11b, and the light source. Information about the lighting patterns of 11r, 11g, 11b and the like is associated with them. That is, for each of the control modes Q1 to Qn, there is a data table in which the gain, target value, etc. are defined as to which of the low-luminance mode and the high-luminance mode. For example, the gain and target values are set smaller as the control mode Q1 approaches the control mode Qn. For example, when the mode is switched between the control mode Qx and the control mode Qy, the mode is switched between the low brightness mode and the high brightness mode.
The illumination control data Dm is set for each light source temperature. As an example, lighting control data Dm corresponding to each of −40 ° C., −30 ° C., −10 ° C., 10 ° C., 25 ° C., 40 ° C., 50 ° C., 60 ° C., and 70 ° C. is prepared. The illumination control data Dm differs in the number and contents of the control modes Q1 to Qn and the luminance range Bl in each control mode Q1 to Qn for each light source temperature.

As shown in FIG. 5, the light source control unit 201 includes, for example, a PMIC (Power Management IC) that controls the power supplied to the light source group 11. The light source control unit 201 refers to the illumination control data Dm relating to the temperature closest to the light source temperature based on the light source temperature signal ST detected by the light source temperature detection unit 600. The light source control unit 201 shifts to the control modes Q1 to Qn that realize the required luminance based on the required luminance signal SL with reference to the illumination control data Dm, and in the shifted control modes Q1 to Qn, the light source control unit 201 goes through the light source driver 300. A current is supplied to the light source group 11. As a result, the display light L has a brightness corresponding to the required luminance signal SL. The output level of the light source control unit 201 is variable. As the output level of the light source control unit 201 becomes higher, the peak value Pk of the light source current (see FIGS. 16 and 17) becomes larger, and the time until the light source current reaches the target value becomes shorter, that is, the light source current increases. The inclination of is large.

For example, the light source control unit 201 determines a target value based on the required brightness signal SL (required brightness), and compares the determined target value with the light intensity detection signal SFB. The light source control unit 201 supplies a current from the light source driver 300 to the light source group 11 when the light intensity detection signal SFB becomes less than the target value, and when the light intensity detection signal SFB becomes equal to or more than the target value, the light source driver 300 Stops the supply of current to the light source group 11. As a result, the light source control unit 201 feedback-controls the current value supplied from the light source driver 300 to the light source group 11 with the target value as the target while monitoring the light intensity detection signal SFB. This target value is set to a different value for each of the light sources 11r, 11g, and 11b.

As shown in FIG. 5, the light source control unit 201 includes a gain setting unit 201a that sets the gain of the light intensity detection signal SFB detected by the light intensity detection unit 500. The gain setting unit 201a sets the gain higher as the required luminance (requested luminance signal SL) decreases. The gain setting unit 201a sets the light intensity detection signal SFB to a value readable by the light source control unit 201 by adjusting the gain of the light intensity detection signal SFB. The light source control unit 201 reads the light intensity detection signal SFB in consideration of the presence / absence and the amount of the gain deviation set by the gain setting unit 201a. Therefore, it is possible to prevent the brightness of the display light L from deviating from the target value due to the variation in gain due to the individual difference of the light source control unit 201.

The light source control unit 201 turns on the switch unit Swr over the lighting permission period Tr (see FIG. 16). The light source control unit 201 turns on the light source 11r by supplying the current Ir from the light source driver 300 to the light source 11r during the lighting permission period Tr.
The light source control unit 201 turns on the switch unit Swg for the lighting permission period Tg (see FIG. 16). The light source control unit 201 turns on the light source 11g by supplying the current Ig from the light source driver 300 to the light source 11g during the lighting permission period Tg.
The light source control unit 201 turns on the switch unit Swb over the lighting permission period Tb (see FIG. 16). The light source control unit 201 turns on the light source 11b by supplying the current Ib from the light source driver 300 to the light source 11b during the lighting permission period Tb.

The light source control unit 201 operates by a so-called field sequential method in which any one of the light sources 11r, 11g, and 11b is selectively turned on and the light sources 11r, 11g, and 11b to be turned on are switched at high speed. The light source control unit 201 supplies the currents Ir, Ig, and Ib to the light sources 11r, 11g, and 11b during the display period Ton, and turns off the switch units Swr, Swg, and Swb during the non-display period Tof. The supply of the currents Ir, Ig and Ib to 11g and 11b is stopped. In the period in which the image M is displayed, the display period Ton and the non-display period Tof are alternately repeated. One frame is composed of one display period Ton and one non-display period Tof. The display period Ton is composed of a plurality of lighting permission periods Tr, Tg, and Tb in a preset order.

