JP3204656B2 - CRT production method - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION [Object of the Invention] (Field of Industrial Application) The present invention relates to a method for producing a CRT for exposing a CRT panel to light.

(Prior Art) For example, when a fluorescent screen is formed in a production process of a color cathode-ray tube, usually, a black stripe and blue, green, and red fluorescent layers are formed in a stripe shape or a dot shape on the inner surface of the panel. In this process, the shadow mask incorporated in the panel is separated, a photosensitive agent is applied to the inner surface of the panel, and then the shadow mask is assembled again, and the photosensitive surface of the panel is exposed to form a photosensitive film having a predetermined shape. I do. Next, the shadow mask of the panel is separated again, a black light absorbing substance is applied to the whole surface of the panel, only the photosensitive film portion of this substance is removed together with the photosensitive film, and a black stripe is formed by the remaining black light absorbing substance. Form.
Further, blue, green, and red phosphors are formed in a predetermined shape.

In the step of forming the fluorescent screen, when exposing the photosensitive surface of the panel, conventionally, loading and unloading of the panel with respect to the exposure table, a manual method,
A method of loading and unloading a panel conveyed by providing a dedicated transfer machine for at least one exposure table with respect to the exposure table is used, but usually, a panel is produced in a predetermined order. There are many so-called first-in, first-out methods.

(Problems to be Solved by the Invention) In the above production method, the next panel is loaded onto the exposure table at the same time as the unloading operation of the panel from the exposure table is completed. Since the capabilities of the exposure table are different, the number of types of products that can be produced simultaneously varies.

SUMMARY OF THE INVENTION The present invention has been made in view of the above problems, and has as its object to provide a method of producing a CRT capable of increasing the level of simultaneous mixed production and increasing the variety of small-lot production without increasing equipment costs.

[Configuration of the invention]

(Means for Solving the Problems) A method for producing a cathode ray tube according to the present invention comprises: a transport unit for sequentially transporting semi-finished cathode ray tubes; a plurality of processing zones arranged along the transport unit and having a plurality of processing units;
A transfer means provided for each of these processing zones, and a transfer means for transferring the CRT semi-finished product between the processing means of each processing zone and the transport means, and a flow number and A production having a product type code defined corresponding to the flow number and representing manufacturing conditions including at least time and a logical processing number defined corresponding to the flow number and indicating processing means to be used in any of the processing zones. Instruction data are respectively set, the CRT semi-finished products are transported in the order of the flow number by the transport means, and the CRT semi-finished products are sequentially transferred from the transport means to the corresponding processing means in different processing zones by the transfer means according to the production instruction data. And process the semi-finished cathode ray tube in accordance with the production instruction data by the processing means at the time indicated by the product code. Semi-finished CRTs with the same processing time are sequentially taken out of the processing means in different processing zones, and semi-finished CRTs with the same processing time are taken out in a first-in first-out order. The CRT semi-finished product obtained by processing the cathode ray tube semi-finished product which has been processed by taking out the CRT semi-finished product which has been taken out by first-in / out-out and sequentially transferred by the transfer means to the transport means and transported by the transport means according to the production instruction data is taken out The semi-finished cathode ray tube which is transferred to the corresponding processing means and processed by the transfer means is sequentially carried out in the order in which the semi-finished cathode ray tubes are processed by different processing zones.

(Function) In the present invention, a CRT semi-finished product is flown in accordance with the flow number of production instruction data, the CRT semi-finished product is sequentially guided to different processing zones in accordance with the production instruction data, and a process corresponding to the time indicated by the type code is performed in accordance with the production instruction data. Means, and sequentially processes the processed CRT semi-finished products from the processing means of the different processing zones to the transfer means by the transfer means, and further processes the CRT semi-finished products conveyed by the transfer means in accordance with the production instruction data. Are transferred to the corresponding processing means in this processing zone where the semi-finished cathode ray tubes with the same processing time are first-in first-out, and the semi-finished cathode ray tubes with the long processing time are first-in / first-out, so that the processing means is efficiently processed. And take out processed semi-finished cathode ray tubes from sequentially different processing zones The order of the processed CRT semi-finished products carried out by the transport means is sequentially processed in different processing zones, thereby improving the processing efficiency of the CRT semi-finished products.

(Example) Hereinafter, a production process of a CRT according to an example of the present invention will be described with reference to the drawings.

