Irradiance Flash Thermal Processing Control

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Solution Overview

Problem

Heat-treating systems face challenges in achieving consistent thermal processing due to variations in thermal efficiency over time and differences in emissivity among workpieces, leading to performance variations and the need for frequent recalibration.

Innovation Solution

A method and apparatus that monitor thermal efficiency parameters and automatically update control information to adjust irradiance flashes, incorporating real-time feedback control and pre-adjustment of electrical pulses to compensate for system changes and workpiece emissivity variations.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If manual recalibration is performed frequently to maintain thermal efficiency, then thermal processing consistency is improved, but loss of time and productivity deteriorate

Engineering Contradiction:

Improvethermal processing consistencyVSAvoidrecalibration time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The system implements automatic feedback control by monitoring thermal efficiency parameters in real-time and using this information to adjust irradiance flash parameters. This closed-loop approach eliminates the need for manual recalibration while maintaining thermal processing consistency, as the system self-corrects for component deterioration, contamination, or aging automatically.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The system performs self-calibration by automatically updating control information based on monitored thermal efficiency parameters. The apparatus measures its own performance degradation and adjusts its operation accordingly, eliminating dependence on external manual intervention for maintaining thermal processing consistency.

Inventive Principle:

Principle #25Self-service

2Reliability

If irradiance flash parameters are adjusted to compensate for emissivity variations among workpieces, then thermal processing consistency is improved, but device complexity increases

Engineering Contradiction:

Improvethermal cycle repeatabilityVSAvoidcontrol system complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The system compensates for emissivity variations by dynamically adjusting irradiance flash parameters such as energy, duration, or intensity. By changing these controllable parameters based on workpiece characteristics, the system achieves consistent thermal cycles across different workpieces without requiring complex hardware modifications.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The system performs preliminary measurement of workpiece emissivity or heating parameters before applying the irradiance flash. This pre-characterization allows the control system to pre-calculate appropriate flash parameters, ensuring thermal processing consistency while keeping the actual heating process simple and rapid.

Inventive Principle:

Principle #10Preliminary action

3Manufacturing precision

If real-time feedback control is implemented during irradiance flash, then thermal processing precision is improved, but use of energy and device complexity increase

Engineering Contradiction:

Improvetemperature control precisionVSAvoidenergy for control systems

Core Design Contradiction:

Manufacturing precisionVSUse of energy by moving object

Solution Approach 1:

The system uses ultra-fast measurement and control that operates on timescales much shorter than the thermal diffusion time. By completing feedback control measurements and adjustments within the millisecond-duration flash itself, the system achieves precise temperature control without adding significant energy consumption or temporal overhead to the thermal processing cycle.

Inventive Principle:

Principle #21Skipping (Rushing through)

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 ensures consistent thermal cycles by automatically adapting to system changes and workpiece variations, reducing the need for manual recalibration and improving repeatability and efficiency of thermal processing.

Implementation Method 1

an irradiance system (180) configured to produce an irradiance flash incident on a surface (104) of a workpiece (106)

Methodology Applied

Scientific EffectRadiant heating: Thermal Radiation

Implementation Method 2

a measurement system (102) configured to monitor at least one thermal efficiency parameter

Methodology Applied

Scientific EffectThermal radiation detection: Thermal Radiation

Data Source

PatentUS9482468B2Repeatable heat-treating methods and apparatus

Publication Date: 2016.11.01 MATTSON TECHNOLOGY INC

AI summary

A first heat-treating method involves monitoring at least one thermal efficiency parameter associated with an irradiance system configured to produce an irradiance flash incident on a surface of a workpiece, and automatically updating control information used by the irradiance system to produce the irradiance flash, in response to the monitoring of the thermal efficiency parameter. A second method involves predicting a heating effect of an irradiance flash to be incident upon a surface of a workpiece, in response to a measurement of a heating parameter of the surface, and pre-adjusting the irradiance flash, in response to the predicted heating effect. A third method involves measuring a temperature of a surface of a workpiece during an initial portion of an irradiance flash incident on the surface, and controlling a power of a remaining portion of the irradiance flash, in response to the temperature.