The second control unit 200 shifts to either the high-luminance mode or the low-luminance mode based on the required luminance signal SL. The second control unit 200 shifts to the low luminance mode when the required luminance signal SL is equal to or less than the threshold value, and shifts to the high luminance mode when the required luminance signal SL exceeds the threshold value. For example, the threshold value is set to a value when the light intensity of the display light L is 4000 candelas.
In the high-luminance mode, the second control unit 200 supplies the currents Ir, Ig, and Ib as rectangular waves to the light sources 11r, 11g, and 11b as shown in FIG. In the high-luminance mode, the second control unit 200 changes the target values Tgt of the currents Ir, Ig, and Ib and the period Ti during which the currents Ir, Ig, and Ib are supplied in accordance with the change in the required brightness. , Adjust the brightness of the display light L.

In the low-luminance mode, the second control unit 200 supplies the currents Ir, Ig, and Ib to the light sources 11r, 11g, and 11b as a plurality of pulses P that are triangular waves, as shown in FIG. In the low-luminance mode, the second control unit 200 adjusts the brightness of the display light L by increasing or decreasing the number of pulses P according to the change in the required brightness.
Not limited to this example, the second control unit 200 increases or decreases the number of pulses P and also increases or decreases the peak value Pk (target value) of the pulse P to increase or decrease the brightness of the display light L. You may adjust.

A method of generating a pulse P in the low-luminance mode will be described.
As shown in FIGS. 5 and 17, the second control unit 200 (light source control unit 201) turns on the switch units Swr and Swc before generating the pulse P in the lighting permission period Tr, and switches units Swr and Swc. Turn Swg, Swb, and Swa off. At this time, the current from the light source driver 300 flows to the ground via the capacitor C1 and the switch unit Swc. As a result, the capacitor C1 is charged with energy. When the capacitor C1 approaches a fully charged state, the current value flowing through the capacitor C1 decreases, and the current Ir supplied to the light source 11r via the switch unit Swr increases. As a result, the waveform of the rising portion of the pulse P is formed. The inclination of the rising portion of the pulse P can be adjusted by the capacitor C1. Then, the second control unit 200 turns on the switch unit Swa when the current Ir reaches the target value. At this time, the current from the light source driver 300 flows to the ground via the switch unit Swa, and the current Ir supplied to the light source 11r decreases. As a result, the waveform of the falling portion of the pulse P is formed.

As shown in FIG. 6, the lighting control data adjustment system 800 generates lighting control data Dm suitable for the shipping product projector device 18k, which is a shipping product of the projector device 18. The illumination control data adjustment system 800 is acquired through the sample product data acquisition device 801 for acquiring the RGB output characteristics at each temperature in the sample projector devices 18a to 18j, which are sample products of the projector device 18, and the sample product data acquisition device 801. A master data generation processing unit 802 that generates master data M1 to M10 based on the RGB output characteristics, a shipping product data acquisition device 810 that acquires RGB output characteristics at each temperature in the shipping product projector device 18k, and master data M1 to master data M1 to A product that generates lighting control data Dm by selecting the optimum master data Mx suitable for the shipped product projector device 18k from among M10 and correcting the optimum master data Mx based on the RGB output characteristics acquired through the shipped product data acquisition device 810. It includes a data generation processing unit 205.
The product data generation processing unit 205 constitutes a part of the shipped product projector device 18k. The sample product data acquisition device 801 and the master data generation processing unit 802 and the shipping product data acquisition device 810 are provided separately from the projector device 18. The sample product data acquisition device 801 and the master data generation processing unit 802, the shipping product data acquisition device 810, and the product data generation processing unit 205 are configured to be capable of transmitting and receiving information to each other by wired communication or wireless communication.

