A method and system for preparing large-size quartz crucibles with high density and high strength

Abstract

This application discloses a method and system for preparing large-size quartz crucibles with high density and high strength, relating to the field of quartz crucible production technology. The method includes storing the current quartz crucible in a crucible buffer area located between the testing institutions corresponding to the currently tested indicators and the next tested indicator if the current test indicator meets the standard testing parameter requirements and all testing institutions corresponding to the next tested indicator are in working condition. If any testing institution corresponding to the next tested indicator of any finished product switches to an idle state and its number is greater than 1, the quartz crucible with the longest waiting time among the finished products with the largest number of the same identification number is selected as the target finished product to be tested. When all test indicators meet the standard testing parameter requirements, it is packaged and stored in the warehouse to improve the finished product qualification rate.

Description

Technical Field

[0001] This application generally relates to the field of quartz crucible production technology, and specifically to a method and system for preparing large-size quartz crucibles with high density and high strength. Background Technology

[0002] Quartz crucibles, as core equipment for pulling large-diameter single-crystal silicon, play an irreplaceable role in semiconductor, photovoltaic, and other fields. The performance of the quartz crucible directly affects the quality and production efficiency of the single-crystal silicon. Currently, common sizes are 18 inches and 20 inches, but with the upgrading of semiconductor chip manufacturing processes and the trend towards larger photovoltaic silicon wafers, the demand for quartz crucibles of 22 inches and above is increasing daily.

[0003] However, the increasing size of these quartz crucibles places higher demands on their fabrication, requiring testing of the finished products to ensure their performance meets usage requirements. Currently, the fabrication of large-sized quartz crucibles relies primarily on manual operation of testing equipment, which is time-consuming and labor-intensive for handling and positioning, and manual recording of test data is prone to errors. Therefore, we propose a method and system for fabricating high-density, high-strength large-sized quartz crucibles to address these issues. Summary of the Invention

[0004] In view of the above-mentioned defects or deficiencies in the prior art, it is desirable to provide a method and system for preparing large-size quartz crucibles with high density and high strength that improves the yield of finished products, ensures stable production, and is highly efficient.

[0005] In a first aspect, this application provides a method for preparing a large-size quartz crucible with high density and high strength, the method comprising the following steps: Obtain the identification number of the finished quartz crucible and its corresponding test index, as well as the test duration and test complexity parameters of the test index; divide the test indexes corresponding to the test durations within the same preset time range into the same test level; obtain the first ranking of the test level according to the test complexity parameters corresponding to each test level; and obtain the second ranking corresponding to each test index according to the first ranking and the test duration of each test index within each test level. Based on the identification number, the standard testing parameter requirements for the finished quartz crucible are determined. The test indicators of the finished quartz crucible are tested according to the second sorting. If the current test indicator meets the standard testing parameter requirements and the testing institutions corresponding to the next test indicator are all in working condition, the finished quartz crucible is stored in the crucible buffer area located between the testing institution corresponding to the currently tested test indicator and the testing institution corresponding to the next test indicator. The crucible waiting time and the number of crucibles corresponding to each identification number in the current crucible buffer area are recorded. If the testing mechanism for the next test indicator corresponding to any quartz crucible finished product in the crucible buffer area is switched to an idle state, then the quartz crucible finished product is taken as the target test finished product; and when the number of target test finished products is greater than 1, the quartz crucible finished product with the longest waiting time among the target test finished products with the largest number of the same identification number is transferred to the testing mechanism in an idle state for testing, and it is determined whether the test indicator meets the standard test parameter requirements. When all the test indicators of the finished quartz crucible meet the requirements of the standard test parameters, it is packaged and stored.

[0006] According to the technical solution provided in this application, the indicators to be detected include at least size, surface quality, internal defects, bulk density, and bending strength; the preset time interval includes at least a first time interval, a second time interval, and a third time interval; the time values ​​of the first time interval, the second time interval, and the third time interval increase sequentially. The testing device includes a dimensional inspection mechanism, a surface quality inspection mechanism, an internal defect inspection mechanism, a density inspection mechanism, and a high-temperature performance inspection mechanism. A crucible buffer area is provided between adjacent inspection mechanisms to store finished quartz crucibles awaiting inspection. The dimensional inspection mechanism is used to inspect the dimensions of the finished quartz crucibles; the surface quality inspection mechanism is used to inspect the surface quality of the finished quartz crucibles; the internal defect inspection mechanism is used to inspect for cracks and porosity in the finished quartz crucibles; the density inspection mechanism is used to inspect the bulk density of the finished quartz crucibles; and the high-temperature performance inspection mechanism is used to inspect the bending strength of the finished quartz crucibles. The detection indicators corresponding to the detection durations within the same preset duration range are divided into the same detection level. A first ranking of the detection levels is obtained based on the detection complexity parameter corresponding to each detection level. A second ranking is obtained based on the first ranking and the detection duration of each detection indicator within each detection level. Specifically, this includes the following steps: Obtain the detection time and detection complexity parameters of the size detection mechanism, surface quality detection mechanism, internal defect detection mechanism, density detection mechanism, and high temperature performance detection mechanism corresponding to each of the indicators to be detected; The detection indexes whose detection duration falls within the first duration interval are obtained and marked as the first detection level; the detection indexes whose detection duration falls within the second duration interval are obtained and marked as the second detection level; and the detection indexes whose detection duration falls within the third duration interval are obtained and marked as the third detection level. Based on the detection complexity parameters corresponding to the indicators to be detected at the same detection level, the level complexity parameters are determined, and the detection levels are sorted in ascending order of the level complexity parameters to obtain the first sort. In the first sorting, each indicator to be detected within each detection level is sorted from smallest to largest according to its corresponding detection duration to obtain the second sorting corresponding to each indicator to be detected.

[0007] According to the technical solution provided in this application, obtaining the identification number of the finished quartz crucible and its corresponding test indicators specifically includes the following steps: If the application scenario of the finished quartz crucible is determined to be the first risk scenario based on the identification number, then the size, surface quality, internal defects, bulk density and bending strength will all be used as the indicators to be tested. If the application scenario of the finished quartz crucible is determined to be the second risk scenario based on the identification number, and the number of finished quartz crucibles with the same identification number that were last tested for volume density is less than a preset number, then the size, surface quality, internal defects and bending strength will be used as the indicators to be tested. The standard detection parameter requirements for volume density in the first risk scenario are higher than those for the second risk scenario.

[0008] According to the technical solution provided in this application, the following steps are also included: If it is determined that the current detected volume density does not meet the requirements of the standard detection parameters, then the value of the preset quantity is adjusted; If the volume density of the next test still does not meet the requirements of the standard test parameters, it is determined that there are abnormal problems in the processing technology data and equipment operation status of each unit of the preparation device. The corresponding preparation device is then shut down for maintenance, and a preset number of test products are produced using the maintenance-upgraded preparation device. The preset number is set to 1, and the volume density of all the test products is tested until the volume density pass rate is greater than or equal to the target pass rate. Then, the preparation device is restored to normal production.

[0009] According to the technical solution provided in this application, the following steps are also included: Obtain the historical test data set corresponding to the finished quartz crucible; the historical test data set shall include at least the historical bulk density test data and historical flexural strength test data of all finished quartz crucibles that have been tested and meet the requirements of the standard test parameters within the same production batch; Based on the historical volume density test data and historical flexural strength test data in the historical test data set, calculate the correlation coefficient between volume density and flexural strength, and determine the risk threshold of volume density based on the correlation coefficient. If the bulk density of the finished quartz crucible is less than or equal to the risk threshold, a detection warning message is generated; the detection warning message is used to characterize that the bending strength of the finished quartz crucible has an abnormal risk. If the bending strength of the finished quartz crucible meets the standard test parameter requirements, the bending strength of the finished quartz crucible will be tested a second time to determine whether the result of the second test is consistent with the bending strength of the finished quartz crucible. If they are consistent, the bulk density will be tested a second time. Calculate the difference between the volume density of the secondary test and the volume density of the finished quartz crucible. If the difference is less than the error density setting value, it indicates that the volume density test is correct, and the risk threshold is updated.

[0010] According to the technical solution provided in this application, the method further includes the following steps: If the total number of crucibles in the crucible buffer area between the testing institution corresponding to the currently completed test indicator and the testing institution corresponding to the next test indicator is greater than or equal to the target crucible buffer number, and the testing institutions corresponding to the next test indicator of all quartz crucible finished products in the crucible buffer area are in working condition, then the transfer speed between the testing institution corresponding to the currently completed test indicator and the current crucible buffer area is adjusted to extend the time for the quartz crucible finished product to reach the current crucible buffer area.

[0011] According to the technical solution provided in this application, adjusting the transfer speed between the testing institution corresponding to the currently tested indicator and the current crucible buffer area specifically includes the following steps: The system obtains the operating speed of the transfer equipment between the testing institution corresponding to the currently completed test index and the current crucible buffer area; and determines the initial adjustment range of the transfer equipment speed based on the proportion by which the total number of crucibles in the crucible buffer area exceeds the target crucible buffer number. The workload of the testing institution corresponding to the next indicator to be tested is obtained. If the testing time corresponding to the workload exceeds the preset testing time, the initial adjustment range and the preset adjustment range are added together as the final adjustment range, and an adjustment command is sent to the transfer equipment. The adjustment command carries the final adjustment range so that the transfer equipment runs at the transfer speed adjusted according to the final adjustment range.

