Modular insertion system for robotic assembly

Abstract

A two-stage insertion system includes: a clamp that clamps a module; a compliant element that provides movement in the XY axis; a first-level insertion control that inserts the module into a slot to a first level; and a second-level insertion control that completes the insertion of the module into the slot, and when the first-level insertion control indicates that the module is aligned with the slot, the second-level insertion control applies sufficient force to complete the insertion of the module into the slot.

Description

[0001] Related Applications

[0002] This application claims priority to U.S. Provisional Patent Application No. 62 / 934,381, filed on November 12, 2019, which is incorporated herein by reference in its entirety. Technical Field

[0003] The present invention relates to robotic assembly, and more particularly to an insertion system for robotic assembly. Background Art

[0004] Robotic assembly systems assemble computer systems and other devices. One of the expensive elements in the assembly is the module, such as a dual in-line memory module (DIMM) that is inserted into a slot on a board. An incorrectly inserted module can damage the module and the slot, which can render the entire board unusable, and considering that there are typically 12 to 24 slots per board, and damaging any one of these slots can scrap the entire board, this is an expensive mistake. Module insertion requires high precision, which takes into account the variations in pitch, yaw, and rotation of components on the board in real-world situations. Incorrect or incomplete module insertion can result in manufacturer defects and rework. Most fatally, board-level failures can result after the board has passed the manufacturer's testing and entered its service life in the end customer product or data center rack. 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 1 is a generalized block diagram of one embodiment of an insertion system.

[0007] Figure 2 is a generalized flow chart of one embodiment of an insertion system.

[0008] Figure 3 is a block diagram of one embodiment of a first configuration of a DIMM insertion system.

[0009] Figure 4 is a flow chart of one embodiment of a first configuration using a module insertion system.

[0010] Figures 5A to 5C FIG. 1 is a schematic diagram of an embodiment of the DIMM insertion system of the first embodiment.

[0011] Fig. 6A and 6B is an exploded view of a first embodiment of a module insertion system.

[0012] Figure 7is a block diagram of one embodiment of a second configuration of a DIMM insertion system.

[0013] Figure 8 is a flow chart of one embodiment of a second configuration using a module insertion system.

[0014] Fig.9A and 9B is an illustration of one embodiment of a second configuration of a module insertion system.

[0015] Figures 10A to 10C is a diagrammatic representation of elements of a second configuration of a module insertion system.

[0016] Fig.11 is an illustration of one embodiment of a module interposer with an improved latch opener.

[0017] Figures 12A to 12D Draws the Fig.11 The latch opener approaches, engages, and fully opens the latch.

[0018] Fig.13A is an illustration of one embodiment of a rocker arm for providing a center insertion force for a second stage insertion of a module.

[0019] Fig. 13B When the DIMM is misaligned in the slot Fig.13A Illustration of the rocker arm.

[0020] Fig. 13C After the DIMM is aligned by the rocker Fig.13A Illustration of the rocker arm.

[0021] Fig.13D After the DIMM is fully inserted Fig.13A Illustration of the rocker arm. DETAILED DESCRIPTION

[0022] A two-stage insertion system for inserting a module, such as a DIMM module, into a slot is described. The two-stage insertion system provides a first insertion stage that tests the accuracy of the alignment of the module with the slot and a second insertion stage that provides the force to fully seat the module in the slot once the alignment is confirmed. In this way, the system ensures that the slot and the module are not damaged by insertion. In one embodiment, the insertion system includes a compliance element that provides flexibility so that the module can be slightly displaced to accommodate positioning differences during insertion.

[0023] Although the inserted module can be any type of module that is inserted into a slot, in one embodiment, the module is a DIMM (dual in-line memory module). Therefore, in the following description, the system may be referred to as a DIMM insertion system. It should be understood that although the term "DIMM" is used, the insertion system can be used to insert any type of module into a suitable slot during assembly.

[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 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 1 1 is a generalized block diagram of one embodiment of an insertion system. The insertion system 100 includes a holder 140 that holds a module, and a two-stage insertion system including a first-stage insertion controller 120 and a second-stage insertion controller 130. The system further includes a compliance element 110 that provides flexibility so that the module can be slightly displaced to accommodate positioning differences during insertion. The compliance element provides small movements in X, Y, and θ. This enables the system to adjust for small imperfections in slot positioning or module shape.

