Optical Reflective Edge Sensor Ambient Light Filtering
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Solution Overview
Problem
Existing edge detection sensors are sensitive to ambient light, slow to respond, and expensive, making them unsuitable for applications requiring precision and energy efficiency, such as semiconductor manufacturing.
Innovation Solution
A precision optical reflective sensor system using a focused beam of light and a photodetector to detect reflected light, with a controller for processing and ambient light filtering, allowing for accurate edge detection in a compact and energy-efficient manner.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If through-beam sensors or image-based edge detectors are used, then edge detection capability is achieved, but sensitivity to ambient light and slow response time occur
Solution Approach 1:
Instead of using through-beam sensors that require light to pass through space (making them sensitive to ambient light), the patent inverts the approach by using a reflective sensor where light travels only from the sensor to the object and back. This eliminates the problematic through-space beam path that picks up ambient light, resolving the contradiction between edge detection capability and ambient light sensitivity
Solution Approach 2:
The patent introduces an optical element (lens or reflector) as an intermediary component that shapes and directs the light path. This optical element creates a controlled light trajectory that reflects off the object edge back to the photodetector, enabling precise edge detection while the controlled geometry reduces ambient light interference
2Measurement precision
If image or video-based edge detection is used, then edge detection is achieved, but slow response time and high cost occur
Solution Approach 1:
The patent replaces complex mechanical/image processing systems with a simple optical detection system. Instead of using cameras requiring frame capture, processing, and analysis (which are slow and expensive), the system uses direct optical reflection detection with a photodetector, providing instantaneous response and lower cost while maintaining edge detection precision
Solution Approach 2:
The patent extracts only the essential function needed for edge detection - detecting reflected light from the object edge - and eliminates all unnecessary components of image-based systems (camera, frame buffer, software processing). This extraction achieves fast response time and low cost while preserving the core edge detection capability
3Measurement precision
If conventional edge detection sensors are used, then edge detection is achieved, but large form factor and high energy consumption occur
Solution Approach 1:
The patent merges the light source and photodetector into a single integrated sensor assembly with shared optical elements. This consolidation eliminates separate housing and power systems for multiple components, reducing overall energy consumption and form factor while maintaining precise edge detection through the combined optical path
Solution Approach 2:
The optical element serves multiple functions: it collimates light from the source, focuses it onto the object, and directs reflected light to the photodetector. This multi-functionality reduces the number of components needed, thereby reducing energy consumption and form factor while preserving detection precision
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 system provides high-precision edge detection with reduced sensitivity to ambient light and improved responsiveness, enabling efficient operation in challenging environments like semiconductor manufacturing.
Implementation Method 1
an optical element positioned to collimate and focus light from the light source to generate a focused beam
Implementation Method 2
an optical element positioned to collimate and focus light from the light source to generate a focused beam
Implementation Method 3
detect light from the focused beam that has been reflected by an object positioned opposite the light source
Data Source
AI summary
A precision edge detection system and sensor assembly is provided that uses a reflection technique to provide an energy efficient device that can be achieved using a relatively small form factor. There is provided an optical reflective sensor assembly that includes a light source, an optical element positioned to collimate and focus light from the light source to generate a focused beam, and at least one photodetector positioned adjacent the light source. The at least one photodetector is configured to detect light from the focused beam that has been reflected by an object positioned opposite the light source.