Viscous Fluid Dispensing Calibration via Iterative Optical Feedback
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Solution Overview
Problem
Current calibration methods for viscous fluid dispensing systems fail to account for additional sources of error, leading to inadequate placement accuracy in dispensing dots of viscous fluids on increasingly dense and complex printed circuit boards.
Innovation Solution
A method involving the use of an external reference point, optical sensors, and iterative recalibration to calculate and adjust the camera-to-needle offset value, ensuring precise placement of fluid dots by accounting for mechanical shifting and software inaccuracies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If preliminary camera-to-needle offset calculation is performed during installation, then initial setup is completed, but placement accuracy remains insufficient due to unaccounted mechanical shifting and software errors
Solution Approach 1:
The patent performs preliminary offset calculation during installation, but then applies iterative correction actions afterward. The system pre-calculates the offset value, dispenses test dots, measures actual positions, and recalculates corrected offset values through multiple iterations to account for mechanical shifting and software errors that weren't present in the initial setup
Solution Approach 2:
The patent implements a feedback loop where the system dispenses fluid dots at calculated positions, uses an optical sensor to measure the actual positions of these dots, compares measured positions with intended positions, and uses this feedback to recalculate and refine the camera-to-needle offset value. This iterative feedback process continues until placement accuracy requirements are met
2Device complexity
If fluid dispenser and camera are mounted with fixed separation distance, then system structure is simplified, but mechanical shifting causes offset value inaccuracies
Solution Approach 1:
The patent transitions from a static offset value (fixed during installation) to a dynamic correction process. The system maintains the simple fixed mounting structure but adds the capability to dynamically calculate and update offset values through iterative measurement and recalculation, allowing the offset to adapt to mechanical shifting while preserving structural simplicity
3Ease of operation
If standard calibration procedures are used, then calibration process is straightforward, but additional error sources are not accounted for
Solution Approach 1:
The patent enables the system to self-correct calibration errors through automated iterative processing. The system automatically dispenses test dots, measures their actual positions, calculates correction values, and updates offset parameters without requiring manual intervention beyond the initial setup, thereby maintaining ease of operation while improving 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
Improves the placement accuracy of viscous fluid dots by iteratively adjusting the camera-to-needle offset, addressing the limitations of preliminary calibration methods and enhancing the precision of fluid dispensing systems.
Implementation Method 1
locating an external reference point with an optical sensor, moving a fluid dispenser to the external reference point, dispensing fluid with the fluid dispenser at the external reference point, locating the dispensed fluid with the optical sensor
Data Source
AI summary
A method for calibrating a fluid dispensing system includes the steps of locating an external reference point with an optical sensor, moving a fluid dispenser to the external reference point, dispensing fluid with the fluid dispenser at the external reference point, locating the dispensed fluid with the optical sensor, calculating a distance between the location of the external reference point and the location of the dispensed fluid, determining a correction value based at least in part on the calculated distance, and using the correction value to improve placement accuracy of dispensed fluid.