[0026] The first level insertion control 120 performs the first level of insertion, lowering the clamp until the module engages with the slot. However, if there is a misalignment, the first level insertion control 120 will not force the module to damage the module or the slot. In one embodiment, the alignment is verified via a sensor at the first level of insertion, and if the alignment is correct, the second level insertion control 130 provides a stronger insertion force to properly place the module in the slot. If at the first level of the insertion control 120, the system determines that there is a misalignment, the clamp 140 is raised. In one embodiment, an alarm can be sounded when a misalignment is detected. In one embodiment, the system can retry one or more insertions.

[0027] If the first level insertion control 120 fails one (or more) attempts, the module and / or slot is considered defective. In one embodiment, the system can send an alarm.

[0028] Figure 2 is a generalized flow chart of one embodiment of an insertion system. The process begins at block 210. At block 220, the system picks a module from a tray, conveyor, or other mechanism that positions the module near the system for insertion.

[0029] At block 230, the gripper is moved over the slot of the module.

[0030] At block 240, insertion is initiated by lowering the gripper. In one embodiment, the slot has chamfers. As the module is lowered into the slot, the compliant element allows a small amount of movement, which allows the module to properly seat in the chamfer and thus seat in the slot.

[0031] At block 250, the gripper is lowered to the first stage and the alignment is verified. The alignment of this stage can be verified by determining whether any displacement or force is detected. This can be accomplished by using a spring with a calibrated position sensor, using a calibrated load cell, or other methods. If the module is properly seated in the slot, no displacement is detected or the force required is very small, while if the module is not positioned correctly, a considerable displacement or force is detected. Displacement is the result of the misaligned spring stage not moving in the z direction while the rest of the system "overtravels" in the z direction, resulting in relative motion being limited in the z direction.

[0032] At frame 260, the process determines whether the alignment is accurate. In one embodiment, this is accomplished by measuring the magnitude of the force applied. This can be accomplished by using a spring with a calibrated position sensor, using a calibrated force sensor, or other methods. If the alignment is accurate, the second insertion stage is activated at frame 270, and the module is lowered into the slot with sufficient force to complete the insertion into the slot. In one embodiment, the second stage insertion uses a rocker arm to apply force to the module from the center. This reduces the risk of deformation due to the insertion process, and ensures that the module is correctly aligned with the slot. The process then ends at frame 275. If the alignment is inaccurate, the process continues to frame 280 at frame 260.

[0033] At block 280, in one embodiment, the process determines whether to retry insertion. In some cases, misalignment may be due to improper clamping or approach errors. In one embodiment, to retry insertion, the clamp is returned to an intermediate position at block 285. In one embodiment, the clamp may also re-clamp the module. The process then returns to block 230, or optionally 220, to restart the process.

[0034] If the process is not retried, or after multiple retries, the system warns of a misalignment problem at block 290. In one embodiment, in addition to or in lieu of the alarm, the system may attempt to insert a new module into the same slot. This ensures that the error is in the slot and not in the module. In one embodiment, the system may try multiple modules before identifying the slot as a problem. The process then ends at block 275.

[0035] Figure 3is a block diagram of an embodiment of a first configuration of a module insertion system. The module insertion system 320 is Figure 1 An embodiment of an insertion system.

[0036] In one embodiment, the module insertion system 320 includes a universal picker 370 that picks up modules from a local pallet 305. In one embodiment, this is a standard pallet on which modules are typically brought to the insertion system. Alternatively, the universal picker 370 can pick up modules from any other source location. In one embodiment, the universal picker 370 is, for example, a SCHUNK TM The parallel gripper of the MPG-plus25 is attached via a rotary actuator such as the MDSUB1-90D-S9PSAPC from SMC, so that the universal picker 370 can be rotated to any position to pick up modules from any local supplier tray or other source. In one embodiment, after the picker places the module in the registration fixture 315, the universal picker 370 rotates out of the way to prevent interference with the board / socket / body part assembly.

[0037] In one embodiment, the universal picker 370 places the module in front of the scanner 310. The scanner 310 scans the QR code, UPC code or other registration code on the module. This enables tracking of each module inserted. It can also verify that the module is the appropriate module for the slot configuration.

