Sensor for measuring reflected light for optimizing deposited performance enhancement coatings on substrates
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Solution Overview
Problem
Current light reflection sensors are inadequate for measuring large areas on solar panels due to their small spot size, requiring multiple readings and separate computing devices, making the process cumbersome and time-consuming for assessing performance enhancement coatings.
Innovation Solution
A portable light reflectance sensor with a spot size of at least 1 cm² for measuring light reflection on solar panels, equipped with a signal processing circuit for real-time analysis and feedback, allowing for single measurements that represent the average coating performance across a larger area, integrated with a mobile coating apparatus for process control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a fiber optic probe with small spot size is used for measurement, then the device complexity is reduced, but the measurement precision and representativeness of coating performance deteriorate
Solution Approach 1:
The patent changes the spot size parameter from small (fiber optic probe) to large (at least 1 cm²), which allows a single measurement to capture variations in coating and substrate surface structure, thereby improving measurement precision and representativeness without significantly increasing device complexity
Solution Approach 2:
The patent transitions from point measurements (1D/0D) to area measurements (2D, at least 1 cm²), enabling spatial integration of surface features and providing a more representative sample of coating performance across the substrate surface
2Measurement precision
If multiple readings are taken with a fiber optic probe to achieve statistically significant samples, then the measurement precision improves, but the loss of time increases
Solution Approach 1:
The patent uses a spot size that is excessively large compared to the fiber optic probe (at least 1 cm² vs. small spot size), which provides sufficient statistical significance in a single measurement, thereby eliminating the need for multiple readings and reducing time loss
3Measurement precision
If a separate computing device is used to run calculations for producing human readable data, then the measurement precision and data analysis capability improve, but the device complexity and ease of operation worsen
Solution Approach 1:
The patent merges the computing device and data analysis capabilities into the portable sensor itself, eliminating the need for separate laptops or computers. This integration maintains data analysis capability while significantly improving ease of operation by making the system self-contained and portable
4Measurement precision
If a separate computing device is required for each solar panel measurement, then the measurement precision is maintained, but the productivity decreases
Solution Approach 1:
The patent creates a universal portable sensor with integrated computing capabilities that can measure multiple solar panels without requiring separate computing devices for each panel. This multi-functional device improves productivity by eliminating setup and transportation time while maintaining measurement 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
Enables efficient, non-destructive assessment of thin film coatings on solar panels, providing accurate and representative data for coating quality control, reducing the need for multiple measurements and separate devices, and facilitating real-time adjustments for optimal coating performance.
Implementation Method 1
measuring light incident on a substrate surface from the light source, and reflected to the photodetector
Implementation Method 2
a photodetector for measuring light incident on a substrate surface from the light source, and reflected to the photodetector
Data Source
AI summary
An innovative portable reflected light sensor for non-destructively measuring characteristics of performance enhancement coatings applied to substrates such as solar photovoltaic panels is described. The innovative portable sensor provides a light source and a photodetector for measuring light incident on a substrate surface from the light source, and reflected to the photodetector. The spot size of the illuminated region of the substrate is at least 1 cm2 in area, thus averaging over a relatively wide portion of the substrate surface relative to existing fiber optic devices. A single measurement may then be representative of the coating. The innovative portable reflected light sensor is adapted to measure substrates in the field, and is especially adapted for assessing coating quality during the coating process. The innovative sensor also comprises a signal processing circuit that performs analysis of the measurements and feeds back status of the coating to the operator for coating process control.