Configurable object application handler for autowiring

Abstract

The present invention discloses an object attachment handler, which comprises: a configurable clamp, which is configured to define open and closed positions based on a software definition of an object to be attached; and a fastening tool, which is automatically configured to apply a defined force curve at a defined position based on the software definition of the object to complete the attachment of the object.

Description

[0001] Related Applications

[0002] This application claims priority to U.S. Provisional Application No. 62 / 934,385, filed on November 12, 2019, and incorporates said application by reference in its entirety. Technical Field

[0003] The present invention relates to application handlers, and more particularly to automatically configurable application handlers for objects in automated manufacturing. Background Art

[0004] Typically, the process of attaching an object such as a heat sink to a circuit board requires custom design and implementation for a specific heat sink configuration. Heat sink configurations vary widely in size, attachment location, and attachment type. As a result, the design and implementation of an automated heat sink assembly station on an assembly line can take weeks, while a fully customized tool is designed, manufactured, and tested in an iterative process. Adapting the station to assemble different types of heat sinks (with different sizes, attachment locations, or attachment types) again involves significant design and implementation of hardware and control software specific to the specific parameters of the heat sink, and implementation by expert users. Similar situations occur for many other object types besides heat sinks, and target mating locations besides circuit boards. BRIEF DESCRIPTION OF THE DRAWINGS

[0005] The present invention is illustrated by way of example and not by way of limitation in the figures of the accompanying drawings in which like reference numerals refer to similar elements and in which:

[0006] Figure 1A An illustrative diagram of one embodiment of an object attachment handler.

[0007] Figure 1B A diagram of one embodiment of an object attachment handler.

[0008] Figure 2A A block diagram illustrating one embodiment of the major elements of an object attachment handler.

[0009] Figure 2B Figures are diagrams illustrating exemplary embodiments of fastening tools for various types of attachments.

[0010] Figure 3 One embodiment of an object attachment handler whose dimensions are settable via software is described.

[0011] Figure 4A One embodiment illustrating the three-dimensional dimensions of an object attachment handler.

[0012] Figure 4B One embodiment of a gripper tip is described.

[0013] Figure 5 One embodiment of a user input is a heat sink that can be attached to a printed circuit board via an object attachment handler.

[0014] Figure 6 A flow chart of one embodiment of defining parameters of an object attachment handler in software.

[0015] Figure 7 A flow chart of one embodiment of commands for an object attachment handler for a heat sink.

[0016] Figure 8 One embodiment of a clamping axis and hammer axis description that may be used for an object attachment handler for heat sink applications is described.

[0017] Fig. 9 One embodiment of a clamping force definition user interface that may be used is shown.

[0018] Fig.10 is an overview of one embodiment of a robotic cell in which an object attachment handler end of an arm tool may be utilized. DETAILED DESCRIPTION

[0019] A configurable object attachment handler is described that can be configured by software. In one embodiment, the handler is an end-of-arm tool for a robotic arm in a robotic cell for automated assembly. In one embodiment, the handler enables the system to handle objects of different sizes and configurations for attachment to a socket, circuit board, or other workpiece. For example, the object for attachment may be a radiator. After the radiator size and attachment mechanism are defined in the software, the system automatically reconfigures the gripper and fastening tool to properly grip, place, position, and attach the radiator. Other types of objects can be similarly defined so that the handler can be automatically configured for them, as will be described below.

[0020] In one embodiment, the user selects the radiator or object details, including the size of the radiator, the attachment mechanism and the location of the attachment mechanism. In another embodiment, the radiator or object details can be read from a QR code or other indicator on a tray or radiator or other device. Once the data is received, the system automatically configures the clamp and the fastening tool. In one embodiment, the configuration fastening tool may include selecting a tip and attaching it to the fastening tool. The tip may be a "hammer" for inserting a push pin, a hook using a spring clip, a suitable screw driver (covering a nut driver) for applying a screw (standard or spring loaded) bolt, a melting tool for a hot pile, etc. In one embodiment, there may be a bracket for the fastening tool tip, which is automatically selected and attached to the clamp. In another embodiment, the replacement of the fastening tool can be done manually.

