Sensor assembly and component handling assembly

Abstract

The utility model relates to a sensor assembly and a component control assembly. A sensor assembly comprising: an inductive sensor arrangeable at a fixed location within the sensor assembly; a carrier assembly comprising an anchor component arrangeable at a fixed location within the carrier assembly; a movable member movable relative to the anchor member wherein the movable member comprises a foot portion adapted to cooperate with the pick-up head assembly, a metal head portion that can interact with a magnetic field generated by the inductive sensor; and a spring member arranged such that a spring is compressed between the anchor member and the foot portion when the foot portion is moved toward the anchor member; and wherein the inductive sensor is operable to provide an output wherein a value of the output depends on a distance between the reference point and the metal head part such that the output represents a magnitude at which the spring part is compressed between the anchor part and the foot portion.

Description

TECHNICAL FIELD

[0001] The present invention relates to a sensor assembly comprising an inductive sensor and a carrier assembly, wherein the inductive sensor is operable to provide an output to a controller indicative of the magnitude by which a spring component in the carrier assembly is compressed. Further provided is a component handling assembly using the sensor assembly. BACKGROUND

[0002] Many component handling assemblies comprise a delivery station in which components held on pick head of a pick-up component are delivered to a receiving surface (e.g. onto the surface of a shuttle designated to carry the components to another station). The pick-up component is typically located at the periphery of a rotatable turntable and the pick-up component extends away from the turntable to move the pick head into a position above the receiving surface. The position of the pick head holding the components relative to the receiving surface is critical to ensure satisfactory delivery of the components to the receiving surface: if the pick head is too far from the receiving surface, then the components will need to fall a greater distance and when they impact the receiving surface, the components will become displaced from a predefined desired position; in other words, when the pick head is too far from the receiving surface, then it is not possible to deliver the components to a predefined desired position on the receiving surface. On the other hand, if the pick head is moved too close to the receiving surface, then the components will be compressed between the pick head and the receiving surface and become damaged.

[0003] In a component handling assembly, a driver component of an actuator pushes against the pick-up component to extend it away from the turntable so that the pick head moves into a position in which the components it holds are delivered to the receiving surface; thus, the position of the pick head is directly related to the position of the driver component.

[0004] Existing solutions for ensuring the optimum distance between the pick head involve first determining a setpoint position for the driver component in a calibration step: the calibration involves positioning the receiving surface (e.g. a shuttle) at a predefined target position under the pick head and then moving the driver component to push against the pick-up to cause the pick head to reach a predefined height above the receiving surface; once the pick head is at the predefined height above the receiving surface, the position of the driver component is determined using a sensor / tracking sensor such as an optical encoder and this measured position defines the setpoint position. Then, for all subsequent operations in which components are delivered to the receiving surface, the receiving surface (e.g. a shuttle) is positioned at a position corresponding to the predefined target position and the driver component is moved to a position corresponding to the setpoint position (this position is determined using a sensor such as an optical encoder) and then the components are delivered to the receiving surface.

[0005] The existing solutions for ensuring an optimal distance between the pick-up head holding the component and the receiving surface are insufficient at least because they cannot take into account changes or variations occurring within the component handling assembly, such as changes or variations occurring within the component handling assembly during operation and / or after operation. For example, parts of the component handling assembly will experience thermal expansion during use and the dimensions of these parts will change, which in turn will cause a change in the distance between the pick-up head holding the component and the receiving surface; parts of the component handling assembly will experience wear and tear over time, which will cause a change in the relative positioning of these parts within the component handling assembly and / or allow a larger play in the position of these parts within the component handling assembly, which in turn will cause a change in the distance between the pick-up head holding the component and the receiving surface. Furthermore, changes in the receiving surface will also cause a change in the distance between the pick-up head holding the component and the receiving surface; for example, the receiving surface is typically the surface of a shuttle and the orientation of the shuttle can be tilted so that some parts of the receiving surface will be closer to the pick-up head than other parts of the receiving surface. In order to achieve a precise distance between the pick-up head holding the component and the receiving surface of the shuttle, the orientation of the shuttle must be precise; in practice, it is difficult and costly to achieve a consistent precise orientation (e.g. a consistent precise planarity) of the shuttle for a number of repetitions over time.

