Inclined Rotary Dispenser with a Wave Gear System

Abstract

The supply system includes a supply unit assembly that supplies a viscous material and a gantry coupled to the frame. The gantry supports the supply unit assembly and moves the supply unit assembly in the x-axis and y-axis directions. The supply unit assembly includes a support bracket fixed to the gantry and a movable bracket rotatably coupled to the support bracket by a first harm gear system, the first harm gear system allowing the movable bracket to rotate about a first axis relative to the support bracket. The supply unit assembly further includes a supply unit rotatably coupled to the movable bracket by a second harm gear system, the second harm gear system allowing the supply unit to rotate about a second axis substantially perpendicular to the first axis relative to the movable bracket.

Description

Technical Field

[0001] The present disclosure generally relates to an apparatus and method for supplying a viscous material onto a substrate such as a printed circuit board, and more particularly, to a method and apparatus for supplying a material onto a substrate using a mechanism for tilting and rotating a supply unit.

Background Art

[0002] There are various types of supply systems used to supply precise amounts of liquid or paste for various applications. One such application is the assembly of integrated circuit chips and other electronic components onto a circuit board. In this application, an automated supply system is used to supply dots of liquid epoxy or solder paste, or some other relevant material, onto a printed circuit board. The automated supply system is also used to supply lines of underfill material and encapsulant material, which can be used to mechanically secure components to a printed circuit board. Exemplary supply systems described above include those manufactured and commercially available by Illinois Tool Works Electronic Assembly Equipment (ITWEAE), which has offices in Hopkinton, Massachusetts.

[0003] In a typical supply system, the supply unit is attached to a moving device or gantry to move the supply unit along three mutually perpendicular axes (x-axis, y-axis, and z-axis) using a servomotor controlled by a computer system or a controller. To supply liquid dots to desired positions on a printed circuit board or other substrate, the supply unit is moved along the coplanar horizontal x-axis and y-axis directions until the supply unit is positioned above the desired position. Thereafter, the supply unit is lowered along the vertically directed z-axis until the nozzle / needle of the supply unit and the supply system is at the appropriate supply height above the substrate. The supply unit supplies a liquid dot, then rises along the z-axis, moves along the x-axis and y-axis to a new position, and descends along the z-axis to supply the next liquid dot. For applications such as underfill encapsulation or supply as described above, the supply unit is typically controlled to supply the line as the supply unit is moved along the x-axis and y-axis along the desired path of the material line. In the case of multiple types of supply units such as injection pumps, z-axis movement before and after the supply operation may not be required.

[0004] Better control of the supply unit is desired to accurately position the supply material closer to the corner where the component edge contacts the substrate, or other spaces / orientations that require such movement. SUMMARY OF THE INVENTION

[0005] One aspect of the present disclosure relates to a supply system for supplying a viscous material onto an electronic substrate. In one embodiment, the supply system includes a frame and a support coupled to the frame. The support receives and supports the electronic substrate during a supply operation. The supply system further includes a supply unit assembly for supplying the viscous material and a gantry coupled to the frame. The gantry supports the supply unit assembly and moves the supply unit assembly in the x-axis direction and the y-axis direction. The supply unit assembly includes a support bracket fixed to the gantry and a movable bracket rotatably coupled to the support bracket by a first wave gear system, wherein the first wave gear system enables the movable bracket to rotate about a first axis relative to the support bracket. The supply unit assembly further includes a supply unit rotatably coupled to the movable bracket by a second wave gear system, wherein the second wave gear system enables the supply unit to rotate relative to the movable bracket about a second axis substantially perpendicular to the first axis.

[0006] The embodiment of the supply system can further include configuring the movable bracket to rotate a maximum of 360 degrees around the entire circumference with respect to the support bracket, and configuring the supply unit to rotate a maximum of 360 degrees around the entire circumference with respect to the movable bracket. The second harmonic gear system can include a mounting plate for receiving and supporting the supply unit. The support bracket can have an L-shaped structure having a first portion coupled to the gantry and a second portion extending vertically from the first portion. The second portion of the support bracket can support the first harmonic gear system. The gantry can include a beam that moves in the y-axis direction and a carriage coupled to the beam that moves in the x-axis direction. The carriage includes a z-axis drive mechanism, and the first portion of the support bracket can be fixed to the z-axis drive mechanism so as to cause the z-axis movement of the supply unit. Each of the first harmonic gear system and the second harmonic gear system can include a housing, a circular spline supported by the housing, a wave generator supported by the housing positioned within the circular spline, a spline portion disposed between the circular spline and the drive wave generator, and a flex spline having a base portion extending from the spline portion, and a mounting hub fixed to the base portion of the flex spline. The housing can be configured to support a motor that drives the rotation of the components of the harmonic gear system. The housing of the first harmonic gear system can be fixed to the second portion of the support bracket, and the housing of the second harmonic gear system is fixed to the movable bracket. The supply system can further include a vision system coupled to one of the frame and the gantry for capturing at least one image of the electronic substrate. The supply system can further include a controller for controlling the supply unit assembly, the gantry, and the vision system so as to perform a supply operation on the electronic substrate.The first harmonic gear system and the second harmonic gear system can be coupled to a controller of the supply system so as to control the operations of the first harmonic gear system and the second harmonic gear system.

