Abstract:
Methods and apparatus implementing a technique for assembling a device, such as a digital convergence monitor, at more than one site where data is supplied from a first site to a second site and then the data is used in assembly of the device at the second site. In one implementation, a method for assembling a device at more than one manufacturing site includes: at least partially assembling a device at a first manufacturing site; adjusting the device at the first manufacturing site, where the adjustment is recorded in data; sending the data from the first manufacturing site to a second manufacturing site; assembling the device at the second manufacturing site; storing the data in the device; and adjusting the device at the second manufacturing site, where the adjustment at the second manufacturing site is recorded in the data.

Description:
This application claims the benefit of U.S. Provisional Patent Application No. 60/132,035, filed Apr. 30, 1999. 
    
    
     BACKGROUND 
     The present disclosure relates to distributed or remote manufacturing at multiple sites, and more specifically to manufacturing and assembling a device, such as a digital convergence monitor, at multiple sites and providing information from one site to another. 
     In a conventional process for manufacturing a cathode ray tube (“CRT”) monitor, an integrated tube component (“ITC”) is assembled. The ITC includes a CRT, a deflection yoke (“DY”), and typically one or more magnets or permalloy components. The construction and operation of CRTs and DYs are well known in the art. In manufacturing, the DY is mounted on the CRT. The location where an electron strikes the front panel of the CRT is referred to as “landing position.” For desirable performance of the monitor and image quality, electrons in the CRT should have landing positions within defined locations or regions, such as phosphor stripes on the front panel of the CRT. The position of the DY is adjusted, as needed, to adjust the landing position of electrons in the CRT. The DY is then fixed in place on the CRT. 
     In addition to striking desired locations in the CRT, electrons should strike at desired times to provide unified dots of color in the image. When the electrons forming the colors of a dot do not strike the phosphor of the panel within the correct time frames, the colors may not blend properly resulting in a undesirable image. This timing problem is referred to as “misconvergence.” Timing synchronization is referred to as “convergence.” Proper convergence provides a desirable image. Accordingly, magnets can be applied to the CRT, ,as needed, to adjust convergence in the CRT. In another process, convergence circuitry in the CRT-DY assembly can be employed to adjust convergence using internal data register control. While convergence can be controlled by the CRT-DY assembly, there may be differences between specific CRT-DY assemblies in their performance relative to specified tolerances. For example, variations in material composition or component construction may cause these differences. The above techniques can be used to compensate,for these differences and correct the convergence of the monitor. 
     SUMMARY 
     The present disclosure describes methods and apparatus implementing a technique for assembling a device, such as a digital convergence monitor, at more than one site where data is supplied from a first site to a second site and then the data is used in assembly of the device at the second site. In one implementation, a method for assembling a device at more than one manufacturing site includes: at least partially assembling a device at a first manufacturing site; adjusting the device at the first manufacturing site, where the adjustment is recorded in data; sending the data from the first manufacturing site to a second manufacturing site; assembling the device at the second manufacturing site; storing the data in the device; and adjusting the device at the second manufacturing site, where the adjustment at the second manufacturing site is recorded in the data. 
     In another implementation, the method for assembling a device at more than one manufacturing site further includes: sending the data from the second manufacturing site to the first manufacturing site; comparing the data recording the adjustment at the first manufacturing site with the data recording the adjustment at the second manufacturing site; and adjusting equipment at the first manufacturing site based on one or more differences between the data recording the adjustment at the first manufacturing site and the data recording the adjustment at the second manufacturing site. 
     In another implementation, a method for assembling a digital convergence monitor at more than one manufacturing site includes: mounting a deflection yoke on a cathode ray tube forming a CRT-DY assembly at a first manufacturing site; measuring landing position in the cathode ray tube; moving the deflection yoke on the cathode ray tube as needed to correct the landing position; fixing the deflection yoke in place on the cathode ray tube; uniquely marking the cathode ray tube with an identification code; placing the CRT-DY assembly in an ITC jig, where the ITC jig includes a memory and the memory of the ITC jig is connected to the deflection yoke; storing control data in the memory of the ITC jig, where the control data is for controlling operation of the deflection yoke; measuring performance of the CRT-DY assembly in the ITC jig, including measuring convergence and distortion in the CRT-DY assembly; adjusting the control data stored in the memory of the ITC jig as needed to correct performance of the CRT-DY assembly, generating revised control data; removing the CRT-DY assembly from the ITC jig; sending the revised control data from the first manufacturing site to a network server, where the network server is accessible from the first manufacturing site and from a second manufacturing site; sending the revised control data from the network server to the second manufacturing site; receiving the CRT-DY assembly at the second manufacturing site; mounting the CRT-DY assembly in a digital chassis forming the digitial convergence monitor, where the digital chassis includes a memory and the memory of the digital chassis is connected to the deflection yoke; retrieving the revised control data from the memory at the second manufacturing site, where the identification code of the retrieved revised control data matches the identification code of the received CRT-DY assembly; storing the retrieved revised control data in the memory of the digital chassis; measuring performance of the digital convergence monitor, including measuring convergence and distortion in the digital convergence monitor; and adjusting the revised control data stored in the memory of the digital chassis as needed to correct performance of the digital convergence monitor, generating final control data. 