[0021] Once the system is configured, it can quickly attach a heat sink or other object in an automated manufacturing environment. Because the heat sink / object definition is software-based, when using a different object, design changes only take a few minutes if it is a new configuration, and a few seconds if it is a previously defined object and no fastening tool changes are required. In one embodiment, the user can scan the object or enter a part number for automatic configuration. In addition, this allows the system to handle multiple types of objects with different types of attachment mechanisms. This allows the robotic assembly system to quickly adjust and improve configuration speed.

[0022] Although the specific examples given in the following description are for heat sinks including push pins, it should be understood by those skilled in the art that actual object attachment handlers can be used to attach / assemble other types of objects, as well as other types of attachment mechanisms. For example, a heat sink with a press fit, push pin, rivet, snap, through-hole attachment can use a hammer or similar mechanism. A heat sink with an adhesive or solder-based attachment can use an adhesive dispenser. A heat sink with an attachment based on bolts, screws, spring screws can use a rotating mechanism. A heat sink with a hot stake attachment can use a melting tool. Once the size of the object and the location and type of the attachment mechanism are defined, the system can automatically position the object and apply the correct attachment method.

[0023] In addition, the system can be used to attach objects other than heat sinks. For example, the system can be used to attach fans, heat pipes, DIMM modules, printed circuit boards to housings or other components that may vary in size or configuration, and such configurable attachment handlers are useful for these components.

[0024] The following detailed description of the embodiments of the present invention refers to the accompanying drawings, in which the same reference numerals indicate similar elements, and the specific embodiments of practicing the present invention are shown by way of illustration. The description of these embodiments is sufficient to enable those skilled in the art to practice the present invention. It should be understood by those skilled in the art that other embodiments may be utilized, and logical, mechanical, electrical, functional and other changes may be made without departing from the scope of the present invention. Therefore, the following detailed description is not restrictive, and the scope of the present invention is limited only by the appended claims.

[0025] Figure 1A A photograph of one embodiment of an object attachment handler. Figure 1B FIG. 1 is a diagram of one embodiment of an object attachment handler. In one embodiment, the object attachment handler includes seven motors. A motor that opens and closes the gripper, the main gripper motor 120. The gripper has open and closed positions defined based on the configuration of the object to be placed. In one embodiment, the position of each jaw of the configurable gripper is individually configurable, providing true symmetrical gripping or calibrated pick-up points.

[0026] In one embodiment, there are two hammers 160 as fastening tools. In one embodiment, each hammer 160 has three degrees of freedom. The position of the hammer 160 in the XY plane is determined based on the position of the attachment element of the object, such as a peg for a radiator. In one embodiment, the hammer 160 is lowered with a hammering force to push in the peg. In one embodiment, when the object is defined, the hammers 130, 135, 140, 145 in the X and Y dimensions are used to move the hammer 160 in the XY plane to the appropriate position for attachment. In one embodiment, during the insertion process, the hammers 160 only change their position in the vertical direction under the control of the Z1 / Z2 motors 150 / 155. In another embodiment, the hammer 160 may be in a neutral position during the initial insertion and may be moved horizontally and vertically for insertion.

[0027] Although the above examples illustrate hammers, for other types of fastening tools, there may be a group of similar motors. For example, for a screw driver, in addition to the XY positioning motor and the vertical movement motor, the fastening system includes a rotation motor to rotate the screw driver when the screw driver is in the correct position. For epoxy fastening tools, in addition to the XYZ positioning motor, there may be a "distribution" motor for distributing epoxy to the correct position. For melting tools, in addition to the XYZ positioning motor, in one embodiment, the variables defined may include the position of the melter to which heating is applied, and the temperature of melting. For spring clamp tools, in one embodiment, the variables defined may include a first position when the spring clamp is hooked, a second position in which the spring clamp is stretched, and a third position in which the spring is released.

