Substrate Transfer Imaging for Precise Tray Alignment
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Solution Overview
Problem
The manufacturing costs of display devices are high due to inefficiencies in the substrate transfer process, particularly in determining and correcting the positioning of substrates during transfer.
Innovation Solution
A substrate transfer system and method that includes a substrate transporter, tray, substrate mover, and imager, which captures images at fixed focal lengths to determine and correct the positioning of substrates on the tray, using a computer processor to analyze images and adjust the substrate mover for precise alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual or conventional automated substrate transfer methods are used, then the transfer process can be completed, but the positioning accuracy of substrates on the tray is insufficient, leading to high manufacturing costs
Solution Approach 1:
The patent replaces conventional mechanical positioning systems with an optical imaging system. The imager captures images of substrates on the tray, and a computer processor analyzes these images to determine precise substrate positions. This optical-mechanical substitution eliminates the need for complex mechanical positioning mechanisms, thereby improving positioning accuracy while reducing manufacturing costs.
Solution Approach 2:
The patent uses optical copying through imaging to determine substrate positions. Instead of relying on physical markers or mechanical references, the system creates optical copies (images) of the substrate arrangement on the tray. The computer processor then analyzes these optical copies to accurately determine substrate positions, achieving high precision without additional physical infrastructure.
2Measurement precision
If multiple separate imaging systems are used to capture substrate positions at different locations, then complete positioning information can be obtained, but the system complexity increases
Solution Approach 1:
The patent makes the imager a multi-functional component that serves multiple purposes: it captures images of substrates at the substrate transporter, tracks substrate movement during transfer, and determines final substrate positions on the tray. This single imager performs what would traditionally require multiple separate imaging systems, thereby reducing device complexity while maintaining comprehensive positioning capability.
Solution Approach 2:
The patent combines the imaging function with the substrate transfer system. The imager is integrated into the transfer system and works in conjunction with the substrate mover and tray. By merging the imaging capability with the existing transfer mechanism, the system achieves comprehensive substrate positioning without adding separate, complex imaging subsystems.
Data Source
AI summary
A system for transferring a substrate includes a substrate transporter at which is captured a first image with which a position of the substrate at the substrate transporter is determined; a tray at which is captured a second image with which a position of each of a plurality of substrates relative to the tray is determined; a substrate mover with which the substrate is movable in a revolving manner between the substrate transporter and the tray, the substrate mover including: an arm portion movable in the revolving manner between the substrate transporter and the tray, and a substrate securing portion movable together with the arm portion; and an imager with which the first image and the second image are captured, the imager connected to the arm portion and movable in the revolving manner between the substrate transporter and the tray together with the arm portion.