How to produce LED spherical screen?

The production process of an LED spherical screen involves several steps and considerations, ‌ including the design, ‌ production, ‌ installation and commissioning stages. ‌
​Design phase: ‌
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The designer first makes a detailed plan according to project requirements and specifications. ‌ determines the sphere diameter, ‌ resolution and pixel spacing (‌, for example, P2.5 represents 2.5mm pixel center spacing) ‌. ‌
Using flexible and bendable LED display modules as the basic building block, ‌ these modules are composed of densely arranged red, green and blue LED beads, ‌ capable of presenting rich colors and delicate images. ‌
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Production stage: ‌
​LED module after special cutting, ‌ folding and splicing process, ‌ according to the shape of spherical surface one by one assembly. ‌
In order to ensure the smooth and flawless surface of the sphere, ‌ technicians use customized connecting parts and curved brackets, ‌ to ensure seamless docking between modules, ‌ to form a continuous and uniform display interface. ‌
The built-in drive circuit, ‌ control board and power supply system also need to be designed and arranged accordingly, ‌ in order to achieve stable signal transmission and power supply. ‌
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Installation phase: ‌
​For spherical screens of different diameters, ‌ installation methods are different. ‌ small spherical screens are usually installed by lifting and mounting, ‌ and medium and large spherical screens may need to be lifted or fixed on the base, ‌ to ensure stability and load bearing. ‌
The medium-sized spherical screen needs to be divided into regions according to latitude and longitude, ‌ to produce the corresponding number of shaped modules, ‌ and site installation. ‌
Due to its large weight, ‌ is usually used to fix the base. ‌ shaped module is transported to the site for splice and installation after production in the factory. ‌
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Debugging phase: ‌
​Through professional calibration software for each LED pixel color, ‌ brightness consistency correction, ‌ to ensure the whole ball image quality balance. ‌
Develop or adopt an image processing algorithm suitable for spherical projection, ‌ makes two-dimensional video content accurately fit and transform on the sphere, ‌ presents distortion-free immersive visual effects. ‌

Different sizes of LED spherical screen, application and installation methods are different. Similarly, the production method of LED spherical screens of different diameters will also be different. The following are several ways to make LED spherical screens:
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For the small spherical screen with a diameter of 1 to 1.5 meters, it is usually used in the indoor field, and the P3 P2 small model product is used, which is suitable for close viewing needs. Hoisting and seat mounting are usually adopted. First of all, the spherical shell steel structure is made, and the flexible soft module is used. The magnetic magnet is installed on the shell steel structure until the whole sphere is covered and the spherical display surface is turned. Usually the finished product is shipped in the production workshop, and the site is directly adjusted and used.
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For a medium-sized spherical screen with a diameter of 1.5 to 6 meters, it is suitable for viewing needs at a moderate distance, and is usually hoisted. First of all, the shape of the steel structure, and then the sphere according to the latitude and longitude of the area, such as 8 lines of longitude, 6 lines of latitude, then the sphere is divided into 16×7=112 areas, to the corresponding production of 7 kinds of shaped modules, each module needs 16 pieces. It is then transported to the site with wooden cases for installation.

If the diameter of the large spherical screen is more than 6 meters, it is suitable for remote viewing, because the weight of the whole sphere is heavy, usually the base is fixed to ensure the load-bearing. The steel structure needs to be made at the project site, the special-shaped module is produced in the factory, numbered and packed, and transported to the site for spliced installation. The shape of the special-shaped module usually shows the shape of the outer arc triangle, the outer arc trapezoid, and the outer arc rectangle.

To sum up, ‌LED spherical screen production is a complex and fine process, ‌ involves from design to installation and commissioning of many links, ‌ need professional technology and fine operation to ensure the quality and effect of the final product. ‌