     In another implemention, the method for assembling a digital convergence monitor at more than one manufacturing site further includes: reading out the final control data stored in the memory of the digital chassis; storing the final control data in memory at the second manufacturing site; sending the revised control data from the second manufacturing site to the network server; sending the revised control data from the network server to the first manufacturing site; retrieving the revised control data from the memory at the first manufacturing site, where the identification code of the retrieved revised control data matches the identification code of the final control data received from the second manufacturing site; and comparing the final control data with the retrieved revised control data at the first manufacturing site. 
     In another implementation, a system for assembling a device at more than one manufacturing site includes: a network server; a first manufacturing site, where the first manufacturing site comprises: first assembly equipment for mounting a deflection yoke on a cathode ray tube, forming a CRT-DY assembly; first measurement equipment for measuring landing position, convegence, and distortion in the CRT-DY assembly; first adjustment equipment for adjusting control data which affects the operation of the deflection yoke; a first data connection connected to the first adjustmnet equipment and the network server; and a second manufacturing site, where the second manufacturing site comprises: second assembly equipment for mounting the CRT-DY assembly in a digital chassis, forming a digital convergence monitor; second measurement equipment for measuring landing position, convegence, and distortion in the digital convergence monitor; second adjustment equipment for adjusting control data which affects the operation of the deflection yoke; a second data connection connected to the second adjustment equipment and the network server, where control data is sent from the first manufacturing site to the second manufacturing site through the network server and the received control data is supplied to the digital convergence monitor. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 shows a distributed manufacturing system. 
     FIG. 2A shows a cathode ray tube-deflection yoke (CRT-DY) assembly. 
     FIG. 2B shows a digital convergence monitor (DCM). 
     FIGS. 3A and 3B show a flowchart of a process for assembling a DCM. 
     FIG. 4 shows a flowchart of a process for providing feedback from a second site to a first site after the process in FIG.  3 . 
     FIG. 5 shows a flowchart of a process for assembling a device, such as a DCM or other device, at two sites where data is supplied from the first site to the second site and then the data is used to complete assembly of the device at the second site. 
     FIG. 6 shows a flowchart of a process for providing feedback from a second site to a first site after the process in FIG.  5 . 
    
    
     DETAILED DESCRIPTION 
     The present disclosure describes methods and apparatus for assembling a device at more than one site where data is supplied from a first site to a second site and then the data is used to complete assembly of the device. FIG. 1 shows a system configuration of sites and a data connection. In one implementation, the device is a digital convergence monitor (“DCM”) and the data is control data for a deflection yoke (“DY”) in the DCM. FIGS. 2A and 2B show components of a DCM. FIGS. 3A and 3B show a process for assembling a DCM. 
     FIG. 1 shows a distributed manufacturing system  100 . Distributed manufacturing system  100  includes a first manufacturing site  105  and a second manufacturing site  110 . Site  105  supplies devices to site  110 . Site  105  can send devices to site  110  through various physical channels, such as by truck, plane, or ship. Site  105  and site  110  are also connected to a network server computer  115  through data connections  120  and  125 , respectively. Data connections  120  and  125  provide data between sites  105  and  110  and server  115 . Data connections  120  and  125  can be implemented in various ways, such as direct private connections to server  115  or Internet connections. For example, server  115  can be a file transfer protocol (“FTP”) server accessible from sites  105  and  110  across the Internet. As described below, data transfer can occur on demand or automatically, such as according to a regular schedule. Sites  105  and  110  include or have access to storage for data to be sent to and received from server  115 . This storage can then be accessible to equipment and work stations within the site, such as through an internal network. In addition, server  115  can be implemented as part of either site  105  or site  110 , in which case a single data connection between sites  105  and  110  can be sufficient. 
     FIG. 2A shows a CRT-DY assembly  200 . CRT-DY assembly  200  includes a cathode ray tube (“CRT”)  205  and a deflection yoke (“DY”)  210 . DY  210  is mounted on CRT  205 . Wedges (not shown) are inserted between CRT  205  and DY  210 , holding DY  210  in place. Alternative techniques can be used for holding DY  210  in place, such as an adhesive or clamps. 