This production process of a CRT shows a case where a CRT panel as a semi-finished CRT is exposed as a manufacturing process.

In FIG. 1, reference numeral 11 denotes an outlet of an upstream process from which a panel PM as a cathode ray tube semi-finished product to be processed is sequentially conveyed from the upstream process. This panel
PM has a photosensitive agent applied to the inner surface and a shadow mask mounted inside. Reference numeral 12 denotes a rejector. When the panel PM conveyed to the outlet 11 of the upstream process is abnormal, the rejector 12 removes the abnormal panel PM. Further, in the exposure process, the gombar 13 as a transporting means for sequentially transporting the panel PM is provided at the starting end position P3 and at the exit of the upstream process.
A transfer mechanism 14 is provided between the transfer mechanism 11 and the transfer mechanism 11. This transfer mechanism
Reference numeral 14 denotes a transfer robot 14a which is an articulated robot provided with a panel transfer unit, and a transfer unit 14b which moves the transfer robot 14a vertically at a high speed. That is, in the transfer mechanism 14, the moving portion 14b is moved to the loading position P.
Then, the transfer robot 14a holds the panel PM at the exit 11 by the transfer robot 14a, and then the moving unit 14b moves to the unloading position P2, and the panel moves to the start position P3 of the conveyor 13.
Transfer the PM.

Along the conveyor 13, a plurality of, for example, two processing zones A and B are provided beside the conveyor 13, and each of the processing zones A and B is provided as at least one or more processing means. Six exposure tables a-f, g-
and transfer mechanisms 15 and 16 as transfer means between the exposure tables a to f and g to l and the conveyor 13. These transfer mechanisms 15 and 16 can be moved in the vertical direction to position the transfer robots 15a and 16a and the transfer robots 15a and 16a at the loading positions for the corresponding exposure tables a to f and gl. It is composed of moving parts 15b and 16b. That is, these transfer mechanisms 15 and 16 are
When the panel PM reaches the loading position P4 or the loading position P6, the transfer robot 15a, 16a holds the panel PM, and the panel PM is exposed to the exposure table a to f or the exposure table g specified by the moving unit 15b, 16b. To the position opposite to any one of the
Loading. Conversely, for the exposed panel PM, the panel robot on the corresponding exposure table is held by the transfer robots 15a and 16a, and
The PM is moved near the conveyor 13 by the moving units 15b and 16b, and is unloaded onto the unloading position P5 or the unloading position P7 on the conveyor 13. The unloaded panel PM is carried out to the next process from the terminal position P8 which is the terminal of the conveyor 13.

17 is a control device that controls the entire system.
Controls the rejector 12, the transfer mechanisms 14, 15, 16 and the conveyor 13 according to the production instruction pattern shown in the following table.

The production instruction pattern in this table is production instruction data that determines the order of loading panels, which are semi-finished cathode ray tubes,
This is data for producing data in a method of repeatedly inputting the data Nos. To 12 in order, that is, instructing production. And
These data are attached to each panel, which is a semi-finished product, and this panel and the data corresponding to this panel are managed by the control device 17.

That is, as production instruction data, for each panel to be sequentially processed, a flow number D1, a type code D2 representing a panel size or the like corresponding to the flow number D1, and one of the flow numbers D1 And logical processing numbers D3 representing the exposure tables a to f and g to l to be used in the processing zones A and B of FIG.

The production instruction data shown in the table indicates that the flow number D1 is N
The manufacturing of the panel of o.1 shall be performed under the manufacturing conditions specified by No.1 of the product code D2, and the exposure table indicated by No.1 of the logical processing number D3 shall be used. " . Hereinafter, each data will be described.

Further, the total number of flow numbers D1 is data for determining the minimum cycle of the pannel flow method, and the contents of D1 from 1 to n may be represented by continuous numerical values. That is, the data indicates the manufacturing and control data of each panel.

The numerical value n may be the number of exposure tables that are always used. In this embodiment, since 12 exposure tables are arranged, n = 12.

The product code D2 encodes the product name of the color cathode ray tube, and is used as a control code number throughout the color cathode ray tube production line. Data such as cathode ray tube manufacturing conditions, semi-finished panel sizes, and equipment series corresponding to the unit code D2 are registered.