[0038] The universal picker 370 places the module in the registration fixture 315. In one embodiment, the registration fixture 315 is shaped to accept the module in almost any alignment. The registration fixture 315 is then closed, forming a fully aligned module for picking up by the gripper 350. In one embodiment, the registration fixture utilizes a SCHUNK TM The WSG 025-064-B servo gripper, and V-groove centering block for precise alignment.

[0039] The gripper 350 picks up the module from the registration fixture 315 .

[0040] The gripper 350 is used to insert the module into the slot. In one embodiment, a camera 325 is mounted at the end of the arm. The camera 325 is used to determine the location of the PCB reference point. In one embodiment, once the reference point is found, the inserted position point is transposed to cover the actual board. This allows to overcome the positional variations in X, Y and θ from part to part.

[0041] In one embodiment, the system further includes a positioning finger 360 that aligns the gripper 350 with the slot. In one embodiment, the positioning finger 360 is lowered before the gripper is lowered. Once the positioning finger is aligned with the slot to ensure that the gripper is correctly positioned, the gripper is lowered to the first stage.

[0042] In one embodiment, the floating double disc 330 provides compliance so that the holder (and therefore the module) can move freely to ensure successful insertion. In one embodiment, the compliant element is from SCHUNK TM An XY compensator such as AGE-XY-50. In one embodiment, the floating dual-disc compliance element 330 provides + / -4 mm of XY compensation and + / -16 degrees of rotational compensation. In one embodiment, the compensation is frictionless and the system has automatic re-centering.

[0043] In one embodiment, the interference test uses a spring-loaded trigger 340 and a camera / sensor 345 to determine if the module is properly aligned at the first stage of insertion. At the first level of insertion (e.g., inserting the module into the slot with the gripper at a predetermined lowering), the spring-loaded trigger is evaluated by the camera / sensor 345. If the spring-loaded trigger 340 indicates that the level of force on the module is too high, it is identified as misalignment. In one embodiment, the spring includes a mark that is detected by the camera / sensor if the compression exceeds a threshold.

[0044] If the level of force (e.g., compression of spring 340) is appropriate, the module is identified as being properly aligned and insertion is complete. This is accomplished by applying a higher level of force to seat the module in the slot and close the latch. In one embodiment, the higher level of force is applied centrally to the module via a central insertion element. In one embodiment, the sensor is mounted in line with the second stage spring system and the threshold force required to install the module is pre-calibrated by tightening into position on the slot.

[0045] In one embodiment, the module insertion system is part of a robotic assembly system and is capable of completing module insertion, from picking to latch closure and insertion completion. The module insertion speed is related to the downward movement of the robot or actuator in the z-axis. The insertion speed is adjusted by mitigating the impact forces generated due to friction. There is also a speed recommended by the supplier for inserting the module, which serves as a manufacturing guide. The total time taken for insertion is also based on the position of the component and the acceleration and deceleration of the robot and its payload. In one embodiment, for the single system shown, the process is about 12 to 16 seconds per cycle. In one embodiment, the system can utilize a dual-arm system in which a universal picker places the module into the registration gripper, and a separate arm including the gripper inserts the previously registered module into the slot, thereby reducing the cycle time to 6 to 8 seconds.

[0046] Figure 4 is a flow chart of one embodiment of inserting an exemplary DIMM module using a first configuration of a module insertion system. Figures 5, 6A, and 6B are illustrations of one embodiment of a first configuration of a module insertion system.

[0047] The process begins at block 410 .

[0048] At block 415, a universal picker is used to remove the DIMMs from a tray or other mechanism for bringing the DIMM modules to the system.

[0049] In one embodiment, at block 420, the DIMMs are scanned to ensure accuracy. In one embodiment, the DIMM module includes a UPC code or other scannable code that identifies the module. In one embodiment, the scanned data is provided to a computer system that verifies the identity of the DIMM module and that it matches the board being assembled. In one embodiment, if there is a mismatch in the scan, an alarm is sounded.

[0050] The universal picker places the DIMM in the alignment fixture at block 425. The alignment fixture is open, which enables it to accept the DIMM regardless of its orientation and physical position.

[0051] At block 430, the alignment fixture is closed. As described above, the alignment fixture is closed by moving the end and side toward the DIMM module to tightly hold the configuration of the DIMM module. Once the alignment fixture is closed, the position of the DIMM module is fixed.

[0052] The gripper therefore picks up the DIMM from the alignment fixture at block 435. This establishes the Z position of the gripper.

