MPC Micro-Assembly Control for Multi-Object Electrode Positioning
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Solution Overview
Problem
Existing techniques for micro- and nano-scale particle manipulation lack the precision and scalability needed for accurate assembly of multiple micro-objects and nano-objects of varying shapes, particularly in industrial applications such as electronics assembly.
Innovation Solution
A system and method utilizing a high-speed camera, photo-transistor-controlled electrodes, and a video projector to generate a dynamic potential energy landscape, enabling precise control of multiple micro- and nano-objects through dielectrophoretic and electrophoretic forces, with model predictive control (MPC) optimization to achieve desired trajectories and positions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If uncontrolled mechanical agitation is used for directed particle assembly, then the process is simple to implement, but the precision and yield are insufficient to achieve near 100% yield required for industrial applications
Solution Approach 1:
The patent replaces uncontrolled mechanical agitation with a controlled electric field-based manipulation system. Electrophoresis and dielectrophoresis forces are used to precisely control particle movement, replacing the mechanical agitation approach with an electric field-based system that enables near 100% assembly yield while maintaining industrial applicability
Solution Approach 2:
The patent changes the control parameter from mechanical agitation to electric field parameters (voltage, frequency, waveform). By adjusting these electric field parameters, the system achieves precise control over particle assembly while maintaining ease of implementation through programmable control
2Manufacturing precision
If a one-step model predictive control approach with capacitance-based model is used, then control precision is improved, but the number of simultaneously actuated electrodes is limited by the spiral-shaped electrode configuration
Solution Approach 1:
The patent segments the electrode array into multiple independently controllable units, allowing different regions to be actuated simultaneously. This segmentation enables parallel control of multiple particles across the entire array, removing the limitation of spiral-shaped electrode configurations and increasing the number of simultaneously actuated electrodes while maintaining precision
Solution Approach 2:
The patent creates a universal control framework that works with various electrode geometries and configurations. The model predictive control approach is adapted to handle different electrode arrangements, making the system versatile for multiple applications while maintaining high position control precision
3Device complexity
If techniques assuming small particles that do not disturb the electric field are used, then the control model is simpler, but the applicability is limited to particles small enough not to disturb the field, excluding larger particles
Solution Approach 1:
The patent changes the modeling approach to account for particle size effects on the electric field. By incorporating particle-induced field disturbances into the control model and adjusting parameters accordingly, the system can handle particles of various sizes while maintaining manageable model complexity through systematic parameter adaptation
4Manufacturing precision
If electrophoretic forces with high frequency signals (MHz) are used for particle manipulation, then particle control is achieved, but the technique is not suitable for assembling micro-objects slightly larger than those discussed, and the control scheme has limited industrial applicability
Solution Approach 1:
The patent changes the frequency parameter from MHz range to lower frequencies suitable for larger micro-objects. By adjusting the frequency, voltage, and waveform parameters, the system achieves effective manipulation of larger particles while maintaining industrial applicability through optimized parameter selection that balances control precision with broader versatility
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
The solution allows for accurate and scalable control of multiple micro- and nano-objects, achieving high precision in assembly tasks, such as positioning chiplets in electronics manufacturing, with the ability to handle objects of varying shapes and sizes.
Implementation Method 1
enabling precise control of multiple micro- and nano-objects through dielectrophoretic and electrophoretic forces
Implementation Method 2
enabling precise control of multiple micro- and nano-objects through dielectrophoretic and electrophoretic forces
Implementation Method 3
A system and method utilizing a high-speed camera, photo-transistor-controlled electrodes, and a video projector to generate a dynamic potential energy landscape
Data Source
AI summary
System and method that allow to jointly cause movement of multiple micro-and-nano-objects to desired positions are described. A high speed camera tracks the locations of the objects. An array of electrodes is used to generate a dynamic potential energy landscape for manipulating objects with both DEP and EP forces. One or more computing devices are used to: process images captured by the camera to estimate positions of the objects; use model predictive control optimization to obtain trajectories and electrode potentials for moving at least some of the objects from estimated positions to further positions; and control the electrodes based on electrode potentials.