Ingot Growth Control via Simultaneous Pulling Speed and Heater Power Adjustment
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Solution Overview
Problem
Existing ingot growth control systems face challenges in quickly and accurately controlling the diameter of ingots during the ingot growing process, leading to overcorrection of diameter and quality issues due to delayed response times in reflecting diameter errors and heater power adjustments.
Innovation Solution
An ingot growth control device and method that simultaneously control the pulling speed and heater power based on filtered diameter data, using PID equations with adjustable delay and reaction times to minimize errors and optimize response speed, allowing independent and rapid adjustment of ingot diameter and quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the control system changes pulling speed to match target pulling speed by reading diameter change amount through current diameter monitoring system and PID controller calculation, then the diameter control follows a multi-step process, but the response time to control diameter and quality actually increases
Solution Approach 1:
The patent divides the control system into three independent controllers: a diameter controller that directly controls pulling speed based on diameter measurement, an average growth controller that calculates average growth rate and outputs temperature correction amounts, and a temperature controller that controls heater power. This segmentation allows each controller to operate independently and simultaneously, eliminating the sequential delay of the traditional multi-step process while maintaining precise diameter control.
2Manufacturing precision
If the system takes several steps to reflect diameter error and correct heater power, then the control process is thorough, but it takes about 1 to 5 minutes to control diameter by changing pulling speed and about 20 minutes to affect actual ingot by heater power control
Solution Approach 1:
The patent implements preliminary action by having the diameter controller directly adjust pulling speed in real-time based on diameter measurement, without waiting for the multi-step process to complete. The average growth controller simultaneously calculates temperature correction amounts based on the diameter error, preparing temperature adjustments in advance. This allows the system to respond immediately to diameter deviations, reducing control time from minutes to seconds while maintaining accuracy.
3Manufacturing precision
If the diameter and quality of ingot are overcorrected due to delayed response time, then the system attempts to compensate for delays, but it becomes difficult to obtain desired ingot diameter and quality
Solution Approach 1:
The patent implements real-time feedback control where the diameter controller continuously monitors diameter measurement and immediately adjusts pulling speed to eliminate diameter error. The average growth controller simultaneously provides feedback on temperature correction amounts based on the same diameter error. This dual feedback mechanism ensures that corrections are applied promptly and accurately, preventing overcorrection while maintaining desired ingot diameter and quality.
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 significantly reduces diameter deviation and pulling speed errors, improving ingot quality and uniformity, with a 63.3% reduction in diameter deviation and 56.8% reduction in pulling speed error compared to traditional methods, resulting in higher crystal quality and productivity.
Implementation Method 1
heating a raw material accommodated in a crucible in a melt state
Implementation Method 2
growing an ingot from a melt accommodated in the crucible to a target diameter
Data Source
AI summary
The present invention relates to an ingot growth control device capable of quickly and accurately controlling a diameter of an ingot during an ingot growing process and improving quality of the ingot, and a control method thereof.In the ingot growth control device and a control method thereof according to the present invention, when an input unit provides diameter data obtained by filtering a diameter measurement value of an ingot, a diameter controller reflects the diameter data to control a pulling speed of the ingot, while a temperature controller reflects the diameter data to control power of a heater.