[0006] It is an object of the present invention to alleviate or eliminate at least some of the above-mentioned problems / disadvantages associated with existing solutions. Utility model content

[0007] According to the invention, this object is achieved by a sensor assembly according to the first aspect, comprising: an inductive sensor, which is arrangeable at a fixed position within the sensor assembly; a carrier assembly comprising an anchor part, which is arrangeable at a fixed position within the carrier assembly; a movable part, which is movable relative to the anchor part, wherein the movable part comprises a foot part, which is suitable for cooperating with a pick-up head assembly, and a metallic head part, which is interactable with a magnetic field generated by the inductive sensor; a spring part, which is arranged such that the spring is compressed between the anchor part and the foot part when the foot part is moved towards the anchor part; wherein the inductive sensor is operable to provide an output, wherein the value of the output depends on the distance between the inductive sensor and the metallic head part, such that the output is representative of the magnitude by which the spring part is compressed between the anchor part and the foot part; and / or

[0008] By means of a component handling assembly according to the second aspect, comprising: a turret arm part having: a pick part having a pick head, wherein the pick part is movable relative to the turret arm part between a first position in which the pick head of the pick head part is at a minimum distance from the turret arm part and a second position in which the pick head of the pick head part is at a maximum distance from the turret arm part; and a biasing means biasing the pick part towards its first position; a drive assembly comprising at least one motor and a drive part, the drive part being operably attached to the motor such that the motor is operable to move the drive part in a first direction or in an opposite second direction; a sensor assembly according to the first aspect, and wherein the sensor assembly is arranged such that the foot part is co-operable with the pick part such that when the motor of the drive assembly is operated to move the drive part in the first direction, the foot part will exert a force on the pick part to move the pick part from its first position towards its second position. BRIEF DESCRIPTION OF DRAWINGS

[0009] Embodiments of the application given by way of example only will be described in the detailed description with reference to the following drawings, in which:

[0010] Figure 1a is a perspective view of a sensor assembly according to an embodiment of the application;

[0011] Figure 1b is a side view of the sensor assembly of Figure 1a ;

[0012] Figure 1c is a cross-sectional view of the sensor assembly of Figure 1a and Figure 1b ;

[0013] Figure 2 is a perspective view of a component handling assembly according to an embodiment of the application;

[0014] Figure 3 is a side view of the component handling assembly of Figure 2 . DETAILED DESCRIPTION

[0015] Figure 1a is a perspective view of a sensor assembly 1 according to an embodiment of the application; Figure 1b is a side view of the sensor assembly 1 ; and Figure 1c is a cross-sectional view of the sensor assembly 1.

[0016] Reference is made to Figure 1a , Figure 1b and Figure 1cAs can be seen, the sensor assembly 1 comprises a carrier assembly 3. The carrier assembly 3 is selectively movable by means of a movable drive component 19 of a drive assembly 19b.

[0017] The sensor assembly 1 further comprises an inductive sensor 2, which comprises a sensor pad 12. The inductive sensor 2 is fixed to the carrier assembly 3. It should be noted that, in one embodiment, the position of the inductive sensor 2 on the carrier assembly 3 can be adjustable; for example, the inductive sensor 2 can be mounted on the carrier assembly 3 by means of a mounting module having position adjustment means which allow the inductive sensor 2 to be moved to a higher fixed position or to a lower fixed position within the sensor assembly 1. However, adjustment of the fixed position of the inductive sensor 2 is not an essential feature of the present application.

[0018] The carrier assembly 3 comprises a head component 8 having a channel 8a defined therein. In this example, the head component 8 further comprises a guide component 8b located in the channel 8a; however, it will be appreciated that the guide component 8b is not essential to the present application.

[0019] The carrier assembly 3 further comprises an anchor component 4, which can be arranged at a fixed position within the carrier assembly 3. In a preferred embodiment, the position of the anchor component 4 in the carrier assembly 3 can be adjustable.

[0020] In this embodiment, the anchor component 4 comprises a plate 4a, which is arranged at a fixed position within the carrier assembly 3. The plate 4a has a through-hole 4b defined therein. The plate 4a is preferably mounted on the carrier assembly 3 (preferably on a fixed portion of the carrier assembly 3) via one or more screw components; the fixed position of the plate 4a can be selectively adjusted by tightening or loosening the one or more screw components. As Figure 1c shown in Figure 1 1, the plate 4a is mounted on a fixed portion 106 of the carrier assembly 3 via a screw component 104; the fixed position of the plate 4a can be selectively adjusted by tightening or loosening the screw component 104 in order to move the plate 4a to a higher or lower position, respectively.

[0021] The sensor assembly 1 further comprises a movable component 6. The movable component 6 comprises a foot portion 21 1, a metal head portion 1 1, and a shaft component 15 connected between the foot portion 21 1 and the metal head 1 1. The shaft component 15 is fixedly connected at one end portion 15a thereof to the metal head portion 1 1 and at the other end portion 15b thereof to the foot portion 21 1.

[0022] The shaft component 15 is arranged to extend through the through-hole 4b defined in the anchor component 4, such that the metal head portion 1 1 is located on one side of the anchor component 4 and the foot portion 21 1 is located on the opposite other side of the anchor component 4.

