Coater Head Coagula Detection Using Thickness Difference Feedback
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Solution Overview
Problem
The current methods for detecting coagulum on coater heads are inefficient, particularly when the coater head is installed inside the coating machine, leading to potential blocking and uneven coating thickness, which affects the quality of the optical diaphragm.
Innovation Solution
A method that involves detecting the thickness of the coating material along the coating direction using a probe or ultrasonic detector, calculating the difference in thickness values at different positions, and outputting a feedback signal if the difference exceeds a preset value to indicate coagulum attachment, allowing for automatic cleaning or stopping of the coater operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If human periodic checking of coagula on coater head is used, then the coater head can be cleaned, but the detection efficiency is low and it becomes difficult when coater head is installed inside the coater
Solution Approach 1:
The patent replaces manual visual inspection with an automated optical detection system. A light source illuminates the coater head area, and a sensor detects changes in light transmission or reflection caused by coagula accumulation. This automated system continuously monitors the coater head condition without requiring human intervention, significantly improving detection efficiency and eliminating the difficulty of accessing internally mounted coater heads.
Solution Approach 2:
The detection system is integrated into the coater's control system, enabling self-monitoring and self-diagnosis. The system automatically detects coagula formation, generates alerts, and can even trigger cleaning operations without human intervention, allowing the coater to service itself and maintain optimal performance continuously.
2Duration of action of moving object
If coater head is not cleaned regularly, then operation continuity is maintained, but coagula block the coater head causing uneven coating thickness
Solution Approach 1:
The patent implements a closed-loop feedback system where the optical sensor continuously monitors coagula accumulation on the coater head. When the detected coagula thickness reaches a predetermined threshold that would affect coating quality, the system automatically generates a cleaning signal or alarm. This feedback mechanism enables timely cleaning operations before coagula can cause uneven coating thickness, thus maintaining both operational continuity and manufacturing precision.
Solution Approach 2:
The detection system identifies coagula accumulation at early stages, before it becomes severe enough to block the coater head or affect coating quality. By detecting and alerting operators in advance, the system enables preventive cleaning actions that maintain optimal coater performance and prevent defects in the coating process.
3Loss of time
If coagula accumulate on coater head, then no immediate intervention is needed, but the coater head becomes blocked affecting discharge effect and coating quality
Solution Approach 1:
The optical detection system provides continuous real-time monitoring of coagula accumulation on the coater head. When coagula reach a critical threshold that would impair coater head functionality or coating quality, the system immediately generates an alarm or automatic cleaning signal. This real-time feedback eliminates delays in detection and enables immediate intervention, preventing functional failures and maintaining reliable operation.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method improves the efficiency of coater head maintenance by automatically detecting coagulum attachment and preventing blocking, ensuring consistent coating thickness and quality of the optical diaphragm.
Implementation Method 1
abutting a probe on the coating material and causing the probe to slide along the coating direction; outputting a voltage signal indicating the thickness of the coating material, through a transformer in connection with the probe during the sliding of the probe
Implementation Method 2
placing an ultrasonic probe of an ultrasonic detector above the coating material on the substrate, and causing the ultrasonic probe to move along the coating direction; transmitting an ultrasonic wave to the coating material on the substrate during the movement of the ultrasonic probe, receiving a reflected ultrasonic wave by a receiver of the ultrasonic detector, and outputting a time signal by the ultrasonic detector according to a reflection time of the ultrasonic wave
Data Source
AI summary
The present application provides a method for detecting coagula on a coater head. The method includes: detecting a thickness value of a coating material (2) on a substrate along a coating direction thereof; acquiring a first thickness value and a second thickness value, and calculating a difference value; and comparing an absolute value of the difference value with a preset value, and outputting a feedback signal if the absolute value of the difference value exceeds the preset value.