As shown in FIG. 7, the sample product data acquisition device 801 includes a light meter 803, a variable ND (Neutral Density) filter 804, a room temperature adjusting unit 806, a constant temperature bath 808, and an inspection light emitting unit 809. Be prepared.
The constant temperature bath 808 is a tank that keeps the temperature of the internal space constant. The room temperature adjusting unit 806 adjusts the temperature of the internal space of the constant temperature bath 808 under the control of the master data generation processing unit 802. Any of the sample projector devices 18a to 18j is housed in the constant temperature bath 808. The constant temperature bath 808 includes a constant temperature bath glass 805 that transmits the display light L from the projector device 18. The constant temperature bath glass 805 reduces the light intensity of the display light L when the display light L is transmitted. The inside of the constant temperature bath 808 is a dark room.
The light meter 803 and the variable ND filter 804 are located in a dark room outside the constant temperature bath 808.
The variable ND filter 804 adjusts the brightness of the display light L passing through the constant temperature bath glass 805 within the detectable range of the light meter 803 under the control of the master data generation processing unit 802.
The light meter 803 detects the brightness of the display light L that has passed through the variable ND filter 804, and outputs the detected detection signal to the master data generation processing unit 802. The inspection light emitting unit 809 irradiates the light intensity detecting unit 500 with inspection light for inspecting the presence / absence and the amount of deviation of the gain set by the gain setting unit 201a.
The master data generation processing unit 802 includes, for example, a microcontroller. The master data generation processing unit 802 includes a storage unit 807 that stores master data M1 to M10. The master data generation processing unit 802 executes the master data generation processing described later.

As shown in FIG. 8, the shipped product data acquisition device 810 includes a light meter 813, a variable ND filter 814, a chamber 818, and an inspection light emitting unit 819.
The chamber 818 is provided in the line where the shipping product projector device 18k is installed, and accommodates the light meter 813 and the shipping product projector device 18k. The inside of the chamber 818 is a dark room.
The variable ND filter 814 has the same configuration as the variable ND filter 804, and is controlled by the product data generation processing unit 205. The light meter 813 has the same configuration as the light meter 803, and outputs a detection signal to the product data generation processing unit 205. The inspection light emitting unit 819 has the same configuration as the inspection light emitting unit 809, and is controlled by the product data generation processing unit 205.

(Master data generation process)
The master data generation process executed by the master data generation processing unit 802 will be described with reference to the flowchart of FIG.
First, as shown in FIG. 9, the master data generation processing unit 802 classifies the sample projector devices 18a to 18j into grades G1 to G10 according to the drive capability of the light source driver 300 (step S1). The sample projector devices 18a to 18j are of the same type and have different serial numbers. Therefore, the sample projector devices 18a to 18j have individual differences. The drive capability of the light source driver 300, which is a type of individual difference, is determined by the relationship between the output level of the light source control unit 201 and the peak value Pk (see FIGS. 16 and 17) of the light source current flowing through the light sources 11r, 11g, and 11b. The higher the drive capability of the light source driver 300, the larger the peak value Pk of the light source current flowing through the light sources 11r, 11g, and 11b, even if the output level of the light source control unit 201 is low. The drive capability varies depending on the individual difference of the light source driver 300. For example, when the drive capacity of the light source control unit 201 of the sample projector device 18b is higher than the drive capacity of the light source control unit 201 of the sample projector device 18a, even if the output levels of the sample projector devices 18a and 18b are the same, the sample projector The peak value Pk of the light source current in the device 18b is higher than the peak value Pk of the light source current in the sample projector device 18a.
As an example, in step S1, the master data generation processing unit 802 calculates a drive capacity value obtained by dividing the peak value Pk of the light source current by a set output level for each of the sample projector devices 18a to 18j. That is, the drive capacity value is calculated by the following formula.
Drive capacity value = peak value Pk / output level Then, the master data generation processing unit 802 sorts the calculated drive capacity values in order of high and low, and then sets the sample projector devices 18a to 18j in order of high and low grade G1 to the drive capacity value. Classify as G10. For example, when the drive capacity value of the sample projector device 18a is the lowest among the sample projector devices 18a to 18j, the sample projector device 18a is classified into grade G1. When the drive capacity value of the sample projector device 18b is the second lowest among the sample projector devices 18a to 18j, the sample projector device 18b is classified into grade G2. Hereinafter, the projector devices 18c to 18j are also similarly classified into grades G3 to G10, respectively.

