Intelligent Optical Film Control Software
Designed for complex layer stacks produced on Low-E glass coating line, the software creates digital models for each coating material and compares them with real-time spectral data from the production line. When the measured data deviates from the reference model, it identifies the layer responsible and recommends process adjustments — enabling process teams to quickly pinpoint coating issues and correct them more effectively. It is particularly valuable for multilayer products, where manually identifying the problem layer can be time-consuming and requires significant expertise.
Functions
- Real-time Monitoring
Monitors the coating spectrum online to provide a continuous view of the current film condition. - Spectrum-to-model Comparison
Compares the real-time measured spectrum with the reference coating-stack model to identify deviations during production. - Problem Layer Identification
Automatically identifies the layer that has deviated from its target thickness to narrow down the source of the problem quickly. - Adjustment Recommendations
Uses algorithm-based analysis to recommend process parameter adjustments to correct the deviation.
Working Principle
- Coating Stack Modeling
A reference spectrum is imported into the software and fitted using a dedicated algorithm to generate a digital model of the coating stack, which is then stored in the database. - Real-time Comparison
During production, the optical coating software calls up the corresponding reference model and receives real-time product spectra from the online inspection system. It calculates the actual film thickness and compares the result against the reference. - Deviation Detection
If film thickness exceeds tolerance, the system alerts the operator, identifies the affected layer, and recommends adjustments.
Advantages
- More Repeatable Processes
Trackable, repeatable process settings and results build a reliable database for standardizing production and driving continuous improvement. - Less Dependence on Individual Experience
Diagnosis of every layer within the coating stack for any deviation and adjustment recommendations reduce reliance on highly experienced process engineers and can shorten the time required to train new personnel. - Faster Adjustment, Less Material Loss
Faster deviation identification and correction reduce adjustment time, material waste, and off-spec results, improving production yield.
CNBM Optoelectronic Equipment (Taicang) Co., Ltd., established in 2009, is a wholly owned subsidiary of China Triumph International Engineering Co., Ltd. (CTIEC). The company specializes in large-area magnetron sputtering coating equipment, with Low-E glass coating lines as its core business. Its 100,000 m² manufacturing base includes an R&D center and nearly 20,000 m² of assembly and commissioning facilities. The company provides equipment R&D, engineering design, manufacturing, installation, commissioning, training and system upgrades. Its coating lines support single-, double- and triple-silver Low-E glass, solar-control glass and other functional coatings. More than 20 Low-E coating lines have been delivered and put into commercial operation. Projects are supplied as complete coating systems or turnkey solutions according to customers’ glass sizes, coating processes and production requirements.