     FIG. 2B shows a DCM  250 . DCM  250  includes CRT-DY assembly  200  mounted in a digital chassis  255 . Digital chassis  255  includes a circuit board  260  and a connection  265  from circuit board  260  to CRT-DY assembly  200 . Connection  265  can be implemented in various ways, such as a cable between circuit board  260  and DY  210  or a hard connection between DY  210  and digital chassis  255  where digital chassis  255  contacts DY  210 . Circuit board  260  includes an EEPROM  270  and control circuitry  275 . EEPROM  270  stores control data which is supplied to DY  210  through connection  265 . Control data adjusts the operation of DY  210  to correct convergence and distortion in the image provided by CRT-DY assembly  200 . In some DCMs, control data can also be used to correct landing position. Control circuitry  275  controls the operation of digital chassis  255 , including the supply of control data from EEPROM  270  to DY  210 . The operation of a DCM and the use of control data is well understood by those of ordinary skill in the art. 
     FIGS. 3A and 3B show a flowchart of a process  300  for assembling a DCM (FIG. 3A continues into FIG.  3 B). To describe process  300  more clearly, references to FIGS. 1,  2 A, and  2 B are used below. A CRT  205  and a DY  210  are built at a first manufacturing site  105 , step  305 . Alternatively, either or both of CRT  205  and DY  210  are built somewhere other than site  105  and then supplied to site  105 . DY  210  is mounted on CRT  205 , step  310 . The landing position of electrons in CRT  205  is measured, step  312 . The position of DY  210  on CRT  205  is adjusted, as necessary, to correct the landing position, step  315 . Correct landing position can be defined by a specified tolerance for landing position to provide a desirable image, such as a specification supplied by the manufacturer of the DCM (which may own some or all of distributed manufacturing system  100 , but, in any case, the party who determines “desirable” performance for the DCM). DY  210  is fixed in place on CRT  205 , such as by inserting wedges between DY  210  and CRT  205 , step  320 . By fixing DY  210  in place, the corrected landing position is preserved. CRT  205  is uniquely marked with an identification code, such as with a barcode, step  325 . Marking CRT  205  completes a CRT-DY assembly  200 . Alternatively, CRT  205  can be marked earlier in process  300  or prior to process  300 , such as during the manufacture of CRT  205 . In another alternative implementation, the marking is applied to DY  210  instead of, or in addition to, CRT  205 . 
     CRT-DY assembly  200  is mounted in an ITC jig, step  330 . ITC jig is a digital chassis (recall digital chassis  255  in FIG. 2B) which is used at site  105  for measurement and adjustment. ITC jig  255  is used for each CRT-DY assembly assembled at site  105 . Alternatively, multiple ITC jigs can be used. As shown in FIG. 2B, ITC jig  255  includes an EEPROM  270 . In mounting CRT-DY assembly  200  in ITC jig  255 , DY  210  is connected to circuit board  260  through connection  265 . Control data (“initial control data”) is supplied to and stored in EEPROM  270  of ITC jig  255 , step  335 . This control data is used to control DY  210 , as noted above. The initial control data is supplied to EEPROM  270  for each CRT-DY assembly placed in ITC jig  255 . The performance of CRT-DY assembly  200  in ITC jig  255  is compared to specified tolerances for convergence and distortion, step  340 . As with landing position, these specified tolerances can be provided by the DCM manufacturer. In addition, other aspects of performance can be measured at this time, such as brightness. The control data in EEPROM  270  is revised to bring CRT-DY assembly  200  performance within tolerance, step  345 . This revised control data reflects adjustments necessary to bring the particular CRT-DY assembly  200  within tolerance and may be different between CRT-DY assemblies. The revised control data is marked with the same marking as CRT-DY assembly  200 , to create a unique association between the revised control data and CRT-DY assembly  200 , step  347 . The association can be created earlier, such as when the initial control data is stored in EEPROM  270 , or later, such as when the revised control data is read out of EEPROM  270  using a separately stored record of the marking on CRT-DY assembly  200 . CRT-DY assembly  200  is removed from ITC jig  255 , step  350 , and sent to a second manufacturing site  110 , step  355 . 
     The marked revised control data in EEPROM  270  of ITC jig  255  is read out of EEPROM  270  and stored in local storage at site  105 , step  360 . The marked revised control data is sent from site  105  to a network server  115 , step  365 . The marked revised control data is then sent from network server  115  to site  110  and stored in local storage at site  110 , step  370 . The transmission from server  115  to site  110  can be at the request of site  110 , or can be automated through hardware or software, so can occur before or after the arrival of CRT-DY assembly  200  at site  110 . 
