CN-122018440-A - Ultrasonic spraying process parameter rapid calibration method and system based on dye tracing and image analysis

CN122018440ACN 122018440 ACN122018440 ACN 122018440ACN-122018440-A

Abstract

The invention relates to a quick calibration method and a quick calibration system for ultrasonic spraying process parameters based on dye tracing and image analysis, wherein the method comprises the following steps of adding selected dye into a spraying solution to serve as a tracer; the method comprises the steps of spraying a colored coating on a substrate by using ultrasonic spraying equipment according to preset parameters, sampling in an effective film forming area of the coating by adopting a standard nine-point method, collecting color images of all sampling points, extracting and calculating color characteristic values corresponding to the color of a tracer, respectively quantitatively evaluating the relative thickness and uniformity of the coating on the basis of the average value and standard deviation of the characteristic values of all the sampling points, and establishing a quantitative relation model of technological parameters and the average value and standard deviation through a plurality of groups of parameter experiments so as to determine an optimal technological parameter window. The invention adopts dye tracing and combines low-cost image acquisition and processing means to realize rapid, visual and quantitative calibration of ultrasonic spraying process parameters, and is particularly suitable for rapid iterative optimization in process research and development and debugging stages.

Inventors

LIU JIAN
PENG YONG
ZHANG NAN
DIAO JIAXI
TAO SHUAI

Assignees

深圳市扶光光伏有限公司

Dates

Publication Date: 20260512
Application Date: 20251231

Claims (9)

1. The ultrasonic spraying process parameter rapid calibration method based on dye tracing and image analysis is characterized by comprising the following steps of: s1, preparing a tracer solution, namely dissolving a selected dye into a spraying solvent to prepare a spraying solution containing a visual tracer; S2, spraying to form a film, namely setting technological parameters of ultrasonic spraying equipment, and spraying the solution prepared in the step S1 on the surface of the clean substrate to form a coating with trace colors; s3, standardized sampling, namely determining at least nine analysis sampling points in an effective film forming area of the coating by adopting a nine-point sampling method; s4, collecting color images of each sampling point, processing each color image, extracting and calculating to obtain a color characteristic value reflecting the tracing color intensity of the point; s5, quantitatively evaluating the coating quality, namely calculating an average value Avg and a standard deviation Std of color characteristic values of all sampling points, wherein the average value is used for evaluating the relative thickness of the coating or the dye deposition amount, and the standard deviation is used for evaluating the uniformity of the thickness of the coating; and S6, technological parameter association and optimization, namely changing one or more technological parameters in the step S2, repeating the steps S2 to S5 to obtain Avg and Std values corresponding to a plurality of groups of technological parameters, establishing a quantitative relation model of the technological parameters and the Avg and Std, screening technological parameter combinations which enable the Avg value to meet the thickness requirement and enable the Std value to be minimum according to the model, and determining the technological parameter combinations as an optimal technological window.
2. The method for rapidly calibrating ultrasonic spraying process parameters based on dye tracing and image analysis according to claim 1, wherein in step S1, the dye is methyl red.
3. The method for rapid calibration of ultrasonic spray process parameters based on dye tracing and image analysis according to claim 2, wherein in step S1, the mass concentration of methyl red in the spray solution is 0.01% to 1%.
4. The method for rapidly calibrating ultrasonic spraying process parameters based on dye tracing and image analysis according to claim 1, wherein in the step S3, the nine-point sampling method is specifically characterized in that an effective film forming area is respectively trisected in the length direction and the width direction, and the center point of four bisecting angle areas, the intersection point of four bisecting lines and the center point of the area are determined, wherein the total nine positions are taken as analysis sampling points.
5. The method for rapidly calibrating ultrasonic spraying process parameters based on dye tracing and image analysis according to claim 1, wherein in step S4, the color characteristic value reflecting the tracing color intensity of the point is obtained by extraction and calculation, specifically, the color image is converted from RGB color space to HSV or HSL color space, the saturation channel values of all pixel points in the sampling point area are extracted, and the average value of the saturation channel values is calculated as the color characteristic value of the point.
6. The method for rapidly calibrating ultrasonic spraying process parameters based on dye tracing and image analysis according to claim 1, wherein in step S4, the color characteristic value reflecting the tracing color intensity of the point is obtained by extracting and calculating, specifically, for a color image, red channel intensity value R, green channel intensity value G and blue channel intensity value B of all pixel points in a sampling point area are calculated, red saturation ratio of each pixel point is calculated according to formula s_r=r/(r+g+b) or s_r=r/(g+b), and then average value of s_r values of all pixel points in the area is taken as the color characteristic value of the point.
7. The method for quickly calibrating ultrasonic spraying process parameters based on dye tracing and image analysis according to claim 1, wherein in step S6, the establishment of a quantitative relation model comprises drawing a main effect diagram and a process window cloud diagram, wherein the main effect diagram is used for intuitively showing the influence trend of a single process parameter on an Avg value or a Std value, the process window cloud diagram takes two key process parameters as an X axis and a Y axis, and takes the Std value as a Z axis or a contour line, and is used for visually displaying a parameter area with optimal uniformity.
8. The method for quickly calibrating ultrasonic spraying process parameters based on dye tracing and image analysis according to claim 1, wherein the ultrasonic spraying process parameters comprise at least one of nozzle height, nozzle moving speed, scanning line spacing, liquid filling flow and ultrasonic power.
9. An ultrasonic spray process parameter calibration system for performing the method of any one of claims 1 to 8, the system comprising: the ultrasonic spraying equipment is used for spraying the solution containing the tracer dye to the substrate according to set parameters; The image acquisition module is used for acquiring color images of preset sampling points on the coating; the image processing and analyzing module is used for extracting the color characteristic values of all the sampling points from the color image and calculating the average value and standard deviation of the color characteristic values of all the sampling points; And the process parameter optimization module is used for establishing a correlation model of the process parameters, the thickness and the uniformity of the coating based on the average value and the standard deviation data obtained under a plurality of groups of different process parameters and outputting an optimal process parameter suggestion.

