Seed Shaft Positioning in Monocrystal Growth Using Image Processing
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Solution Overview
Problem
The existing monocrystal growth process lacks accuracy in positioning the seed shaft for welding, leading to inefficiencies and potential welding accidents due to manual control and large errors in determining the seed shaft's position relative to the liquid level.
Innovation Solution
A method and device that utilize a counterweight to gradually descend the seed shaft, combined with a camera and image processing system to accurately position the seed shaft by aligning its pixel image with a reference circle, ensuring the seed shaft is flush with the heat shield's lower edge before extending into the molten silicon for welding, allowing for precise control and automation of the crystal growth process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual method is used to lower the seed shaft for welding, then the operation is simple, but the positioning accuracy and efficiency are poor
Solution Approach 1:
The patent replaces the manual mechanical operation of lowering the seed shaft with an automated image processing system. The camera captures images of the seed shaft and heat shield, the image processing apparatus automatically analyzes these images to determine positions, and the system automatically controls the descent of the seed shaft. This substitution of manual mechanical operation with an automated vision-based system resolves the contradiction by significantly improving positioning accuracy while maintaining reasonable system complexity through the use of standard imaging and processing components.
2Productivity
If automated image processing system is introduced to position the seed shaft, then the positioning accuracy is improved, but the device complexity increases
Solution Approach 1:
The image processing apparatus automatically performs all positioning operations without requiring external manual intervention. The system captures images, processes them to identify the seed shaft and heat shield positions, calculates the required descent distance, and automatically controls the seed shaft positioning. This self-service automation improves productivity by eliminating manual operations and waiting time, while the complexity is managed by integrating these functions into a unified automated control system that operates independently.
3Manufacturing precision
If manual control is used for seed shaft descent, then the system is easy to operate, but the welding accuracy and consistency are poor
Solution Approach 1:
The patent implements a feedback-based positioning system where the camera continuously monitors the position of the seed shaft relative to the heat shield, the image processing apparatus analyzes this visual feedback to determine the exact positioning state, and the system adjusts the seed shaft descent accordingly. This closed-loop feedback mechanism ensures high welding accuracy by constantly comparing the actual position with the target position and making real-time adjustments, while the automated nature of the feedback process maintains ease of operation by eliminating the need for manual measurement and judgment.
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
This solution enables accurate and automated positioning of the seed shaft, reducing the risk of welding errors and improving the consistency of the crystal growth process by ensuring the seed shaft is correctly aligned with the molten silicon, preventing abnormal welding and crystal defects.
Implementation Method 1
using a camera apparatus to acquire a pixel image of the seed shaft and the lower edge of the heat shield
Implementation Method 2
using a counterweight to hang a seed shaft to gradually descend in a first direction
Data Source
AI summary
A monocrystal growth method and device. The method includes loading silicon material into a crucible for melting to form molten silicon liquid; lowering a heat shield to a preset position, a first preset distance is formed between a lower edge of the heat shield and a liquid level of the molten silicon liquid; in a first stage, using a counterweight to hang a seed shaft to gradually descend in a first direction, using a camera apparatus to acquire a pixel image of the seed shaft and the lower edge of the heat shield for comparison to reference; then a second stage is entered, in which the image processing apparatus records a current position of the seed shaft, the seed shaft is continuously lowered until the seed shaft extends into the molten silicon liquid for welding; seeding; shouldering; body growth; and tailing.