Inspection Substrate Groove and Paint Layer for Scratch Detection

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Solution Overview

Problem

The high cost and time-consuming nature of automatic optical inspection (AOI) for detecting scratches on workpieces during cutting processes, which can lead to the production of defective products if issues with cutting apparatus components are not identified early.

Innovation Solution

An inspection substrate with a groove portion for simulated cutting and a paint layer to enhance visibility of scratches, allowing for cost-effective inspection of cutting apparatus components by simulating the cutting process and detecting paint layer peeling.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If automatic optical inspection apparatus is used to inspect the top surface of the workpiece, then the inspection accuracy is improved, but the inspection cost increases significantly

Engineering Contradiction:

Improveinspection accuracyVSAvoidinspection cost

Core Design Contradiction:

Measurement precisionVSEase of manufacture

Solution Approach 1:

The invention creates a simulated workpiece (inspection substrate) that copies only the essential features needed for inspection - a groove portion replicating the workpiece surface and a paint layer replicating the surface coating. This simplified copy can be inspected using low-cost methods while still detecting scratches and contact traces that would appear on actual workpieces, thereby resolving the contradiction between inspection accuracy and cost.

Inventive Principle:

Principle #26Copying

2Area of stationary object

If automatic optical inspection apparatus inspects the whole top surface sequentially, then the inspection coverage is improved, but the inspection time increases

Engineering Contradiction:

Improveinspection coverageVSAvoidinspection time

Core Design Contradiction:

Area of stationary objectVSLoss of time

Solution Approach 1:

The inspection substrate uses a paint layer that provides high visual contrast against the groove portion and any scratches or contact traces. This color/reflectivity difference enables rapid visual or low-cost optical detection of defects across the entire surface area, allowing comprehensive inspection coverage without requiring time-consuming sequential scanning by expensive AOI apparatus.

Inventive Principle:

Principle #32Color changes

3Ease of manufacture

If inspection areas and inspection positions are limited, then the inspection cost is reduced, but the possibility of overlooking scratches increases

Engineering Contradiction:

Improveinspection costVSAvoiddefect detection reliability

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The inspection substrate divides the inspection function into distinct segments: the groove portion represents the workpiece surface, the paint layer represents the protective coating, and the groove geometry allows the cutting blade to pass through while enabling detection of contact traces. This segmented design ensures that scratches and contact traces from partition plates or nozzles are clearly visible against the paint layer, maintaining high defect detection reliability with low-cost inspection methods.

Inventive Principle:

Principle #1Segmentation

Data Source

PatentUS12220839B2Inspection substrate

Publication Date: 2025.02.11 DISCO CORP

AI summary

An inspection substrate for use in inspecting whether or not a constituent element of a cutting apparatus forms a scratch on a top surface of a workpiece when a cutting blade cuts the workpiece, the inspection substrate includes a top surface side of the inspection substrate having a groove portion for simulated cutting, the groove portion having a width that the cutting blade can pass through, and a paint layer disposed on the top surface side of the inspection substrate to improve visibility of a scratch formed on the top surface side.