Next, the master data generation processing unit 802 generates master data M1 to M10 for each grade G1 to G10, stores the master data M1 to M10 in the storage unit 807 (step S2), and ends the master data generation process. .. The master data generation process according to step S2 is executed before the shipment product projector device 18k is manufactured.
In this step S2, the master data generation processing unit 802 reads out the sub-flow chart shown in FIG. 14 for generating the master data M1 to M10.

The processing related to the sub-flow chart of FIG. 14 is executed for each of the sample projector devices 18a to 18j. As a result, master data M1 to M10 corresponding to grades G1 to G10 are generated. Each master data M1 to M10 has master data at each temperature. In the following example, a case where the grade G1 master data M1 is generated will be described. In this case, before the start of the sub-flow chart of FIG. 14, the sample projector device 18a belonging to grade G1 is installed in the constant temperature bath 808, and the power of the sample projector device 18a is turned on.

First, the master data generation processing unit 802 sets the temperature inside the room temperature adjusting unit 806 to the target temperature via the room temperature adjusting unit 806 (step S11). Then, the master data generation processing unit 802 waits for the temperature in the room temperature adjusting unit 806 to stabilize at the target temperature (step S12; NO). Then, when the master data generation processing unit 802 determines that the temperature in the room temperature adjusting unit 806 is stable at the target temperature (step S12; YES), the master data generation processing unit 802 acquires gain deviation information which is an IC characteristic of the light source control unit 201 (step S12; YES). Step S13). In this step S13, the master data generation processing unit 802 irradiates the light intensity detection unit 500 with the inspection light through the inspection light emission unit 809. The inspection light is light having a preset brightness. Then, the master data generation processing unit 802 measures the light intensity detection signal SFB when the light intensity detection unit 500 is irradiated with the inspection light in a state where the gain is set to the set value by the gain setting unit 201a. Then, the master data generation processing unit 802 acquires gain deviation information indicating a deviation from the set value of the gain based on the difference between the measured light intensity detection signal SFB and the reference value. This reference value is, for example, the average of the light intensity detection signals SFB when the light intensity detection unit 500 is irradiated with the inspection light in a state where the gain is set to the set value by the gain setting unit 201a in the plurality of projector devices 18. The value.

Next, the master data generation processing unit 802 takes into account the acquired gain deviation information and acquires the RGB output characteristics at the target temperature adjusted by the room temperature adjusting unit 806 (step S14).
As shown in FIG. 10, the RGB output characteristic is a characteristic showing the relationship between the output level of the light source control unit 201 and the brightness of the display light L detected by the light meter 803.
In step S14, the master data generation processing unit 802 sets the output level of the light source control unit 201 to the first value, drives only the light source 11r, and drives only the light source 11r to display the light L through the light meter 803. The brightness of the light is measured and plotted at the point P1 where the first value and the brightness of the red light intersect. Next, the master data generation processing unit 802 sets the output level of the light source control unit 201 to a second value larger than the first value, drives only the light source 11r, and displays light through the light meter 803. The brightness of the red light, which is L, is measured and plotted at the point P2 where the second value and the brightness of the red light intersect. Hereinafter, points P3 to Pn (n is a natural number) are plotted in the same manner. The master data generation processing unit 802 acquires the R output characteristic related to the light source 11r shown by the polygonal line Lr in FIG. 10 by linearly interpolating between the points P1 to Pn. Similarly to this, the master data generation processing unit 802 acquires the G output characteristic related to the light source 11g shown by the polygonal line Lg in FIG. 10 and the B output characteristic related to the light source 11b shown by the polygonal line Lb in FIG. With the above, the RGB output characteristics are acquired.
For example, when the gain is deviated so as to exceed the set value and the correction is not performed in consideration of the gain deviation information, the current of the light intensity detection signal SFB with respect to the light intensity of the light irradiated to the light intensity detection unit 500 Since the value is high, the brightness of the display light L adjusted based on the light intensity detection signal SFB is also high. In this way, in order to suppress the increase in the brightness of the display light L as the gain exceeds the set value, the correction is performed in consideration of the gain deviation information. For example, when the gain deviation information includes information indicating that the gain is deviated so as to exceed the set value, the master data generation processing unit 802 adds the acquired gain deviation information to the points P1 to Pn, and thus points P1 to Pn. , The bending lines Lr, Lg, and Lb are corrected so as to shift downward, that is, in the direction of decreasing brightness. Further, similarly to this, when the master data generation processing unit 802 includes, for example, information that the gain is deviated so as to be lower than the set value, the gain deviation information is added by adding the acquired gain deviation information. , Points P1 to Pn, and by extension, the polygonal lines Lr, Lg, and Lb are corrected so as to deviate in the upward direction, that is, in the brightness increasing direction. The correction amount at this time is a value corresponding to the amount of deviation between the gain included in the gain deviation information and the set value.