Further, the logical processing number D3 is set for each of the arranged exposure units, and the type of the exposure unit of any one of the processing zones A and B to be used by the panel of the manufacturing condition of the product code D2 is set. , And is determined by the logical processing number D3. That is, it is a data number for representing each of the exposure units.

Note that the logical processing number D3 is, for convenience of the sink method,
The process of forming a black stripe, and blue, green,
It is provided for each process of forming each red phosphor layer. In addition, the logical processing number D3 may be one or plural depending on the contents of the system.

Then, when specifying the exposure table to be used, one of the processing zones A and B is specified based on the flow number D1.
For example, if the flow number D1 is odd, the processing zone A
If the flow number D1 is even, the processing number is divided into processing zones B. In this way, one of the processing zones A and B is determined corresponding to the flow number D1.

By the way, recent market demands for color cathode-ray tubes tend to be orders of small lots of various kinds, and in order to respond to this, it is necessary to increase the number of kinds produced by simultaneous production. That is, it is necessary to increase the number of exposure units that are always used, and for this purpose, it is necessary to automatically control the number of exposure units used according to the production schedule. In this case, the exposure cycle time of the color cathode ray tube differs depending on the product, and the cycle time may not be constant. In the case of simultaneous production of products having different exposure cycle times as described above, the exposure cycle time of the product having the largest exposure cycle time is usually determined. In this case, the number of exposure units used is wasted. In order to eliminate this waste, a combined production system of an exposure cycle is required.

When creating such a production method incorporating a plurality of different exposure cycle times in 12 patterns, products with an exposure cycle time of 4 use the same exposure table,
The production cycle time, which is the standard unit of production, is
12 can produce 3 products. That is, a single exposure table can produce a product with the same exposure cycle time, and other exposure tables can be allocated to other products, thereby reducing the number of exposure tables.

For example, when the exposure cycle time is 6, it is possible to arrange six exposure stages and determine six production instruction patterns. However, in order to provide flexibility to the system, 12 exposure stages are arranged and 12 exposure stages are arranged. A production instruction method based on a pattern production instruction pattern is adopted. The production instruction data in this case is shown in the table.

Then, the panel is exposed based on the production instruction data according to the production instruction pattern shown in the table.

In FIG. 1, the panel PM flows from the upstream and the number D1
When sent in order, the logical processing number D3 corresponding to the panel PM is checked from the information data of the panel PM. If an abnormal panel is found, the panel is rejected without performing the transfer operation. In this case, the transfer mechanism 14 moves the moving unit 14b backward and returns to the unloading position P2 at the facility origin. The panel flow is
At first, the flow regularly is 1-2-3-4-5..., But this flow becomes an unpredictable data flow due to abnormal stop or the like. For this reason, it is necessary to check the interval of the exposure cycle at the entrance of the exposure system, and check the abnormal panel according to the logical processing number D3.

If the panel PM is a normal panel, the panel PM is transferred from the upstream process by the transfer robot 14a of the transfer mechanism 14,
It is transferred onto the start position P3 of the conveyor 13. Conveyor 13
Transports the pre-exposure panel and the exposed panel,
Operates once per cycle time.

The panel before exposure is conveyed by this conveyor 13,
Transfer to processing zone A is loading position of conveyor 13
When P4 is reached, the transfer mechanism 15 in the processing zone A operates to transfer the panel to any of the corresponding exposure tables a to f. Further, the transfer of the panel to the processing zone B is performed from the loading position P6 of the conveyor 13 to any of the corresponding exposure tables g to l by the transfer mechanism 16.

In transferring the panel, the control unit 17 located above the transfer mechanism 15 receives the production instruction data D1, D2, D3, etc. corresponding to the panel each time, and processes the zones A, B based on the data. Is selected, and each panel to be subsequently fed is alternately guided to different processing zones A and B, and transferred to the corresponding exposure table. And two groups of processing zones A and B
To expose the panel.

In the processing zone A, the exposed panel is transferred by the transfer mechanism 15 from the corresponding exposure table to the unloading position P5 of the conveyor 13. In the processing zone B, the wafer is transferred from the corresponding exposure table to the unloading position P7 of the conveyor 13 by the transfer mechanism 16.

Further, the transfer mechanisms 15 and 16 are configured such that the transfer robots 15a and 16a move the loading positions P4 and P6 on the conveyor 13 respectively.
The cycle from the transfer of the panel to the exposure tables a to f and gl by the moving units 15b and 16b to the unloading or preparation for the next operation from the next exposure table is defined as one cycle time. Therefore, processing zones A and B
The panel loading operation is performed once per cycle time, that is, once per cycle time, and the unloading operation is performed in the next one cycle time.