[0007] Another aspect of the present disclosure relates to a method of supplying a viscous material onto an electronic substrate. In one embodiment, the method includes delivering an electronic substrate to a supply position, capturing at least one image of the electronic substrate, analyzing the at least one image of the electronic substrate to determine a position of the electronic substrate, and performing a supply operation by rotating a supply unit coupled to a support bracket by a movable bracket. The movable bracket is rotatably coupled to the support bracket by a first harmonic gear system that enables the movable bracket to rotate about a first axis relative to the support bracket. The supply unit is rotatably coupled to the movable bracket by a second harmonic gear system that enables the supply unit to rotate about a second axis substantially perpendicular to the first axis relative to the movable bracket.

[0008] Embodiments of the method may further include configuring the movable bracket to rotate up to 360 degrees in total around the support bracket, and configuring the supply unit to rotate up to 360 degrees in total around the movable bracket. The support bracket can have an L-shaped structure having a first portion coupled to the gantry and a second portion extending vertically from the first portion. The second portion of the support bracket can support the first harmonic gear system. The gantry can include a beam that moves in the y-axis direction and a carriage coupled to the beam. The carriage can be configured to move in the x-axis direction. The carriage includes a z-axis drive mechanism, and the first portion of the support bracket can be fixed to the z-axis drive mechanism to effect z-axis movement of the supply unit. Each of the first harmonic gear system and the second harmonic gear system can include a housing, a circular spline supported by the housing, a wave generator supported by the housing and positioned within the circular spline, a spline portion disposed between the circular spline and the wave generator, a flex spline having a base portion extending from the spline portion, and a mounting hub fixed to the base portion of the flex spline. The first harmonic gear system and the second harmonic gear system can be coupled to a controller of the supply system to control the operation of the first harmonic gear system and the second harmonic gear system.

[0009] Various aspects of at least one embodiment are discussed below with reference to the accompanying figures. These figures are not intended to be drawn to scale. The figures are included to provide illustration and further understanding of the various aspects and embodiments, and are incorporated herein and form a part of this specification, but are not intended as a definition of any limitation of a particular embodiment. The drawings, together with the remainder of the specification, function to explain the principles and operations of the described and claimed aspects and embodiments. In the figures, each identical or substantially identical component shown in the various figures is represented by like reference numerals. For clarity, not every component is labeled in every figure.

Brief Description of the Drawings

[0010]

Figure 1

Figure 2

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Figure 11A

Figure 11B

Figure 11C

Figure 12A

Figure 12B

Figure 12C

Figure 12D

Mode for Carrying Out the Invention

[0011] Various embodiments of the present disclosure relate to a viscous material supply system and a device including the supply system. The embodiments disclosed herein relate to a technique for supplying a material onto an electronic substrate by a supply system including a supply unit that tilts and rotates to supply the material onto the electronic substrate.

[0012] For purposes of illustration only and not limitation, the present disclosure will now be described in detail with reference to the accompanying drawings. The present disclosure is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the drawings. The principles described herein are applicable to other embodiments and may be practiced or carried out in various ways. Also, the phraseology and terminology used herein are for the purpose of description and should not be regarded as limiting. Any reference herein to an example, embodiment, component, element, or act of a system and method in the singular is intended to include embodiments that include a plurality thereof, and any reference herein to an embodiment, component, element, or act in the plural is intended to include embodiments that include only a singular thereof. References in the singular or plural are not intended to limit the systems or methods, their components, acts, or elements disclosed herein. The use of the terms "comprising," "including," "having," "containing," "involving," and variations thereof herein is meant to encompass the item listed before the term and its equivalent and additional items. References to "or / and" are to be construed in an inclusive sense such that any term so described may include any one of the described terms, one or more, and all thereof. Additionally, if the usage of terms between this specification and documents incorporated herein by reference is inconsistent, the usage of terms in the documents incorporated herein by reference is supplementary to the usage in this specification, and if the inconsistency results in a contradiction, the usage in this specification is valid.

[0013] FIG. 1 schematically shows a supply system generally designated 10 in accordance with one embodiment of the present disclosure. The supply system 10 is used to supply a viscous material (e.g., an adhesive, an encapsulant, an epoxy, a solder paste, an underfill material, etc.) or a semi-viscous material (e.g., a solder flux, etc.) onto an electronic substrate 12 such as a printed circuit board or a semiconductor wafer. The supply system 10 can alternatively be used in other applications such as for applying an automotive gasket material, or for applications in certain medical fields, or for applying a conductive ink, etc. It should be understood that references to viscous or semi-viscous materials as used herein are illustrative and are intended to be non-limiting. In one embodiment, the supply system 10 includes an array of a first supply unit and a second supply unit generally designated 14 and 16, respectively, and a controller 18 that controls the operation of the supply system. It should be understood that the supply units may also be referred to herein as supply pumps and / or supply heads. Although two supply units are shown, it should be understood that an array of supply units can use a single or multiple supply units.

[0014] In addition, the supply system 10 can include a frame 20 having a base or support 22 for supporting the electronic substrate 12, a supply unit gantry 24 movably coupled to the frame 20 for supporting and moving the supply units 14, 16, and a weight measuring device or scale 26 that, for example, as part of a calibration procedure, measures the supplied amount of the viscous material and provides weight data to the controller 18. In the supply system 10, other transfer mechanisms such as a conveyor system (not shown) or a moving beam may be used to control the loading and unloading of the electronic substrate to and from the supply system. The gantry 24 can move using a motor under the control of the controller 18 to position the supply units 14, 16 at a predetermined position above the electronic substrate. The supply system 10 can include a display unit 28 connected to the controller 18 for displaying various information to the operator. An optional second controller for controlling the supply units may be provided. Also, each of the supply units 14, 16 can use a z-axis sensor to detect the height at which the supply unit is disposed above the electronic substrate 12 or above a mechanism mounted on the electronic substrate. The z-axis sensor is coupled to the controller 18 and relays the information obtained by the sensor to the controller.