[0012] According to the technical solution provided in this application, the method is applied to a quartz crucible preparation system. The quartz crucible preparation system includes a data monitoring module that is communicatively connected to a preparation device and a detection device. The data monitoring module is used to monitor in real time the production progress of the preparation device and the total number of crucibles in the crucible buffer area between the preparation device and the detection device. The method further includes the following steps: If the total number of crucibles in the crucible buffer area between the detection device and the preparation device is greater than or equal to the target number of crucibles in the buffer area, the transfer speed between the sandblasting unit and the current crucible buffer area is adjusted to extend the time for the finished quartz crucible to reach the current crucible buffer area.

[0013] According to the technical solution provided in this application, the method further includes the following steps: The processing technology data and equipment operating status of each unit of the preparation device are collected in real time. If the processing technology data and / or the equipment operating status exceed the allowable fluctuation range, an alarm message is issued and the corresponding preparation device is shut down.

[0014] Secondly, this application provides a system for preparing large-size quartz crucibles with high density and high strength, used to realize the above-mentioned method for preparing large-size quartz crucibles with high density and high strength, characterized in that the system comprises: The system comprises multiple preparation devices and one testing device; each preparation device includes a feeding unit, a melting unit, a sandblasting unit, and a cleaning unit; the feeding unit pre-treats the raw materials and transfers them to the melting unit; the melting unit vacuums and melts the pre-treated raw materials to obtain a quartz crucible semi-finished product; the sandblasting unit sprays a barium coating onto the inner wall of the quartz crucible semi-finished product to obtain a quartz crucible finished product; and the testing device tests the quartz crucible finished product. A control unit is communicatively connected to the preparation device and the detection device, and the control unit is used to detect and control the operating status of the preparation device and the detection device in real time; The control unit is further configured to determine the corresponding standard testing parameter requirements and a second sorting based on the identification number and corresponding test index of the quartz crucible product prepared by the preparation device, and to test each of the test indexes of the quartz crucible product according to the second sorting. If the current test index meets the standard testing parameter requirements and the testing institutions corresponding to the next test index are all in working condition, then the current quartz crucible product is stored in a crucible buffer area located between the testing institutions corresponding to the currently tested test index and the testing institutions corresponding to the next test index, and the crucible waiting time and the current crucible buffer are recorded. The number of crucibles corresponding to each identification number within the area; if the testing institution for the next test indicator corresponding to any quartz crucible finished product within the crucible buffer area is switched to an idle state, then the quartz crucible finished product is taken as the target test finished product; and when the number of the target test finished products is greater than 1, the quartz crucible finished product with the longest waiting time among the target test finished products with the largest number of the same identification number is transferred to the testing institution in an idle state for testing, and it is determined whether the test indicator meets the standard testing parameter requirements; when all the test indicators of the quartz crucible finished product meet the standard testing parameter requirements, it is packaged and stored.

[0015] As can be seen from the above technical solution, this application has at least the following beneficial effects: This application discloses a method for preparing a large-size quartz crucible with high density and high strength, comprising: obtaining the identification number of the finished quartz crucible and its corresponding test index, as well as the test duration and test complexity parameters of the test index; classifying the test indexes corresponding to the test durations within the same preset time interval into the same test level; obtaining a first ranking of the test levels according to the test complexity parameters corresponding to each test level; obtaining a second ranking of each test index according to the first ranking and the test duration of each test index within each test level; determining the standard test parameter requirements of the finished quartz crucible based on the identification number; testing each test index of the finished quartz crucible according to the second ranking; if the current test index meets the standard test parameter requirements and the testing institutions corresponding to the next test index are all in working condition, then... The finished quartz crucibles are stored in a crucible buffer area located between the testing institution corresponding to the currently completed test indicator and the testing institution corresponding to the next test indicator. The waiting time of the crucibles and the number of crucibles corresponding to each identification number in the current crucible buffer area are recorded. If the testing institution corresponding to the next test indicator of any finished quartz crucible in the crucible buffer area switches to an idle state, the finished quartz crucible is taken as the target test product. When the number of target test products is greater than 1, the quartz crucible with the longest waiting time among the target test products with the largest number of the same identification number is selected and transferred to the testing institution in an idle state for testing, and it is determined whether the test indicator meets the standard test parameter requirements. When all test indicators of the finished quartz crucible meet the standard test parameter requirements, it is packaged and stored.

[0016] This application precisely controls the quality standards of each quartz crucible by determining standard testing parameter requirements based on its identification number. Simultaneously, it establishes a first and second priority order based on testing time and complexity, prioritizing indicators with high testing time and low complexity to reduce overall testing time. For example, dimensions and surface quality, which have high testing time, are prioritized for testing first, quickly identifying obviously non-conforming products and avoiding wasted resources on subsequent complex tests. Furthermore, when the testing mechanism for the next required indicator for any quartz crucible within the crucible buffer area becomes idle, that quartz crucible is designated as the target product for testing. If the number of target products for testing is greater than one, the quartz crucible with the highest number of products with the same identification number and the longest waiting time is selected for testing, improving equipment utilization and making the testing process smoother and more efficient. Attached Figure Description

[0017] Other features, objects, and advantages of this application will become more apparent from the following detailed description of non-limiting embodiments with reference to the accompanying drawings.

[0018] Figure 1A schematic diagram of the quartz crucible preparation system.

[0019] Figure 2 This is a schematic diagram of the single-piece preparation device and the detection device.

[0020] Figure 3 This is a flowchart of a method for preparing large-size quartz crucibles with high density and high strength.

[0021] Figure 4 The flowchart for obtaining the second sort.

[0022] Figure 5 A flowchart for obtaining the identification number of the finished quartz crucible and its corresponding test indicators.

[0023] The diagram is labeled as follows: 1. Preparation device; 2. Detection device; 3. Feeding unit; 4. Melting unit; 5. Sandblasting unit; 6. Cleaning unit; 7. Dimension detection mechanism; 8. Surface quality detection mechanism; 9. Internal defect detection mechanism; 10. Density detection mechanism; 11. High temperature performance detection mechanism; 12. Data monitoring module; 13. Transfer equipment. Detailed Implementation

[0024] The present application will now be described in further detail with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the invention and not intended to limit it. Furthermore, it should be noted that, for ease of description, only the parts relevant to the invention are shown in the accompanying drawings.

[0025] It should be noted that, unless otherwise specified, the embodiments and features described in this application can be combined with each other. This application will now be described in detail with reference to the accompanying drawings and embodiments.

[0026] like Figure 1 As shown, this application provides a quartz crucible preparation system, including: multiple preparation devices 1 and a detection device 2; each preparation device 1 includes a feeding unit 3, a melting unit 4, a sandblasting unit 5, and a cleaning unit 6; the feeding unit 3 is used to pre-treat the raw materials and transfer them to the melting unit 4; the melting unit 4 is used to evacuate and melt the pre-treated raw materials to obtain a quartz crucible semi-finished product; the sandblasting unit 5 is used to spray a barium coating onto the inner wall of the quartz crucible semi-finished product to obtain a quartz crucible finished product; the detection device 2 is used to detect the quartz crucible finished product; The control unit is communicatively connected to the preparation device 1 and the detection device 2. The control unit is used to detect and control the operating status of the preparation device 1 and the detection device 2 in real time. The control unit is also used to determine the corresponding standard testing parameter requirements and the second sorting according to the identification number and corresponding test index of the quartz crucible product prepared by the preparation device 1, and to test each test index of the quartz crucible product according to the second sorting. If the current test index meets the standard testing parameter requirements and the testing mechanism corresponding to the next test index is in working condition, the current quartz crucible product is stored in the crucible buffer area located between the testing mechanism corresponding to the currently tested test index and the testing mechanism corresponding to the next test index, and the crucible waiting time and the current crucible buffer are recorded. The number of crucibles corresponding to each identification number within the area; if the testing institution for the next test indicator corresponding to any quartz crucible product within the crucible buffer area is switched to an idle state, then the quartz crucible product is taken as the target test product; when the number of target test products is greater than 1, the quartz crucible product with the longest waiting time among the target test products with the largest number of the same identification number is transferred to the testing institution in an idle state for testing, and it is determined whether the test indicator meets the standard testing parameter requirements; when all test indicators of the quartz crucible product meet the standard testing parameter requirements, it is packaged and stored.