[0028] Other motor groups and position definitions may be used as appropriate for a particular application. In one embodiment, there may be two sets of independently moving attachment mechanisms, such as a positioner that ensures the object remains in place, and an attachment that applies the attachment mechanism while the positioner holds the object in place.

[0029] Figure 2A 2 is a block diagram illustrating one embodiment of the main elements of the attachment system 200. The attachment handler 205 includes a gripper 210, one or more fastening tools 220 having a tool head 225. As described above, in one embodiment, there are two fastening tools 220A, 220B, corresponding to the attachment mechanisms on both sides of the object, such as pegs for a heat sink. Of course, the system can include a single fastening tool 220, or more than two fastening tools 220 can be included. For example, a configuration can include four fastening tools.

[0030] The attachment handler 205 is configured and controlled by a control system 230. In one embodiment, the control system is a computer system that may include a processor 232, a memory 240, and other elements. The processor 232 may be a microprocessor or a simple control unit. In one embodiment, the control system 230 may be a remote device or a cloud-based system rather than a local computer. Although the control system 230 is illustrated as an integral element, in some embodiments, the various parts of the control system 230 may be on different devices that may not be collocated.

[0031] Configuration logic 234 configures the attachment handler 205. The configuration includes the positioning of the fastening tool 220 and the dimensions of the gripper 210 in the open and closed positions. In addition, the configuration logic 234 may define the location of the tray from which the object is picked up, and the location of the element to which the object is attached. In one embodiment, the controller 236 controls the movement of the attachment handler 205. In one embodiment, the controller 236 may be a physical part of the attachment handler system.

[0032] In one embodiment, the configuration is based on the characteristics of the object being attached. Those characteristics include the size, shape, attachment mechanism, and attachment mechanism location of the object. In one embodiment, the user can enter this data via the user interface 246. In one embodiment, the user or system can scan an identifier, such as a QR or UPC code, and automatically identify the object and its characteristics for attachment. In one embodiment, the system can have a database 242 of such devices so that once the characteristics are entered or obtained in another way, the system can extract the data from the database 242. In one embodiment, the configuration memory 244 stores other configuration data for the attachment handler and its movement. In one embodiment, the log 245 stores data from the executed attachment process.

[0033] In one embodiment, the user interface 246 provides an alert when a fault is detected. For simplicity, other conventional elements that may be present in the system, such as a robotic arm, a camera to provide fiducial-based alignment, motors, etc., are not shown.

[0034] Figure 2B Some exemplary fastening tools are described. The fastening tool may include a hammer 250 for inserting pegs, push pins, rivets, etc. In one embodiment, the fastening tool tip 255 may be customized for the type of attachment mechanism used. For example, to insert a peg, a rubber tip shaped to fit the peg may be used. This is to ensure that the force is applied vertically and reduce the risk of slippage. In one embodiment, the hammer head 250 has a vertical insertion motion. In one embodiment, the motion pattern of the vertical head includes initially applying a force at a first level, and then applying a greater force until the part is fully seated and the object is attached.

[0035] The screwdriver head 260 also moves vertically, but once placed provides rotational motion for inserting screws, bolts and other such fasteners. The screwdriver tip 265 can be customized according to the specific type of screw or bolt used. In one embodiment, a screw dispenser is associated with the screwdriver head 260, as known in the art. Alternatively, the screw or bolt may already be positioned, and the screwdriver head is lowered to insert the screwdriver tip 265 into the screw, and then rotated, as known in the art.

[0036] Adhesive head 270 is designed to apply adhesive. In one embodiment, adhesive head 270 dispenses adhesive, such as epoxy or solder, for attaching objects. In one embodiment, adhesive head can move while dispensing adhesive from dispensing element 275. In one embodiment, adhesive head can dispense dots of adhesive. In one embodiment, additional motors can control dispensing.