[0015] As described above, before performing the supply operation, the substrate, for example, a printed circuit board, must be aligned or otherwise positioned relative to the supply unit of the supply system. The supply system further includes a vision system 30. In one embodiment, the vision system 30 is coupled to a vision system gantry 32, and the vision system gantry 32 is movably coupled to the frame 20 for supporting and moving the vision system. In another embodiment, the vision system 30 may be provided on the supply unit gantry 24. As described above, the vision system 30 is used to verify the position of landmarks or components known as references on the electronic substrate. Once the position is determined, the controller can be programmed to manipulate the movement of one or more of the supply units 14, 16 to supply material onto the electronic substrate.

[0016] The systems and methods of the present disclosure relate to supplying materials onto an electronic substrate, such as a printed circuit board. The description of the systems and methods provided herein refers to an exemplary electronic substrate 12 (e.g., a printed circuit board) supported on a support 22 of a supply system 10. In one embodiment, the supply operation is controlled by a controller 18, which may include a computer system configured to control a material supply unit. In another embodiment, the controller 18 may be operated by an operator. The controller 18 operates the movement of a vision system gantry 32 to move a vision system to acquire one or more images of the electronic substrate 12. The controller 18 is further configured to operate the movement of a supply unit gantry 24 to move the supply units 14, 16 to perform the supply operation.

[0017] Embodiments of the present disclosure relate to a harmonic drive device for tilting and rotating a supply unit of a supply system, and provide alternative and comparable means for accurately supplying simultaneously to one or more electronic substrates, or two or more patterns associated with a single electronic substrate. The methods disclosed herein further support the use of various types of supply units, including but not limited to augers, pistons, and injection pumps.

[0018] Referring to FIGS. 2 and 3, a supply system is shown generally at 40. As shown, the supply system 40 includes a frame 42 that supports the major subassemblies of the supply system. The supply system 40 further includes a gantry system shown generally at 44 that moves in the x-axis and y-axis directions. The supply system 40 further includes a supply unit assembly shown generally at 46 that is supported by the gantry system 44. FIG. 2 shows the supply system 40 with the supply unit assembly 46, and FIG. 3 shows the supply system 40 with the supply unit assembly removed. A conveyor system (not shown) within the supply system 40 can be used to control the loading and unloading of substrates, such as electronic substrate 12, to and from a support 50 of the supply system. The gantry system 44 can move in the x-axis and y-axis directions to position the supply unit assembly 46 at a predetermined location on the electronic substrate, under the control of a controller, using motors similar to the controller 18 of the supply system 10.

[0019] In one embodiment, as shown in FIGS. 2 and 3, the gantry system 44 can be configured to include a left side rail 52, a right side rail 54, and a beam 56 extending between the two side rails. The beam 56 moves in the y-axis direction along the side rails 52, 54 to effect the y-axis movement of the supply unit assembly 46. The gantry system 44 further includes a carriage 58 coupled to the beam 56 that moves along the length of the beam to effect the x-axis movement of the supply unit assembly 46. Specifically, the carriage 58 supports the supply unit assembly 46 and moves in the x-axis direction along the length of the beam to move the supply unit 48 above a desired location on the electronic substrate 12 positioned on the support 50 of the supply system 40. In certain embodiments, the movement of the gantry system 44 in the x-y plane (i.e., the movement of the beam 56 and the carriage 58) can be achieved by employing ball screw mechanisms driven by respective motors, as is well known in the art.

[0020] In one embodiment, the exemplary supply system described herein can embody the Camalot™ supply system sold by ITWEAE, Inc. of Hopkinton, Massachusetts.

[0021] The supply unit assembly 46 moves the supply unit 48 in the z-axis direction by the z-axis drive mechanism 60 shown in FIG. 2. The z-axis movement amount can be determined by measuring the distance between the tip of a needle (not shown) of the supply unit 48 and the electronic substrate 12. During movement, the supply unit 48 can be positioned with a nominal clearance height above the electronic substrate 12. The clearance height can be maintained at a relatively consistent height above the electronic substrate 12 during movement from one supply position to another. When reaching a predetermined supply position, the z-axis drive mechanism 60 lowers the supply unit 48 onto the electronic substrate 12, thereby enabling the supply of material onto the electronic substrate.

[0022] Referring to FIGS. 2 and 3, the supply unit 48 moves above the electronic substrate 12 to perform a supply operation by the supply unit. However, before supplying, the position of the electronic substrate 12 relative to the supply unit 48 is determined so that accurate supply can be performed. Specifically, in one embodiment, the carriage 58 can be configured to include an optical element or camera designed to acquire an image of the electronic substrate 12. Although the camera is shown as being attached to the carriage 58, it should be understood that it can be attached separately to the beam 56 or an independent gantry. In this specification, the camera can be referred to as a "vision system" or "imaging system". To position the electronic substrate 12 relative to the supply unit 48 and the gantry system 44, images of at least two reference portions provided on the electronic substrate 12 are acquired by the camera. If the position of the electronic substrate 12 is off, the gantry system 44 can be operated to account for the actual position of the electronic substrate. In one embodiment, the camera can be calibrated to determine the camera-to-needle offset distance for the supply unit 48.

[0023] In another embodiment, a laser or other calibration distance measuring device can be used to achieve visual positioning and clearance height detection.

