Ingot Alignment Using Optical Centerline and Movable Mounting Block
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Solution Overview
Problem
Conventional methods for aligning semiconductor or solar-grade ingots with mounting blocks are inefficient due to imperfections in ingot shape, leading to wasted material and inaccurate positioning, which is time-consuming and difficult to correct without reliable verification.
Innovation Solution
An alignment system using a movable mounting block, optical devices (lasers) for precise centerline alignment, and adjustable supports that allow independent movement in multiple degrees of freedom to accurately position the ingot on at least four support points, eliminating the need for shims and improving adhesive application access.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If V-block halves are used to align the ingot with the mounting block, then the ingot can be positioned and centered, but the alignment accuracy is poor and material waste occurs due to inability to align predetermined centerline
Solution Approach 1:
The patent replaces the mechanical V-block alignment system with an optical alignment system using lasers and visual markers. The laser alignment device projects a reference line that aligns with the predetermined centerline of the ingot, allowing precise alignment without relying on mechanical contact points that cannot accommodate shape imperfections. This substitution of mechanical alignment with optical alignment enables accurate centerline alignment while minimizing material waste.
Solution Approach 2:
The patent introduces visual markers (such as crosshairs or dots) placed on the ingot surface as intermediary reference points for alignment. These markers serve as mediators between the physical ingot and the alignment system, allowing operators to visually verify alignment with the predetermined centerline. The markers act as an intermediary reference system that bridges the gap between the imperfect physical ingot shape and the ideal alignment requirement.
2Manufacturing precision
If shims are used to correct off-center positioning, then alignment can be improved, but the process becomes extremely time-consuming and difficult to verify
Solution Approach 1:
The patent performs alignment actions before the cutting process begins by using the optical alignment system to pre-position the ingot correctly on the mounting block. The predetermined centerline is identified and marked in advance, and the ingot is aligned to this pre-established reference before any cutting occurs. This preliminary alignment action eliminates the need for time-consuming iterative adjustments with shims during or after mounting.
Solution Approach 2:
The patent implements a visual feedback mechanism where operators can directly observe the alignment status through visual markers and laser reference lines. This real-time visual feedback allows operators to verify alignment accuracy immediately and make precise adjustments if needed, eliminating the uncertainty and time consumption associated with shim-based correction methods where verification is difficult.
3Area of stationary object
If the mounting block is disposed vertically in close proximity to the ingot, then space is saved, but the operator has little room to apply adhesive making the process difficult
Solution Approach 1:
The patent introduces a movable mounting block that can be dynamically repositioned between a vertical position for alignment and a horizontal position for adhesive application. This dynamic positioning capability allows the system to adapt to different operational requirements: vertical orientation optimizes alignment precision, while horizontal orientation provides adequate workspace for adhesive application. The mounting block's ability to change orientation resolves the spatial conflict between compact workspace and operational accessibility.
4Device complexity
If conventional V-block alignment method is used, then simple equipment is required, but reliable verification of optimal positioning is not possible
Solution Approach 1:
The patent replaces the simple but unreliable mechanical V-block alignment system with an optical alignment system using lasers and visual markers. While this increases device complexity, it provides reliable verification of alignment through direct visual observation of markers aligned with laser reference lines. The optical system transforms alignment verification from an indirect mechanical process to a direct visual process, ensuring reliable confirmation of optimal positioning.
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
Enables faster and more accurate alignment of ingot centerlines with mounting blocks, minimizing material waste and simplifying the adhesive application process by allowing precise adjustments and optical verification.
Implementation Method 1
at least one laser for aligning a predetermined centerline of the ingot with a reference line
Data Source
AI summary
An alignment system for aligning an ingot of semiconductor or solar-grade material is provided. The alignment system includes a mounting block for attachment to the ingot, an optical device for aligning a predetermined centerline of the ingot with a reference line, and adjustable supports configured for supporting the ingot on at least four support points and configured to adjust the position of the ingot. The mounting block is movable between a horizontal position and a vertical position.