[0023] A metal head portion 11 is located between the anchor member 4 and the inductive sensor 2. The metal head portion 11 can interact with the magnetic field generated by the inductive sensor 2. In this embodiment, the inductive sensor 2 and the movable member 6 are arranged such that the sensor pad 12 is aligned with the metal head portion 11.

[0024] The foot portion 211 is located within the channel 8a of the head member 8; more specifically, the foot portion 211 is located within the guide member 8b which is located in the channel 8a of the head member 4. A free end 211a of the foot portion 211 protrudes from the guide member 8b. The foot portion 211 further comprises a tip member 16 which can abut the pick-up head assembly. The tip member 16 protrudes from the free end of the foot portion 211. In this embodiment, the tip member 16 is partially embedded in the foot portion 211; however, it will be appreciated that the tip member 16 can alternatively be mounted on the surface of the free end of the foot portion 211. In this embodiment, the tip member 16 is composed of a rubber material; however, it will be appreciated that the tip member 16 can have any suitable composition.

[0025] The movable member 6 is movable relative to the carrier assembly 3 and the inductive sensor 2: the foot end portion 211 is linearly movable through the guide member 8b (and / or the foot end portion 211 is linearly movable through the channel 8a) and the shaft member 15 is linearly movable through the through-hole 4b of the anchor member 4.

[0026] The sensor assembly 1 further comprises a spring 9 which is arranged between the anchor member 4 and the foot member 211. In this embodiment, a first end 9a of the spring 9 abuts or is attached to the foot member 211 and an opposite second end 9b of the spring 9 abuts or is attached to the anchor member 4. As Figure 1c As can be seen in the middle, the first end 9a of the spring 9 abuts or is attached to a second end 211b of the foot member 211 which is opposite the free end 211a; this second end 211b of the foot member 211 is attached to the shaft 15; the opposite second end 9b of the spring 9 abuts or is attached to a surface of the anchor member 4 which faces the foot member 211.

[0027] The fixed position of the anchor member 4 can be selectively adjusted, possibly by tightening or loosening the screw member 104, in order to move the anchor member 4 to a higher or lower position, respectively, in order to account for different spring lengths / forces.

[0028] The inductive sensor 2 is operable to provide an output, wherein the value of the output is dependent on the distance between the metal head portion 11 and the sensor pad 12 of the inductive sensor 2, such that the value of the output is representative of the magnitude by which the spring member 9 is compressed between the anchor member 4 and the foot portion 211. Thus, the magnitude by which the spring member 9 is compressed is representative of the force applied to the tip member 16. In this embodiment, the more the spring member 9 is compressed, the greater the value of the output of the inductive sensor 2; in other words, when the spring member 9 is fully compressed, the value of the output of the inductive sensor 2 will be at a maximum value; and when the spring member 9 is not compressed at all, the value of the output of the inductive sensor 2 will be at a minimum value.

[0029] When a force greater than the biasing force applied by the spring 9 to the foot member 211 is applied to the tip member 16, the moveable member 6 moves such that the foot portion 211 moves in a direction towards the anchor member 4 (the foot member 211 will move through the guide member 8b (and / or the channel 8a) towards the anchor member 4. In embodiments, the free end 211a of the foot member 211 is moveable into the guide member 8b (and / or the channel 8a), leaving only the portion of the tip member 16 protruding from the guide member 8b (and / or the channel 8a); as the foot portion 211 moves towards the anchor member 4, the shaft member 15 will move through the through-hole 4b; and the spring member 9 will be compressed between the anchor member 4 and the foot portion. As the shaft member 15 is fixedly connected at one end 15a thereof to the metal head portion 11 and at the other end 15b thereof to the foot portion 211, as the foot portion 211 moves in a direction towards the anchor member 4, the metal head portion 11 will also correspondingly move in a direction towards the sensor pad 12 of the inductive sensor 2, thereby decreasing the distance between the sensor pad 12 and the metal head portion 11, and causing the value of the output of the inductive sensor 2 to increase.

[0030] Likewise, when the movable component 6 is moved such that the foot portion 211 is moved in a direction away from the anchor component 4 (e.g. when the spring component 9 is in a compressed state, by the force applied by the spring component 9 to the foot portion 211, the movable component 6 can be moved such that the foot portion 211 is moved in a direction away from the anchor component 4 (the foot component 211 will move in a direction away from the anchor component 4 through the guide component 8b (and / or the channel 8a)) (i.e. when the spring component 9 is compressed between the foot portion 211 and the anchor component 4, the spring component 9 will spring back towards the uncompressed state, thereby applying a force to the foot portion 211 which moves the foot portion 4 in a direction away from the anchor component 4); since the shaft component 15 is fixedly connected at one end 15a thereof to the metal head portion 11 and at the other end 15b thereof to the foot portion 211, when the foot portion 211 is moved in a direction away from the anchor component 4, the metal head portion 11 will also correspondingly move in a direction away from the sensor pad 12, thereby increasing the distance between the sensor pad 12 and the metal head portion 11, and causing the value of the output of the inductive sensor 2 to decrease.