[0024] The supply system typically has a supply unit that is directed vertically, and thus perpendicularly to a substrate that is fixed horizontally. In some applications, it is advantageous to tilt the supply unit from the vertical and deposit the material to be supplied at a location that is not directly accessible from the vertical orientation. When the tilting supply unit is articulable in various desired directions, it may be advantageous to change not only the angle of the supply unit from the vertical, but also the direction in which the supply unit tilts, and in some cases deposit material along the bottom edge of the part along two or more sides.

[0025] As will be appreciated by those skilled in the art of moving structures, the mechanisms used to tilt and rotate the supply unit 48 increase the mass and introduce additional compliance as additional mechanisms are added, thus reducing the structural rigidity. As the supported mass increases and the structural rigidity decreases, the natural frequency of the assembly decreases. Thus, it is left to the designer to provide the necessary degrees of freedom with a minimum increase in mass and with the highest possible rigidity.

[0026] Embodiments of the supply system 40 of the present disclosure achieve this goal by incorporating a very small and highly integrated rotary actuator that includes a motor, a strain-wave harmonic reduction gear box, and a high-rigidity rotary cross-roller bearing, such as those available from Harmonic Drive, Beverly, Massachusetts. The high integration in the wave gear box actuator helps minimize increases in mass and compliance. The wave gear box further has the benefit of very low backlash. Also, the assembled motor, bearing, and gear box unit helps minimize the number of parts that need to be purchased, assembled, and tested.

[0027] Referring to FIGS. 4 and 5, the supply unit assembly 46 includes a drive device that supports the supply unit 48. The supply unit 48 is shown in FIG. 4 in its operating position and in FIG. 5 in a pre-operating position where it is separated from the components of the supply unit assembly that support the supply unit. As shown, the supply unit assembly 46 includes a support bracket 62 having an L-shaped structure. The first portion 64 of the support bracket is fixed to the z-axis drive mechanism 60 of the carriage 58, and the second portion 66 extends vertically from the first portion. The supply unit assembly 46 further includes a movable bracket 68 that is rotatably coupled to the support bracket 62 by a first wave gear system 70 at the second portion 66 of the support bracket. In the illustrated embodiment, the movable bracket 68 rotates relative to the support bracket 62 about a generally vertical axis A.

[0028] The movable bracket 68 includes a second harmonic gear system 72 that supports the supply unit 48. As shown in the figure, the second harmonic gear system 72 includes a mounting plate 74 that receives and supports the supply unit 48 when the supply unit is in the operating position. The second harmonic gear system 72 rotates and tilts the supply unit 48 to a desired position during the supply operation around an axis B that is substantially perpendicular to the axis A. In one embodiment, the first harmonic gear system 70 is configured similarly even if it is not identical to the second harmonic gear system 72.

[0029] It should be understood that the orientation of the movable bracket 68 relative to the support bracket 62 around the axis A and the orientation of the supply unit 48 relative to the movable bracket can be changed to adapt to a specific application. For example, the movable bracket 68 can be rotatably coupled to the support bracket 62 around a substantially horizontal axis, and the supply unit can be rotatably coupled to the movable bracket around a substantially vertical axis.

[0030] FIG. 6 shows a cross-sectional view of the supply unit assembly 46 showing the first harmonic gear system 70 and the second harmonic gear system 72. The movable bracket 68 rotates relative to the support bracket 62 by a maximum of 360 degrees over the entire circumference, that is, from 0 degrees to 360 degrees. Similarly, the supply unit 48 rotates relative to the movable bracket 68 by a maximum of 360 degrees over the entire circumference, that is, from 0 degrees to 360 degrees. Therefore, the amount of rotation and tilt of the supply head 48 is unlimited.

[0031] Referring to FIGS. 7 and 8, the harmonic gear systems 70, 72 are shown in exploded perspective and cross-sectional views. As described above, the first harmonic gear system 70 and the second harmonic gear system 72 are similarly configured, if not identical. As shown, the harmonic gear systems 70, 72 include a housing 76. In the case of the first harmonic gear system 70, the housing 76 is fixed to the second portion 66 of the support bracket 62. In the case of the second harmonic gear system 72, the housing 76 is fixed to the movable bracket 68. In one embodiment, the housing 76 of the harmonic gear systems 70, 72 supports a motor that drives the rotation of the components of the harmonic gear system and is coupled to a controller of the supply system 40 that controls the operation of the harmonic gear system.

[0032] In one embodiment, the harmonic gear systems 70, 72 further each include a circular spline 78 and a wave generator 80 supported by the housing 76, with the wave generator positioned within the circular spline. The harmonic gear systems 70, 72 further include a flex spline 82 having a spline portion 84 disposed between the circular spline 78 and the wave generator 80 and a cup-shaped base 86 extending from the spline portion. The harmonic gear systems 70, 72 further include a mounting hub 88 fixed to the base 86 of the flex spline 82. FIGS. 9 and 10 show the components of the harmonic gear systems 70, 72 assembled together.

[0033] Referring to FIG. 11A, in one embodiment, the wave generator 80 includes a special designed thin ball race bearing assembly that fits onto an elliptical hub. Since the wave generator 80 is coupled to the shaft of a motor provided within the housing 76, it functions as a high-efficiency torque converter and is used as the input portion of the harmonic gear systems 70, 72.

[0034] Referring to FIG. 11B, in one embodiment, the flex spline 82 has a thin cylindrical cup made of alloy steel, and the open end of the cup (spline portion 84) has external teeth. The flex spline 82 is compliant in the radial direction but highly rigid in the twisting direction. When the wave generator 80 is inserted into the flex spline 82, the spline portion 84 of the flex spline takes an elliptical shape. The flex spline 82 is used as an output portion and is connected to the output flange (base 86).

