How to ensure a high-precision environment in the production of precision instruments
Release time:
2024-12-19
The production environment for precision instruments must ensure high precision conditions, which requires addressing multiple aspects.
- Precision Air Conditioning System
- Precision instrument production workshops require the installation of high-precision air conditioning systems. For example, using constant temperature and humidity air conditioning, the temperature control accuracy can reach ±0.1℃ or even higher. This air conditioning system can quickly and accurately adjust indoor temperature through advanced compressor technology and temperature sensor feedback mechanisms.
- The layout of the air conditioning system is also crucial. By adopting a zoned control approach, the production area is divided into several small zones based on the sensitivity of different precision instruments to temperature, with each zone having its own independent temperature adjustment unit. For instance, in a photolithography machine production workshop, the optical system part of the photolithography machine is extremely sensitive to temperature changes, so the air conditioning system in this area can be set with stricter temperature parameters.
- Thermal Isolation Measures
- The walls, roofs, and floors of the building should be well insulated. High-performance insulation materials, such as polystyrene foam boards and polyurethane foam boards, can be used. These materials have low thermal conductivity and can effectively prevent external heat from entering.
- For internal heat sources, such as heat generated by production equipment, reasonable equipment layout and cooling systems should be implemented. For example, placing heat-generating processing equipment away from precision instruments and equipping them with dedicated air-cooled or water-cooled cooling devices can prevent heat from interfering with the production environment of precision instruments.
- Dehumidification and Humidification Equipment
- Install appropriate dehumidification and humidification equipment according to the requirements of precision instrument production. In areas with high humidity, using rotary dehumidifiers can effectively reduce air humidity. Rotary dehumidifiers use hygroscopic media to adsorb moisture from the air, controlling air humidity at very low levels, such as relative humidity of 10% - 20%.
- When the air humidity is low, ultrasonic humidification equipment or electrode humidification equipment can be used to increase air humidity. Ultrasonic humidification equipment atomizes water molecules through ultrasonic vibrations and releases them into the air, achieving high humidification efficiency and precise control of the humidification amount.
- Humidity Monitoring and Feedback
- Install high-precision humidity sensors to monitor humidity changes in the production environment in real-time. These sensors can accurately transmit humidity data to the control system.
- The control system automatically adjusts the operation of dehumidification or humidification equipment based on the data feedback from the sensors. For example, when humidity exceeds the set value, the dehumidification equipment automatically turns on; when humidity falls below the set value, the humidification equipment starts working, ensuring that humidity remains within the range required for precision instrument production, with a general relative humidity error controlled within ±5%.
- Air Filtration System
- A multi-stage filtration system is used to purify the air. Pre-filters can filter out larger dust particles, such as those larger than 5μm; medium-efficiency filters can further filter particles in the range of 1 - 5μm; high-efficiency filters (HEPA) are used to remove tiny particles smaller than 1μm. For precision instrument production with extremely high cleanliness requirements, such as semiconductor chip manufacturing, ultra-high-efficiency filters (ULPA) are also used, which can filter out particles larger than 0.1μm, ensuring that air cleanliness reaches Class 1 or higher.
- The maintenance of the air filtration system is also crucial. Regularly replace filters based on their service life and actual pollution conditions. Generally, pre-filters are replaced every 1 - 3 months, medium-efficiency filters every 3 - 6 months, and high-efficiency filters every 6 - 12 months to ensure that the filtration effect remains optimal.
- Cleanroom Design
- For precision instrument production environments, the design of cleanrooms must meet strict standards. The building materials for cleanrooms should be dust-free and corrosion-resistant. The floor can use epoxy self-leveling flooring, and the walls can use color steel plates. These materials have smooth surfaces, are easy to clean, and do not release particulate matter.
- Personnel and materials entering and exiting the cleanroom must go through strict air showers and transfer windows. When personnel enter the cleanroom, they must pass through the air shower system, which uses high-speed clean air to blow away dust particles they carry. Materials are transferred through transfer windows, which purify the materials during the transfer process to prevent external contaminants from entering the cleanroom.
- Equipment Vibration Isolation Measures
- Precision instrument production equipment should be installed on vibration isolation platforms. For example, using air spring dampers or rubber vibration pads. Air spring dampers can be adjusted according to the weight and vibration frequency of the equipment, effectively isolating vibrations generated during equipment operation. For high-precision measuring instruments, such as coordinate measuring machines, using air spring dampers can reduce vibration transmission rates to below 5%.
- The foundation of the building can also be treated for vibration isolation. During the building design phase, isolation bearings or vibration pads can be used to reduce the impact of external vibrations on the production environment. For example, in precision instrument production workshops near traffic routes, installing isolation bearings between the building foundation and the ground can effectively isolate vibrations generated by vehicle traffic.
- Noise Control
- Select low-noise production equipment. During the equipment procurement phase, attention should be paid to the noise indicators of the equipment, prioritizing equipment with noise levels below certain standards (e.g., below 70dB (A)).
- Sound-absorbing treatments should be applied to the walls and ceilings of the production workshop. Sound-absorbing panels, sound-absorbing cotton, and other materials can be used to absorb and reflect sound waves, reducing noise levels in the workshop. Through reasonable sound-absorbing design, the noise in the workshop can be controlled to around 50 - 60dB (A), providing a relatively quiet environment for precision instrument production.
- Electromagnetic Shielding Facilities
- For precision instruments that are susceptible to electromagnetic interference, the production environment should be equipped with electromagnetic shielding rooms. The walls, ceilings, and floors of the electromagnetic shielding room are made of metal materials (such as copper plates, steel plates, etc.), which can reflect and absorb external electromagnetic radiation.
- The doors and windows of the shielding room also need special treatment. Electromagnetic shielding doors and windows are used, with the shielding doors having good sealing performance and filled with electromagnetic shielding materials inside; the shielding windows use conductive glass, which can effectively block the intrusion of electromagnetic interference.
- Design of electromagnetic compatibility for equipment
- During the design phase of precision instruments, their electromagnetic compatibility must be considered. The internal circuits of the instruments should be reasonably laid out, separating parts that are prone to electromagnetic interference (such as high-frequency circuits, power circuits, etc.) from sensitive circuits, and using shielded cables to connect the circuits to reduce electromagnetic radiation and conducted interference.
- Conduct electromagnetic compatibility testing on electrical equipment in the production environment. Regularly use electromagnetic compatibility testing equipment, such as spectrum analyzers and electromagnetic interference testers, to test the equipment, ensuring that the electromagnetic interference generated by the equipment is within the specified range and does not affect the production of precision instruments.
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