[0027] It should be noted that the system includes multiple preparation devices 1 and one detection device 2. Multiple preparation devices 1 can simultaneously perform quartz crucible preparation, ensuring production efficiency. Simultaneously, the detection device 2 performs quality inspection on the finished quartz crucibles to ensure they meet the corresponding quality requirements. Specifically, in the quartz crucible production process, the feeding unit 3 includes at least the screening, cleaning, and crushing of raw materials. Its purpose is to remove impurities from the raw materials and ensure that the particle size and purity of the raw materials meet the requirements for subsequent melting. After completing the aforementioned operations, the feeding unit 3 transfers the raw materials to the melting unit 4, providing suitable raw materials for the subsequent melting process. The melting unit 4 is used to prepare the quartz crucibles. The specific process is as follows: First, the internal space of the melting unit 4 is evacuated to create a low-pressure environment. Under vacuum conditions, the gas content in the raw materials is reduced, preventing the generation of bubbles during melting, thereby improving the quality of the quartz crucible. Then, the raw materials processed by feeding unit 3 are melted under high temperature, causing them to melt and fuse into a uniform liquid state. This liquid state is then solidified using specific processes and molds to obtain a semi-finished quartz crucible. Here, the specific processes and molds mentioned above include, for example, centrifugal casting, where the liquid raw material is injected into a high-speed rotating mold after melting into a uniform liquid state. Centrifugal force is used to evenly distribute the liquid raw material on the inner wall of the mold, and as the mold rotates, the liquid raw material gradually cools and solidifies. This process allows for a more uniform wall thickness of the quartz crucible, effectively reducing stress concentration points and improving product quality. For example, in the production of some high-precision quartz crucibles, centrifugal casting can ensure that the crucible wall thickness tolerance is controlled within a very small range, meeting the stringent dimensional accuracy requirements of the semiconductor industry. Another process is vacuum casting, where molten raw material is filled into the mold cavity under negative pressure in a vacuum environment. Because the process is performed under vacuum, it further eliminates tiny air bubbles in the liquid raw materials, while allowing the materials to adhere more tightly to the mold, improving the density and surface finish of the formed product. For quartz crucibles with extremely high requirements for internal defects and surface quality, such as those used in the high-end photovoltaic industry, vacuum casting technology can better meet production needs. Graphite molds, with their excellent high-temperature resistance and chemical stability, can withstand high temperatures without deformation or chemical reaction with the quartz raw materials during quartz crucible preparation. Their shape and size are designed according to the specifications of the target quartz crucible. Common graphite molds are divided into upper and lower parts, forming a cavity that matches the shape of the quartz crucible after mold closing. After the liquid raw materials are injected into the mold, the graphite mold can quickly conduct heat, allowing the raw materials to cool and solidify uniformly. For example, when producing large-sized quartz crucibles, graphite molds can be customized according to different diameter and depth requirements to ensure that the produced crucibles meet specific size standards. Ceramic molds also possess high-temperature resistance and corrosion resistance, and their high surface finish gives quartz crucibles excellent surface quality.When using ceramic molds, a release agent is usually applied to the mold surface to facilitate demolding of the semi-finished quartz crucible. Some small, high-precision quartz crucibles are often produced using ceramic molds. Utilizing the fine structure of ceramic molds, quartz crucibles with complex shapes or special requirements can be manufactured to meet the application needs of specific fields.

[0028] Sandblasting unit 5 is used to spray a barium coating onto the inner wall of the semi-finished quartz crucible. Here, the barium coating improves the high-temperature resistance and chemical stability of the quartz crucible, effectively resisting high temperatures and chemical corrosion during subsequent processes such as pulling single-crystal silicon, extending the service life of the quartz crucible, ensuring smooth production, and ultimately improving the quality of the final product. Cleaning unit 6 is used to clean the sandblasted quartz crucible. Its purpose is to remove impurities, dust, and particles that may remain from the sandblasting process, ensuring the surface of the finished quartz crucible is clean and preventing these impurities from affecting subsequent use.

[0029] Furthermore, crucible buffer area A is used to temporarily store finished quartz crucibles awaiting testing, qualified product storage area C is used to store quartz crucibles that have passed all tests, unqualified product storage area D is used to store quartz crucibles that have failed a certain test, and unqualified product storage area D can be classified and stored according to the unqualified indicators to facilitate subsequent data traceability; secondary testing area B is used to provide secondary testing for finished quartz crucibles with abnormalities.

[0030] Testing device 2 is used to conduct comprehensive testing on the finished quartz crucibles. Testing indicators include at least dimensional accuracy, surface quality (scratches, cracks, etc.), internal defects (porosity, inclusions, etc.), bulk density, and flexural strength. By testing these indicators, it can be determined whether the finished quartz crucibles meet the relevant quality requirements. Only quartz crucibles that pass the testing can enter the subsequent use stages, thus ensuring the quality and performance of the product.

[0031] Furthermore, such as Figure 2 As shown, the testing device 2 includes a size testing mechanism 7, a surface quality testing mechanism 8, an internal defect testing mechanism 9, a density testing mechanism 10, and a high-temperature performance testing mechanism 11; and a crucible buffer area is provided between two adjacent testing mechanisms, which is used to store the finished quartz crucibles waiting to be tested; the size testing mechanism 7 is used to test the size of the finished quartz crucibles, the surface quality testing mechanism 8 is used to test the surface quality of the finished quartz crucibles; the internal defect testing mechanism is used to test the cracks and pores of the finished quartz crucibles, the density testing mechanism 10 is used to test the bulk density of the finished quartz crucibles; and the high-temperature performance testing mechanism 11 is used to test the bending strength of the finished quartz crucibles.

[0032] It should be noted that the dimensional inspection mechanism 7 is used to accurately measure various dimensional parameters of the finished quartz crucible, such as the crucible's diameter, height, and wall thickness. By comparing the measured data with preset standard dimensions, it is determined whether the crucible's dimensions are within the allowable dimensional tolerance range. If the dimensions are not within the allowable tolerance range, it indicates that the current finished quartz crucible will affect its compatibility with other equipment and may even cause problems during the crystal pulling process, requiring secondary inspection or transfer to the non-conforming product storage area. Here, both the preset standard dimensions and the allowable dimensional tolerance range can be obtained from the corresponding standard inspection parameter requirements.

[0033] The surface quality inspection unit 8 is mainly used to inspect the surface condition of finished quartz crucibles. If the surface of the quartz crucible has defects such as scratches, pinholes, or pits, stress concentration may occur during high-temperature use, leading to crucible breakage and affecting the production of monocrystalline silicon. The surface quality inspection unit 8 mainly uses optical inspection equipment, electron microscopes, and other tools to conduct a detailed inspection of the crucible surface to ensure that the surface quality meets the corresponding standards, guaranteeing the stability and reliability of the crucible during use.

[0034] The internal defect inspection unit 9 is used to detect internal defects such as cracks and pores in finished quartz crucibles. These internal defects may occur during the raw material melting and forming process and are not directly visible to the naked eye, but they can seriously affect the performance and service life of the crucible. Commonly used inspection methods include ultrasonic testing and X-ray testing. Ultrasonic testing uses ultrasonic waves emitted into the crucible and determines the presence of internal defects based on the propagation characteristics of ultrasonic waves in different media. X-ray testing uses X-rays to penetrate the crucible and form an image of the internal structure, visually displaying the location and shape of internal defects, so as to promptly detect and reject unqualified products.

[0035] The density testing unit 10 is used to test the bulk density of the finished quartz crucible. Bulk density is an important indicator reflecting the uniformity and compactness of the quartz crucible material. If the density is uneven or does not meet the standard, it indicates problems such as uneven mixing of raw materials or insufficient melting during the production process, which will affect the physical properties and chemical stability of the crucible. Here, the density testing unit 10 uses methods such as Archimedes' principle to calculate its bulk density by measuring the weight of the crucible in air and liquid, thereby assessing product quality.

[0036] The high-temperature performance testing unit 11 is used to test the bending strength of the finished quartz crucible, which is a key indicator for measuring the mechanical properties of the quartz crucible under high-temperature conditions. During the pulling of single-crystal silicon, the quartz crucible needs to withstand the combined effects of high temperature and mechanical stress. If the bending strength is insufficient, deformation or even cracking may occur at high temperatures, leading to crystal pulling failure. The high-temperature performance testing unit 11 simulates the high-temperature environment of actual use, applying a certain bending load to the crucible and measuring its bending strength to ensure that the product meets the high-temperature performance requirements of practical applications.

[0037] A crucible buffer area, located between two adjacent testing units, is used to temporarily store finished quartz crucibles awaiting testing. Since the testing times vary between units, and the testing process may be affected by factors such as equipment maintenance and calibration, the crucible buffer area serves as a buffer and adjustment mechanism. When a testing unit is busy or malfunctions, other completed crucibles can be temporarily stored in the buffer area, preventing production interruptions. Simultaneously, it facilitates the rational arrangement of crucible testing sequences based on the working status of each testing unit, improving the efficiency and flexibility of the entire testing process.

[0038] Furthermore, a control unit, communicatively connected to the preparation apparatus 1 and the detection apparatus 2, is used to monitor and control the operating status of the preparation apparatus 1 and the detection apparatus 2 in real time. Here, the control unit includes at least a data monitoring module 12 and a processing module E; such as... Figure 2 As shown, the data monitoring module 12 is communicatively connected to the preparation device 1 and the detection device 2. The data monitoring module 12 is used to monitor the production progress of the preparation device 1 and the working status of the detection device 2 in real time. The processing module E is used to control the corresponding devices to perform corresponding actions based on the various data.