[0037] The hot stake head 280 is designed to melt a post inserted through a heat sink or object to complete the fastening. The hot stake head 280 can provide insertion force as well as melting. In one embodiment, the shape of the melter 285 can depend on the shape of the stake used. For example, as is known in the art, a hollow stake can have a different melter 285 to melt the stake and fasten the object.

[0038] In one embodiment, the spring head 290 is designed to attach a spring clip. The spring head 290 has a hook to capture the spring, stretch it, and release it in the correct position. In one embodiment, the hook 295 portion can rotate to release the spring. In another embodiment, the spring head 295 can rotate to release the spring. If the hook 295 rotates, it can be controlled by a separate motor.

[0039] Other types of fastening tools may be used in the system.

[0040] Figure 3 One embodiment illustrating the dimensions of the object attachment handler that can be set via the X, Y, and Z positions of the fastening tool, the displacement between the tip and the fastening tool along the X, Y, and Z axes (EOA_x / y / z), and the travel distance of the fastening tool.

[0041] Figure 4A One embodiment illustrating the three-dimensional dimensions of an object attachment handler. Figure 4B One embodiment of a gripper tip is described.

[0042] Figure 5An embodiment of user input for a heat sink, which may be one of the objects attached to a printed circuit board. In one embodiment, the heat sink characteristics include X and Y dimensions and height Z. In one embodiment, the characteristics also include the location of the fasteners. In one embodiment, as illustrated, the location includes the distance between the fasteners in the X and Y directions, and the fastener height. In one embodiment, the fastener definition includes the height before insertion and the height after insertion. In one embodiment, the heat sink characteristics also include the type of fastener (here, a push button). Alternative ways of defining the fastener location may be used.

[0043] Figure 6 Flowchart of one embodiment of defining parameters of an object attachment handler in software. The process begins at block 610. At block 620, characteristics of an object for insertion are received. In one embodiment, this may be input by a user. In one embodiment, this may be retrieved from a database or other source. In one embodiment, the characteristics include size, attachment mechanism used, location of the attachment mechanism. In one embodiment, the characteristics may also include the stiffness of the object, which defines the force with which the gripper holds the object, and the force that may be used for insertion to ensure that no damage is caused to the object or the attachment mechanism.

[0044] At block 630, the size of the gripper is automatically set in an open state and a closed state based on the characteristics of the object to be inserted. Typically, the gripper opens wide enough to fit around the top portion of the object, which may be wider than the area held by the gripper. The size of the closed gripper is also set. In one embodiment, the height at which the gripper is closed is also automatically set based on the object configuration.

[0045] Based on the properties of the object, force parameters for the grip are automatically set at block 640. The force parameters define how strongly the gripper holds the object.

[0046] At block 650, the location of the object to be picked up is received. In one embodiment, the object is picked up from a tray or conveyor. In one embodiment, this data may be configuration data available to the system.

[0047] At block 660, the insertion location of the object is received. In one embodiment, the object is placed in the appropriate location in the assembly (such as a circuit board). The disposal of the object's destination is not addressed here, but in one embodiment, a new board or device on which the object is inserted is received via a conveyor. In one embodiment, this data may be configuration data available to the system.

[0048] At block 670, based on the properties of the object, the location and application of the fastening are automatically set. In one embodiment, the location of the fastening tool may include one or more locations where the fastening tool is used, as well as a specific purpose. For example, for push pins, the location of the push pins, the height of the push pins before and after full insertion, and the amount of force used to insert them will be set. For screws, the location of the screws, the height of the screw heads before and after full insertion, and the force used to screw them in will be set.

[0049] At block 680, the release of the clamp is automatically set. In one embodiment, the clamp returns to the neutral position after insertion. Using the neutral position makes it easier to perfectly repeat the process every time. The process then ends at block 690.

