3D-Aware Dispensing Control for Contoured Electronic Substrates
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Solution Overview
Problem
Existing dispensing systems face challenges in accurately and efficiently generating control programs for dispensing liquid or viscous materials onto complex substrates with three-dimensional contours, often resulting in collisions or inefficient material application due to the need for manual creation or extensive CAD model libraries.
Innovation Solution
The system uses a camera and height sensor to generate a two-dimensional image and height map of the substrate, allowing for the creation of a control program that positions the applicator relative to the substrate, avoiding collisions and ensuring precise material application by correlating the image and height data to determine the optimal dispensing positions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a technician manually creates the control program, then the dispensing process can be customized for specific substrates, but the process becomes slow and inefficient
Solution Approach 1:
The system performs self-measurement and self-programming by automatically capturing substrate images, generating 3D models, and creating control programs without technician intervention. The automated image processing and coordinate extraction systems enable the dispensing system to program itself, eliminating manual control program creation while maintaining substrate-specific customization.
Solution Approach 2:
Manual control program creation is replaced with automated optical measurement and computational processing. The system uses cameras, image processing algorithms, and 3D modeling software to automatically generate control programs, substituting manual mechanical programming with automated digital systems.
2Manufacturing precision
If a CAD model library is used to generate control programs, then dispensing accuracy can be improved, but significant time and financial overhead is required to maintain the library
Solution Approach 1:
Instead of maintaining a library of pre-existing CAD models, the system creates accurate 3D digital copies of each substrate by capturing images and generating models from actual measurements. This on-demand copying eliminates the need for maintaining extensive CAD libraries while providing precise digital representations for control program generation.
Solution Approach 2:
The system performs preliminary measurement and 3D model generation for each substrate before dispensing operations. By capturing substrate geometry and creating control programs in advance through automated imaging, the system ensures dispensing accuracy without requiring pre-maintained CAD libraries.
3Ease of operation
If the control program does not account for three-dimensional contours, then the dispensing process is simpler, but the applicator may collide with components or damage substrate elements
Solution Approach 1:
The system transitions from 2D planar dispensing to 3D contour-aware dispensing by capturing substrate topography through image processing and generating 3D models. The control program incorporates Z-axis height information to adjust applicator positioning, enabling safe navigation over three-dimensional contours while maintaining operational simplicity through automated 3D modeling.
Data Source
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AI summary
Systems and methods for dispensing a liquid or viscous material onto a substrate are disclosed herein. One exemplary method of positioning an applicator of a dispensing system to apply a liquid or viscous material to an electronic substrate includes generating a two-dimensional image of the electronic substrate using a camera communicatively connected to the dispensing system. Based on the two-dimensional image of the electronic substrate, a first set of one or more sub-regions of the electronic substrate having one or more components that protrude above the surface of the electronic substrate is identified. The method further includes using height information relating to the one or more sub-regions having the one or more components to determine a control program for the dispensing system to position the applicator relative to the electronic substrate and dispense the liquid or viscous material onto the electronic substrate.