Real-Time Centerline Deviation Detection in Roll-to-Roll Sensor Production
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Solution Overview
Problem
Current sensor and sensor array production processes are inefficient, leading to the production of thousands of out-of-specification units due to delayed detection of centerline deviations, which are costly and require large-scale clean rooms.
Innovation Solution
A real-time notification system for centerline deviations in roll-to-roll sensor and sensor array production, allowing for immediate adjustments and reducing the production of out-of-specification units, implemented through pattern illumination-based annealing and functional molecule attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If real-time notification system is implemented, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The patent implements a real-time notification system that continuously monitors the roll-to-roll production process and immediately alerts operators when centerline deviations occur. This feedback mechanism enables immediate corrective action, preventing thousands of defective sensor units from being produced and significantly improving manufacturing precision despite the added system complexity.
2Productivity
If roll to roll production process is used, then productivity is improved, but manufacturing precision deteriorates
Solution Approach 1:
The real-time notification system monitors the high-speed roll-to-roll production process continuously, detecting centerline deviations as they occur. This enables immediate correction while maintaining high productivity, preventing the typical quality degradation associated with rapid production processes.
3Device complexity
If delayed notification of centerline deviation is used, then device complexity is reduced, but loss of time increases
Solution Approach 1:
The system provides immediate real-time notification of centerline deviations through continuous monitoring, eliminating delayed detection. This allows operators to correct issues instantly, preventing the accumulation of defective units and reducing overall production time losses despite the added complexity of the notification system.
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 the production of large numbers of high-quality sensors and sensor arrays with minimal defects, eliminating the need for large-scale clean rooms and enhancing production efficiency.
Implementation Method 1
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Data Source
AI summary
A process of making sensors and sensor arrays that provided real time notification of any centerline deviation. Such production process can be adjusted in real time. Thus, large numbers of units can be made—even in millions of per day—with few if any out of specification units being produced. Such process does not require large-scale clean rooms and is easily configurable.