[0039] The data monitoring module 12 is communicatively connected to the preparation device 1 and the detection device 2, and is used to monitor the production progress of the preparation device 1 in real time. This monitoring includes multiple aspects, such as monitoring the frequency and amount of raw material addition in the feeding unit 3 to determine whether the raw material supply is stable and meets production rhythm requirements. If abnormal raw material addition is detected, such as insufficient or excessive addition, it may affect the production quality of the subsequent melting unit 4. The data monitoring module 12 can promptly issue an alarm to notify the staff for adjustments. The data monitoring module 12 is also used to monitor the working status of the melting unit 4 in real time, including parameters such as melting temperature, time, and vacuum degree. These parameters directly affect the quality of the quartz crucible semi-finished product. If the melting temperature is unstable, it may lead to uneven internal structure of the quartz crucible, affecting its performance. By monitoring these parameters in real time, the data monitoring module 12 can promptly detect deviations in the production process, helping operators take timely measures to ensure the stability of the production process and the consistency of product quality. Additionally, the data monitoring module 12 monitors the working status of the detection device 2 in real time, such as whether the dimensional detection mechanism 7 and the surface quality detection mechanism 8 are working properly. If a testing facility malfunctions, such as equipment crashing or sensor failure, the data monitoring module 12 can immediately detect this anomaly and promptly notify relevant personnel for repair. Simultaneously, monitoring the workload of each testing facility is also crucial. Understanding the current number of testing tasks and estimated completion times for each facility is essential for rationally scheduling the testing of quartz crucibles. For example, if a testing facility has a lighter workload while others are busy, the waiting quartz crucibles can be prioritized for testing at the less busy facility, extending testing time, preventing equipment idleness, and making the entire testing process more efficient and orderly.

[0040] By monitoring production progress and testing status, problems can be identified in a timely manner, and production and testing strategies can be adjusted, thereby improving production efficiency, reducing production costs, ensuring product quality, and ultimately enhancing the competitiveness and reliability of the entire quartz crucible preparation system.

[0041] like Figure 3 As shown, this application provides a method for preparing a large-size quartz crucible with high density and high strength, comprising the following steps: S100. Obtain the identification number of the finished quartz crucible and its corresponding test index, as well as the test duration and test complexity parameters of the test index; divide the test indexes corresponding to the test durations within the same preset time range into the same test level; obtain the first ranking of the test level according to the test complexity parameters corresponding to each test level; and obtain the second ranking corresponding to each test index according to the first ranking and the test duration of each test index within each test level.

[0042] It should be noted that the identification number of each finished quartz crucible is a unique identifier. Different identification numbers correspond to different testing parameters with varying testing durations and complexity. The corresponding standard testing parameters are retrieved from the finished product testing database based on the identification number. Since the quality standards of quartz crucibles from different batches and for different applications differ, obtaining the matching standard testing parameters through the identification number provides an accurate basis for subsequent testing.

[0043] Furthermore, the indicators to be tested include at least size, surface quality, internal defects, bulk density, and flexural strength; the preset time intervals include at least a first time interval, a second time interval, and a third time interval; the time values ​​of the first time interval, the second time interval, and the third time interval increase sequentially.

[0044] Here, dimensional inspection is used to measure whether the quartz crucible conforms to design specifications (such as diameter, height, and wall thickness), affecting its compatibility with other equipment; surface quality inspection is used to detect potential surface defects such as scratches and pinholes, which may cause problems during use; internal defect inspection is used to address potential internal defects such as cracks and pores in the quartz crucible, preventing malfunctions under high temperatures or stress; bulk density inspection reflects the uniformity and density of the quartz crucible material; and bending strength inspection measures the quartz crucible's ability to resist bending deformation at high temperatures, ensuring its reliability in practical applications. Furthermore, the preset time interval includes at least three intervals: a first time interval, a second time interval, and a third time interval, with the duration values ​​of the first, second, and third time intervals increasing sequentially. This division is based on a comprehensive consideration of factors such as the required inspection time, equipment preparation time, and operational complexity for different inspection indicators. For example, some testing projects that use automated optical measurement equipment may have a faster testing speed and will be classified into the higher efficiency range; while those testing projects that require complex sample preparation, long-term testing, or high-precision equipment calibration will be classified into the lower efficiency range.

[0045] like Figure 4 As shown, the indicators to be detected corresponding to the detection duration within the same preset duration range are divided into the same detection level. A first ranking of the detection levels is obtained based on the detection complexity parameter corresponding to each detection level. A second ranking is obtained based on the first ranking and the detection duration of each indicator to be detected within each detection level. The specific steps include: S101a. Obtain the detection time and detection complexity parameters of the size detection mechanism 7, surface quality detection mechanism 8, internal defect detection mechanism 9, density detection mechanism 10, and high temperature performance detection mechanism 11 corresponding to each indicator to be tested.

[0046] This requires a detailed analysis of the various testing organizations responsible for different indicators. Organizations 7 (dimensional inspection), 8 (surface quality inspection), 9 (internal defect inspection), 10 (density inspection), and 11 (high-temperature performance inspection) each differ in their testing time and complexity parameters. Testing time can be measured by the time required to complete the inspection for that indicator; the complexity parameter involves multiple aspects such as the technical difficulty required for the inspection, the number of operational steps, the skill level required of the operators, and the complexity of the testing equipment. For example, dimensional inspection may use simple measuring tools or automated optical measuring instruments, making operation relatively simple but with a longer testing time; while high-temperature performance inspection organization 11 needs to simulate a high-temperature environment, requiring sophisticated equipment and a complex testing process, resulting in a shorter testing time.

[0047] S102a. Obtain the indicators to be detected whose detection duration is in the first duration interval and mark them as the first detection level; obtain the indicators to be detected whose detection duration is in the second duration interval and mark them as the second detection level; obtain the indicators to be detected whose detection duration is in the third duration interval and mark them as the third detection level.

[0048] Based on the obtained testing time information, the dimensional testing mechanism 7 and the surface quality testing mechanism 8 are classified as the first testing level because their testing times fall within the first time range, indicating relatively short testing times and the ability to complete a greater number of testing tasks within the same time frame. The internal defect testing mechanism 9 and the density testing mechanism 10, with testing times in the second time range, are classified as the second testing level, as their testing times are shorter than the first testing level. The high-temperature performance testing mechanism 11 has the shortest testing time, falling within the third time range, and is classified as the third testing level. This classification helps to prioritize projects with shorter testing times in subsequent testing processes, improving the overall efficiency of the testing work.

[0049] For example, the detection time of the size detection mechanism 7 is, for example, 5 minutes; the detection time of the surface quality detection mechanism 8 is, for example, 8 minutes; the detection time of the internal defect detection mechanism 9 is, for example, 15 minutes; the detection time of the density detection mechanism 10 is, for example, 20 minutes; and the detection time of the high temperature performance detection mechanism 11 is, for example, 1 hour. The first time interval is, for example, 0-10 minutes; the second time interval is, for example, 10-20 minutes; and the third time interval is, for example, greater than 20 minutes. Then, the size detection mechanism 7 and the surface quality detection mechanism 8 are marked as the first detection level, the detection time of the internal defect detection mechanism 9 and the density detection mechanism 10 is marked as the second detection level, and the high temperature performance detection mechanism 11 is marked as the third detection level.

[0050] S103a. Based on the detection complexity parameters corresponding to the indicators to be detected at the same detection level, determine the level complexity parameters, and sort the detection levels in ascending order of the level complexity parameters to obtain the first sort.

[0051] This process involves summing the detection complexity parameters corresponding to the indicators to be tested within the same detection level to obtain the level complexity parameter. For example, if the first detection level includes size and surface quality testing, with the former having a complexity parameter of 1 and the latter a complexity parameter of 2, then the level complexity parameter is 3. The levels are then sorted from smallest to largest complexity parameter to obtain the first ranking. For example: first detection level, second detection level, third detection level. The purpose of generating the first ranking is to perform low-complexity tests first, quickly screen out obviously defective products, avoid ineffective use of high-complexity testing resources (such as high-temperature performance testing equipment), and improve the overall testing time.

[0052] S104a. In the first sorting, each indicator to be detected within each detection level is sorted from smallest to largest according to the corresponding detection duration to obtain the second sorting corresponding to each indicator to be detected.

[0053] Based on the initial ranking, the indicators to be tested within each ranking are sorted by testing time from shortest to longest, resulting in a second ranking. For example: within the first ranking: dimensional inspection (5 minutes), surface quality inspection (8 minutes); within the second ranking: internal defect inspection (15 minutes), bulk density inspection (20 minutes); within the third ranking: flexural strength inspection only (60 minutes). By further optimizing the sequence within the same ranking, shorter-duration inspections are prioritized, reducing the overall waiting time for individual products and improving the efficiency of the inspection line.

[0054] S200. Based on the identification number, determine the standard testing parameter requirements for the finished quartz crucible. Test the finished quartz crucible according to the second order. If the current test index meets the standard testing parameter requirements and the testing institutions corresponding to the next test index are all in working condition, then store the current finished quartz crucible in the crucible buffer area and record the crucible waiting time and the number of crucibles corresponding to each identification number in the current crucible buffer area. The crucible buffer area is the area between the testing institutions of the testing device 2 corresponding to two adjacent test indices.

