Inside Hisense's Ultra-Automated TV Factory: AI, Robotics, and Mini-LED Tech

Advanced Automation in TV Manufacturing

• 🚀 The Hisense TV factory showcases a highly automated production line with seven first-of-their-kind machines, a third assisted by AI/ML, and over 70% overall automation.
• 💡 Automation is driven by the need to improve quality and reduce defects, especially with increasingly large TV panels, leading to over a 90% reduction in back panel deformation defects.
• 🤖 AI and machine learning are employed for tasks like automated glue dispensing for LED light bars, optimizing flow rates and pressure for 9% glue savings.
• ⚙️ Advanced systems include automated primer coating machines that use machine vision and AI to adjust for 58% primer consumption reduction and fewer defects.

Panel Assembly and Quality Control

• ✨ Automated spring-loaded applicators ensure even application of reflective films for backlight uniformity, reducing dark spots.
• 🔍 Machine vision and AI analyze backlight uniformity, replacing subjective human inspection for significantly improved accuracy.
• 🧩 The panel assembly process is now highly automated, with robots achieving better than 0.02 mm precision, a critical improvement for large modern TV panels.
• 🛠️ Robots are used for affixing front bezels with screws, contributing to a 44% reduction in defects at this stage.

Core Component Integration and Testing

• 🧠 Mainboards and power supplies are installed, with robots handling screw placement, improving efficiency and reducing defects.
• 🔊 While speaker placement is currently a manual step due to robot maintenance, Hisense is researching automation for this process.
• 🔌 Cable and wiring harness installation is still a manual step requiring multiple people, though automation research is ongoing.
• ✅ Internal inspection is enhanced by AI/ML capabilities to detect errors, with human intervention for fixes.
• 🔥 Every panel undergoes a 10-minute burn-in on the line to catch early failures before full Quality Assurance.

QA, Packaging, and R&D

• 🎯 Quality Assurance utilizes precision 3D machine vision and an 8-axis robot with force control for thorough testing.
• 📦 Automated packaging systems handle the wrapping, padding, and boxing of TVs, significantly reducing manual labor for heavy consumer electronics.
• 🚚 Autonomous vehicles are used to supply materials like screws and connectors to workstations, optimizing supply chain efficiency.
• 💡 The R&D center explores cutting-edge technologies like RGB Mini-LED backlight technology, which offers superior color saturation and brightness for HDR content.
• 🌍 Hisense highlights its goal of becoming a world-class provider of multi-scenario display solutions and its commitment to constructing China's first zero-carbon factory.