LED参数测量及其质量控制的研究与应用
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摘要
LED参数测量和质量控制是LED封装产业中重要的环节,在应用领域内,大功率LED光源在汽车车灯上的应用是将来的必然趋势。LED的封装产业和应用领域中,存在一些难以解决的问题：如何对LED测量系统中的关键量具进行分析?如何实现在线准确测量LED的参数?如何对LED关键参数的测量过程进行质量控制?如何分析和解决大功率LED在车灯中的散热?
本文根据最小二乘法对LED光谱测试仪的测量系统进行了研究；利用质量控制图分别对LED的主波长和光强的测量过程做质量做分析；设计了LED参数高精度在线自动测量程序；用ANSYS软件对大功率LED车灯腔体的热耦合做了分析。主要研究工作如下：
1.提出基于最小二乘法的光谱测试仪中像位—峰值波长线性回归方程的系数求解法。根据F检验法和t检验法分别对线性回归方程做显著性检验,证明了像位—峰值波长线性回归方程的可靠实用；利用方差分析法对光谱测试仪的测量能力进行有效评估,结果显示光谱测试仪有稳定的测量能力。
2.对LED主波长测量过程做质量控制图分析。设计了LED主波长测试方法框架图,分析了色度学参数的测量过程；对LED主波长测量过程分别用休哈特控制图和EWMA控制图进行分析,给出小偏移数据质量控制的正确分析方法。
3.提出了趋势控制图对光强的测量过程进行质量控制。针对测试过程中的光强质量水平远好于可接受的质量水平时,提出应用平滑系数Bayes控制法可避免将合格的产品误判为不合格。根据样品均值趋势控制法,分析了光强测试过程中的误差源,并对LED光强测量系统提出改进措施。
4.设计了LED参数在线自动测量程序。全面分析了LED参数的测量过程,设计了参数相应的LabVIEW子程序模块。提出的基于斜率单调递减的色度图四分区法,提高了测量LED参数的速度；提出的查表法,提高了LED参数的测量精度。
5.设计了LED车灯的散热装置三维模型,并以此模型用ANSYS软件进行了LED车灯腔体在无任何散热装置、风扇散热、翅片散热器、翅片和风扇组合四种情况下的热耦合分析。
LED industrial chain is mainly composed of chip research, packaging industry and its application. The measurement of LED Parameter and its quality control are very important for LED packaging industry. For LED application. it is the inevitable trend in the future that the power LEDs is applied to the car lamps. But there are still many technical problems existed in LED packaging industry and its application:how to analyze the key measuring implements in LED measurement system, how to measure accurately LED Parameter on-line, how to control the qualities of LED key Parameter, how to analyze and solve heat dissipation of power LEDs in the car lamps.
According to the least square method, the measurement system of LED spectrometer is researched. The measurement process of LED dominant wavelengths and intensities are analyzed by means of the quality control charts. On-line automatic measuring program with high-precision for LED Parameter is designed. Based on ANSYS software, thermal coupling in power LED lamps is analyzed. The main research works are as follows.
1. By means of least square method, the coefficients of linear regression equation for the spectrometer phases and peak wavelengths are solved. According to the F-test and t-test, the significance of the linear regression equation is tested and the results verify the linear regression equation reliable and practical. By means of square difference analysis, the measurement capability of the spectrometer is effectively evaluated and the results verify that its measurement capability is stable.
2. The measurement process of LED dominant wavelengths is analyzed by means of the quality control chart. The measurement framework of LED dominant wavelengths is designed, and the test process of the colorimetric parameter is analyzed totally. The measurement process of LED dominant wavelengths are analyzed according to Shewhart control chart and the EWMA (Exponentially Weighted Moving Average) control chart, and the correct analysis method for small offset data in the quality control is pointed.
3. For the measured data of LED intensities, the smoothed-factor Bayes control method is presented to control the LED quality. The measurement characteristics and methods are analyzed for LED intensities. When LED intensity quality data in the test process are much better than the acceptable quality level, Smoothed-Factor Bayes Control Method can be recommended to avoid good products to be distinguished unqualified products. According to the trend analysis for sample mean values, the error sources in LED intensity test process are analyzed, and the improvement measures are proposed for LED intensity measurement system.
4. On-line automatic measurement program for LED Parameter is designed. Total measurement process of LED Parameter is comprehensively analyzed, and based on LabVIEW, the corresponding modules for subprograms are also designed. In order to improve measurement speeds of LED Parameter, the chromaticity diagram is presented to divide it into4different regions according to the slopes monotonic decreasing. And in order to improve its measurement accuracy, the looking-up table method is proposed.