[0055] The standard testing parameters for the finished quartz crucible are determined based on the identification number, specifically including the following steps: Obtain the finished product testing database and find the standard testing parameter requirements corresponding to the identification number in the finished product testing database; the finished product testing database includes at least multiple identification numbers and the standard testing parameter requirements corresponding to each identification number.

[0056] The finished product testing database stores standard testing parameters covering multiple aspects of quartz crucible quality standards. For example, regarding dimensions, it specifies the allowable tolerance ranges for diameter, height, and wall thickness; regarding surface quality, it clarifies the acceptable levels of defects such as scratches and pinholes; regarding internal defects, it sets corresponding limits on the size, number, and location of cracks and pores; and physical properties such as bulk density and flexural strength also have corresponding standard value ranges. Using the identification number as an index ensures that each quartz crucible can obtain a precise testing standard matching its batch, model, or application scenario. For instance, quartz crucibles used in the semiconductor field and those used in the photovoltaic field have different performance requirements due to different application scenarios. Even with similar dimensions, they may differ in internal defect standards and flexural strength requirements. The identification number allows for accurate retrieval of the applicable testing standards, ensuring the scientific rigor and accuracy of the testing work and preventing substandard products from entering the market or qualified products from being misjudged due to incorrect testing standards.

[0057] Here, the finished product testing database is shown in Table 1. "G-xxx-xxx-xxx" represents a specific model of quartz crucible from a specific production batch used in a specific application scenario. Furthermore, the data in the standard testing parameter requirements in Table 1 are merely illustrative and do not constitute a limitation on the standard testing parameter requirements for quartz crucibles.

[0058] Table 1 Finished Product Testing Database

[0059] In this process, the quartz crucibles are inspected one by one according to the second sorting determined in step S100. During the inspection, the actual test results of each indicator to be tested are compared with the standard test parameter requirements. If the current indicator to be tested meets the standard test parameter requirements, and the testing mechanisms corresponding to the next indicator to be tested are all in working condition, it indicates that the next indicator to be tested for the current quartz crucible cannot be tested immediately. To avoid quartz crucibles accumulating in front of the testing device 2 and affecting the smoothness of the testing process, the current quartz crucible is transferred to the crucible buffer area for temporary storage. At the same time, the waiting time of the quartz crucible and the number of crucibles corresponding to each identification number in the current crucible buffer area are recorded. Here, the crucible buffer area is set between the testing mechanisms of the testing device 2 corresponding to two adjacent indicators to be tested, playing a buffering and adjustment role to ensure the orderly progress of the testing process. A timer can be used to record the waiting time of the quartz crucibles, and this timer is communicatively connected to the processing module E, so that the processing module E can determine the quartz crucibles to be prioritized for the next testing process based on the waiting time corresponding to each identification number.

[0060] Additionally, if the current test indicator meets the standard test parameter requirements, and there is an available testing institution for the next test indicator, the current quartz crucible can be transferred to an available testing institution for testing the next test indicator. If the current test indicator does not meet the standard test parameter requirements, the quartz crucible can be transferred to the non-conforming product storage area D.

[0061] Furthermore, if the total number of crucibles in the crucible buffer area between the testing institution corresponding to the currently completed test indicator and the testing institution corresponding to the next test indicator is greater than or equal to the target crucible buffer number, and the testing institutions corresponding to the next test indicators of all quartz crucible finished products in the crucible buffer area are in working condition, then the transfer speed between the testing institution corresponding to the currently completed test indicator and the current crucible buffer area is adjusted to extend the time for the quartz crucible finished products to reach the current crucible buffer area.

[0062] Specifically, when the total number of crucibles in the crucible buffer area between the testing institution corresponding to the currently completed test indicator and the testing institution corresponding to the next test indicator reaches or exceeds the preset target crucible buffer number, and all testing institutions corresponding to the next test indicator for all quartz crucible products in the current crucible buffer area are in operation, to avoid excessive crucible accumulation in the buffer area, the operating speed of the transfer device 13 between the testing institutions corresponding to the currently completed test indicator and the testing institution corresponding to the next test indicator can be adjusted to extend the time for quartz crucible products to reach the current crucible buffer area. For example, if there are too many crucibles in the current crucible buffer area, the speed of the transfer device 13 can be reduced, allowing the testing institution corresponding to the next test indicator sufficient time to process the existing quartz crucible products, ensuring the balance and stability of the entire testing process. Here, the target crucible buffer number can be determined based on factors such as production experience and the processing capacity of the testing equipment to ensure the efficient and stable operation of the testing process.

[0063] Furthermore, the transfer speed between the testing institution corresponding to the currently tested indicator and the current crucible buffer area is adjusted, specifically including the following steps: The operating speed of the transfer device 13 between the testing institution corresponding to the currently completed test index and the current crucible buffer area is obtained; and the initial adjustment range of the transfer speed of the transfer device 13 is determined according to the proportion by which the total number of crucibles in the crucible buffer area exceeds the target number of crucibles. The workload of the testing institution corresponding to the next indicator to be tested is obtained. If the testing time corresponding to the workload exceeds the preset testing time, the initial adjustment range and the preset adjustment range are added together as the final adjustment range, and an adjustment command is sent to the transfer equipment 13. The adjustment command carries the final adjustment range so that the transfer equipment 13 runs at the transfer speed adjusted according to the final adjustment range.

[0064] It should be noted that before adjusting the transfer speed, the current operating speed of the transfer equipment 13 between the testing institution corresponding to the currently tested indicators and the current crucible buffer area must first be obtained. For example, if the current operating speed of the transfer equipment 13 is 5 quartz crucibles per minute, the initial adjustment range of the transfer speed is determined based on the proportion by which the total number of crucibles in the crucible buffer area exceeds the target crucible buffer number. When the actual total number of crucibles in the crucible buffer area exceeds the target crucible buffer number, the transfer speed needs to be adjusted. For example, if the target crucible buffer number is set to 50, but there are 80 crucibles in the actual crucible buffer area, the excess ratio is (80-50)÷50=60%. An initial adjustment range is assigned according to the excess ratio. Assuming that every 10% excess corresponds to a 5% reduction in the transfer speed, then the initial adjustment range is a 30% reduction in the transfer speed. The purpose of this adjustment method is to reduce the speed at which new finished quartz crucibles enter the crucible buffer area, avoiding excessive accumulation of crucibles in the crucible buffer area.

[0065] In addition to considering the number of crucibles in the crucible buffer area, it is also necessary to obtain the workload of the testing organization corresponding to the next test indicator. Here, workload can be measured by testing time, which refers to the estimated time required for the testing organization to complete all current test tasks. The preset testing time can be set based on experience and equipment performance. For example, if a testing organization is expected to take 2 hours to complete the testing of a normal number of crucibles according to the standard procedure, this can be set as the preset testing time. If the current testing time calculated based on the workload is 3 hours, exceeding the preset testing time, it indicates that the testing organization is heavily overloaded and its processing capacity is nearing saturation.

[0066] When the workload of the testing agency exceeds the preset testing time, in order to further alleviate the pressure on the testing agency and ensure the smoothness of the testing process, it is necessary to increase the adjustment range of the transfer speed. In this case, the previously determined initial adjustment range and the preset adjustment range are added together to obtain the final adjustment range. Assuming the preset adjustment range is a further reduction of 20% in the transfer speed, plus the previous initial adjustment range of 30%, the final adjustment range is a reduction of 50% in the transfer speed. Then, the system sends an adjustment command to the transfer equipment 13, which carries the information of the final adjustment range. After receiving the adjustment command, the transfer equipment 13 will operate according to the adjusted transfer speed, for example, originally transporting 5 quartz crucibles per minute, now transporting 3 per minute, thereby reducing the workload of the testing agency and making the entire production and testing process more coordinated and efficient.

[0067] In addition, if the total number of crucibles in the crucible buffer area is less than the target number of crucibles to be buffered and the detection mechanisms corresponding to the next indicator to be tested are all in operation, the current speed can be continued without adjusting the transfer speed of the transfer equipment 13.

[0068] S400. If the testing mechanism for the next test indicator corresponding to any quartz crucible finished product in the crucible buffer area is switched to an idle state, then the quartz crucible finished product is taken as the target test finished product; and when the number of target test finished products is greater than 1, the quartz crucible finished product with the longest waiting time among the target test finished products with the largest number of the same identification number is selected and transferred to the testing mechanism in an idle state for testing, and it is determined whether the test indicator meets the standard test parameter requirements.

[0069] In this process, if the testing facility corresponding to the next test parameter for any quartz crucible in the crucible buffer area becomes idle, to improve equipment utilization and fully utilize testing resources, a screening process is performed in the crucible buffer area. The quartz crucible with the most identical identifiers and the longest waiting time among the target test products is selected and transferred to an idle testing facility for testing. Then, the test parameters for this quartz crucible are tested to determine if it meets the standard testing parameter requirements. This prioritizes crucibles with long waiting times while quickly testing a large number of crucibles from the same batch, improving testing efficiency while ensuring balanced testing.