     At site  110 , CRT-DY assembly  200  is mounted in a digital chassis  255  forming a DCM  250 , step  375 . This digital chassis  255  is unique for CRT-DY assembly  200 , and will not be re-used for another CRT-DY assembly (unlike the ITC jig at site  105 , described above). Marked revised control data matching the marking on CRT-DY assembly  200  is retrieved from storage at site  110 , step  377 . The matching revised control data is stored in EEPROM  270  of digital chassis  255 , step  380 . The performance of DCM  250  is compared to specified tolerances for convergence and distortion, step  385 . As described above, the specifications can be supplied by the DCM manufacturer. If any changes are necessary, the control data in EEPROM  270  is modified to bring the performance within specified tolerances, step  390 . This final control data remains with DCM  250 , stored in EEPROM  270 . In one implementation, a DCM includes external controls, accessible by a consumer, which can be used to further modify the control data and adjust the performance of the DCM. DCM  250  is then packaged and shipped. Alternatively, external packaging can be provided later. 
     FIG. 4 shows a flowchart of a process  400  for providing feedback from the second site (site  110  in FIG. 1) to the first site (site  105  in FIG. 1) after step  390  of process  300  in FIG.  3 B. The final control data and the marking for the matching CRT-DY assembly are read out of EEPROM  270  and stored in site  110 , step  405 . The marked final control data is sent from site  110  to server  115 , step  410 , and then sent from server  115  to site  105 , step  415 . At site  105 , the marked revised control data (previously stored in step  360  of process  300 ) which matches the marking of the marked final control data is retrieved, step  420 , and the two sets of control data are compared, step  425 . Accordingly, the revised control data and final control data which correspond to the same CRT-DY assembly are compared. Variations between the two sets of data are identified and analyzed, and adjustments can be made to equipment or procedures based on those variations, step  430 . Variation between the two sets of data can indicate that the revised data did not actually place CRT-DY assembly  200  within specified tolerance. These variations can arise from faults within the adjustment equipment of site  105 . For example, the ITC jig is used repeatedly for many CRT-DY assemblies and so may gradually lose quality of performance due to wear. This loss may come from degraded connections or material in the circuit board. In another example, the measuring equipment at site  105  may need to be replaced or adjusted to conform with equipment at site  110 . Variations can also indicate problems in the transportation process between site  105  and site  110  which have lead to changes in performance of the CRT-DY assembly, such as shifting of the DY relative to the CRT. 
     FIGS. 2-4 illustrate implementations where the device is a DCM. FIG. 5 shows a flowchart of a process  500  for assembling a device, such as a DCM or other device, at two sites where data is supplied from the first site to the second site and then the data is used to complete assembly of the device at the second site. To describe process  500  more clearly, references to FIG. 1 are made below. The device is partially assembled at a first manufacturing site  105 , step  505 . The performance of the partially assembled device is measured and, if necessary, adjusted at site  105 , step  510 . The adjustment can be made to improve performance of the device or bring the performance of the device within a specified level of performance. The adjustment to the device is reflected in data associated with the device, such as data stored in memory included in or connected to the device (e.g., the control data in the EEPROM of the ITC jig, described above). In addition, the data is marked with an identification code to correspond to the specific partially assembled device. The data is sent to a network server  115 , step  515 . The data is then sent from the server  115  to a second manufacturing site  110 , step  520 . Alternatively, the data can be sent directly from site  105  to site  110 . The partially assembled device is sent to site  110  and additional components are added, step  525 . Alternatively, the device can be disassembled before being sent to site  110  and re-assembled at site  110 , with or without additional components. In another alternative, additional components are not added at site  110 , but the measurements performed at site  110  are different from those performed at site  105 . The data received at site  110  from site  105  which matches the device is stored in the device, step  530 . The performance of the device is measured and, if necessary, adjusted at site  110 , step  535 . The data is modified in accordance with the adjustment made. After the device has been adjusted, the device is complete. Alternatively, further processing or assembly is performed on the device at site  110  or at another site. 
     FIG. 6 shows a flowchart of a process  600  for providing feedback from the second site (site  110  in FIG. 1) to the first site (site  105  in FIG. 1) after step  535  of process  500  in FIG.  5 . The data reflecting the adjustment of step  535  is sent back from site  110  to server  115 , step  605 . The data is then sent from server  115  to site  105 , step  610 . The data from the adjustment in step  535  is compared with the data from the adjustment in step  510 , step  615 . The data are matched for comparison using markings on the device and stored within the data. Any variation between the data is used to adjust equipment or processes at site  105 . As described above, these variations may reflect faults in the system at site  105  which can be corrected through feedback from site  110 . 
     Various implementations have been described above. However, this description is illustrative and not limiting. Accordingly, additional implementations are possible. For example, control data can be stored in various locations, such as in storage at one of the sites or in remote storage accessible across a network. In another example, assembly can occur at more than two sites with data being transferred among some or all of the sites, or assembly can occur within a single site where data is transferred between locations within the site.