Automated Height Sensor Positioning via Calibration Signal

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Solution Overview

Problem

Existing methods for determining the position of noncontact height sensors, such as laser height sensors, in fluid dispensing systems are prone to human error and operator stress, leading to inaccuracies in creating a topographical map of electronic substrates, which can result in misplaced material dispensing.

Innovation Solution

An apparatus and method that automatically determines the position of a height sensor using a calibration device that generates an alignment signal in response to electromagnetic radiation from the height sensor, eliminating the need for manual alignment and reducing operator stress, thereby improving the accuracy of the camera-height sensor offset vector and enabling precise material dispensing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If manual alignment method is used to determine height sensor position, then operator can perform calibration, but human error and operator stress lead to inaccuracies in topographical mapping

Engineering Contradiction:

Improveheight sensor position accuracyVSAvoidcalibration accuracy

Core Design Contradiction:

Measurement precisionVSReliability

Solution Approach 1:

The calibration device performs self-alignment with the height sensor through automatic detection of electromagnetic radiation alignment, eliminating the need for manual operator intervention. The system self-calibrates by detecting when the height sensor's electromagnetic radiation is properly aligned with the calibration device, thereby removing human error and operator stress from the calibration process.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The patent replaces the manual mechanical alignment process with an automated electromagnetic detection system. Instead of operators manually positioning and aligning the height sensor, the system uses electromagnetic radiation detection to automatically determine when proper alignment is achieved, substituting mechanical manual operation with automated electromagnetic field-based positioning.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Measurement precision

If automated alignment is implemented, then accuracy is improved, but additional calibration devices and systems are required

Engineering Contradiction:

Improvecamera-height sensor offset accuracyVSAvoidcalibration system complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The calibration device serves as an intermediary element that facilitates automatic alignment between the height sensor and the imaging device. This intermediary component enables the automated detection and alignment process by providing a reference target that responds to electromagnetic radiation, allowing the system to determine proper positioning without complex direct sensor-to-sensor communication.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Ease of manufacture

If contact height sensors are used, then calibration can be performed by making an indentation, but the substrate is damaged and the method is obsolete

Engineering Contradiction:

Improvecalibration process simplicityVSAvoidsubstrate damage

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The patent replaces the mechanical contact-based calibration method with a non-contact electromagnetic radiation-based method. Instead of physically indenting the substrate with a contact sensor, the system uses electromagnetic radiation from the height sensor to automatically calibrate position, eliminating mechanical damage to the substrate while maintaining calibration functionality.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 approach enhances the accuracy of material dispensing on electronic substrates by automatically aligning the height sensor, reducing errors and operator fatigue, and allowing for more precise positioning of the dispensing assembly, leading to improved topographical mapping and material deposition.

Implementation Method 1

a height sensor (21) configured to emit electromagnetic radiation

Methodology Applied

Scientific EffectElectromagnetic radiation: Light

Implementation Method 2

a calibration device (66) configured to receive the electromagnetic radiation emitted from the height sensor and to cause an alignment signal to be communicated to the controller when the electromagnetic radiation is received by the calibration device

Methodology Applied

Scientific EffectElectromagnetic radiation reception: Absorption (EM radiation)

Data Source

PatentUS8944001B2Automated position locator for a height sensor in a dispensing system

Publication Date: 2015.02.03 NORDSON CORP

AI summary

Apparatus and methods of determining a position of a height sensor in a dispensing system. The dispensing system includes a dispenser, height sensor, camera, and a calibration device configured to receive a signal from the height sensor. The calibration device may include an optical sensor that generates an alignment signal in response to receiving light from the height sensor and/or a fiducial that causes the height sensor to generate the alignment signal in response to a detected height change. The alignment signal is used to automatically determine the position at which the height sensor is aligned with the calibration device. The position of the height sensor relative to a camera is determined by aligning the camera with the calibration device and recording its position. The recorded coordinates of the camera are compared to the coordinates of the height sensor when the height sensor is automatically aligned with the calibration device.