The master data generation processing unit 802 determines whether or not the RGB output characteristics have been acquired at each temperature (step S15). Each temperature is, for example, −40 ° C., −30 ° C., −10 ° C., 10 ° C., 25 ° C., 40 ° C., 50 ° C., 60 ° C., 70 ° C. When the master data generation processing unit 802 determines that the RGB output characteristics have not been acquired at each temperature (step S15; NO), the master data generation processing unit 802 returns to the processing of step S11 and acquires the RGB output characteristics via the room temperature adjusting unit 806. Set the target temperature to no temperature. That is, by repeating the processes of steps S11 to S15, the RGB output characteristics are acquired at each temperature.

When the master data generation processing unit 802 determines that the RGB output characteristics have been acquired at each temperature (step S15; YES), the master data generation processing unit 802 generates master data M1 at each temperature based on the RGB output characteristics at each temperature, and generates master data M1 at each temperature. The master data M1 in the above is stored in the storage unit 807 (step S16), and the sub-flow chart of FIG. 14 ends. The master data M1 includes the same contents as the lighting control data Dm shown in FIG. 11 described above. The master data M2 to M10 are also generated by the sub-flow chart shown in FIG. 14, similarly to the master data M1.

(Product data generation process)
Next, the product data generation process executed by the product data generation processing unit 205 will be described with reference to the flowchart of FIG.
First, the drive capacity determination unit 205a determines the drive capacity of the light source driver 300 of the shipped projector device 18k (step S21). In this step S21, for example, the drive capacity determination unit 205a calculates the drive capacity value of the light source driver 300 of the shipping product projector device 18k as described above.
Then, the master data selection unit 205b selects the optimum master data Mx from the master data M1 to M10 based on the determined drive capability (step S22). In step S22, the master data selection unit 205b sets the master data corresponding to the group to which the sample projector device closest to the calculated drive capacity value among the drive capacity values of the sample projector devices 18a to 18j belongs as the optimum master data Mx. select.
Then, the product data generation processing unit 205 stores the selected optimum master data Mx as temporary lighting control data Dm in the storage unit 203 (step S23). In steps S24 to S26, the shipped projector device 18k operates based on the provisional lighting control data Dm.

Next, the output characteristic acquisition unit 205c acquires the gain deviation information of the shipment product projector device 18k through the shipment product data acquisition device 810 (step S24) in the same manner as in step S13, and adds the acquired gain deviation information. Then, the RGB output characteristics at room temperature of the shipped projector device 18k are acquired (step S25). Steps S24 and S25 are the same processes as in steps S13 and S14. Since the process according to step S24 only acquires the RGB output characteristics at room temperature, it can be performed in a shorter time than the master data generation process for acquiring the RGB output characteristics at each temperature.

Then, the product data generation processing unit 205 acquires the comparison data Mc shown in FIG. 11 based on the acquired RGB output characteristics (step S26). The comparison data Mc is data to be compared with the optimum master data Mx, and the brightness range Bl in each control mode Q1 to Qn is different from the optimum master data Mx.

Next, the data generation unit 205d generates the lighting control data Dm by correcting the optimum master data Mx based on the difference between the comparison data Mc and the optimum master data Mx at room temperature (for example, 25 ° C.) (step S27).
In this step S27, as shown in FIG. 12, the product data generation processing unit 205 sets the difference values Df1 and Df2 between the luminance range Bl1 of the optimum master data Mx at room temperature and the luminance range Bl2 of the comparison data Mc in the control mode Q1. get. The difference value Df1 is a difference value of the maximum values of the luminance ranges Bl1 and Bl2. The difference value Df2 is the difference value of the minimum values of the luminance ranges Bl1 and Bl2. Then, the product data generation processing unit 205 corrects the brightness range Bl of the control mode Q1 of the optimum master data Mx of each temperature by using the difference values Df1 and Df2 as correction values. For example, the product data generation processing unit 205 increases the upper limit value of the brightness range Bl1 of the optimum master data Mx by the difference value Df1 and increases the lower limit value of the brightness range Bl1 of the optimum master data Mx by the difference value Df2. In the control modes Q2 to Qn, the luminance range Bl is corrected in the same manner. That is, the correction value based on the comparison between the optimum master data Mx at room temperature and the comparison data Mc is also used for the correction of the optimum master data Mx at each temperature other than room temperature. Therefore, the correction of the optimum master data Mx can be simplified.