[0050] Figure 7 Flowchart of one embodiment of commands for an object attachment handler for a heat sink. At block 720, the characteristics of the heat sink as the object to be inserted are defined. For such a heat sink, in one embodiment, the characteristics are the size of the heat sink and the location of the push pin. Figure 5 Describes the defined heat sink characteristics.

[0051] Return to Figure 7 , after providing the heat sink characteristics, automatically sets the parameters of the object attachment handler. The parameters include the basic position of the fastening tool, how fast and how low to insert the push pin, the open and closed position of the gripper, etc.

[0052] At block 730, a ready state command is sent to set the gripper to an open position. In one embodiment, the gripper starts in a neutral position and returns to the neutral position between insertions.

[0053] At block 740, a pick command is sent. The gripper moves to the pick position, lowers and closes to insert the inserted heat sink, and lifts up.

[0054] An insert command is sent at block 750. The insert command moves the gripper to the insert position and places the heat sink in the insert position.

[0055] An attach command is sent at block 760. The attach command moves the hammer to the attach position and applies an insertion force to the push pin.

[0056] A release command is sent at block 770. The release command opens the clamp and releases the heat sink.

[0057] At block 780, a homing command is sent. The homing command returns the gripper to a neutral position, ready to pick up the next heat sink. The process then ends at block 790. Although this flowchart describes one embodiment of a process for inserting a heat sink into a circuit board, one skilled in the art will appreciate that this process can be used to insert other types of objects into circuit boards or other types of components. In addition, some steps, such as homing, may be skipped. Furthermore, these commands are merely exemplary. Actual commands may be more or less detailed.

[0058] Figure 8 An embodiment of a clamp axis and hammer axis description that may be used is described. The clamp axis defines the position of the clamp. In one embodiment, it includes a pick position and a pick open state, which is the position where the clamp is open. The clamp closed state defines the position where the clamp is closed. The placement position defines the position where the heat sink or other item is placed on the workpiece. The release defines the distance from the home position of the released object. The hammer axis defines the position of the tightening. For the Z dimension (e.g., vertical travel), the dimensions define the starting point and the maximum travel.

[0059] Fig. 9 An embodiment of a user interface for inputting clamping force and clamp position is illustrated. The clamping force defines the force with which the clamp closes. In one embodiment, this depends on the material of the particular heat sink.

[0060] Fig.10 An overview of one embodiment of a robotic unit in which an object attachment handler end of arm tooling may be utilized. The robotic unit includes a robotic arm which may include an object application handler as an end of arm tooling. In one embodiment, it may include a conveyor belt through which a plate into which objects are inserted may be moved. In one embodiment, it may include a tray feeder from which objects may be picked up.

[0061] In the foregoing description, the present invention has been described with reference to specific exemplary embodiments of the present invention. However, it will be apparent that various modifications and changes may be made thereto without departing from the broader spirit and scope of the present invention as set forth in the appended claims. Therefore, the description and drawings should be regarded as illustrative rather than restrictive.

Claims

1. A software-configured object attachment handler, comprising: A control system comprising: a memory storing a plurality of object configurations for a plurality of objects, each object configuration including dimensions, attachment mechanisms, and attachment mechanism locations for a particular object; an interface for inputting an object configuration for an inserted object; a configurable gripper that is automatically configured by the control system to open and closed positions based on software definition of the object to be attached; a fastening tool automatically configured to apply a defined force curve at a defined location based on the software definition of the object to complete the attachment of the object; The control system controls the software-configured object attachment handler to attach the object to be attached to a workpiece.

2. The object attachment handler according to claim 1, wherein the position of each jaw of the configurable gripper is individually defined.

3. The object attachment handler of claim 1, wherein the fastening tool further comprises a head and a motor providing three degrees of movement so that the fastening tool is aligned with the attachment mechanism of the object to be attached and lowered into position to complete the attachment.