[0035] Referring to FIG. 11C, in one embodiment, the circular spline 78 includes a rigid ring with internal teeth. When the harmonic gear systems 70, 72 are assembled, the internal teeth of the circular spline 78 engage with the teeth of the spline portion 84 of the flex spline 82 across the major axis of the harmonic gear system. The circular spline 78 has two more teeth than the flex spline 82 and is fixed to the housing 76.

[0036] Referring further to FIGS. 12A - 12D, in one embodiment, the flex spline 82 has a slightly smaller diameter than the circular spline 78 and two fewer teeth than the circular spline 78. Due to the elliptical shape of the wave generator 80, the teeth of the flex spline 82 engage with two opposing regions of the circular spline 78 across the major axis of the ellipse. Each time the wave generator 80 rotates 180 degrees clockwise, the teeth of the flex spline 82 advance counterclockwise by one tooth with respect to the circular spline 78. Each time the wave generator 80 makes one full clockwise rotation, the flex spline 82 moves counterclockwise by two teeth from its original position with respect to the circular spline 78. Since the teeth of the gears are always fully engaged in the region along the major axis, the backlash for the harmonic gear systems 70, 72 is zero.

[0037] While the spline portion 84 of the flex spline is elliptical in shape, the base portion 86 of the flex spline 82 is limited to a circular shape. This structure slightly spreads the teeth of the flex spline 82 outward to form a corning angle, which functions as a preload between the outer teeth of the flex spline and the inner teeth of the circular spline 78. This preload serves to enhance the zero backlash of the harmonic gear systems 70, 72 and to ensure consistent stability.

[0038] FIG. 12A shows the wave generator 80 and the flex spline 82 at the 0-degree position with respect to the circular spline 78. FIG. 12B shows the wave generator 80 and the flex spline 82 at the 90-degree position with respect to the circular spline 78. FIG. 12C shows the wave generator 80 and the flex spline 82 at the 180-degree position with respect to the circular spline 78. FIG. 12D shows the wave generator 80 and the flex spline 82 at the 360-degree position with respect to the circular spline 78.

[0039] In one embodiment, a controller or control system, such as the controller 18, can have a suitable operating system with application-specific software for controlling the operation of the supply system 40. In certain embodiments, an operator of the supply system 40 can manually operate the supply system via a keyboard and a mouse provided with the control system, or automatically by pre-programming the control system via the keyboard and the mouse through the control system. The controller is further configured to analyze at least one image of the electronic substrate 12 to determine the position of the electronic substrate in the x-axis direction, y-axis direction, and θ direction, calculate the rotation angle of the electronic substrate, and rotate the supply unit 48 to match the angle of the electronic substrate during the supply operation.

[0040] During operation, when depositing materials onto a substrate such as an electronic component, the supply unit 48 of the supply unit assembly 46 is positioned close to the electronic substrate by operating the gantry system. The controller controls the automatic movement of the supply unit 48 by operating the gantry system 44 and supplies materials onto the electronic substrate 12 by rotating the supply unit around the A-axis and B-axis. The controller controls the movement (linear and rotational) of the supply unit of the supply unit assembly 46 by controlling the operations of the gantry system 44 and the driving device.

[0041] Therefore, the movable bracket 68 is configured to rotate 360 degrees around the full circumference with respect to the support bracket 62, and it should be apparent that the supply unit 48 rotates 360 degrees around the full circumference with respect to the movable bracket. This enables the supply unit 48 to deposit materials at locations on the electronic substrate 12 that are difficult to reach. The supply system 40 disclosed in this specification adopts a unique combination of driving devices that control the direction of the supply unit 48 while having the benefit of improving the speed and accuracy of supply applications.

[0042] As described above, an embodiment of the supply system can be configured to accurately supply simultaneously to one or more electronic substrates, or two or more patterns related to a single electronic substrate, in synchronous mode or asynchronous mode. Specifically, when the electronic substrate is not properly positioned as determined by the controller, the supply system can switch from synchronous mode where supply is made to two electronic substrates or patterns to asynchronous mode where supply is made to only one electronic substrate or pattern. The method disclosed in this specification further supports the use of various types of supply pumps including, but not limited to, augers, pistons, and injection pumps.

[0043] Exemplary supply operations for two substrates or two substrate patterns can consist of delivering a first electronic substrate pattern to a supply position, delivering a second electronic substrate pattern to the supply position, positioning the first electronic substrate pattern and a first supply unit, positioning a second supply unit at a predetermined distance from the first supply unit, supplying material from the first supply unit to a desired position on the first electronic substrate pattern, and supplying material from the second supply unit to a desired position on the second electronic substrate pattern. In certain embodiments, the step of supplying material from the first supply unit can include lowering the first supply unit towards the first electronic substrate pattern. Similarly, the step of supplying material from the second supply unit can include lowering the second supply unit towards the second electronic substrate pattern.

[0044] Another exemplary supply operation can consist of delivering a first electronic substrate pattern and a second electronic substrate pattern to their respective supply positions, positioning a first supply unit above the first electronic substrate pattern, positioning a second supply unit at a predetermined distance from the first supply unit, supplying material from the first supply unit to a desired position on the first electronic substrate pattern, and supplying material from the second supply unit to a desired position on the second electronic substrate pattern. Supplying material from the first supply unit includes lowering the first supply unit towards the first electronic substrate pattern. Similarly, supplying material from the second supply unit includes lowering the second supply unit towards the second electronic substrate pattern. In certain embodiments, the predetermined distance is determined by specifying a first reference point associated with the first electronic substrate pattern and a second reference point associated with the second electronic substrate pattern.