[0031] The sensor assembly 1 further comprises a mounting module 18 configured to allow the sensor assembly 1 to be mounted on a drive assembly 19b, the drive assembly 19b comprising a movable drive component 19. The carrier assembly 3 is movable relative to the mounting module 18. The drive component 19 of the drive assembly 19b is operable in cooperation with the carrier assembly 3 to selectively move the carrier assembly 3. The mounting module 18 is fixed to the drive assembly 19b such that the mounting module 18 and the drive assembly have a fixed position; the drive component 19 is selectively operated to move to apply a force to the carrier assembly 3 to force the carrier assembly 3 to move in a direction towards the pick-up component.

[0032] Figure 2 is a perspective view of a component handling assembly 20 according to an embodiment of the application; Figure 3 is a side view of the handling assembly 20. Reference is made to Figure 2 and Figure 3 It can be seen that the component handling assembly 20 comprises a turret arm component 21 having a pick-up component 22. The pick-up component 22 comprises a pick-up head 23. The pick-up component 22 is movable relative to the turret arm component 21 between a first position in which the pick-up head 23 of the pick-up component 22 is at a minimum distance from the turret arm component 21 and a second position in which the pick-up head 23 of the pick-up component 22 is at a maximum distance from the turret arm component 21.

[0033] The component manipulation assembly 20 further includes a biasing device 24 that biases the pickup component 22 toward its first position. In this embodiment, the biasing device 24 includes a blade 24 fixed at its first end 24a to the turntable arm component 21 and at its opposite second end 24b to the top portion 22a of the pickup component 22. When the pickup component 22 moves toward its first position, the second end 24b of the blade 24 moves with the pickup component 22, while the first end 24a of the blade remains in a fixed position; thus, when the pickup component 22 moves toward its first position, the blade 24 flexes; when the blade 24 is in its flexed state, the blade 24 applies a tension force to the top portion 22a of the pickup component 22, which biases the pickup component 22 toward its first position. It should be understood that in this invention, the biasing device 24 may take any suitable form and is not limited to the blade 24.

[0034] The component manipulation assembly further includes an airflow generating device 25, which is selectively operable to generate a negative airflow or a positive airflow. The airflow generating device 25 is fluidly connected to the pickup member 22 such that when the airflow generating device is operated to generate a negative airflow, a vacuum can be selectively provided at the pickup head 23, allowing the component to be held on the pickup head 23 by the vacuum; and when the airflow generating device 25 is operated to generate a positive airflow, the component held on the pickup head can be blown from the pickup head 23 onto the receiving surface. In this embodiment, the airflow generating device 25 is fluidly connected to the pickup member 22 via a conduit 25a.

[0035] The component manipulation assembly 20 further includes a drive assembly 19b and a sensor assembly 1 according to any of the embodiments of the aforementioned sensor assembly 1.

[0036] Drive assembly 19b includes at least one motor and drive component 19 (in Figure 2 or Figure 3 Invisible in the middle, but in Figure 1b , Figure 1c As can be seen in the image, the drive member 19 is operatively attached to the motor, such that the motor is operable to move the drive member 19 in a first direction (indicated by arrow 31a) or in the opposite second direction (indicated by arrow 31b). The first direction 31a is toward the pickup member 22; while the second direction 31b is away from the pickup member 22.

[0037] The sensor assembly 1 is attached to the drive assembly 19b via the mounting module 18. The carrier assembly 3 of the sensor assembly 1 is movable relative to the mounting module 18. The drive component 19 of the drive assembly 19b is operable in cooperation with the carrier assembly 3 to selectively move the carrier assembly 3 in a direction towards the pick-up component 22. The sensor assembly 1 is arranged such that the drive component 19 of the drive assembly 19b (which is not visible in Figure 2 or Figure 3 but is visible in Figure 1b , Figure 1c ) is selectively operable to apply a force to the carrier assembly 3 of the sensor assembly 1 to move the carrier assembly 3 in a first direction 31a towards the pick-up component 22. (The inductive sensor 2, the anchor component 4 and the movable component 6 will all move with the carrier component 3 towards the pick-up component 22).