[0070] S500. When all the test indicators of the finished quartz crucible meet the standard test parameter requirements, it shall be packaged and stored.

[0071] In this process, once the finished quartz crucible has undergone a series of tests and all the test indicators meet the predetermined standard test parameter requirements, it indicates that the finished quartz crucible is of qualified quality and meets the standards for use. These qualified finished quartz crucibles are then transferred to the qualified product storage area C for packaging, and then transported to the warehouse for storage, awaiting subsequent use in semiconductor, photovoltaic and other related production fields. Furthermore, such as Figure 5 As shown, obtaining the identification number of the finished quartz crucible and its corresponding test index includes the following steps: S101b If the application scenario of the finished quartz crucible is determined to be the first risk scenario based on the identification number, then the size, surface quality, internal defects, bulk density and bending strength will all be used as indicators to be tested.

[0072] S102b If the application scenario of the finished quartz crucible is determined to be the second risk scenario based on the identification number, and the number of finished quartz crucibles with the same identification number that were last tested for volume density is less than a preset number, then the size, surface quality, internal defects and bending strength will be used as the indicators to be tested.

[0073] Among them, because different application scenarios have different performance requirements for quartz crucibles, the standard for volumetric density, as one of the important performance indicators, also varies in different scenarios.

[0074] Here, the application scenarios are divided into first-risk scenarios and second-risk scenarios. The standard detection parameters for volumetric density in the first-risk scenario are higher than those in the second-risk scenario. For example, in the semiconductor manufacturing field (which can be considered the first-risk scenario), the requirements for the purity and density uniformity of the quartz crucible are extremely high; even slight density differences can affect the quality of semiconductor products. However, in some ordinary photovoltaic production scenarios (which can be considered the second-risk scenario), the density requirements are relatively less stringent. Understanding this difference is the basis for adopting different detection strategies subsequently.

[0075] In other words, the first risk scenario has stringent product quality requirements, and full-indicator testing can eliminate defective products to the greatest extent possible, avoiding semiconductor production failures due to insufficient density or strength, and reducing quality risks in high-value scenarios. The second risk scenario, for scenarios with relatively low density requirements (such as ordinary photovoltaic production), allows for optimization of testing costs while ensuring basic performance.

[0076] The identification number is a unique identifier for the finished quartz crucible, which is associated with information such as its production batch, model, and application scenario. Therefore, the application scenario can be determined by the identification number, and thus the corresponding test indicators can be identified.

[0077] If the finished quartz crucible is used in the first-risk scenario, since the first-risk scenario has high density requirements, in order to ensure quality, the finished quartz crucible needs to be tested for all indicators.

[0078] For quartz crucibles used in the second risk scenario, the bulk density requirement is relatively lenient (e.g., target value ≥ 2.15 g / cm³), allowing for a reduction in density testing frequency when the production process is stable. The sampling interval can be controlled by the "preset quantity," meaning sampling testing is sufficient. Here, the preset quantity can be set according to the actual situation.

[0079] Differentiated detection strategies based on the risk level of the application scenario can meet the stringent requirements of high-risk scenarios while improving detection efficiency through sampling in low-risk scenarios, thus achieving a dynamic balance between quality and cost.

[0080] Furthermore, the method also includes the following steps: If the current volume density does not meet the requirements of the standard testing parameters, adjust the value of the preset quantity. If the volume density of the next test still does not meet the standard test parameter requirements, it is determined that there are abnormal problems in the processing technology data and equipment operation status of each unit of the preparation device 1. The corresponding preparation device 1 is then shut down for maintenance, and the maintenance-upon preparation device 1 is used to produce a preset number of test products. The preset number is set to 1, and the volume density of all test products is tested until the volume density pass rate is greater than or equal to the target pass rate. Then, the preparation device 1 is restored to normal production.

[0081] It should be noted that if the bulk density of the currently tested quartz crucible does not meet the standard testing parameters, for example, the measured value is <2.15 g / cm³, which is lower than the density standard for the second risk scenario, then the preset quantity should be reduced. For example, the preset quantity is the interval threshold for determining whether bulk density testing is necessary in the second risk scenario; for instance, if the original preset quantity was 20, it would be reduced to 5. The preset quantity represents the maximum number of pieces in the same batch that do not require bulk density testing. When density non-compliance occurs, reducing the preset quantity can increase the subsequent testing frequency (e.g., from testing once every 50 pieces to testing once every 30 pieces), so as to monitor density fluctuations more frequently and detect potential problems in a timely manner.

[0082] If the volume density in the next test still does not meet the standard (i.e., two consecutive tests fail), it is determined that there is an abnormality in the processing data or equipment operating status of preparation device 1 (such as temperature fluctuations in melting unit 4, uneven spraying in sandblasting unit 5, etc.). The corresponding preparation device 1 will be shut down for maintenance, production will be stopped to investigate equipment malfunctions or process parameter deviations (such as checking the vacuum level of melting unit 4, raw material ratio, etc.). Consecutive failures indicate that there may be systemic problems in the production process, such as equipment aging or process parameter drift. Shutdown maintenance can prevent the continuous production of non-conforming products, and at the same time, a comprehensive inspection can pinpoint the root cause of the problem and prevent the quality problem from escalating.

[0083] After maintenance, a preset number of test products are produced using preparation device 1. The volume density of each of the preset number of test products is tested until the pass rate is greater than or equal to the target pass rate (e.g., the target pass rate is 95%). If all test products are qualified (since the pass rate is 100% when the preset quantity is 1), it is confirmed that the equipment or process problem has been resolved, and normal production of preparation device 1 is resumed.

[0084] Continuous testing ensures the production system returns to stability, prevents recurrence of defects due to incomplete maintenance, and guarantees the quality of subsequent products.

[0085] Furthermore, the method also includes the following steps: Obtain the historical test data set corresponding to the finished quartz crucibles; the historical test data set shall include at least the historical bulk density test data and historical flexural strength test data of all finished quartz crucibles that have been tested and meet the standard test parameter requirements within the same production batch; Based on historical volume density test data and historical flexural strength test data in the historical test data set, calculate the correlation coefficient between volume density and flexural strength, and determine the risk threshold of volume density based on the correlation coefficient. If the bulk density of the current finished quartz crucible is less than or equal to the risk threshold, a detection warning message is generated; the detection warning message is used to characterize that the bending strength of the finished quartz crucible has an abnormal risk. If the bending strength of the finished quartz crucible meets the standard test parameter requirements, the bending strength of the finished quartz crucible will be tested a second time to determine whether the result of the second test is consistent with the bending strength of the finished quartz crucible. If they are consistent, the bulk density will be tested a second time. Calculate the difference between the volume density of the secondary test and the volume density of the finished quartz crucible. If the difference is less than the error density setting value, it indicates that the volume density test is correct, and the risk threshold is updated.

[0086] It should be noted that historical testing data sets corresponding to the finished quartz crucibles can be obtained from the crucible production records. These historical testing data sets comprise all relevant data from finished quartz crucibles within the same production batch that have been tested and meet the standard testing parameters. This primarily includes historical bulk density and flexural strength test data. This historical data characterizes the bulk density and flexural strength performance of the product under normal production conditions for that production batch. For example, a production batch may contain 100 qualified quartz crucibles; the bulk density values ​​and performance data (flexural strength data) of these crucibles under high-temperature conditions are recorded in this set.

[0087] The correlation coefficient between volumetric density and flexural strength is calculated using historical volumetric density and flexural strength test data. Here, the correlation coefficient measures the strength of the linear relationship between two variables, ranging from -1 to 1. A correlation coefficient close to 1 indicates a strong positive correlation between volumetric density and flexural strength, meaning that as volumetric density increases, flexural strength tends to increase as well. A correlation coefficient close to -1 indicates a strong negative correlation, and a correlation coefficient close to 0 indicates a weak linear relationship. By calculating this correlation coefficient, the degree of association between volumetric density and flexural strength can be quantified.

[0088] Specifically, the Pearson Correlation Coefficient can be used for calculation.

[0089] The mean values ​​of the bulk density data and the mean values ​​of the flexural strength data are calculated using the following formulas: ; ; in, The mean of the volume density data. For the number of data points, For the i-th volume density data, This represents the average of the flexural strength data. This represents the i-th flexural strength data.

[0090] Covariance measures the overall error between two variables, reflecting whether their trends are consistent. The covariance is calculated using the following formula: ; in, For covariance.

[0091] Calculate the standard deviation of bulk density and the standard deviation of flexural strength using the following formulas: ; ; in, The standard deviation of the bulk density, This represents the standard deviation of the bending strength.

[0092] Substituting the calculated values ​​into the Pearson correlation coefficient formula, we get: ; in, The correlation coefficient.

[0093] The risk threshold is determined based on the calculated correlation coefficient. This risk threshold is used to identify quartz crucibles that may have an abnormal flexural strength. For example, if the calculated correlation coefficient shows a strong positive correlation between bulk density and flexural strength, a lower bulk density value can be set as the risk threshold. When the bulk density is less than or equal to the risk threshold, it indicates an abnormality in flexural strength. Here, the risk threshold can be matched based on experience and the correlation coefficient.