[0045] Another exemplary supply operation for two substrates can consist of: (1) calibrating the actual distance between each of the supply units and the camera; (2) identifying the actual positions of the reference positions on the single or multiple substrates; (3) moving the first supply unit to the first supply position on the first substrate; (4) performing supply at the first supply position on the first substrate; (5) moving the second supply unit to the first supply position on the second substrate, where this movement is slight and thus rapidly executable; (6) performing supply at the first supply position on the second substrate; and (7) repeating steps (3) to (6) for each of the remaining supply positions on the substrate. The above operations can be executed when performing supply on a single substrate having multiple patterns thereon.

[0046] When using three or more supply units, it is further contemplated that this simultaneous supply method can be adopted for every other substrate. For example, when using three supply units, the first supply unit, the second supply unit, and the third supply unit can simultaneously supply the first substrate, the third substrate, and the fifth substrate respectively. After supplying these substrates, the supply units can be moved so that the supply is performed on the second substrate, the fourth substrate, and the sixth substrate respectively by the first supply unit, the second supply unit, and the third supply unit.

[0047] In an exemplary embodiment, a method of supplying material can include delivering at least two electronic substrates having at least two identical patterns to a supply position, obtaining data regarding the at least two patterns, determining whether the at least two patterns are sufficiently suitable for simultaneous supply based on the obtained data for performing a simultaneous supply operation on the at least two patterns, and when the two patterns are sufficiently suitable for simultaneous supply, performing a simultaneous supply operation on the at least two patterns.

[0048] Supplying the material can include positioning a first supply unit above a first position of a first pattern and positioning a second supply unit above a first position of a second pattern. As described above, the second supply unit can be arranged at a predetermined distance from the first supply unit. Specifically, the material can be supplied from the first supply unit and the second supply unit to the respective first positions of the first pattern and the second pattern. When the supply is performed, the first supply unit moves above a second position of the first pattern of the electronic substrate, and the second supply unit simultaneously moves above a second position of the second pattern of the electronic substrate. When moving, the material can be supplied from the first supply unit and the second supply unit to the respective second positions of the first pattern and the second pattern.

[0049] In another exemplary embodiment, a method of supplying material can include: (1) identifying the positions of two or more positions on an electronic substrate; (2) based on the identified positions, determining whether the supply positions of the first pattern and the supply positions of the second pattern are sufficiently suitable for simultaneous supply to perform a simultaneous supply operation on the first pattern and the second pattern; (3) moving a first supply unit to a supply position on the first pattern and moving a second supply unit to a supply position on the second pattern, wherein the supply position of the first pattern corresponds to the supply position on the second pattern; (4) supplying to the first supply position on the first pattern by the first supply unit and supplying to the first supply position on the second pattern by the second supply unit; and (5) repeating steps (3) and (4) for each remaining supply position on the first pattern and the second pattern of the electronic substrate. As described above, before implementing this method, the distance between the first supply unit and the camera and the distance between the second supply unit and the camera can be calibrated.

[0050] In one embodiment, to perform a static adjustment once for each substrate provided to the dispenser, the vision system and the controller identify and calculate the distance from one part of the substrate to another part of the same substrate and any rotation of the substrate with respect to the gantry system, and adjust the second supply unit once before simultaneous supply. In another embodiment, an automatic adjustment mechanism can be used to perform a dynamic adjustment while supplying. Thus, in cases where two patterns are not well-suited for simultaneous supply, i.e., examples where two substrates are not well-suited for simultaneous supply, the method includes simultaneously executing a first supply operation for a first pattern (or substrate) by a first supply unit and a second supply operation for a second pattern (or substrate) by a second supply unit. This can be achieved by dynamically positioning the second supply unit by the automatic adjustment mechanism while continuing the supply by the first supply unit and the second supply unit.

[0051] The dispenser of the embodiments of the present disclosure can supply different patterns simultaneously. In such a method, the gantry carrying the supply unit and the automatic adjustment mechanism associated with the second supply unit (and / or the first supply unit) can be operated to supply different patterns simultaneously. By this method, the lines supplied by the first supply unit and the second supply unit can be drawn synchronously.

[0052] Therefore, in the case of a dispenser having a plurality of supply units, the distance and relative position of each of the plurality of supply units can be made to match the distance and relative spacing between each of the plurality of substrates or members. After collecting and analyzing the positioning information from the automatic vision positioning system, a first supply unit among the plurality of supply units is positioned above a first supply position on a first substrate or member. After performing the supply operation, the gantry can be operated to perform the required position adjustment in the x-axis and y-axis planes. This position adjustment may be necessary to position a second supply unit among the plurality of supply units above a corresponding first supply position of a second substrate or member among the plurality of substrates or members. Since the distance and relative position between each of the plurality of supply units are only approximately similar but not necessarily identical to the distance and relative position between each of the plurality of substrates or members, any such adjustment of the gantry is very slight and is therefore carried out quickly. Each of the remaining plurality of supply units can be similarly used to supply material to the corresponding first supply position of each of the remaining substrates or members, after which a large movement of the gantry in the x-axis and y-axis directions is required. However, if the number of substrates or members is greater than the number of supply units, it may be necessary to reposition the gantry to complete the supply operation for all of the substrates. This method is repeated to perform the supply at each of the second and subsequent supply positions. It should be understood that the steps can be interchanged as may be required by an improvement in throughput or process.