[0038] The sensor assembly 1 is arranged such that the foot portion 211 (more specifically the distal component 16 of the foot portion 211) is aligned over or abuts the top portion 24a of the pick-up component 22; such that when the motor of the drive assembly 19b is operated to move the drive component 19 in the first direction 31a, the drive component 19 of the drive assembly 19b will apply a force to the carrier assembly 3 of the sensor assembly 1 to move the carrier assembly 3 in the first direction 31a towards the pick-up component 22, such that the distal component 16 of the foot portion 211 of the sensor assembly 1 will apply a force to the pick-up component 22 (said applied force being greater than and opposite to the biasing force applied to the pick-up component 22 by the biasing means 24) to move the pick-up component 22 from its first position towards its second position.

[0039] The spring component 9 in the sensor assembly 1 has a sufficiently high spring rate to resist a force equivalent to the biasing force applied to the pick-up component 22 by the biasing means 24 when the pick-up component 22 is in its second position, such that compression of the spring component 9 only occurs as a reaction to the opposing force applied to the pick-up head 22. More specifically, in this embodiment, the spring component 9 has a sufficiently high spring rate to resist a force equivalent to the pulling force applied by the leaf 24 to the top portion 22a of the pick-up component 22 when the pick-up component 22 is in its second position.

[0040] The component handling assembly 20 further comprises a controller 40 operably connected to the inductive sensor 2 of the sensor assembly 1 such that the controller 40 can receive an output from the inductive sensor 2, and the controller 40 is further operably connected to the drive assembly 19b such that the controller 40 can control the motor of the drive assembly 19b. The controller 40 is configured to operate the motor of the drive assembly 19b to move the drive part 19 in the first direction 31a until the output of the inductive sensor 2 increases to be within a predefined range. In a preferred embodiment, the predefined range is between a non-zero value and a predetermined maximum value, wherein the predetermined maximum value is equal to the output of the inductive sensor 2 when the spring part 9 is compressed by 50 pm. In another embodiment, the predefined range is between a predefined minimum value and a predetermined maximum value, wherein the predefined minimum value is equal to the output of the inductive sensor 2 when the spring part 9 is compressed by 10 pm, and the predetermined maximum value is equal to the output of the inductive sensor 2 when the spring part 9 is compressed by 50 pm.

[0041] The controller 40 is further operably connected to the air flow generating means 25; the controller is configured to selectively operate the air flow generating means 25 to generate a negative air flow and / or a positive air flow.

[0042] The component handling assembly 20 according to any of the previously mentioned component handling assembly embodiments can be used to perform a method of transporting a component held on a pick-up head to a receiving surface according to a further aspect of the application, the method comprising the steps of:

[0043] moving the pick-up head holding the component towards the receiving surface such that the component is pressed against the receiving surface and the receiving surface provides a counter force against the component which forces the foot portion 211 of the movable part 6 to move towards the anchor part 4, thereby compressing the spring part 9 between the anchor part 4 and the foot portion 211;

[0044] continuing to move the pick-up head holding the component towards the receiving surface until the output of the inductive sensor 2 increases to be within a predefined range. This allows the component held on the pick-up head 23 to be placed onto the receiving surface with a desired level of force even if the distance between the respective pick-up head 23 and the receiving surface (e.g. the surface of the respective shuttle receiving the component from the respective pick-up head 23) changes during operation of the component handling assembly 20.

[0045] In a preferred embodiment of the method, if after the drive member 19 has been moved in the first direction 31a by a distance equal to the predefined threshold distance, the output of the inductive sensor 2 is not within the predefined range (i.e. the output of the inductive sensor 2 has not increased by a sufficient amount to be within the predefined range), the method further comprises the step of repeatedly moving the drive member 19 in the first direction 31a by a predefined increment (e.g. operating the motor of the drive assembly 19b to move the drive member 19) such that the tip member 16 of the foot portion 211 is moved in the first direction 31a by a corresponding predefined increment towards the pick-up member 22 to move the pick-up head 23 by a corresponding predefined increment towards the receiving surface until the output of the inductive sensor 2 increases to be within the predefined range. Thus, a preferred embodiment can comprise the steps of detecting that the drive member has been moved by a distance equal to the predefined threshold distance and that the output of the inductive sensor is not within the predefined range; in response to said detection, repeatedly moving the drive member by a predefined increment such that the pick-up head 23 is moved by a corresponding predefined increment towards the receiving surface until the output of the inductive sensor increases to be within the predefined range. In embodiments, the predefined increment is within the range 0.001 mm - 0.05 mm.

[0046] During operation of the component handling assembly 20: the pick-up member 22 will initially be in its first position; thus, initially the spring member 9 will be in an uncompressed state. The controller 40 will have operated the air flow generating means 25 such that the air flow generating means 25 generates a negative air flow in order to create a vacuum at the pick-up head 23; the vacuum will hold a component to be transported to the receiving surface on the pick-up head 23. In this example, the receiving surface will be the surface of a movable shuttle; however, it will be appreciated that the present application is not limited to the receiving surface being defined by the surface of a shuttle. The component in question can have been picked up by the pick-up member 22 from a processing or testing station.