Then, in taking out the panel onto the conveyor 13, the processed panels are alternately transferred from the different processing zones A and B onto the conveyor 13, and the panels processed by the conveyor 13 are sequentially subjected to different processing. Unload in the order processed by zones A and B. In this case, within the same processing zone A or processing zone B, panels having the same exposure cycle time are taken out in a first-in first-out order. It becomes a jump. However, in each case, sequentially different processing zones A,
By taking out the processed panels alternately from B, the processing in each of the processing zones A and B can be efficiently performed.

For the control as described above, for example, the control system is configured so that the processing zone A handles odd data of the flow number D1 and the processing zone B handles even data. For this reason, it is necessary to detect the flow abnormality of the flow number D1.

Here, in the upstream process which is the entrance of this production line,
The first flow of the flow number D1 is regularly indicated by the control device of the process, and is, for example, a repetition of a numerical value of 1 to 12. Therefore, the flow coming out of the outlet 11 of the upstream process flows regularly as 1-2-3-4-5..., The loading position P1, the unloading position P2 of the transfer mechanism 14, and the starting end position of the conveyor 13. P3, transfer mechanism 15
Up to the loading position P4.

On the other hand, when panels with different exposure cycles are simultaneously produced simultaneously, unloading from the exposure table as well as the exposure cycle interval may have the same timing as other panels and panel information data indicated by the logical processing number D3. is there. This is due to the characteristics of the phosphor screen formation process.
This is because when at least one exposure system is installed, the panel of the upstream exposure system and its panel information data are passed over the panel having a long exposure cycle to the downstream process.

However, due to the combined production method using different exposure cycle times in the processing zones A and B, abnormal stop of the equipment, and the like, a sequence of odd-numbered / even-numbered data that is not regularly repeated occurs. For example, if the flow of data D1 is 1
Should come to the exposure system in a regular flow such as -2-3 ..., but in the case of 1-φ-2-3 ..., the processing zone A corresponds to odd numbers and the processing zone B corresponds to even numbers. Therefore, this data arrangement is regarded as violation data.
Therefore, the panel flow is returned to normal by automatic processing such as shifting the unloading timing in the processing zones A and B.

In other words, the flow of the flow number D1 is 1 as described above.
In the case of -φ-2-3, if an odd number of flow numbers φ continue, the panel is regarded as a violation panel and is returned to normal by the following processing.

 Timing 1 is loaded into zone A.

Timing of φ = timing of loading to zone B, but no loading operation.

 Timing 2 is loaded into the B zone.

According to this flow, the unloading timing of the other exposed panel and the loading timing of the flow number No. 2 interfere at the timing of the flow number No. 2 in the B zone, so the unloading operation at this timing Is stopped, the unloading operation is performed after the next production cycle time, and the flow is returned to normal.

In this case, an abnormal stop of the equipment or a reject operation on the panel does not occur. In addition, when an abnormality occurs, for example, when the exposure table cannot be used, an unassigned exposure table is temporarily used to maintain a normal panel flow.

Next, the exposed panel unloaded on the conveyor 13 is transported to the terminal position P8, where it is transferred by a panel transfer machine in a downstream process (not shown), and is processed in the next process. At this time, the panel information data is also passed to the control device that controls the downstream process.

The input of the panel and the panel information data corresponding to the panel to the cathode ray tube production system is performed by extracting information data for one panel from the production instruction pattern shown in the table, In this method, the panel is paid out to the production line, and the panel information data is also transmitted to the lower-level control device as shown in FIG. Also, when an index is added to each panel, the panel data shift is necessary.

As such a control system, for example, a three-layer configuration as shown in FIG. 2 may be adopted. In FIG. 2, a group-level CPU is a control CPU of a lower-level block CPU group, and a block-level CPU is a lower-level local CP.
The U group of control CPUs, and the local level CPU is a production control CPU of each facility.

In addition, the group CPU is the entrance of the process that each block CPU is in charge of controlling, and the panel data that is a semi-finished product is
Pass to U. The block CPU passes the panel data to the local CPU responsible for the equipment. This data is shifted together at the determined timing between the three levels of CPUs,
The data shifts as the panel moves.

