OSC Low-E is a professional solution for Low-E coating industry mainly focus on:
- thin film design
- refractive index fitting and management
- inversion fitting
- uniformity adjustment and control
- resource management
- coating line running status simulation
- coating line running tracking, evaluation and improvement
OSC Low-E is developed based on Filmstar which has fast calculation and optimization together with our working experience on low-E industry.
The excellent performance of OSC Low-E such as fast calculation, accurate inversion can significantly improve the efficiency and reduce waste. Coating line resource management, production data management and technology accumulation are solid upgrade and guarantee for product quality then enhance the comprehensive strength of customers.
Low emission (known as low-E) glass is a thin film product with multiple layers of metal or other compounds coated on the glass.
Comparing with ordinary glass and traditional architectural coated glass, the low-E coating has a high transmittance of visible light and high reflectance of the far-infrared and then has excellent thermal insulation and good light transmission.
However, the issues of low-e coating production line such as low efficiency, huge waste, non-sustainable development and others have plagued the majority of Low-E coating companies, and even Low-E coating upstream and downstream enterprises.
The current Prominent issues are:
- Adjustment depends on experience, manual calculation or excel:passable for heat-reflective glass, single silver design but not suitable for the double silver, three silver and more complex design.
- Spectrum and color can not meet the requirements. Even Sometime achieve objective,the coating equipment parameters have to be re-adjusted after exception handling. There is no plan at all for reciprocating and wasting a lot of time.
- Uniformity, consistency can not be controlled, especially the problem of high angle interference color can not be solved.
- Acknowledge of Coating line equipment, materials and process control is limited to equipment manufacturers or reference books. There is no specific details and verifiable traceability relationship.
- Adjustment is a wheel war and lead to staff fatigue, complain and high turnover rate.
- A lot of waste (glass, coating target, electricity).
- Orders can not be delivered in time, new orders can not undertake.
- Customer Complaints.
OSC Low-E is developed based on Filmstar, a famous optical thin film software from USA and it is popular for arround 30 years.
OSC Low-E continues Filmstar's advantages such as high computing power and high optimization speed and combines our practical application and practical operation of Low-E industry.
It was developed by our domestic and foreign Low-E coating experts and software engineers combining first line users' needs, practical experience of product development engineers and process adjustment engineers, a number of cutting-edge technology and so on.
It highlights to solve the actual problems of users rapidly and effectively.
We obtained the actual verification of good results after several years of top coating production line tests and many times functional amendment based on the actual process running parameters.
Development is a procedure to get correct thin film design based on spectrum or color target through solving equations with many strategies.
Development can be done without occupying the time for production. Imitation or customized color need enough time to design the thin film stack and get the required spectrum, color and also taking into account the physical properties such as resistivity, resistance Acid and alkali, abrasion resistance and so on.
Inversion fitting is the key step of adjustment. The speed and accuracy of the inversion fitting directly determine the efficiency and product quality.
Thickness of each layer is inverted according to the thin film stack and known spectrum by Solving equations with many strategies.
We can get the adjusted thickness through comparing simulated thickness with the standard thickness.
Through the step-by-step inversion fitting, you can adjust the actual thin film thickness to the standard thickness resulting in the desired spectrum, color And physical characteristics.
The refractive index of the material(substrate, coating material) is the most important data for the thin film calculation(Development, inversion fitting).
- Fitting the refractive index of the material by the photometric method need one or more of the transmittance, the reflectance and the film thickness. When the accuracy of the test data is the same, the fitting result is more reliable with more data type.
- We can fit the refractive index of a substrate or a kind of coating material. In general, we need know the refractive index of the substrate(can be fitted in advance) before we can fit the refractive index of coating material.
- Multi-angle photometric data may be helpful for the convergence of the refractive index fitting procedure.
Uniformity refers to the difference between the different positions of the glass.
The problems that may arise from uniformity include overall optical properties (color, emissivity), physical properties (abrasion resistance, temperature shock), chemical properties (acid and alkali resistance), etc.
The reason is one or more Layers of thin film design are different(thickness or composition) from one position to others.
There are many factors that affect the uniformity, including the structure of the equipment itself, magnets, gas distribution pipes, shielding, target substrate distance, etc., but also the auxiliary gas settings.
The uniformity is adjusted by modeling factors both in terms of positions and in real time.
The uniformity is controlled by monitoring the spectrum/resistance of each piece of glass real time during the production process and adjusting it in case deviation from normal level.
Our solution has been implenmentated on difference Low-E coating production line in China. The main products of these production lines are 3-Ag and 2 Ag.
We have more users in the following industries and application fields:
- Low-E coating production line.
- University Laboratory
The coating equipment of users who use OSC Low-E sucessfully:
- VON ARDENNE sputtering line.
- xxx sputtering line.
- User self-made sputtering line.
Product Composition
Software, Instrument(optional:spectrometer and Surface resistance measurement module), server on demand,desktop,laptop and so on.
Pre-sales consulting and demo
User needs research, product features, price estimates, delivery estimates.
Make solution
Make solution accoring to user's request: hardware,software,customized function, training, delivery, price, time and so on.
Implement Solution
Hardware and software procurement, custom features development and testing, the overall training, on-line commissioning, acceptance and others.
Training
- We provide at east one time training for all clients to make sure they can use our products well. The training plan will be prepared according to the basic knowledge of participants,request,product features,technical difficulty and so on. The minimum training time is 5 working days.
- On-demand training needs: hardware upgrade, product replacement, new employee onboard. We will coordinate according to the actual situation.
Technical Support
Instruction for usage, trouble shooting, questions via telphone,email, remote control, instant conversation and so on.
Technical Consultation
Upgrade coating production line,Renovation project,repair,product development,material search ect.
After-sales Service
Warranty of Hardware, debug for software, upgrade function of software etc.
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Is there any requirement on the format of online spectrometer?
We support most of the commercial spectral file formats.
We also provide extended methods to support more spectral file formats, please contact us to confirm.
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Do you provide a computer? What are the requirements on the computer?
For new users, we provide options to purchase computer with our solution. The computer is well-known brand, high level configuration, after our testing, to meet the performance requirements of our software.
The user-provided computer, we will implement our solution on users' computer and we will explain to the user to replace the computer in case there is an unsolvable problem from computer itself.
We recommend a branded machine with high configuration (CPU and memory) to ensure longer use and better performance.
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Is it harder to use? Do you provide training?
The difficulty varies from person to person.
Generally, it will better when you have some basic knowledge of optical thin film (included in the training content) and software operating skills (similar to Office)
We will provide training to our new users and reponse to training request of existing users.
We will try to ensure all of our users can have good practice on our solution.
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Is the calculation speed really so fast?
After multi-user, multiple production line products (double silver, single silver), multi-computing platform (from XP to Win10) test, users feel the calculation time is only 1% or less of other similar products.
Of course, the thin film stack adjustment speed and performance of quality control are constrained by too many factors. We will try our best to help users to improve that.
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Do you offer a free trial?
Because most of our solution need configure based on the actual situation of the user's line and develop their own material parameters. It need a period of time to get familiar with our products and achieve the best results. We do not provide an online trial in order to avoid wasting time.
However, we provide presentations, demo show and instructions that familiarize users with our products and provide technical specifications to ensure that users buy the products and services they want.
Please contact us for further information.