[0094] For example, the risk threshold comparison table is shown in Table 2. The correlation coefficient ranges and specific risk threshold data in the table are for illustrative purposes only and are not limitations on this solution. Here, the risk thresholds corresponding to different correlation coefficient ranges in the risk threshold comparison table can be further refined according to the type of application scenario to make the risk thresholds more accurate.

[0095] Risk Threshold Comparison Table

[0096] When inspecting finished quartz crucibles, if their bulk density is found to be less than or equal to a risk threshold, the system will generate a detection alert. This alert alerts operators that the flexural strength of the finished quartz crucible may be at risk. This is a preliminary judgment based on previously calculated correlation coefficients and the set risk threshold. While it cannot directly determine that the flexural strength is unqualified, it indicates that further testing is required. For example, in actual production, when the bulk density of a crucible is detected to reach the risk threshold, the system will display a notification box informing staff that the crucible's flexural strength may be problematic and requires close monitoring.

[0097] If the tested flexural strength of the finished quartz crucible meets the standard testing parameters, it indicates that the flexural strength test of the finished quartz crucible may have been a false positive. A second test is required to determine if the result of the second test is consistent with the previously tested flexural strength. If the results are inconsistent, it indicates a malfunction in the current high-temperature performance testing mechanism 11. If the results are consistent, it may indicate a malfunction in the current density testing mechanism 10. A second test of the bulk density of the finished quartz crucible is required. The difference between the second test's bulk density and the previously tested bulk density is calculated. If the difference is less than the error density setting value, it indicates that the aforementioned density testing mechanism 10 is correct, and the data in the risk threshold comparison table needs to be updated. If the difference is greater than or equal to the error density setting value, it indicates that the aforementioned density testing mechanism 10 is incorrect, and the incorrect density testing mechanism 10 should be replaced. Here, the error density setting value can be set according to the actual situation.

[0098] After all crucibles have been inspected, those quartz crucibles whose bending strength does not meet the standard testing parameters are marked and transferred to the non-conforming product storage area. Marking non-conforming products facilitates differentiation and management, preventing confusion with conforming products; transferring them to the non-conforming product storage area prevents these non-conforming products from entering subsequent production stages or the market, ensuring the consistency and reliability of product quality. For example, in the non-conforming product storage area, non-conforming products are affixed with prominent labels indicating the reason for non-conformity and batch information, facilitating subsequent analysis and processing, such as rework or scrapping.

[0099] Furthermore, the method also includes the following steps: If the total number of crucibles in the crucible buffer area between the detection device 2 and the preparation device 1 is greater than or equal to the target number of crucibles in the buffer area, the transfer speed between the preparation device 1 and the current crucible buffer area is adjusted to extend the time for the finished quartz crucible to reach the current crucible buffer area.

[0100] It should be noted that when determining whether the total number of crucibles in the crucible buffer area between the detection device 2 and the preparation device 1 at the initial moment exceeds the target crucible buffer number, if the total number of crucibles between the detection device 2 and the preparation device 1 is less than the target crucible buffer number, there is no need to adjust the transfer speed between the preparation device 1 and the current crucible buffer area. If the total number of crucibles is greater than or equal to the target crucible buffer number, it indicates that the current crucible buffer area is full of finished quartz crucibles. In this case, it is necessary to adjust the transfer speed between the preparation device 1 and the current crucible buffer area. That is, by reducing the transfer speed, the time for finished quartz crucibles to reach the current crucible buffer area is extended, so as to avoid the finished quartz crucibles from failing to enter the current crucible buffer area normally during the transfer process and causing accumulation on the corresponding transfer equipment 13. This ensures that the production and testing work can proceed in an orderly manner and maintains the balance and efficient operation of the entire production and testing system.

[0101] Furthermore, the method also includes the following steps: The processing technology data and equipment operating status of each unit of the preparation device 1 are collected in real time. If the processing technology data and / or equipment operating status exceed the allowable fluctuation range, an alarm message is issued and the corresponding preparation device 1 is shut down.

[0102] It should be noted that during the preparation of the quartz crucible, all units of the preparation apparatus 1, including the feeding unit 3, melting unit 4, sandblasting unit 5, and cleaning unit 6, are continuously operating. To ensure the normal operation of the production process and the stability of product quality, it is necessary to collect the processing technology data and equipment operating status of these units in real time. The processing technology data covers the key parameters of each unit during operation, such as the amount and frequency of raw material added in the feeding unit 3; the temperature and vacuum degree in the melting unit 4; the sandblasting pressure and spraying time in the sandblasting unit 5; and the cleaning solution concentration and cleaning time in the cleaning unit 6. The equipment operating status includes the rotation speed of the equipment, the operating status of each component, and information such as abnormal vibration or noise. These data and status information are collected in real time using sensors, monitoring instruments, and automated control systems for subsequent analysis and judgment.

[0103] During production, each processing data point and equipment operating status parameter has its allowable fluctuation range. This allowable fluctuation range is determined based on equipment design requirements, production process standards, and long-term production experience. For example, the temperature of melting unit 4 is allowed to fluctuate within ±5℃ of the set temperature. If the temperature exceeds this range, it may cause changes in the internal structure of the quartz crucible, affecting its quality. Similarly, equipment operating status also has corresponding standards. For instance, if the vibration amplitude of the equipment exceeds a certain value, it indicates a mechanical fault that requires timely handling. The system compares the real-time collected data and status information with the pre-set allowable fluctuation range to determine if any abnormalities exist.

[0104] When processing data and / or equipment operating status exceed the allowable fluctuation range, the system will immediately issue an alarm notification. Alarm methods can be varied, such as audible and visual alarms, attracting operators' attention with flashing lights and loud siren sounds; or notifications can be sent via SMS, system pop-ups, etc. The purpose of issuing alarm notifications is to promptly inform operators of any abnormalities in the production process and the need for appropriate measures. Simultaneously, to prevent further deterioration of the abnormality, affecting product quality or even damaging equipment, the system will automatically shut down the corresponding preparation unit 1. Shutdown prevents the continued production of defective products, reduces economic losses, and avoids more serious safety accidents caused by equipment failure. After shutdown, operators can check and adjust the equipment and process based on the alarm information and collected data, troubleshoot the problem, and then resume production, thereby ensuring the stability of the production process and the reliability of product quality.

[0105] This application also provides a large-size quartz crucible with high density and high strength, comprising: a quartz crucible prepared using the above-described method for preparing a large-size quartz crucible with high density and high strength.

[0106] The quartz crucibles manufactured using the above-described preparation method ensure high density and strength through meticulous attention to every detail, from raw material selection and processing technology to quality inspection. In actual production, this close integration allows for standardized and large-scale production, improving efficiency, reducing costs, enhancing market competitiveness, and meeting the growing demand for large-size, high-quality quartz crucibles from the semiconductor and photovoltaic industries.

[0107] The above description is merely a preferred embodiment of this application and an explanation of the technical principles employed. Those skilled in the art should understand that the scope of the invention involved in this application is not limited to technical solutions formed by specific combinations of the above-described technical features, but should also cover other technical solutions formed by arbitrary combinations of the above-described technical features or their equivalents without departing from the inventive concept. For example, technical solutions formed by substituting the above features with (but not limited to) technical features with similar functions disclosed in this application.

Claims

1. A method for preparing a large-size quartz crucible with high density and high strength, characterized in that, The method includes the following steps: Obtain the identification number of the finished quartz crucible and its corresponding test index, as well as the test duration and test complexity parameters of the test index; divide the test indexes corresponding to the test durations within the same preset time range into the same test level; obtain the first ranking of the test level according to the test complexity parameters corresponding to each test level; and obtain the second ranking corresponding to each test index according to the first ranking and the test duration of each test index within each test level. Based on the identification number, the standard testing parameter requirements for the finished quartz crucible are determined. The test indicators of the finished quartz crucible are tested according to the second sorting. If the current test indicator meets the standard testing parameter requirements and the testing institutions corresponding to the next test indicator are all in working condition, the finished quartz crucible is stored in the crucible buffer area located between the testing institution corresponding to the currently tested test indicator and the testing institution corresponding to the next test indicator. The crucible waiting time and the number of crucibles corresponding to each identification number in the current crucible buffer area are recorded. If the testing mechanism for the next test indicator corresponding to any quartz crucible finished product in the crucible buffer area is switched to an idle state, then the quartz crucible finished product is taken as the target test finished product; and when the number of target test finished products is greater than 1, the quartz crucible finished product with the longest waiting time among the target test finished products with the largest number of the same identification number is transferred to the testing mechanism in an idle state for testing, and it is determined whether the test indicator meets the standard test parameter requirements. When all the test indicators of the finished quartz crucible meet the requirements of the standard test parameters, it is packaged and stored.