[0053] At block 440, the robotic arm is moved over the DIMM socket.

[0054] At block 445, in one embodiment, the alignment fingers are lowered to engage the edge of the slot. In one embodiment, the alignment fingers are used to identify the edge of the slot and properly position the gripper to insert the DIMM into the slot. During this alignment, at block 450, the floating disk compliance element causes the gripper to shift to adjust the alignment position.

[0055] The clamp assembly is lowered to the interference point at block 455. The interference point is the point where the DIMM will interfere with the edge of the socket if it is misaligned, but will experience little stress if properly aligned.

[0056] At box 460, the process determines whether the upward pressure on the gripper is above a threshold. In one embodiment, this is determined using a spring with a mark showing the compression level. When the mark shows, the pressure is above the threshold (the spring has been compressed a certain amount). Other ways of determining the pressure level can be used.

[0057] If the pressure is not above the threshold, then at block 470, the second stage is engaged and stronger pressure is applied to fully seat the DIMM in the slot and the slot is closed. In one embodiment, a spring with a second flag is also used to monitor the pressure applied during this second stage to verify that the pressure applied is sufficient to fully seat the DIMM module. The process then ends at 480.

[0058] If the pressure is above the threshold at the interference point, as determined at block 460, an alert for alignment error or latch closed condition is sent at block 465 in one embodiment. In another embodiment, the system may attempt reinsertion. In one embodiment, the process returns to block 425 to restart the insertion process by placing the DIMM in an alignment structure for reinsertion. In another embodiment, the process returns to block 440 to reinsert the DIMM, placing the gripper on the socket.

[0059] Figures 5A to 5C is a diagram of one embodiment of a module insertion system. Figure 5A A front view of one embodiment of a module insertion system is shown showing a DIMM in a gripper 545. The module insertion system 510 includes an alignment finger actuator 520 that raises and lowers the alignment finger 525. After the misalignment spring stage 535 indicates that the module is properly aligned, the insertion spring stage 530 controls full insertion. An adjustable travel force optical sensor is used to sense the insertion distance.

[0060] Figure 5B A side view of one embodiment of a module insertion system is shown. A pneumatic regulator 550 is shown, as well as an alignment compensator 555. Also depicted is a universal picker 560 and a universal picker rotary actuator 565 that enables the universal picker 550 to pick up a board regardless of its configuration.

[0061] Figure 5C One embodiment of a top view of a module insertion system is shown. A camera 570 and a light 575 are shown.

[0062] Fig. 6A and 6B is an exploded view of one embodiment of a module insertion system. A robotic arm end attachment 605 attaches the mechanism to a robotic assembly system. In one embodiment, the system includes a return to center floating coupling 650 that provides movement to adjust the positioning of the gripper as described above. The position mark 640 is observed by an adjustable light sensor 645 when the pressure is at a calibration point. In one embodiment, the calibration point is 40 pounds of pressure.

[0063] As described above, the alignment fingers 672 are moved by the pneumatic cylinder 670 to provide alignment of the system to the slot. In one embodiment, the gripper 680 has interchangeable finger tips 675, enabling the gripper 680 to grip panels of various thicknesses and sizes.

[0064] Figure 7 is a block diagram of one embodiment of a second configuration of a module insertion system. The module insertion system 720 removes a module from the tray 705 and inserts it into a slot (not shown). In one embodiment, the module is scanned for verification prior to insertion.

[0065] In one embodiment, module insertion system 720 comprises visual interface 725.In one embodiment, visual interface 725 is a removable camera for verifying the positioning of slot.In one embodiment, this is completed based on the reference point on the board.In one embodiment, the output of visual interface 725 is sent to computer system 760 for analysis.

[0066] The load cell 735 is used to provide a force measurement to indicate the insertion force. After the module has been engaged with the slot but before a level of force is applied that would damage the board, the load cell 735 output is used to determine if the module is properly aligned. In one embodiment, the load cell outputs the force measurement value to the computer system 760. The load cell 735 is used to ensure that the inserted module is properly aligned. The load cell 735 measures the force when the module is slid into the slot and the force when the insertion is complete. The computer system uses the output of the load cell 735 to determine if the module is misaligned or there is another problem. If the sensor value exceeds the amount of force required to slide the module into the slot, then at the first level, something in the system is misaligned.