[0053] As described above, in one embodiment, the supply unit can be attached to a separate z-axis drive mechanism. With this configuration, when appropriate, without limitation, independent operations including supply, cleaning (such as by an automatic needle / nozzle cleaner), purification, and calibration (x-axis or y-axis position or z-axis position) can be performed. However, it should be noted that the dispenser can be particularly suitable for non-contact supply such as flowing out or ejecting materials from the needle / nozzle. When configured for non-contact supply, the supply operation can be performed by two (or three or more) supply units attached to a single z-axis drive mechanism.

[0054] One embodiment of the present disclosure relates to a method of supplying between a synchronous mode and an asynchronous mode. As described above, when using a vision system to determine whether one or more substrates are sufficiently suitable for simultaneous supply, or whether one or more patterns are sufficiently suitable for simultaneous supply, if they are sufficiently suitable for simultaneous supply, by adopting a synchronous operation mode, the supply unit can supply to the substrate or pattern simultaneously. However, if they are not sufficiently suitable for simultaneous supply, by adopting an asynchronous operation mode, the substrate or pattern can be automatically and independently supplied asynchronously.

[0055] As used herein, "sufficiently suitable for simultaneous supply" means that after the controller inspects data related to one or more images acquired by the vision system or camera, two or more substrates or patterns are located at known positions, such known positions are within a predetermined tolerance range, and none of the other acquired data indicates a reason not to supply to one or more of the substrates or patterns.

[0056] As used herein, "acquired data" means data generated inside the supply system such as vision data, or data transferred from an external supply source based on a previous process.

[0057] Thus, although some aspects of at least one embodiment of the present disclosure have been described, it should be understood that various modifications, changes, and improvements will readily occur to those skilled in the art. Such modifications, changes, and improvements are intended to be part of the present disclosure and are intended to be within the spirit and scope of the present invention. Accordingly, the foregoing description and drawings are merely illustrative. Some aspects of the present invention will be described below. [Aspect 1] In a supply system for supplying a viscous material onto an electronic substrate, a frame, a support coupled to the frame, which receives and supports the electronic substrate during the supply operation, a supply unit assembly for supplying the viscous material, a gantry coupled to the frame, which supports the supply unit assembly and moves the supply unit assembly in the x-axis direction and the y-axis direction, the supply unit assembly includes a support bracket fixed to the gantry, a movable bracket rotatably coupled to the support bracket by a first harmonic gear system, wherein the first harmonic gear system enables the movable bracket to rotate around a first axis with respect to the support bracket, a supply unit rotatably coupled to the movable bracket by a second harmonic gear system, wherein the second harmonic gear system enables the supply unit to rotate around a second axis substantially perpendicular to the first axis with respect to the movable bracket, a supply system. [Aspect 2] The movable bracket is configured to rotate a maximum of 360 degrees around the full circumference with respect to the support bracket, and the supply unit rotates a maximum of 360 degrees around the full circumference with respect to the movable bracket. The supply system according to Aspect 1. [Aspect 3] The second harmonic gear system includes a mounting plate for receiving and supporting the supply unit. The supply system according to Aspect 1. [Aspect 4] The support bracket has an L-shaped structure including a first portion coupled to the gantry and a second portion extending vertically from the first portion. The supply system according to Aspect 1. [Aspect 5] The second portion of the support bracket supports the first harmonic gear system. The supply system according to Aspect 4. [Aspect 6] The gantry includes a beam moving in the y-axis direction and a carriage coupled to the beam and moving in the x-axis direction. The supply system according to Aspect 4. [Aspect 7] The carriage includes a z-axis drive mechanism, and the first portion of the support bracket is fixed to the z-axis drive mechanism so as to cause the z-axis movement of the supply unit. The supply system according to aspect 6. [Aspect 8] Each of the first harmonic gear system and the second harmonic gear system includes a housing, a circular spline supported by the housing, a wave generator supported by the housing positioned within the circular spline, a flex spline having a spline portion disposed between the circular spline and the wave generator and a base portion extending from the spline portion, and a mounting hub fixed to the base portion of the flex spline. The supply system according to aspect 1. [Aspect 9] The housing supports a motor that drives the rotation of the components of the harmonic gear system. The supply system according to aspect 8. [Aspect 10] The housing of the first harmonic gear system is fixed to the second portion of the support bracket, and the housing of the second harmonic gear system is fixed to the movable bracket. The supply system according to aspect 8. [Aspect 11] The supply system according to aspect 1, further comprising a vision system coupled to one of the frame and the gantry to capture at least one image of the electronic substrate. [Aspect 12] The supply system according to aspect 11, further comprising a controller for controlling the supply unit assembly, the gantry, and the vision system to perform a supply operation on the electronic substrate. [Aspect 13] The first harmonic gear system and the second harmonic gear system are coupled to the controller of the supply system so as to control the operations of the first harmonic gear system and the second harmonic gear system. The supply system according to aspect 1. [Aspect 14] In a method of supplying a viscous material onto an electronic substrate, delivering the electronic substrate to a supply position, capturing at least one image of the electronic substrate, and analyzing the at least one image of the electronic substrate to determine the position of the electronic substrate Performing a supply operation by rotating a supply unit coupled to a support bracket by a movable bracket, wherein the movable bracket is rotatably coupled to the support bracket by a first harmonic gear system that enables the movable bracket to rotate around a first axis with respect to the support bracket, and the supply unit is rotatably coupled to the movable bracket by a second harmonic gear system that enables the supply unit to rotate around a second axis substantially perpendicular to the first axis with respect to the movable bracket. [Aspect 15] The method according to aspect 14, wherein the movable bracket is configured to rotate a maximum of 360 degrees around the full circumference with respect to the support bracket, and the supply unit is configured to rotate a maximum of 360 degrees around the full circumference with respect to the movable bracket. [Aspect 16] The method according to aspect 14, wherein the support bracket has an L-shaped structure having a first portion coupled to the gantry and a second portion extending vertically from the first portion, and the second portion of the support bracket supports the first harmonic gear system. [Aspect 17] The method according to aspect 16, wherein the gantry includes a beam that moves in the y-axis direction and a carriage that is coupled to the beam and moves in the x-axis direction. [Aspect 18] The method according to aspect 17, wherein the carriage includes a z-axis drive mechanism, and the first portion of the support bracket is fixed to the z-axis drive mechanism so as to cause the z-axis movement of the supply unit. [Aspect 19] Each of the first harmonic gear system and the second harmonic gear system includes a housing, a circular spline supported by the housing, a wave generator supported by the housing positioned within the circular spline, a flex spline having a spline portion disposed between the circular spline and the wave generator and a base extending from the spline portion, and a mounting hub fixed to the base of the flex spline. The method according to aspect 14. [Aspect 20] The method according to aspect 14, wherein the first harmonic gear system and the second harmonic gear system are coupled to a controller of the supply system so as to control the operations of the first harmonic gear system and the second harmonic gear system.

