Dispenser Calibration via Dynamic Motion Replication
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing dispensing systems for viscous materials like solder paste face challenges in accurately calibrating the amount dispensed due to the static nature during calibration, which affects the consistency and accuracy of material deposition.
Innovation Solution
The system mimics the movement of the dispenser during the calibration routine, using a weigh scale to adjust parameters such as gantry speed or auger screw rotation to ensure the material flows consistently, replicating the dispensing operation on a substrate, and adjusts shot size for jetter-type dispensers to achieve accurate deposition within predetermined tolerances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the dispenser is kept static during calibration, then the calibration process is simplified, but the accuracy and consistency of material deposition deteriorates
Solution Approach 1:
The patent applies the Dynamics principle by transitioning the calibration process from a static state to a dynamic state. The dispenser is moved during calibration to replicate the actual dispensing motion, which ensures that the material flows consistently and accurately. This dynamic calibration approach resolves the contradiction by maintaining calibration simplicity while significantly improving material deposition accuracy and consistency.
2Manufacturing precision
If the dispenser moves during calibration, then the accuracy and consistency of material deposition improves, but the calibration process complexity increases
Solution Approach 1:
The patent applies the Self-service principle by designing a calibration system that uses the dispenser's own motion capabilities to perform calibration. The system leverages the existing gantry and dispenser mechanisms already present in the dispensing system, eliminating the need for separate complex calibration equipment. This approach improves material deposition consistency while avoiding significant increases in overall system complexity.
3Device complexity
If traditional weighing methods are used for calibration, then the equipment required is simple, but the ability to control dispensed amount accurately deteriorates
Solution Approach 1:
The patent applies the Feedback principle by implementing a closed-loop calibration system. The weigh scale measures the actual amount of material dispensed, and this measurement is fed back to the controller, which adjusts the dispensing parameters accordingly. This feedback mechanism enables accurate control of the dispensed amount while using relatively simple weighing equipment, resolving the contradiction between equipment simplicity and measurement precision.
Data Source
AI summary
A method of calibrating a dispenser of the type having a material dispensing unit that is configured to dispense material on a substrate includes providing a weigh scale having a plate configured to receive material dispensed on the plate, dispensing one or more patterns of material on the plate; weighing the amount of material dispensed on the plate, and comparing the weighed amount of material to a designated amount of material. The act of dispensing one or more patterns of material replicates at least a portion of patterns of material dispensed on the substrate during a dispensing operation. A controller for performing the method is further disclosed.