[0067] In one embodiment, the float mechanism 740 provides compliance, allowing the position of the module relative to the slot to be slightly displaced to allow insertion. The retainer 745 is coupled to the float mechanism so that it can be displaced to provide compliance.

[0068] Fig. 10A and 10B One embodiment of a floating mechanism for use is depicted. In one embodiment, side-to-side movement of the central metal element and end-to-end movement of the frame elements provide compliance. In one embodiment, the floating mechanism 740 is made of a material having a relatively high ultimate strength to elastic modulus ratio. In one embodiment, the material is a metal. In one embodiment, the metal is a semi-hard to fully hardened aluminum alloy, or another material for bending. In one embodiment, the material is a 6000 series aluminum alloy, preferably in its semi-hard to fully hardened state, such as a T4 to T6 state. In one embodiment, the length and thickness of the floating mechanism 740 are designed to provide stability of approximately + / - 0.3 mm of side-to-side and fore-and-aft movement.

[0069] In one embodiment, the gripper is a parallel gripper to pick up and place the module. In one embodiment, a gripper from FESTO is used. TM XYZ gripper.

[0070] In one embodiment, a slot latch opener 750 is attached to the system. In one embodiment, when the holder is over the slot, the slot latch opener 750 is lowered to automatically open the slot before the module is inserted. This can eliminate a separate latch opening process. In one embodiment, the latch opener is a rigid arm shaped to engage with the slot latch. Fig. 10C One embodiment of a slot latch opener 750 is depicted. Figures 12A to 12D Another embodiment of a slot latch opener is depicted.

[0071] Figure 8 8 is a flow chart of one embodiment of a second configuration using a module insertion system. The process begins at block 810. In one embodiment, the module being inserted is a DIMM module. At block 815, a gripper is used to pick up the DIMM from a tray. At block 820, the DIMM is scanned to ensure accuracy.

[0072] At block 840, the robotic arm moves over the DIMM slot. At block 845, the slot latch opener is lowered to engage with the DIMM slot latch and open it (if it is closed). In one embodiment, a separate motor lowers the slot latch opener.

[0073] The float mechanism allows for a small amount of movement as the DIMM is lowered into the socket at block 850. Chamfers at the edges of the socket allow the system to self-align with the float mechanism to provide flexibility of movement.

[0074] At block 855, the system lowers the gripper including the DIMM board to a first distance and verifies the force curve. The force curve is the force applied to the gripper (via the DIMM board) over time. The force curve has a predictable level as the gripper is lowered to insert the DIMM into the slot. Due to impact with the chamfered portion of the slot and / or other changes, there may be slight variations in the level of force detected. However, a properly inserted DIMM board in the slot is still below the threshold.

[0075] At box 860, the process determines whether the observed force curve matches the expected curve of the aligned DIMM module. If the DIMM module / slot is misaligned, or the latch is closed, the detected force will be above a threshold, which is the maximum force that a properly aligned DIMM may experience. In one embodiment, the maximum force applied at this insertion stage is lower than the force that would damage the DIMM board or slot. Therefore, even if the DIMM is misaligned, there is no damage. If the force curve matches the expected force curve and is not above the threshold, a stronger pressure is applied at box 865 to complete the insertion. The insertion is completed and the latch is closed. The process then ends at box 880.

[0076] If the curves do not match, indicating that the latch is not open, the DIMM and / or slot are misaligned, or there is another problem that prevents the insertion from being completed, the process continues to box 870. At box 870, the process in one embodiment warns of an error. As described above, in one embodiment, the system can retry the insertion before sending an alarm. In one embodiment, if multiple retries fail, the DIMM board and / or slot is considered damaged and skipped instead of sending an alarm. The process then ends at box 880. Although the process only shows one DIMM insertion, in an actual system, such DIMM insertion processes will occur in rapid succession.

[0077] Fig.9A and 9B is an illustration of one embodiment of a second configuration of a module insertion system. Fig. 9B An exploded view of the system is shown.