Explanation of Symbols

[0058] 10 Supply System 12 Electronic Substrate 14 Supply Unit 16 Supply Unit 18 Controller 20 Frame 22 Support 24 Supply Unit Gantry 26 Meter 28 Display Unit 30 Vision System 32 Vision System Gantry 40 Supply System 42 Frame 44 Gantry System 46 Supply Unit Assembly 48 Supply Unit 50 Support 52 Left Side Rail 54 Right Side Rail 56 Beam 58 Carriage 60 z - Axis Drive Mechanism 62 Support Bracket 64 First Part 66 Second Part 68 Movable Bracket 70 First Harmonic Gear System 72 Second Harmonic Gear System 74 Plate 76 Housing 78 Circular Spline 80 Wave Generator 82 Flexspline 84 Spline Portion 86 Cup - shaped Base 88 Hub

Claims

1. In a supply system for supplying a viscous material onto an electronic substrate, a frame, a support coupled to the frame, the support receiving and supporting the electronic substrate during a supply operation, a supply unit assembly for supplying the viscous material, a gantry coupled to the frame, the gantry supporting the supply unit assembly and moving the supply unit assembly in an x-axis direction and a y-axis direction, wherein the supply unit assembly a support bracket fixed to the gantry, a movable bracket rotatably coupled to the support bracket by a first wave gear system, the first wave gear system enabling the movable bracket to rotate about a first axis relative to the support bracket, a supply unit rotatably coupled to the movable bracket by a second wave gear system, the second wave gear system enabling the supply unit to rotate about a second axis substantially perpendicular to the first axis and relative to the movable bracket, each of the first wave gear system and the second wave gear system a housing, a circular spline supported by the housing, a wave generator supported by the housing and positioned within the circular spline, a flex spline having a spline portion disposed between the circular spline and the wave generator and a base extending from the spline portion, and a mounting hub fixed to the base of the flex spline.

2. The supply system according to claim 1, wherein the movable bracket is configured to rotate a maximum of 360 degrees around the full circumference relative to the support bracket, and the supply unit is configured to rotate a maximum of 360 degrees around the full circumference relative to the movable bracket.

3. The supply system according to claim 1, wherein the second wave gear system includes a mounting plate for receiving and supporting the supply unit.

4. The supply system according to claim 1, wherein the support bracket has an L-shaped structure having a first portion coupled to the gantry and a second portion extending perpendicularly from the first portion.

5. The supply system according to claim 4, wherein the second portion of the support bracket supports the first wave gear system.

6. The supply system according to claim 4, wherein the gantry includes a beam that moves in the y-axis direction and a carriage that is coupled to the beam and moves in the x-axis direction.

7. The supply system according to claim 6, wherein the carriage includes a z-axis drive mechanism, and the first portion of the support bracket is fixed to the z-axis drive mechanism so as to cause the z-axis movement of the supply unit.

8. The supply system according to claim 1, wherein the housing supports a motor that drives the rotation of each component of the first and second harmonic gear systems.

9. The supply system according to claim 4, wherein the housing of the first harmonic gear system is fixed to the second portion of the support bracket, and the housing of the second harmonic gear system is fixed to the movable bracket.

10. The supply system according to claim 1, further comprising a vision system that is coupled to one of the frame and the gantry and captures at least one image of the electronic substrate.

11. The supply system according to claim 10, further comprising a controller that controls the supply unit assembly, the gantry, and the vision system so as to perform a supply operation on the electronic substrate.

12. The supply system according to claim 1, wherein the first harmonic gear system and the second harmonic gear system are coupled to a controller of the supply system so as to control the operations of the first harmonic gear system and the second harmonic gear system.

13. In a method of supplying a viscous material onto an electronic substrate by the supply system according to claim 1, delivering the electronic substrate to a supply position; capturing at least one image of the electronic substrate; analyzing the at least one image of the electronic substrate to determine the position of the electronic substrate; and performing a supply operation by rotating the supply unit.

Images