4. The object attachment handler according to claim 1, wherein the fastening tool is a hammer for attaching the object by pushing down the attachment mechanism.

5. The object attachment handler of claim 4, wherein the hammer is used with the attachment mechanism comprising one or more of: a push pin, a rivet, a snap, and a through hole. The object attachment handler according to claim 4 , wherein the hammer is used for press fitting.

7. The object attachment handler of claim 4, wherein the hammer is positioned to be aligned with the attachment mechanism, and the hammer is configured to be lowered to a set distance with a set level of force to complete the attachment of the attachment mechanism.

8. The object attachment handler according to claim 1, further comprising: a user interface that enables a user to define objects for attachment; and Configuration logic configures the configurable gripper and the fastening tool based on a defined object.

9. The object attachment handler of claim 8, wherein the user interface comprises a scanner for scanning an object identification code, and further comprises a database providing data about the object.

10. The object attachment handler of claim 8, wherein the configuration of the clamp includes setting an open dimension and a closed dimension.

11. The object attachment handler of claim 1, wherein the fastening tool comprises a heat stake head having a melter for use with a heat stake.

12. The object attachment handler of claim 1, wherein the fastening tool further comprises a rotation mechanism for use with a bolt, screw based attachment of the attachment mechanism.

13. The object attachment handler of claim 1, wherein the fastening tool further comprises a rotation mechanism for use with a spring screw based attachment of the attachment mechanism.

14. A software configured object attachment handler, comprising: A control system comprising: An interface for inputting object configurations; a memory storing a plurality of object configurations for a plurality of objects, each object configuration including dimensions, attachment mechanisms, and attachment mechanism locations for a particular object; a configurable gripper that is automatically set to open and closed positions based on the object configuration, the setting being effected by the control system; and a fastening tool automatically configured to attach the object to a workpiece at a defined position based on the object configuration; and The control system controls the software-configured object attachment handler to insert an object for insertion into the workpiece.

15. The object attachment handler of claim 14, wherein the fastening tool further comprises a head and a motor providing three degrees of movement so that the fastening tool is aligned with an attachment mechanism of the object and moved to complete the attachment.

16. The object attachment handler according to claim 14, wherein the fastening tool is a hammer for attaching the object by pushing down the attachment mechanism.

17. The object attachment handler of claim 16, wherein the hammer is used with the attachment mechanism comprising one or more of: a push pin, a rivet, a snap, and a through hole.

18. The object attachment handler of claim 16, wherein the hammer is used for press fitting.

19. The object attachment handler of claim 16, wherein the hammer is positioned to align with the attachment mechanism, and the hammer is configured to be lowered to a set distance with a set level of force to complete the attachment of the attachment mechanism.

20. The object attachment handler of claim 14, wherein the interface comprises one or more of the following: A user interface for inputting data; A scanner for scanning an object identification code; and A database provides data about the object.

21. The object attachment handler of claim 14, wherein when the attachment mechanism is a heat stake, the fastening tool comprises a heat stake head.

22. The object attachment handler of claim 14, wherein the fastening tool comprises a rotation mechanism for use with a bolt, screw based attachment of the attachment mechanism.

23. The object attachment handler of claim 14, wherein the fastening tool comprises a rotation mechanism for use with a spring screw based attachment of the attachment mechanism.

24. A method of utilizing a software defined object attachment handler, comprising: receiving object configuration data, the object configuration data including dimensions, attachment mechanisms, and attachment mechanism locations for a particular object; setting a gripper opening and closing dimension, a starting position of one or more fastening tools, and an attachment process for the one or more fastening tools based on the configuration data; picking up an object with the gripper and inserting the object into a workpiece; fastening the object into the workpiece using the fastening tool; Receive new object configuration data; and The gripper and the fastening tool are automatically reconfigured based on the new object configuration data without requiring user interaction.

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