[0047] A shuttle having a surface on which one or more components can be received will be positioned beneath the pick-up head 23. The shuttle can be located on a track and can be driven to a position in which its surface is aligned beneath the pick-up head 23.

[0048] Whilst the component is held on the pick-up head 23 by the vacuum, the controller 40 operates the motor of the drive assembly 19b to move the drive member 19 in the first direction 31a. The first direction 31a is a direction towards the pick-up member 22.

[0049] The drive component 19 of the drive assembly 19b will apply a force to the carrier assembly 3 of the sensor assembly 1 to move the carrier assembly 3 in the first direction 31a towards the pick-up component 22 to bring the tip component 16 of the foot portion 211 into contact with the pick-up component 22. When the drive component 19 of the drive assembly 19b continues to apply a force to the carrier assembly 3 of the sensor assembly 1 to move the carrier assembly 3 in the first direction 31a towards the pick-up component 22, the force applied by the drive component to the carrier assembly 3 will be transmitted through the carrier assembly 3 to the tip component 16 of the foot portion 211 such that the tip component 16 of the foot portion 211 applies a force to the pick-up component 22 to move the pick-up component from its first position towards its second position.

[0050] Since the spring component 9 in the sensor assembly 1 has a sufficiently high spring rate to resist a force equivalent to the biasing force applied by the biasing means 24 to the pick-up component 22 when the pick-up component 22 is in its second position, movement of the pick-up component 22 from its first position towards its second position will not cause any compression of the spring component 9 in the sensor assembly 1. More specifically, since the spring component 9 has a sufficiently high spring rate to resist a force equivalent to the pulling force applied by the leaf 24 to the top portion 22a of the pick-up component 22 when the pick-up component 22 is in its second position, movement of the pick-up component 22 from its first position towards its second position will not cause any compression of the spring component 9 in the sensor assembly 1.

[0051] However, once the member held on the pick-up head 23 abuts the surface of the shuttle, the surface of the shuttle will prevent any further movement of the pick-up head 23 in the first direction 31a; this will cause a reaction force to be applied by the surface of the shuttle against the member which is being pressed onto the shuttle surface by the pick-up head 23. This reaction force is transmitted through the member, through the pick-up head 23, through the pick-up component 22 to the tip component 16 of the foot portion 211 of the moveable component 6.

[0052] The reaction force will force the foot portion 211 of the moveable component 6 to move towards the anchor component 4, thereby causing compression of the spring component 9 between the anchor component 4 and the foot portion 211. The more the drive component 19 moves in the first direction 31a, the greater the reaction force transmitted to the tip component 16 of the foot portion 211 of the moveable component 6 and, therefore, the more the spring component 9 will be compressed between the anchor component 4 and the foot portion 211.

[0053] The controller 40, which is operatively connected to the inductive sensor 2 of the sensor assembly 1, will receive the output from the inductive sensor 2. The controller 40 operates the motor of the drive assembly 19b to continue to move the drive member 19 in the first direction 31a until the output from the inductive sensor 2 increases to be within a predefined range. In this embodiment, the predefined range is between a predefined maximum and a predefined minimum, wherein the predefined maximum is equal to the output of the inductive sensor 2 when the spring member 9 is compressed by 50 pm, and the predefined minimum is equal to the output of the inductive sensor 2 when the spring member 9 is compressed by 10 pm. (The less the spring member 9 is compressed, the greater the distance between the metal head portion 11 and the sensor pad 12, and therefore the smaller the value of the output of the inductive sensor 2; the more the spring member 9 is compressed, the smaller the distance between the metal head portion 11 and the sensor pad 12, and therefore the greater the value of the output of the inductive sensor 2; therefore, the predefined maximum occurs when the spring member is compressed by 50 pm, and the predefined minimum occurs when the spring member 9 is compressed by 10 pm).

[0054] It will be appreciated that the predefined maximum and the predefined minimum are determined in a calibration step, which is preferably performed prior to use of the component handling assembly 20; the calibration step preferably involves compressing the spring member by 10 pm and reading and recording the output value from the inductive sensor 2 to obtain the predefined minimum; and compressing the spring member by 50 pm and reading and recording the output from the inductive sensor 2 to obtain the predefined maximum. In this way, even if the distance between the pick-up head 23 and the receiving surface changes over time, the component handling assembly 20 can always operate such that the pick-up head 23 exerts the desired level of force on the component when delivering the component to the receiving surface.

[0055] Once the output from the inductive sensor 2 increases to be within the predefined range, the controller 40 prevents the motor of the drive assembly 19b from moving the drive member 19 in the first direction 31a further. At this point, the component is released from the pick-up head 23: in order to do this, the controller 40 operates the air flow generating means to prevent the air flow generating means from generating a negative air flow, so as to remove the vacuum used to hold the component on the pick-up head 23. Once the vacuum is removed, the component will be released from the pick-up head 23, and the component will have been delivered to the surface of the shuttle.

