Wire Net Bow Detection for Ingot Cut-Through Monitoring
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Solution Overview
Problem
Existing ingot slicing machines lack automated monitoring for cut-through detection, relying on manual analysis, which leads to inefficiencies, high production costs, and incomplete cuts, resulting in conjoined silicon wafers that do not meet processing requirements.
Innovation Solution
A method and system that automatically determine if an ingot is cut through by measuring bow values in the wire net, comparing them to a standard value, and adjusting the cutting process accordingly, using detection parts to continuously monitor the wire net's position and height, and automatically adjusting the cutting plan to ensure complete cuts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual analysis and determination method is used to check whether the ingot is cut through, then the system complexity is low, but the productivity is low and the loss of time is high
Solution Approach 1:
The patent replaces the manual mechanical inspection system with an automated optical detection system. Detection parts including cameras and light sources are used to automatically capture images of the wire net and ingot, substituting human visual inspection with machine-based optical measurement and analysis.
Solution Approach 2:
The system performs self-inspection by automatically detecting whether the ingot is cut through using the detection parts. The control unit automatically analyzes the captured images and determines cut-through status without requiring external manual intervention, enabling the system to monitor and adjust its own operation.
2Reliability
If manual analysis method is used to determine cut-through status, then the device complexity is low, but the loss of time increases and reliability decreases
Solution Approach 1:
The patent replaces manual visual inspection with an automated optical detection system comprising cameras, light sources, and image processing units. This substitution ensures consistent, objective measurement of cut-through status, eliminating human error and variability while maintaining reliable quality control.
Solution Approach 2:
The system implements feedback by continuously monitoring the cut-through status through detection parts and using the control unit to analyze the results. Based on the detection results, the system can automatically adjust cutting parameters or alert operators, creating a closed-loop control system that maintains high reliability.
3Measurement precision
If manual inspection is performed after each ingot cutting, then the measurement precision is low, but the device complexity is low
Solution Approach 1:
The patent replaces imprecise manual visual inspection with high-precision optical detection systems. Cameras capture detailed images of the wire net and ingot interface, and image processing algorithms precisely determine whether the cut has penetrated through, achieving measurement precision far exceeding human capability.
Solution Approach 2:
The system creates optical copies (images) of the cutting zone using cameras and light sources. These digital copies allow for precise analysis and measurement without physically interfering with the cutting process, enabling high-precision detection through image processing and analysis.
Data Source
AI summary
A processing method of cutting through a workpiece includes following steps: obtaining measured bow values of all areas in a wire net when a feed rate of a workpiece cutting reaches a preset threshold, comparing the measured bow values of all areas in an obtained wire net with a standard bow value when the workpiece is cut through, determining that the workpiece has been cut through when the measured bow values of all areas in the wire net are less than or equal to the standard bow value, and determining that the workpiece is not cut through when any area of the wire net has a measured bow value greater than the standard bow value.