Control Dispensing Application Height: Measure and Output to Correct Nozzle Height (Z)
In bonding, sealing, and dispensing processes, variations in the height of the target affect the application amount and bead shape. The CL-3000 Series measures the height without contact and outputs the measured values to the equipment to be used for nozzle height correction.
Three Issues That Occur When Application Height Varies
In bonding, sealing, and dispensing processes, variations in the height of the target directly lead to defects in the application amount and bead shape.
Variations in Target Height Affect Application Quality
Due to workpiece warpage, individual differences in jigs, and variations in previous processes, the distance (height) between the nozzle and the application surface is not constant. If the distance changes, the width and height of the application bead (application line of sealant/adhesive) will change even with the same discharge amount, leading to overflow or insufficient application. If the height of the target cannot be grasped within the process, the basis for final quality such as bonding strength and airtightness becomes ambiguous, causing rework in subsequent processes or outflow defects.
Applying Without Measuring Height Results in Unstable Application Amount and Bead Shape
If application is performed with the nozzle height fixed, the application amount and bead cross-section will vary by the height difference of the target. Excessive application leads to material loss and poor drying/curing, while insufficient application leads to poor adhesion or seal breakage. Without a system to measure the height, pass it to the dispensing equipment (dispenser), and use it for nozzle height correction, setting conditions becomes dependent on individual skills, making it impossible to maintain stable quality during mass production.
Contact Methods and Visual Inspection Cannot Measure in Real Time Within the Process
Since height gauges and dial gauges touch the target, they cannot measure moving or conveying targets inline, often relying on sampling. Visual inspection and limit samples are difficult to quantify, and judgments vary from person to person. Without a means to capture height numerically without stopping the process, signs of abnormalities may be missed, delaying the discovery of defects until after application and curing.
4 Steps: Measurement → Output → Correction → Inspection
This connects height measurement before application, output to the equipment, nozzle height correction, and bead shape inspection after application within the process.
- 1 Before application: Measure height and warpage – Process 1. Non-contact measurement of application surface height and height difference using a laser displacement sensor. Captures the distance between the nozzle and the application surface numerically.
- 2 Output: Pass to equipment/PLC – Process 2. Output the acquired height to the equipment. The equipment can use that value as a reference to correct the nozzle height (Z).
- 3 Correct and apply – Process 3. Apply with the nozzle height corrected according to the height difference of the target. Suppresses variations in application amount and bead shape.
- 4 After application: Inspect bead shape – Process 4. 3D inspection of bead height, width, and volume using the LJ-X8000 Series. Detects abnormalities such as breaks and dents.
Comparison of Methods for Measuring Application Height
Depending on the measurement method, there are significant differences in the ease of measuring height within the process, outputting to equipment, and understanding the application shape.
| Comparison items | CL-3000 Series (Laser coaxial / LJ-X8000 Series used together for application shape) |
Contact method (height gauge, etc.) | Visual inspection / limit sample | 2D image processing |
|---|---|---|---|---|
Non-contact / Effect on target |
CL-3000 Series (Laser coaxial / LJ-X8000 Series used together for application shape)
○ Non-contact, no effect
|
Contact method (height gauge, etc.)
× Contact, risk of scratching
|
Visual inspection / limit sample
○ Non-contact
|
2D image processing
○ Non-contact
|
Inline measurement |
CL-3000 Series (Laser coaxial / LJ-X8000 Series used together for application shape)
◎ Inline measurement even during operation
|
Contact method (height gauge, etc.)
× Mainly sample inspection
|
Visual inspection / limit sample
× Difficult to quantify
|
2D image processing
△ Possible depending on conditions
|
Height quantification and output to equipment |
CL-3000 Series (Laser coaxial / LJ-X8000 Series used together for application shape)
◎ Quantified and output to equipment
|
Contact method (height gauge, etc.)
△ Quantification is possible, but output is manual
|
Visual inspection / limit sample
× Cannot output
|
2D image processing
△ Not suited for height information
|
Dispensing amount/bead shape (height/width/volume) |
CL-3000 Series (Laser coaxial / LJ-X8000 Series used together for application shape)
○ Measured with 3D inspection
(LJ-X8000 Series) |
Contact method (height gauge, etc.)
× Cannot measure shape
|
Visual inspection / limit sample
× Mainly presence/absence detection
|
2D image processing
△ Not suited for height/volume
|
Affected by steps, warpage, and materials |
CL-3000 Series (Laser coaxial / LJ-X8000 Series used together for application shape)
◎ Coaxial design is highly resistant to steps and materials
|
Contact method (height gauge, etc.)
