Die Coater Lip Inspection for Precise In-Line Gap Measurement
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Solution Overview
Problem
Existing die coaters face challenges in accurately measuring the position and height of lips and shims due to assembly tolerances and deviations, leading to inconsistent electrode quality, and require manual inspection that is prone to user error and time-consuming separate measurement processes.
Innovation Solution
A die coater inspection device with a sensor module and control system that includes position and distance detection sensors to automatically measure lip and shim positions and heights, allowing for precise inspection without manual contact or separate inspection lines.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual measurement with micrometer is used, then measurement capability is achieved, but measurement precision deteriorates due to user error and difficulty accessing narrow gaps
Solution Approach 1:
The patent replaces manual mechanical measurement with micrometer with an automated optical measurement system. The imaging device captures images of the discharge port gap, and image processing algorithms automatically calculate the gap distance, eliminating the need for manual micrometer operation and associated user errors.
Solution Approach 2:
The patent introduces an intermediary imaging system that indirectly measures the gap by capturing visual information and processing it through image analysis algorithms. This intermediary approach allows measurement of narrow gaps that are difficult to access directly with physical tools.
2Measurement precision
If separate inspection line is provided, then inspection capability is achieved, but productivity deteriorates due to additional time and process steps
Solution Approach 1:
The patent merges the inspection function directly into the die coater assembly process. The imaging device is integrated to measure the discharge port gap in-situ during or immediately after assembly, combining the assembly and inspection operations into a unified process flow without requiring separate inspection lines.
Solution Approach 2:
The patent performs gap measurement immediately after assembly while the components are still in position, capturing the gap dimension before any potential shifts occur. This preliminary measurement ensures accurate data is obtained while the assembly is in its intended configuration.
3Ease of manufacture
If die and shim are disassembled for cleaning, then maintenance is achieved, but manufacturing precision deteriorates due to position deviation upon reassembly
Solution Approach 1:
The patent performs gap measurement before disassembly for cleaning, capturing the gap dimension while the components are in their assembled state. This preliminary measurement allows verification of assembly quality before maintenance activities that might cause position deviations.
Solution Approach 2:
The patent uses image processing to provide feedback on the actual gap dimension, allowing operators to verify assembly quality and detect deviations. This feedback mechanism helps identify assembly issues before disassembly and ensures proper reassembly after maintenance.
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
Enables accurate and efficient inspection of die coaters in-line, reducing user error and increasing production efficiency by automating the measurement of lip and shim positions and heights, ensuring consistent electrode quality.
Implementation Method 1
an image signal obtained by the imaging device may be processed to calculate a distance between the first lip and the second lip
Data Source
AI summary
A die coater inspection device including: a sensor module configured to inspect a lip or the shim of the die coater; a control part configured to control an operation of the sensor module; and a storage part in which reference data on the thickness of the lip or the shim is stored.