[0056] In a preferred embodiment, once the output from the inductive sensor 2 increases to be within a predefined range, the controller 40 will operate the air flow generating means to generate a positive air flow; this positive air flow will blow the component away from the pick-up head 23, thereby assisting in the removal of the component from the pick-up head 23 (and thus assisting in the delivery of the component onto the surface of the shuttle). This can cause the component to become loosely attached to the pick-up head 23 by friction when the pick-up head 23 applies a pressing force to the component; the positive air flow will overcome any frictional attachment between the pick-up head 23 and the component, so that the position of the component on the surface of the shuttle does not become displaced when the pick-up head moves away from the component. However, it will be appreciated that the application of a positive air flow to assist in the removal of the component from the pick-up head 23 is not essential to the present application.

[0057] The controller 40 then operates the motor of the drive assembly 19b to move the drive member 19 in its opposite second direction 31b. Thus, the removal of the drive member 19 applies a force to the carrier assembly 3 of the sensor assembly 1 in the first direction 31a towards the pick-up member 22, thereby removing the force applied to the pick-up member 22 by the tip member 16 via the foot portion 211. When the force applied to the pick-up member 22 by the tip member 16 via the foot portion 211 is removed, the biasing force applied to the pick-up member by the biasing means 24 will cause the pick-up member 22 to move back to its first position; in particular, the pulling force applied to the top portion 22a of the pick-up member 22 by the leaf 24 will cause the pick-up member 22 to move back to its first position. In one embodiment, as the pick-up member 22 is moved by the pulling force of the leaf 24, the pick-up member 22 pushes against the tip member 16 of the foot portion 211, which causes the carrier 3 to move upwards in a direction away from the receiving surface.

[0058] In a preferred embodiment, the drive assembly 19b of the component handling assembly 20 further comprises a distance sensor configured to measure the distance that the drive member 19 has moved in the first direction 31a from a predefined reference position and to output a distance measurement value indicative of said measured distance. In this further embodiment, the controller 40 is operatively connected to said distance sensor, such that the controller 40 receives the distance measurement value from the distance sensor; the controller 40 is configured to compare the received distance measurement value with a predefined threshold distance and, if the received distance measurement value is equal to or larger than the predefined threshold distance, the controller 40 operates the motor of the drive assembly 19b to repeatedly move the drive member 19 in the first direction 31a with a predefined increment until the output from the inductive sensor 2 increases to be within a predefined range. The predefined threshold distance is determined in the calibration step and is the distance that the drive member 19 has moved in the first direction 31a from a predefined reference position when the pick-up head 23 is a predefined distance away from the receiving surface (e.g. the surface of the shuttle positioned underneath the pick-up head 23) that has been positioned at a predefined position underneath the pick-up head 23 (the predefined position preferably corresponds to the position at which the surface of the shuttle will be away from the pick-up head 23 when the component handling assembly 20 is in use); preferably, the predefined threshold distance is the distance that the drive member 19 has moved in the first direction 31a from a predefined reference position when the pick-up head 23 occupies a predefined position (or within a predefined range of positions) in which components are to be released from the pick-up head 23 onto the receiving surface. In an embodiment, during operation of the component handling assembly 20, after the shuttle having the receiving surface has been positioned underneath the pick-up head 23, when the drive member 19 has moved a distance in the first direction 31a equal to the predefined threshold distance, but the output from the inductive sensor 2 is not within said predefined range, this means that the receiving surface (i.e. the surface of the shuttle) is further away from the pick-up head 23 compared to the distance of the receiving surface from the pick-up head 23 during the calibration step (e.g. the reason for the receiving surface being further away from the pick-up head can be due to thermal expansion of parts of the assembly, and / or due to wear and tear of parts of the assembly). Then, the controller 40 operates the motor of the drive assembly 19b to repeatedly move the drive member 19 in the first direction 31a with a predefined increment until the output from the inductive sensor 2 increases to be within a predefined range. Thus, even if the distance between the pick-up head 23 and the receiving surface changes, components will be placed onto the receiving surface with a desired level of force.

[0059] Various modifications and variations to the described embodiments of the present application will be apparent to those skilled in the art without departing from the scope of the application as defined in the appended claims. Although the application has been described in connection with specific preferred embodiments, it should be understood that the application as claimed should not be unduly limited to such specific embodiments.