Description

Ultrasonic spraying process parameter rapid calibration method and system based on dye tracing and image analysis Technical Field The invention belongs to the technical field of material surface treatment and manufacturing process optimization, and particularly relates to a method and a system for quickly calibrating ultrasonic spraying process parameters based on dye tracing and image analysis. Background Ultrasonic spraying technology utilizes ultrasonic energy to atomize liquid into micron-sized liquid drops, and uniformly deposits the liquid drops on the surface of a substrate through a spray head, and is widely applied to the fields of photovoltaic films, electronic packaging, biosensors, functional coatings and the like. Uniformity and consistency of the sprayed film thickness are key indexes for determining the coating performance, and the indexes are directly and complexly influenced by various process parameters such as nozzle height, moving speed, scanning interval, liquid flow, ultrasonic power and the like. Currently, calibration of the sprayed film thickness and uniformity thereof mainly depends on off-line detection by a precise instrument, such as measuring the film thickness by using a step analyzer and a profilometer, or analyzing the surface morphology and components by using a laser confocal microscope, a spectrum ellipsometer and other devices. Although the method has high measurement accuracy, the method has the remarkable defects of expensive equipment, complex and professional operation, low detection speed, high environmental requirements, and usually only destructive or sampling detection. In the process development and debugging stage, the spraying effect needs to be evaluated quickly by frequently adjusting parameter combinations, and the traditional detection method is time-consuming, labor-consuming and high in cost, so that the iteration efficiency of process optimization is severely restricted, and the method becomes a bottleneck in technology development. Disclosure of Invention The invention aims to overcome the defects in the prior art, and aims to the urgent need of rapid parameter calibration in the development and debugging stage of an ultrasonic spraying process, and provides the rapid parameter calibration method and system for the ultrasonic spraying process, which have the advantages of low cost, simplicity and convenience in operation, rapid feedback and visual result quantification, so as to accelerate the process optimization process. In order to solve the technical problems, the technical scheme adopted by the invention is as follows. In a first aspect, the invention provides a method for rapidly calibrating ultrasonic spraying process parameters based on dye tracing and image analysis, which is characterized by comprising the following steps: s1, preparing a tracer solution, namely dissolving a selected dye into a spraying solvent to prepare a spraying solution containing a visual tracer; S2, spraying to form a film, namely setting technological parameters of ultrasonic spraying equipment, and spraying the solution prepared in the step S1 on the surface of the clean substrate to form a coating with trace colors; s3, standardized sampling, namely determining at least nine analysis sampling points in an effective film forming area of the coating by adopting a nine-point sampling method; s4, collecting color images of each sampling point, processing each color image, extracting and calculating to obtain a color characteristic value reflecting the tracing color intensity of the point; s5, quantitatively evaluating the coating quality, namely calculating an average value Avg and a standard deviation Std of color characteristic values of all sampling points, wherein the average value is used for evaluating the relative thickness of the coating or the dye deposition amount, and the standard deviation is used for evaluating the uniformity of the thickness of the coating; and S6, technological parameter association and optimization, namely changing one or more technological parameters in the step S2, repeating the steps S2 to S5 to obtain Avg and Std values corresponding to a plurality of groups of technological parameters, establishing a quantitative relation model of the technological parameters and the Avg and Std, screening technological parameter combinations which enable the Avg value to meet the thickness requirement and enable the Std value to be minimum according to the model, and determining the technological parameter combinations as an optimal technological window. Further, in step S1, the dye is methyl red. The methyl red has the advantages of stable chemical property, bright color, good solubility in common solvents, low cost and the like, and the color saturation and the deposition amount of the methyl red are in good correlation in a certain concentration range. When in use, the water-soluble film can be a methyl red ethanol solution. Further, in the step