2. The method for preparing a large-size quartz crucible with high density and high strength according to claim 1, characterized in that, The indicators to be tested include at least size, surface quality, internal defects, bulk density, and flexural strength; the preset time interval includes at least a first time interval, a second time interval, and a third time interval; the time values ​​of the first time interval, the second time interval, and the third time interval increase sequentially. The testing device (2) includes a size testing mechanism (7), a surface quality testing mechanism (8), an internal defect testing mechanism (9), a density testing mechanism (10), and a high-temperature performance testing mechanism (11); and a crucible buffer area is provided between two adjacent testing mechanisms, the crucible buffer area being used to store finished quartz crucibles awaiting testing; the size testing mechanism (7) is used to test the size of the finished quartz crucibles, the surface quality testing mechanism (8) is used to test the surface quality of the finished quartz crucibles; the internal defect testing mechanism is used to test the cracks and pores of the finished quartz crucibles, the density testing mechanism (10) is used to test the bulk density of the finished quartz crucibles; the high-temperature performance testing mechanism (11) is used to test the bending strength of the finished quartz crucibles. The detection indicators corresponding to the detection durations within the same preset duration range are divided into the same detection level. A first ranking of the detection levels is obtained based on the detection complexity parameter corresponding to each detection level. A second ranking is obtained based on the first ranking and the detection duration of each detection indicator within each detection level. Specifically, this includes the following steps: Obtain the detection time and detection complexity parameters of the size detection mechanism (7), surface quality detection mechanism (8), internal defect detection mechanism (9), density detection mechanism (10) and high temperature performance detection mechanism (11) corresponding to each of the indicators to be detected; The detection indexes whose detection duration falls within the first duration interval are obtained and marked as the first detection level; the detection indexes whose detection duration falls within the second duration interval are obtained and marked as the second detection level; and the detection indexes whose detection duration falls within the third duration interval are obtained and marked as the third detection level. Based on the detection complexity parameters corresponding to the indicators to be detected at the same detection level, the level complexity parameters are determined, and the detection levels are sorted in ascending order of the level complexity parameters to obtain the first sort. In the first sorting, each indicator to be detected within each detection level is sorted from smallest to largest according to its corresponding detection duration to obtain the second sorting corresponding to each indicator to be detected.

3. The method for preparing a large-size quartz crucible with high density and high strength according to claim 2, characterized in that, Obtaining the identification number of the finished quartz crucible and its corresponding test indicators includes the following steps: If the application scenario of the finished quartz crucible is determined to be the first risk scenario based on the identification number, then the size, surface quality, internal defects, bulk density and bending strength will all be used as the indicators to be tested. If the application scenario of the finished quartz crucible is determined to be the second risk scenario based on the identification number, and the number of finished quartz crucibles with the same identification number that were last tested for volume density is less than a preset number, then the size, surface quality, internal defects and bending strength will be used as the indicators to be tested. The standard detection parameter requirements for volume density in the first risk scenario are higher than those for the second risk scenario.

4. The method for preparing a large-size quartz crucible with high density and high strength according to claim 3, characterized in that, It also includes the following steps: If it is determined that the current detected volume density does not meet the requirements of the standard detection parameters, then the value of the preset quantity is adjusted; If the volume density of the next test still does not meet the requirements of the standard test parameters, it is determined that there are abnormal problems in the processing technology data and equipment operation status of each unit of the preparation device (1). The corresponding preparation device (1) is shut down for maintenance, and the prepared device (1) after maintenance is used to produce a preset number of test products. The preset number is set to 1 to test the volume density of all the test products until the volume density test pass rate is greater than or equal to the target pass rate. Then the preparation device (1) is restored to normal production.

5. The method for preparing a large-size quartz crucible with high density and high strength according to claim 2, characterized in that, It also includes the following steps: Obtain the historical test data set corresponding to the finished quartz crucible; the historical test data set shall include at least the historical bulk density test data and historical flexural strength test data of all finished quartz crucibles that have been tested and meet the requirements of the standard test parameters within the same production batch; Based on the historical volume density test data and historical flexural strength test data in the historical test data set, calculate the correlation coefficient between volume density and flexural strength, and determine the risk threshold of volume density based on the correlation coefficient. If the bulk density of the finished quartz crucible is less than or equal to the risk threshold, a detection warning message is generated; the detection warning message is used to characterize that the bending strength of the finished quartz crucible has an abnormal risk. If the bending strength of the finished quartz crucible meets the standard test parameter requirements, the bending strength of the finished quartz crucible will be tested a second time to determine whether the result of the second test is consistent with the bending strength of the finished quartz crucible. If they are consistent, the bulk density will be tested a second time. Calculate the difference between the secondary detection volume density and the previously detected volume density of the quartz crucible. If the difference is less than the error density setting value, it indicates that the volume density detection is correct, and the risk threshold is updated.

6. The method for preparing a large-size quartz crucible with high density and high strength according to claim 1, characterized in that, The method further includes the following steps: If the total number of crucibles in the crucible buffer area between the testing institution corresponding to the currently completed test indicator and the testing institution corresponding to the next test indicator is greater than or equal to the target crucible buffer number, and the testing institutions corresponding to the next test indicator of all quartz crucible finished products in the crucible buffer area are in working condition, then the transfer speed between the testing institution corresponding to the currently completed test indicator and the current crucible buffer area is adjusted to extend the time for the quartz crucible finished product to reach the current crucible buffer area.

7. The method for preparing a large-size quartz crucible with high density and high strength according to claim 6, characterized in that, Adjusting the transfer speed between the testing institution corresponding to the currently tested indicator and the current crucible buffer area involves the following steps: Get the operating speed of the transfer device (13) between the testing institution corresponding to the currently completed test index and the current crucible buffer area; and determine the initial adjustment range of the transfer speed of the transfer device (13) according to the proportion of the total number of crucibles in the crucible buffer area exceeding the target crucible buffer number. Obtain the workload status of the testing institution corresponding to the next indicator to be tested. If the testing time corresponding to the workload status exceeds the preset testing time, the initial adjustment range and the preset adjustment range are superimposed as the final adjustment range, and an adjustment instruction is sent to the transfer equipment (13). The adjustment instruction carries the final adjustment range so that the transfer equipment (13) runs at the transfer speed adjusted according to the final adjustment range.

8. The method for preparing a large-size quartz crucible with high density and high strength according to claim 1, characterized in that, Based on the identification number, the standard testing parameter requirements for the finished quartz crucible are determined, specifically including the following steps: Obtain the finished product testing database and search for the standard testing parameter requirements corresponding to the identification number in the finished product testing database; the finished product testing database includes at least multiple identification numbers and the standard testing parameter requirements corresponding to each identification number.

9. The method for preparing a large-size quartz crucible with high density and high strength according to claim 1, characterized in that, The method is applied to a quartz crucible preparation system, which includes a data monitoring module (12) that is communicatively connected to a preparation device (1) and a detection device (2). The data monitoring module (12) is used to monitor in real time the production progress of the preparation device (1) and the total number of crucibles in the crucible buffer area between the preparation device (1) and the detection device (2). The method further includes the following steps: If the total number of crucibles in the crucible buffer area between the detection device (2) and the preparation device (1) is greater than or equal to the target number of crucibles, the transfer speed between the preparation device (1) and the current crucible buffer area is adjusted to extend the time for the finished quartz crucible to reach the current crucible buffer area.

10. A system for preparing a large-size quartz crucible with high density and high strength, used to implement the method for preparing a large-size quartz crucible with high density and high strength as described in any one of claims 1-9, characterized in that, The system includes: Multiple preparation devices (1) and one detection device (2); each preparation device (1) includes a feeding unit (3), a melting unit (4), a sandblasting unit (5), and a cleaning unit (6); the feeding unit (3) is used to pre-treat the raw materials and transfer them to the melting unit (4); the melting unit (4) is used to evacuate and melt the pre-treated raw materials to obtain a quartz crucible semi-finished product; the sandblasting unit (5) is used to spray a barium coating onto the inner wall of the quartz crucible semi-finished product to obtain a quartz crucible finished product; the detection device (2) is used to detect the quartz crucible finished product; The control unit is communicatively connected to the preparation device (1) and the detection device (2), and is used to detect and control the operating status of the preparation device (1) and the detection device (2) in real time. The control unit is further configured to determine the corresponding standard testing parameter requirements and a second sorting based on the identification number and corresponding test index of the quartz crucible product prepared by the preparation device (1), and to test each of the test indexes of the quartz crucible product according to the second sorting. If the current test index meets the standard testing parameter requirements and the testing institutions corresponding to the next test index are all in working condition, the current quartz crucible product is stored in the crucible buffer area located between the testing institution corresponding to the currently tested test index and the testing institution corresponding to the next test index, and the crucible waiting time and the current crucible buffer time are recorded. The number of crucibles corresponding to each identification number in the storage area; if the testing institution for the next test indicator corresponding to any quartz crucible finished product in the crucible buffer area is switched to an idle state, then the quartz crucible finished product is taken as the target test finished product; when the number of the target test finished products is greater than 1, the quartz crucible finished product with the longest waiting time among the target test finished products with the largest number of the same identification number is transferred to the testing institution in an idle state for testing, and it is determined whether the test indicator meets the standard testing parameter requirements; when all the test indicators of the quartz crucible finished product meet the standard testing parameter requirements, it is packaged and stored.

Images