Substrate Crack Detection via Length Measurement
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Solution Overview
Problem
Conventional substrate detection systems fail to accurately identify cracked substrates during delivery, leading to detection errors and subsequent damage to other substrates, as sensors can only detect cracks in specific areas and not the entire substrate length.
Innovation Solution
A substrate detection system comprising a conveyer and a detection device with a sensor and processor that measures the length or time of each substrate passing through, comparing it to a predetermined value to stop the conveyer if a crack is detected, ensuring continuous detection without stopping the conveyer and expanding the detection area for improved accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a sensor is positioned at a specific location to detect substrates, then the device complexity is reduced, but the detection precision deteriorates because cracks outside the sensor's detection range are missed
Solution Approach 1:
The patent transitions from point-based detection (0D/1D) to area-based detection (2D) by positioning the sensor to detect the entire width of the substrate. This dimensional expansion ensures that cracks at any position across the substrate width are captured, resolving the contradiction between simple sensor positioning and high detection precision.
2Measurement precision
If the conveyer stops to allow detection of each substrate, then the detection precision is improved, but the productivity deteriorates due to continuous stopping
Solution Approach 1:
The patent implements continuous detection during substrate delivery by positioning the sensor to cover the entire substrate width. This allows the conveyer to maintain continuous motion while achieving accurate crack detection, eliminating the need to stop the conveyer for each substrate and thus maintaining high productivity without sacrificing detection precision.
3Device complexity
If a sensor detects only a specific part of the substrate, then the detection device complexity is reduced, but the reliability deteriorates because detection errors occur when cracks are outside the detection area
Solution Approach 1:
The patent expands the detection coverage from a narrow point or line to the full width of the substrate by strategically positioning the sensor. This dimensional expansion ensures that cracks at any position across the substrate are detected, significantly improving reliability while maintaining relatively simple device structure.
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 enhances detection accuracy by covering the entire substrate length, reducing detection errors and potential losses by immediately stopping the conveyer when a cracked substrate is identified, thus preventing further damage during delivery.
Implementation Method 1
the sensor can be constructed to detect the time in which each substrate passed through the top side of the sensor
Data Source
AI summary
A substrate detection system is disclosed to include a conveyer that delivers the substrates, a sensor that detects the length of each substrate being delivered by the conveyer over the top side of the sensor, and a processor that compares the detection length value of each substrate detected by the sensor with a predetermined length value stored therein so as to immediately stops the conveyer when the detection length value of one substrate is unequal to the predetermined length value. In an alternate form, the time value in which each substrate passed over the sensor is used as a parameter for judgment.