The product data generation processing unit 205 writes the corrected optimum master data Mx as lighting control data Dm in the storage unit 203 (step S28), and ends the product data generation processing. As a result, since the shipping product projector device 18k can use the illumination control data Dm suitable for the shipping product projector device 18k, the brightness and chromaticity of the display light L can be brought close to the target values.

The second control unit 200 may execute a part of the control content of the first control unit 100, and conversely, a part of the control content of the second control unit 200 may be executed by the first control unit 200. The control unit 100 may execute it. Further, the first and second control units 100 and 200 may be configured as one control unit.

(effect)
According to the embodiment described above, the following effects are obtained.
(1) The DMD type projector device 18 (shipped projector device 18k) includes a plurality of light sources 11r, 11g, 11b, a light source driver 300 for driving the light sources 11r, 11g, 11b, and a light source driver based on the lighting control data Dm. It includes a light source control unit 201 that lights a plurality of light sources 11r, 11g, 11b via a 300, and a DMD display element 30 that generates display light L based on the light emitted by the plurality of light sources 11r, 11g, 11b. The manufacturing method of the projector device 18 is determined in step S21, which is an example of the first step of determining the drive capability of the light source driver 300, and in step S21 among a plurality of master data M1 to M10 set for each drive capability. Acquires step S22, which is an example of the second step of selecting the optimum master data Mx closest to the drive capability of the light source driver 300, and RGB output characteristics indicating the relationship between the output level of the light source control unit 201 and the brightness of the display light L. Step S25, which is an example of the third step, and step S27, which is an example of the fourth step of generating the lighting control data Dm by correcting the optimum master data Mx based on the acquired RGB output characteristics, and the generated lighting. A step S23 for storing the control data Dm in the storage unit 203 and a step for turning on the light sources 11r, 11g, and 11b based on the lighting control data Dm stored in the storage unit 203 are provided.
According to this configuration, the lighting control data Dm is generated according to the individual difference of the projector device 18. Therefore, it is possible to prevent the brightness and chromaticity of each pixel of the display light L from deviating from the target value regardless of the individual difference of the projector device 18.
Specifically, the drive capability of the light source driver 300 for each projector device 18 varies. According to the above configuration, the optimum master data Mx having the closest drive capability of the light source driver 300 is selected from the master data M1 to M10, and the lighting control data Dm is generated based on the selected optimum master data Mx. Therefore, it is possible to prevent the brightness and chromaticity of the display light L from deviating from the target value due to the variation in the drive capacity. As a result, the display quality of the virtual image V is improved.

(2) The light source control unit 201 includes a gain setting unit 201a that sets the gain of the light intensity detection signal SFB indicating the light intensity of the light emitted by the light sources 11r, 11g, and 11b. The manufacturing method of the projector device 18 includes step S24, which is an example of a fifth step of acquiring gain deviation information of the gain set by the gain setting unit 201a. In step S25, the RGB output characteristics are acquired by adding the acquired deviation information.
Due to individual differences in the projector device 18, the gain set by the gain setting unit 201a deviates. According to the above configuration, the RGB output characteristics are acquired in consideration of the gain deviation information. Therefore, it is possible to prevent the brightness and chromaticity of the display light L from deviating from the target value due to the deviation of the gain. As a result, the display quality of the virtual image V is improved.