5. The three-dimension model of heat-dissipation devices for LED lamps is designed. Based on ANSYS software, the thermal coupling in power LED car lamp is analyzed under four conditions such as non-heat-dissipation device, cooling fan, fin radiator, the device of fin radiator and cooling fan. As important references, the analysis results are very useful for heat dissipating arrangement design in power LED car lamp.
本文根据最小二乘法对LED光谱测试仪的测量系统进行了研究；利用质量控制图分别对LED的主波长和光强的测量过程做质量做分析；设计了LED参数高精度在线自动测量程序；用ANSYS软件对大功率LED车灯腔体的热耦合做了分析。主要研究工作如下：
1.提出基于最小二乘法的光谱测试仪中像位—峰值波长线性回归方程的系数求解法。根据F检验法和t检验法分别对线性回归方程做显著性检验,证明了像位—峰值波长线性回归方程的可靠实用；利用方差分析法对光谱测试仪的测量能力进行有效评估,结果显示光谱测试仪有稳定的测量能力。
2.对LED主波长测量过程做质量控制图分析。设计了LED主波长测试方法框架图,分析了色度学参数的测量过程；对LED主波长测量过程分别用休哈特控制图和EWMA控制图进行分析,给出小偏移数据质量控制的正确分析方法。
3.提出了趋势控制图对光强的测量过程进行质量控制。针对测试过程中的光强质量水平远好于可接受的质量水平时,提出应用平滑系数Bayes控制法可避免将合格的产品误判为不合格。根据样品均值趋势控制法,分析了光强测试过程中的误差源,并对LED光强测量系统提出改进措施。
4.设计了LED参数在线自动测量程序。全面分析了LED参数的测量过程,设计了参数相应的LabVIEW子程序模块。提出的基于斜率单调递减的色度图四分区法,提高了测量LED参数的速度；提出的查表法,提高了LED参数的测量精度。
5.设计了LED车灯的散热装置三维模型,并以此模型用ANSYS软件进行了LED车灯腔体在无任何散热装置、风扇散热、翅片散热器、翅片和风扇组合四种情况下的热耦合分析。
LED industrial chain is mainly composed of chip research, packaging industry and its application. The measurement of LED Parameter and its quality control are very important for LED packaging industry. For LED application. it is the inevitable trend in the future that the power LEDs is applied to the car lamps. But there are still many technical problems existed in LED packaging industry and its application:how to analyze the key measuring implements in LED measurement system, how to measure accurately LED Parameter on-line, how to control the qualities of LED key Parameter, how to analyze and solve heat dissipation of power LEDs in the car lamps.
According to the least square method, the measurement system of LED spectrometer is researched. The measurement process of LED dominant wavelengths and intensities are analyzed by means of the quality control charts. On-line automatic measuring program with high-precision for LED Parameter is designed. Based on ANSYS software, thermal coupling in power LED lamps is analyzed. The main research works are as follows.
1. By means of least square method, the coefficients of linear regression equation for the spectrometer phases and peak wavelengths are solved. According to the F-test and t-test, the significance of the linear regression equation is tested and the results verify the linear regression equation reliable and practical. By means of square difference analysis, the measurement capability of the spectrometer is effectively evaluated and the results verify that its measurement capability is stable.
2. The measurement process of LED dominant wavelengths is analyzed by means of the quality control chart. The measurement framework of LED dominant wavelengths is designed, and the test process of the colorimetric parameter is analyzed totally. The measurement process of LED dominant wavelengths are analyzed according to Shewhart control chart and the EWMA (Exponentially Weighted Moving Average) control chart, and the correct analysis method for small offset data in the quality control is pointed.
3. For the measured data of LED intensities, the smoothed-factor Bayes control method is presented to control the LED quality. The measurement characteristics and methods are analyzed for LED intensities. When LED intensity quality data in the test process are much better than the acceptable quality level, Smoothed-Factor Bayes Control Method can be recommended to avoid good products to be distinguished unqualified products. According to the trend analysis for sample mean values, the error sources in LED intensity test process are analyzed, and the improvement measures are proposed for LED intensity measurement system.
4. On-line automatic measurement program for LED Parameter is designed. Total measurement process of LED Parameter is comprehensively analyzed, and based on LabVIEW, the corresponding modules for subprograms are also designed. In order to improve measurement speeds of LED Parameter, the chromaticity diagram is presented to divide it into4different regions according to the slopes monotonic decreasing. And in order to improve its measurement accuracy, the looking-up table method is proposed.
5. The three-dimension model of heat-dissipation devices for LED lamps is designed. Based on ANSYS software, the thermal coupling in power LED car lamp is analyzed under four conditions such as non-heat-dissipation device, cooling fan, fin radiator, the device of fin radiator and cooling fan. As important references, the analysis results are very useful for heat dissipating arrangement design in power LED car lamp.
引文
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