DIABCS Block Control System Enhances Optoelectronic LCD Quality

The manufacturing process of LCD optoelectronic panels is complicated. It includes panel making, liquid crystal injection, liquid-crystal molecule arrangement, module packaging and bonding, and more. Module packaging and bonding is a material-oriented process that combines numerous components, such as the front panel frame, polarizer, color filter, liquid crystal, TFT glass, driver IC chip, PCB, diffuser film, plastic frame, backplane and controller board. Various assembly processes are required, and the process control of module packaging and bonding matters significantly to the LCD quality.

Recently Delta introduced the DIABCS Block Control System to production lines of notebook LCD panels for an optoelectronic panel manufacturer in China. It was integrated with the customer's automated machines and workstations to facilitate production and process control with machine-to-machine connection, data collection, and edge computing to improve the LCD panel quality.

The optoelectronic panel manufacturer has a large number of production lines that produce LCD modules and panels for smartphones and tables. Delta first standardized communication among all the equipment with the Manufacturing Execution System (MES) for fast changeover and high production efficiency.

Delta then integrated the DIABCS system seamlessly with the customer's existing MES system to achieve fully automated production and enable the communication between production equipment and its MES system. The DIABCS system helped the manufacturer implement material and recipe control, real-time equipment monitoring, and anomaly tracking.

Delta's DIABCS system benefits customers from the following advantages and services:

• Vertical communication between equipment and the MES system
Delta standardizes communication among all the equipment, and the DIABCS system enables data collection and equipment control. It can upload all the production data to the MES system via a single communication protocol.

• Flexible material management and changeover
The DIABCS system integrates with a MES system for efficient material control such as polarizers and UV glue, and reduces the errors of manual record keeping. Automatic parameter adjustment for different materials and in-process inspections enables flexible changeover, and auto-sampling inspections ensure the quality of products.

• Troubleshooting and redundant mechanisms
Production data collection in real time via the DIABCS system helps the optoelectronic manufacturer quickly find the root causes and troubleshoot anomalies. In addition, a redundant mechanism runs automatically for data flow and material flow backup in case the host system malfunctions.

• System loading reduction for high efficiency
The DIABCS system can reduce the MES system loading by providing organized data after computing and analyzing all the raw data acquired. It can also rapidly perform the commands given from the MES system to raise the efficiency for production line management.

Delta implemented production and equipment control with the DIABCS system to enhance notebook LCD quality for the optoelectronic panel manufacturer. Delta provides a one-stop-shop service including project consulting, overall demand assessment and practical implementation. It also offers comprehensive solutions based on its extensive experience and well-developed technology in smart manufacturing.