Claims

1. A sensor assembly comprising: an inductive sensor arrangeable at a fixed position within the sensor assembly; a carrier assembly comprising an anchor component arrangeable at a fixed position within the carrier assembly; a movable component movable relative to the anchor component, wherein the movable component comprises a foot portion adapted to cooperate with a pick head assembly, and a metallic head portion interactable with a magnetic field generated by the inductive sensor; a spring component arranged such that when the foot portion is moved towards the anchor component, the spring is compressed between the anchor component and the foot portion; wherein the inductive sensor is operable to provide an output, wherein a value of the output is dependent on a distance between the inductive sensor and the metallic head component, such that the output is representative of an amplitude at which the spring component is compressed between the anchor component and the foot portion.

2. The sensor assembly of claim 1, wherein, the anchor component comprises a plate arrangeable at a fixed position within the carrier assembly, and wherein the anchor component has a through hole defined therein; and wherein the movable component comprises a shaft component connected between the metallic head portion and the foot portion; and wherein the shaft component is arranged to extend through the through hole in the anchor component, such that the metallic head portion is located on one side of the anchor component, and the foot portion is located on an opposite other side of the anchor component.

3. The sensor assembly of claim 1 or 2, wherein, the foot portion comprises a tip portion abuttable against a pick head assembly.

4. The sensor assembly of claim 1 or 2, wherein, the inductive sensor comprises a sensor pad; and wherein the inductive sensor is arranged such that the sensor pad is aligned with the metallic head portion, such that when the foot portion is moved towards the anchor component and the spring is compressed between the anchor component and the foot portion, the metallic head portion is moved towards the sensor pad.

5. The sensor assembly of claim 1 or 2, wherein, the anchor component is mounted on a fixed portion of the carrier assembly via one or more screw components, and wherein the fixed position of the anchor component is selectively adjustable by tightening or loosening the one or more screw components.

6. A component handling assembly comprising: a turret arm component having a pick component with a pick head, wherein the pick component is movable relative to the turret arm component between a first position in which the pick head of the pick component is at a minimum distance from the turret arm component, and a second position in which the pick head of the pick component is at a maximum distance from the turret arm component, and biasing means biasing the pick component towards its first position; a drive assembly comprising at least one motor and a drive component operatively attached to the motor, such that the motor is operable to move the drive component in a first direction or in an opposite second direction; The sensor assembly according to any one of claims 1-5, and wherein the sensor assembly is arranged such that the foot portion is co-operable with the pick-up component such that when the motor of the drive assembly is operated to move the drive component in the first direction, the foot portion will exert a force on the pick-up component to move the pick-up component from its first position towards its second position.

7. The component handling assembly of claim 6, wherein, The spring component has a spring stiffness sufficiently high to resist a force equivalent to a biasing force exerted by the biasing means on the pick-up component when the pick-up component is in its second position, such that compression of the spring component only occurs as a reaction to an opposing force exerted on the pick-up head.

8. The component handling assembly according to claim 6 or 7, further comprising a controller operably connected to the inductive sensor of the sensor assembly such that the controller can receive the output from the inductive sensor, and the controller is further operably connected to the drive assembly such that the controller can control the motor of the drive assembly; and wherein The controller is configured to operate the motor to move the drive component in a first direction until the output of the inductive sensor increases to be within a predefined range.

9. The component handling assembly of claim 8, wherein, The predefined range is any non-zero value less than a predetermined maximum value, wherein the predetermined maximum value is equal to the output of the inductive sensor when the spring component is compressed by 50 pm.

10. The component handling assembly of claim 8, wherein, The predefined range is between a predefined minimum value and a predetermined maximum value, wherein the predefined minimum value is equal to the output of the inductive sensor when the spring component is compressed by 10 pm and the predetermined maximum value is equal to the output of the inductive sensor when the spring component is compressed by 50 pm.

11. The component handling assembly of claim 8, wherein, The drive assembly further comprises a distance sensor configured to measure a distance that the drive component has moved from a predefined reference position and to output a distance measurement indicative of the distance that the drive component has moved from the predefined reference position; and wherein the controller is operably connected to the distance sensor such that the controller can receive the distance measurement and compare the received distance measurement to a reference distance measurement, and if the distance measurement exceeds a predefined threshold value, the controller is configured to operate the motor of the drive assembly to repeatedly move the drive component in a first direction by a predefined increment until the output of the inductive sensor increases to be within the predefined range.

12. A component handling assembly according to claim 6 or 7, wherein, The component handling assembly further comprises air flow generating means selectively operable to generate a negative air flow and / or a positive air flow; wherein the air flow generating device is fluidly connected to the pick-up component such that when the air flow generating device is operated to generate a negative air flow, a vacuum can be selectively provided at the pick-up head such that a component can be held on the pick-up head by the vacuum; and when the air flow generating device is operated to generate a positive air flow, a component held on the pick-up head can be blown from the pick-up head onto a receiving surface.

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