Angle-Dependent Reflectivity Analysis for Surface Material Detection
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Solution Overview
Problem
Current methods for detecting material coverage on surfaces, such as solder flux, in manufacturing processes are inefficient and fail to accurately determine uniformity and presence, leading to suboptimal process control and quality issues.
Innovation Solution
An apparatus utilizing angle-dependent reflectivity analysis with a camera and light source to differentiate between smooth and rough surfaces, determining material presence and coverage by analyzing image intensity, which can be integrated into manufacturing systems for real-time monitoring.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional detection methods are used to detect material coverage, then the detection process is simple, but the detection accuracy and reliability are insufficient
Solution Approach 1:
The patent uses optical reflectivity changes caused by material coverage to detect presence and uniformity. The inspection system captures images where material-covered areas reflect light differently than uncovered areas, enabling accurate detection through optical property changes rather than complex physical measurements
Solution Approach 2:
The patent replaces traditional mechanical or contact-based detection methods with an optical inspection system using cameras and light sources. This substitution maintains simplicity while dramatically improving detection accuracy by utilizing light reflection properties to identify material coverage status
2Productivity
If manual inspection methods are used to determine material uniformity, then the equipment cost is low, but the productivity and time efficiency are reduced
Solution Approach 1:
The patent creates an optical copy (image) of the surface with material coverage for analysis. By capturing a visual representation of the surface and analyzing it through software, the system achieves rapid inspection without physical contact or complex mechanical scanning, thereby improving productivity while keeping the physical apparatus relatively simple
Solution Approach 2:
The patent introduces light as an intermediary between the inspection system and the material coverage. Light reflects off the surface and carries information about material presence and uniformity to the camera, enabling fast non-contact detection without requiring complex direct measurement equipment
3Reliability
If insufficient material coverage is not detected, then the inspection process is fast, but the product quality and process control deteriorate
Solution Approach 1:
The patent implements a feedback mechanism where the inspection system detects material coverage status and provides information back to the process control. This allows real-time identification of insufficient coverage areas, enabling corrective actions to be taken while maintaining fast inspection throughput through automated image analysis
Solution Approach 2:
The patent performs inspection at an optimal point in the process where material coverage can be effectively evaluated. By detecting coverage issues early through optical inspection, the system prevents defective products from progressing further, ensuring quality reliability without adding significant time loss through preventive rather than corrective inspection timing
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 detection of material coverage, optimizing flux dispense processes and ensuring quality standards by identifying areas requiring reapplication or removal, thus improving manufacturing efficiency and product quality.
Implementation Method 1
Angle-dependent reflectivity analysis with a camera and light source to differentiate between smooth and rough surfaces
Data Source
AI summary
Embodiments herein relate to identifying whether a threshold amount of material is on a surface. In particular, an apparatus may have an inspection module to receive an image of a surface captured by a camera, where the surface is illuminated by a light source positioned at an angle to the surface. The apparatus may then analyze the received image to identify a measurement of light intensity of one or more portions of the surface; and determine, based on the analysis, whether each of the one or more portions of the surface includes a threshold amount of a material on the surface.