This data is available at each facility and process exit at the lower CP
It is passed from U to the upper CPU. At this time, each CPU collates the data shifted by itself with the data received from the lower CPU, and uses a data check method that verifies the consistency between the panel and the data once per production cycle. Has adopted.

Here, in order to avoid data shift, use a multitasking real-time monitor based on time devised mainly for equipment control, data shift is all other processing,
For example, priority is given to timer interrupt or emergency stop interrupt, etc., and a data shift control time zone having a high safety factor from a macro perspective is set.

Generally, data skew is mostly due to secondary factors,
In this case, the shift is eliminated by adjusting the data to the CPU corresponding to the panel.

In addition, a monitoring device for searching and displaying the exposure system so as to be visible is provided. Here, in the case of the first-in first-out method, since the interval at which the pre-exposure panel is loaded onto the exposure table is equal to or longer than the exposure cycle, the collision of the panel can be avoided. Can respond to.

Further, if an abnormal stop of the equipment occurs due to an equipment abnormality or the like in the upstream process, the flow order of the panel and the panel information data becomes more irregular, and the flow becomes unpredictable in a human system. Therefore, a problem occurs for troubleshooting or the like.

For these reasons, not only the panel information data of the exposure system itself but also the panel information data of the preceding and succeeding processes can be searched and displayed for a considerable amount of time in real time.

Such real-time search display of panel information data is important in a production system that handles complicated data. In this system, since the exposure cycle and the flow of the panel are sequentially monitored based on the exposure table, it is possible to construct a production system with a high automation level.

In the above embodiment, the exposure processing of the panel has been described, but the present invention can be similarly applied to, for example, an anti-doming processing step.

〔The invention's effect〕

According to the present invention, a plurality of processing means which can be used simultaneously are provided, and the CRT semi-finished products are processed by the corresponding processing means at the time indicated by the type code for each type, and the CRT semi-finished products having the same processing time are first-in first-out by the processing means. Semi-finished cathode ray tubes with a long processing time are first-in, first-out by processing means, and the use of processing means is made more efficient, and by sequentially processing in different processing zones, semi-finished cathode ray tubes such as panels are efficiently processed. , The simultaneous mixed production level can be increased, and the multi-product small-lot productivity can be increased.

[Brief description of the drawings]

FIG. 1 is a plan view showing an embodiment of a cathode ray tube processing method according to the present invention, and FIG. 2 is a system configuration diagram showing a hierarchical configuration of a control system used in the present invention. 13 ... Conveyor as transport means, 15, 16 ... Transfer mechanism as transfer means, a ~ ... Exposure table as processing means, A, B ... Processing zone, PM ... Semi-finished cathode ray tube Panel.

──────────────────────────────────────────────────続 き Continued on the front page (58) Field surveyed (Int.Cl. ⁷ , DB name) H01J 9/227 H01J 9/48

Claims (1)

(57) [Claims] 1. A transport means for sequentially transporting semi-finished cathode ray tubes, a plurality of processing zones arranged along the transport means and having a plurality of processing means; Transfer means for transferring semi-finished cathode ray tubes between the means and the transporting means, and for each semi-finished cathode ray tube to be sequentially processed, includes a flow number and at least a time defined corresponding to the flow number. Production instruction data having a type code representing a manufacturing condition and a logical processing number defined corresponding to the flow number and representing a processing means to be used in any of the processing zones is set, and each CRT is set by the transporting means. The semi-finished products are transported in the order of the flow number, and the CRT semi-finished products are sequentially changed by the transfer means from the transport means according to the production instruction data. The CRT semi-finished product is transferred to the corresponding processing means in the processing zone, and the CRT semi-finished product is processed in accordance with the production instruction data at the time indicated by the product code in the above-mentioned processing step. , Semi-finished cathode ray tubes with the same processing time are taken out in the first-in first-out order, semi-finished cathode ray tubes with different processing times are taken out of the semi-finished cathode ray tube with the longer processing time in the first-in / first-out order and sequentially transferred to the transport means. The CRT semi-finished product transferred by the transport means in accordance with the production instruction data is transferred to the corresponding processing means of the processing zone from which the processed CRT semi-finished product is taken out, and processed by the transport means. Characterized in that semi-finished CRT tubes are unloaded in the order in which they are sequentially processed by different processing zones. The method of production down tube.