Screen Printing Device Optical Axis Calibration
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Solution Overview
Problem
Current screen printing devices with two imaging optical axes face challenges in achieving high printing position precision due to errors in optical axis alignment and positional deviations, leading to printing positional deviations and requiring complex calibration processes, making it difficult to confirm substrate positioning precision before production.
Innovation Solution
A screen printing device and method that includes an imaging unit with two imaging optical axes for recognizing marks on a substrate and mask plate, using optical axis calibration and surface correction data to correct positional deviations, and a precision evaluation unit to assess and improve positioning precision through verification substrates and masks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single imaging unit with two imaging optical axes is used to image both substrate and mask plate, then the imaging unit can be moved by a single travel unit to enable both imaging, but printing position precision deteriorates due to optical axis alignment errors and positional deviations
Solution Approach 1:
The patent applies preliminary action by performing optical axis calibration and surface correction data creation before actual printing operations. The system pre-detects and stores positional deviation data from multiple reference points, then uses this pre-acquired data to correct positioning errors during printing, thereby maintaining high precision without requiring complex real-time correction mechanisms
Solution Approach 2:
The patent changes parameters by measuring positional deviations at multiple reference points across the imaging surface and creating surface correction data that compensates for local variations. This involves detecting parameters such as horizontal direction positional deviations at different locations and using this data to adjust positioning calculations, thereby correcting systematic errors in the imaging and printing system
2Manufacturing precision
If optical axis calibration and surface correction data creation are performed to correct positional deviations, then printing position precision is improved, but device complexity and calibration process complexity increase
Solution Approach 1:
The system applies self-service by automatically performing optical axis calibration and surface correction data creation using its own imaging unit and control unit. The control unit automatically processes image data from multiple reference points, calculates positional deviations, generates correction data, and stores it for future use, eliminating the need for external manual calibration operations
Solution Approach 2:
The patent implements feedback by using the imaging unit to detect positional deviations at multiple reference points, then feeding this information back to the control unit which creates surface correction data. This correction data is subsequently applied to compensate for positioning errors, forming a closed-loop system that continuously improves printing precision based on actual measured deviations
3Measurement precision
If multiple reference points are used to create surface correction data, then local positional deviations are corrected, but measurement and detection difficulty increases
Solution Approach 1:
The patent applies segmentation by dividing the imaging surface into multiple regions with distributed reference points. Instead of attempting to measure the entire surface at once, the system images individual reference points at specific locations (e.g., four corners and center), processes each point's positional data separately, then combines this segmented information to create comprehensive surface correction data
Data Source
AI summary
Prior to a mark imaging process executed for the purpose of detecting a position of recognition marks for positioning the substrate and the mask, an optical axis calibration processing process of detecting a horizontal relative position between imaging optical axes, and a surface correction data creation processing process of detecting a local positional deviation of the imaging optical axes, which is caused by the travel of the imaging unit, are executed. Before starting production, a production pre-start precision evaluation process for evaluating a substrate positioning precision is executed by using a verification substrate and a verification mask, and after starting the production, a production post-start precision evaluation process for evaluating a substrate positioning precision after starting the production is executed by using a commercial production substrate and a commercial production mask.