[0078] Fig.11 1 is an illustration of an embodiment of a module inserter with a slot latch opener. This example depicts a DIMM inserter. A module inserter 1110 holds a DIMM module 1120. The module inserter includes two latch openers 1130 on either side of the module. The latch openers 1130 are designed to engage with latches 1150 of a slot 1140. A standard DIMM slot 1140 includes two latches that must be opened to insert a DIMM module and automatically close when the DIMM module 1120 is fully seated in the slot 1140. It can be seen in this example that the DIMM module 1120 is above the slot and has not yet engaged with the slot. In one embodiment, the latch openers 1130 are designed to be lowered to open the latches 1150 before the DIMM module 1120 engages with the slot 1140. In one embodiment, the latch openers 1130 are attached to the DIMM inserter 1110 via hinges 1135. In one embodiment, the latch opener 1130 is lowered and rotated outward as it engages to open the latch. Figures 12A to 12D The process is depicted.

[0079] Figures 12A to 12D Draws the Fig.11 The latch opener approaches, engages, and fully opens the latch. Fig. 12A The latch opener is shown approached. The hook or catch portion of the latch opener is designed to engage the latch regardless of the exact angle of approach and regardless of small shifts in position between the latch opener and the latch. Fig. 12B As shown, once the latch opener hooks the latch, the latch opener is lowered and this action fully opens the latch, as shown in Fig.12D As shown. In one embodiment, when the latch opener is lowered, the latch opener is free to pivot about the hinge so that the movement of the latch opening system is downward. This enables a simple mechanism for the latch opener while still providing accurate and fast latch opening. The shape of the latch opener head has a lock catch that engages with the latch spine so that the latch opener remains in contact with the latch when it is rotated to the open position. In one embodiment, the latch opener head has a prong that is sufficiently released to allow the latch opener to fully rotate without getting stuck on the latch. In one embodiment, a full rotation can be 0 to 20 degrees, as shown.

[0080] Fig.13A 1 is an illustration of one embodiment of a rocker arm for providing a center insertion force for the second level insertion of a module. The module interposer 1310 includes a gripper 1320 to grip a DIMM module 1340 for insertion into a slot 1350. In one embodiment, the module interposer 1310 includes a rocker arm 1330 to provide a downward force on the DIMM module 1340 for insertion. This moves the insertion force from the edge of the DIMM module 1340 through the gripper 1320 to the center of the DIMM module 1340 through the rocker arm 1330.

[0081] In one embodiment, the rocker arm 1330 is movably attached so that it can rotate around a central axis and move forward and backward. In one embodiment, the rocker arm 1330 has a V-shaped groove, which is shaped so that the rocker arm can firmly push the module. These two movements enable the rocker arm 1330 to align with the DIMM module 1340 even if the DIMM module is held unevenly.

[0082] exist Fig.13A In the illustration of , DIMM module 1340 is held at a slight angle by the holder. This can be seen from the interface between the holder 1320 and the module 1340 and the fact that one corner of the module 1340 contacts the slot 1350 and the other does not.

[0083] Fig. 13B When the DIMM is misaligned, but the DIMM module is partially in the socket Fig.13A13. An illustration of a rocker arm 1330. It can be seen that DIMM module 1340 is still misaligned, with one side of the module almost fully seated and the other side higher. Rocker arm 1330 is fully engaged with the DIMM module. However, it can be seen that clamp 1320 has partially released the DIMM module, which is now supported by the socket and held in place by the rocker arm. Socket 1350 has an outer protruding flange that aligns with module 1340, and a long center slot with spring contacts that engage each of the traces on the module once module 1340 is fully inserted. Thus, misalignment of module 1340 when it initially contacts socket 1350 can be corrected, but if module 1340 is still misaligned, proper contact cannot be made.

[0084] Thus, after initial contact with the slot 1350, the gripper 1320 is partially released and the rocker arm 1330 is able to slide along the top edge of the module 1340 and maintain the same angle as the module when the module is aligned with the slot. The module 1340 is aligned with the slot 1350 by the torque applied to it from the top edge of the flange of the slot 1350 during insertion.

[0085] Fig. 13C After the DIMM is aligned by the rocker Fig.13A DIMM module 1340 is now properly seated in the socket, but has not yet been re-gripped by the clamp, or pushed down to close latch 1360. Clamp 1320 now properly holds DIMM module 1340 due to the release of the clamp and the alignment of the socket and the rocker.

[0086] Fig.13D After the DIMM is fully inserted Fig.13A Once the DIMM module 1340 is positioned in the slot 1350, the rocker is used to push the DIMM module 1340 downward to fully seat it and close the latch 1360.