(3) The method for manufacturing the projector device 18 is executed before step S21, and includes step S2 which is an example of the sixth step of generating master data M1 to M10 at each of the first temperature and the second temperature. In step S25, which is an example of the third step, RGB output characteristics at a third temperature (for example, room temperature) closer to the first temperature than the second temperature are acquired. In step S27, which is an example of the fourth step, correction values (difference values Df1 and Df2) are determined based on the acquired RGB output characteristics at the third temperature and the selected optimum master data Mx at the first temperature. The lighting control data Dm of the first temperature and the second temperature is generated by correcting the optimum master data Mx of each of the first temperature and the second temperature by the correction value. The light source control unit 201 refers to the light source 11r, 11g with reference to the illumination control data Dm of the temperature which is closer to the light source temperature, whichever of the first temperature and the second temperature, based on the light source temperature detected by the light source temperature detection unit 600. , 11b are driven.
According to this configuration, the correction value determined based on the optimum master data Mx at the first temperature is applied not only to the optimum master data Mx at the first temperature but also to the optimum master data Mx at the second temperature. To. Therefore, it is not necessary to acquire the correction value at each temperature, and the correction of the optimum master data Mx can be simplified.
Further, it is not necessary to acquire the RGB output characteristics at each temperature in order to acquire the correction value at each temperature. Therefore, the shipped product data acquisition device 810 does not need to change the temperature in the chamber 818, and the configuration of the shipped product data acquisition device 810 can be simplified.

(4) The DMD type projector device 18 includes a plurality of light sources 11r, 11g, 11b, a light source driver 300 for driving the light sources 11r, 11g, 11b, and a plurality of light sources via the light source driver 300 based on the lighting control data Dm. It includes a light source control unit 201 that lights 11r, 11g, 11b, and a DMD display element 30 that generates display light L based on the light emitted by the plurality of light sources 11r, 11g, 11b. The DMD type projector device 18 is determined by the drive capacity determination unit 205a for determining the drive capacity of the light source driver 300 and the drive capacity determination unit 205a among a plurality of master data M1 to M10 set for each drive capacity. The master data selection unit 205b that selects the optimum master data Mx closest to the drive capability of the light source driver 300, and the output characteristic acquisition unit that acquires RGB output characteristics that indicate the relationship between the output level of the light source control unit 201 and the brightness of the display light L. It includes 205c and a data generation unit 205d that generates lighting control data Dm by correcting the optimum master data Mx based on the acquired RGB output characteristics.
According to this configuration, the lighting control data Dm is generated according to the individual difference of the projector device 18.

(5) The HUD device 1 includes a projector device 18, a plane mirror 61 and a concave mirror 62 which are examples of an optical relay unit that guides the display light L radiated from the projector device 18 to a windshield 3 which is an example of a projected member. To be equipped.
According to this configuration, the lighting control data Dm is generated according to the individual difference of the projector device 18. Therefore, the display quality of the virtual image V displayed on the windshield 3 can be improved.

The present disclosure is not limited to the above embodiments and drawings. Changes (including deletion of components) can be made as appropriate without changing the gist of the present disclosure. An example of the modification will be described below.

(Modification example)
In the above embodiment, the correction value based on the comparison between the optimum master data Mx at room temperature and the comparison data Mc is also applied to the correction of the optimum master data Mx other than room temperature. However, the present invention is not limited to this, and the correction value of each temperature may be acquired and the correction value may be applied to the master data Mx of each temperature.

In the above embodiment, the output characteristic acquisition unit 205c has acquired the RGB output characteristics at room temperature in the shipping product projector device 18k by adding the acquired gain deviation information, but the gain deviation information is not added. May be good.

In the above embodiment, the HUD device 1 is for in-vehicle use, but it is not limited to the in-vehicle use, and may be mounted on a vehicle such as an airplane or a ship. Further, although the display light L from the HUD device 1 is projected on the windshield 3, it may be projected on a dedicated combiner.

In the above embodiment, the second control unit 200 has shifted to either the high-luminance mode or the low-luminance mode based on the required luminance signal SL indicating the light intensity of the external light, but the HUD is not limited to this. Assuming that the required brightness is changed by the viewer 4 operating an operation unit (not shown) provided in the device 1 or the vehicle 2, the mode may be shifted between the above modes.
The variable ND filters 804 and 814 in the above embodiment may be omitted.