△ Difficult to measure at steps
|
Visual inspection / limit sample
× Large individual variation
|
2D image processing
× Affected by colors and patterns
|
Role (Area of expertise) |
CL-3000 Series (Laser coaxial / LJ-X8000 Series used together for application shape)
Dispensing height measurement, output, and shape inspection
|
Contact method (height gauge, etc.)
Dimensions of stationary targets
|
Visual inspection / limit sample
Presence/absence and visual confirmation
|
2D image processing
Appearance inspection of flat surfaces
|
Reasons to Choose the CL-3000 Series
The CL-3000 Series is a coaxial laser displacement sensor based on the multi-color confocal method that measures the height of the dispensing target without contact regardless of the material, and outputs the measured values to the equipment to be used for nozzle height correction. The bead shape after dispensing can be complemented by 3D inspection with the LJ-X8000 Series, completing dispensing height management within the process, which is difficult with contact methods or visual inspection.
CL-3000 Series Supporting Height Control for Dispensing
A coaxial laser displacement sensor based on the multi-color confocal method. It measures the height of the dispensing target without contact, and outputs the measured values to the equipment to be used for nozzle height correction.
Supporting Dispensing Height Measurement and Output for Nozzle Z Correction — CL-3000 Series
Confocal Displacement Sensor
This coaxial laser displacement sensor uses the multi-color confocal method to measure height and displacement inline and without contact, regardless of the material. Because of coaxial measurement, height can be measured stably even in deep holes or on dispensing surfaces with steps, and the acquired measurement values can be output to the equipment to be used for nozzle height (Z) correction. If you want to cover everything from understanding the workpiece height and warpage before dispensing to inspecting the bead shape (height, width, volume) after dispensing, you can use the LJ-X8000 Series 2D/3D laser profiler together to achieve both height measurement and 3D inspection of the dispensing shape within the process.
Get Detailed Materials for the CL-3000 Series
You can download a free catalog summarizing configurations, specifications, and application examples from height measurement to output to equipment and dispensing shape inspection.
Examples of Height Measurement in Dispensing and Coating Processes
It is used for height measurement before coating, nozzle height correction, and bead shape inspection after coating.
Injector/Nozzle Height Control
The height of the target is measured without contact before coating/dispensing, and the value is output to the equipment to correct the injector (nozzle) height. Because of coaxial measurement, the height of recessed areas in holes can also be stably measured.
Coater Nozzle Height Control
By measuring the distance between the coating nozzle and the wafer and adjusting the height, stable coating accuracy is maintained.
Applied Bead (Sealant) Shape Inspection
The height, width, and volume of the bead or sealant after application are measured in 3D to detect slight defects such as breaks and depressions. The applied shape is inspected without being affected by color or gloss.
Frequently Asked Questions About Dispensing Height Control (CL-3000 Series)
Q How is dispensing height control performed?
A
First, the CL-3000 Series measures the height of the dispensing target without contact and outputs the measured value to the equipment. The measured value can be sent to the equipment or PLC via analog output or field networks such as EtherNet/IP™, EtherCAT, and PLC link. The equipment can use this value as a reference to correct the nozzle height (Z), enabling dispensing that matches the height variations of the target.
Q The dispensing amount is unstable. Can this be improved with height measurement?
A
If the distance (height) between the nozzle and the dispensing surface changes, the dispensing amount and bead shape will vary. By measuring the height before dispensing and sending it to the equipment to correct the nozzle height, variations in the dispensing amount due to target variations can be suppressed.
Q What are the advantages compared to contact-type height gauges?
A
Because the CL-3000 Series is non-contact, it can measure moving or conveying dispensing targets inline without damaging the target. Because the height can be output as a numerical value, the height can be monitored in real time without relying on visual inspection or sample inspection.
Q Can it measure even on surfaces with steps or recessed areas in holes?
A
The CL-3000 Series uses the multi-color confocal method with a coaxial laser, allowing stable height measurement even in recessed areas of holes or on surfaces with steps.
Q Can the bead shape after dispensing also be inspected?
A
By using the LJ-X8000 Series together, the height, width, and volume of the bead or sealant after dispensing can be measured in 3D, and defects such as breaks and depressions can be detected without being affected by color or gloss.
Q Can it measure dispensing targets with different materials or colors?
A
The CL-3000 Series uses the multi-color confocal method to measure height with a single sensor head regardless of the material. Stable height measurement is possible even for targets with different reflection conditions.
Q Please feel free to contact us regarding challenges with dispensing height control.
A
You can check the catalog or use the inquiry form to find out about configurations for height measurement of dispensing targets, output to equipment, and applied shape inspection.
