China's optical glass inspection technology has reached the world's leading level
A few days ago, Huawei held a new product launch conference in Wuhan and announced at the conference that Huawei had shipped 100 million mobile phones on May 30. Compared with the global shipment of 1.456 billion smart phones in 2018, Huawei is leading the fast-running trend of China's mobile phone industry with a strong catching-up trend. The boom in the mobile phone market has driven a surge in demand for accessories such as host chips, optical lenses, and cover glass. Take only cell phone cover glass as an example, about 3 billion pieces of cell phone cover glass are shipped annually in China. According to a research report from the Industrial Securities Research Institute, benefiting from the accelerated penetration of 3D glass, the mobile phone protective cover glass market is expected to reach 54 billion yuan in 2019, and the entire glass back cover market is nearly 100 billion yuan. At present, smart phones are entering the era of stock, and major mobile phone manufacturers are looking for new mobile phone performance to seek differentiated competitive advantages. As a key part of future industry competition, mobile phone back covers have also become a hot spot for upstream and downstream manufacturers to compete. . Earlier, mobile phone covers were mainly made of acrylic, but with the popularity of technology and smart phones, current smart phones and tablet computers have almost all adopted cover glass. Cover glass is a glass lens with the characteristics of high strength, high light transmittance, good toughness, scratch resistance, good stain resistance, and strong water gathering. Its inner surface must be close to the touch module and display screen. The bonding and outer surface have sufficient strength to achieve protection, product identification and decoration functions for flat screens, touch modules, etc., are important parts of consumer electronic products, and are widely used in electronic products such as mobile phones and tablets. It is understood that the mobile phone cover glass process is strict, which is a category with extremely high testing requirements in the 3C field, including many complex links such as glass shape punching, tempering, polishing, silk screen, coating, and cleaning. And every production link involves glass quality inspection, with more than 10 procedures. At present, almost all processes are manual inspections. Take Bourne Optics, the world's largest mobile phone glass panel manufacturer, as an example. Among its more than 140,000 employees, more than 40% are performing manual inspections of cover glass. Other statistics show that at present, there are more than 100,000 full-time inspectors in China's mobile phone cover glass inspection field, and the annual salary expenditure exceeds 10 billion yuan. Even with a lot of labor costs, the glass quality inspection pass rate is still difficult to guarantee. It is understood that due to the strong light exposure during the glass inspection process, the vision of workers dropped to 0.6 within 3 months, resulting in an average monthly loss rate of employees of 20%. This has further aggravated the fluctuations in the quality of inspectors, resulting in difficulty in increasing the yield rate. Limited by technological breakthroughs, the industry's pain points that have plagued the detection of mobile phone cover panels have become a constraint on the upgrading and development of China's mobile phone manufacturing industry. With the advancement of machinery, optics, and artificial intelligence algorithms, how to overcome the efficiency and accuracy of AOI (Automatic Optical Inspection) detection technology, achieve online quality control, and effectively reduce costs has always been an unsolved problem for practitioners. In this context, some manufacturers have begun to try to purchase overseas equipment, but they have to bear high technology introduction and service costs for them. In order to realize the independent and controllable core technology and develop the world's leading new industrialized testing equipment, various domestic research institutes, universities and enterprises have conducted a lot of exploration. In August 2017, Zhang Zhengtao, a researcher at the Precision Perception and Control Research Center of the Institute of Automation of the Chinese Academy of Sciences, led the laboratory's scientific and technological achievements industrialization team Zhongke Huiyuan, and developed China's first AOI intelligent detection equipment, which was subsequently developed for more The applied series of equipment, after two years of online operation and verification, has reached the technical index requirements of the customer's Industry 4.0 intelligent production workshop, and is currently the only supplier in China that can provide complete equipment. Based on the accumulation of artificial intelligence machine learning algorithm technology of the Institute of Automation of the Chinese Academy of Sciences, the Huiyuan team of China Science and Technology combined information processing, intelligent control methods, precision mechanism design and integration, etc., and proposed precision inspection technology and methods based on microvision, which were successfully applied In the major installations of the 'Shenguang' project in my country, on this basis, Zhongke Huiyuan transformed it into a fully automated production line in the cover glass industry. Through this technology, in the head color printing process and the mirror silver printing process, which are the most difficult to control in the cover glass industry, the full quality leak detection rate can be strictly controlled below 1%, and the over-detection rate controlled below 2% , Which is far lower than the misjudgment rate that is generally higher than 5% under the industry’s implementation of manual full inspection Reduced labor costs, increased the yield rate, and helped the industry move toward a higher end. In addition to solving the problem of optical glass inspection, Zhongke Huiyuan has now formed a good solution ability in optical, mechanical, electrical, soft, and computing. It pays special attention to the mining and analysis of industrial big data before, during and after industrial inspection. Form a data closed loop to achieve seamless process quality monitoring throughout the process. At the same time, the technical achievements of Zhongke Huiyuan can also be extended to the detection fields of LCD display screens, car navigation screens, aviation connectors, semiconductors, custom furniture, etc. Currently, the products that have been mass-produced and applied include cover glass finished product detectors and white sheet detection. Instrument, high-precision 3D glass back cover detector, silk-screen online quality control instrument, sapphire surface detector, etc., have a broad market application prospects in the production of electronic components and optical components, 3C manufacturing and other fields. At present, it has cooperated with the upstream and downstream industries such as Byrne Optics, Lens Technology, Apple, Huawei, and Samsung.