1 HUD device 2 Vehicle 3 Windshield 4 Viewer 5 Light source drive device 7 Illumination sensor 10 Light source group 11 Light source group 11b, 11g, 11r Light source 13 Photosynthesis unit 13a Reflection mirror 13b, 13c Dycroic mirror 15 Prism 15a Inclined surface 15b, 15c Orthogonal Surface 18 Projector device 18a to 18j Sample projector device 18k Shipment product Projector device 19 Display unit 30 DMD display element 30a Micromirror 40 Projection optical system 43 Light source drive unit 49 Voltage detection unit 50 Transmission screen 54, 55, 61 Plane mirror 62 Concave mirror 65 Concave mirror drive unit 70 Housing 70a Opening 71 Translucent unit 100 First control unit 200 Second control unit 201 Light source control unit 201a Gain setting unit 202 Display element control unit 203,807 Storage unit 205 Product data generation processing unit 205a Drive capacity determination unit 205b Master data selection unit 205c Output characteristic acquisition unit 205d Data generation unit 300 Light source driver 500 Light intensity detection unit 600 Light source temperature detection unit 700 Video signal input unit 800 Lighting control data adjustment system 801 Sample product Data acquisition device 802 Master Data generation processing unit 803 Light meter 804 Variable ND filter 805 Constant temperature tank glass 806 Room temperature adjustment unit 808 Constant temperature tank 809 Inspection light radiation unit 810 Shipment data acquisition device 815 Light meter 814 Variable ND filter 818 Chamber 819 Inspection light radiation unit R Red light B Blue light G Green light C Illumination light C1 Condenser G1-G10 Grade L Display light M Image L1 Inverter M1-M10 Master data Mc Comparison data Mx Optimal master data P Pulse Q1-Qn, Qx, Qy Control mode V Virtual image SE Video signal SL Required brightness signal SFB Light intensity detection signal Ib, Ig, Ir Current Df1, Df2 Difference value ST Light source temperature signal Bl, Bl1, Bl2 Brightness range Lb, Lg, Lr Broken line SV Voltage detection signal Dm Lighting control data Tr, Tg , Tb Lighting permission period Ax Rotation axis Pk Peak value Swa, Swb, Swc, Swg, Swr Switch part To display period Tof non-display period

Claims (5)

Display based on a plurality of light sources, a light source driver for driving the plurality of light sources, a light source control unit for lighting the plurality of light sources via the light source driver based on lighting control data, and light emitted by the plurality of light sources. A method for manufacturing a DMD light source device including a DMD display element that generates light.
The first step of determining the drive capability of the light source driver and
Among the plurality of master data set for each drive capability, the second step of selecting the optimum master data closest to the drive capability of the light source driver determined in the first step, and
The third step of acquiring the output characteristic indicating the relationship between the output level of the light source control unit and the brightness of the display light, and
A fourth step of generating the lighting control data by correcting the optimum master data based on the acquired output characteristics is provided.
Manufacturing method of projector equipment. The light source control unit includes a gain setting unit that sets a gain of a light intensity detection signal indicating the light intensity of light emitted by the plurality of light sources.
The manufacturing method of the projector device includes a fifth step of acquiring gain deviation information set by the gain setting unit.
In the third step, the output characteristic is acquired by adding the acquired deviation information.
The method for manufacturing a projector device according to claim 1. The method for manufacturing the projector device is executed before the first step, and includes a sixth step of generating the plurality of master data at each of the first temperature and the second temperature.
In the third step, the output characteristics at a third temperature closer to the first temperature than the second temperature are acquired.
In the fourth step, a correction value is determined based on the acquired output characteristics at the third temperature and the selected optimum master data at the first temperature, and the first temperature and the second temperature are respectively determined. The lighting control data is generated by correcting the optimum master data of the above by the correction value.
The method for manufacturing a projector device according to claim 1 or 2. Display based on a plurality of light sources, a light source driver for driving the plurality of light sources, a light source control unit for lighting the plurality of light sources via the light source driver based on lighting control data, and light emitted by the plurality of light sources. A DMD light source device including a DMD display element that generates light.
A drive capability determination unit that determines the drive capability of the light source driver,
A master data selection unit that selects the optimum master data closest to the drive capacity of the light source driver determined by the drive capacity determination unit among a plurality of master data set for each drive capacity.
An output characteristic acquisition unit that acquires an output characteristic indicating the relationship between the output level of the light source control unit and the brightness of the display light, and an output characteristic acquisition unit.
It includes a data generation unit that generates the lighting control data by correcting the optimum master data based on the acquired output characteristics.
Projector device. The projector device according to claim 4,
An optical relay unit that guides the display light radiated from the projector device to the projected member is provided.
Head-up display device.