[0087] Note that elements from the described embodiments may be mixed. In one embodiment, the system includes a compliant element and a two-stage insertion. But for example, the latch opener of the second embodiment may be combined with the compliant element of the first embodiment, the alignment fingers of the first embodiment may be applied to the second embodiment, and so on.

[0088] 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 are to be regarded as illustrative rather than restrictive.

Claims

1. An insertion system, comprising: A holder, the holder holding the module; a compliant element that provides theta rotation and translation along the XY axis, the compliant element providing flexibility so that the module can be slightly displaced to accommodate positioning differences during insertion; a rocker arm positioned at the center of the module for insertion; a first level insertion control that inserts the module into a slot to a first level using the holder; A second level insertion control, the second level insertion control uses the rocker arm to complete the insertion of the module into the slot, and when the first level insertion control indicates that the module is aligned with the slot, the second level insertion control uses the rocker arm to apply force at the center of the module to complete the insertion of the module into the slot.

2. The insertion system of claim 1, further comprising: Alignment fingers align the holder with the slot before the first level of insertion control inserts the module into the slot.

3. The insertion system of claim 1, further comprising: A slot latch opener is lowered to open the slot latch, the slot latch opener extending below the holder.

4. The insertion system of claim 3, wherein the slot latch opener comprises: a tang and a protrusion, wherein the tang and the protrusion engage with the slot latch and rotate to open the slot latch.

5. The insertion system of claim 1, further comprising: A picker picks up the module from the tray.

6. The insertion system of claim 5, further comprising: a registration fixture that receives the module from the picker; The gripper picks up the aligned modules from the registration fixture, thereby ensuring that the gripper remains aligned.

7. The insertion system of claim 1, wherein the compliant element comprises: Rigid frame; and A flexible arm provides lateral movement to achieve compliance.

8. The insertion system of claim 7, wherein the flexible arm is made of semi-hard or fully hard aluminum.

9. The insertion system of claim 1, wherein the compliant element comprises a floating double disc that provides free movement along a plane.

10. The insertion system of claim 1, wherein the first level insertion control comprises: a first spring set, wherein the first spring set is compressed when the module is inserted into the slot to a first level; and A sensor determines whether the first spring set has been compressed beyond a force threshold when the module is inserted to the first level, wherein compression beyond the force threshold indicates that the module is misaligned.

11. The insertion system of claim 10, wherein the sensor is a light sensor and the marking indicates a level of compression.

12. The insertion system of claim 1, wherein the first level insertion control comprises: a load cell that measures force; and A processor determines whether the force curve indicates proper alignment.

13. The insertion system of claim 1, wherein the swing arm is displaced about a hinge and is movable back and forth to engage the module.

14. The insertion system of claim 1, wherein the gripper releases the module when the module is in the slot, and the rocker arm and the slot align the module before completing the insertion.

15. A robotic insertion system for inserting a module into a slot, comprising: a holder, the holder holding the module; a compliant element that provides theta rotation and XY translation to the holder, the compliant element providing flexibility so that the module can shift slightly to accommodate positioning differences during insertion; a rocker arm positioned at the center of the module for insertion; The clamp inserts the module into the slot, using the clamp to the first level of insertion control; A robotic insertion system that completes the insertion of the module into the slot, and when the first-level insertion control indicates that the module is aligned with the slot, the robotic insertion system uses the rocker arm to apply force to complete the insertion of the module into the slot.

16. The robotic insertion system of claim 15, wherein the force applied to accomplish the insertion of the module is applied by a swing arm positioned at a central top region of the module.

17. The robotic insertion system of claim 15, wherein the compliant element comprises a floating double disc providing free movement along a plane.

18. The insertion system of claim 15, wherein the first level insertion control comprises: a load cell that measures force; and A processor determines whether the force curve indicates proper alignment.

19. A method of inserting a module into a slot using two-stage insertion, comprising: holding the module with a holder having theta rotation and movement along the XY axis to achieve compliance using a compliant element that provides flexibility so that the module can be slightly displaced to accommodate positioning differences during insertion; inserting the module into the slot to a first level using the holder; determining whether the first level of insertion indicates that the module is properly aligned with the slot; and re-clamping the module when the module is not properly aligned with the slot; as well as When the module is properly aligned with the slot, insertion of the module into the slot is accomplished by using a rocker arm to apply sufficient force to seat the module in the slot.

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