System and method for aligning a movable cart with an assembly device

Abstract

A system is provided for aligning a mobile cart with an assembly apparatus. The assembly apparatus 10 has at least one article of a plurality of articles for replacement in the assembly apparatus. The assembly apparatus includes a docking station. The mobile cart 100 is configured to receive a used article and / or provide a new article to the assembly apparatus. The mobile cart includes an interface configured for docking in the docking station of the assembly apparatus. The system includes a sensor 120 associated with one of the assembly apparatus and the mobile cart, and a laser associated with the other of the assembly apparatus and the mobile cart. The sensor 120 and the laser are configured to align the mobile cart 100 with the assembly apparatus 10 after initial docking of the mobile cart in the docking station of the assembly apparatus.

Description

Technical Field

[0001] [Cross - Reference to Related Applications] This application claims the benefit under 35 U.S.C. § 119(e) of co - pending U.S. Provisional Patent Application No. 63 / 138,856, filed on January 19, 2021, entitled "SYSTEM AND METHOD FOR ALIGNING A MOVABLE CART TO AN ASSEMBLY APPARATUS", which is hereby incorporated by reference in its entirety for all purposes.

[0002] This application generally relates to stencil printers and related methods for printing a viscous material, such as solder paste, onto an electronic substrate, such as a printed circuit board (PCB), and more specifically to systems and methods for fully automating such stencil printers and methods.

Background Art

[0003] When manufacturing surface - mount printed circuit boards, devices such as stencil printers and / or dispensers can be used to deposit solder paste onto the circuit board. Typically, a circuit board having a pattern of pads or some other conductive surface, onto which the solder paste will be deposited, is automatically fed into the device.

[0004] In a stencil printer, before printing solder paste onto a circuit board, the circuit board is properly aligned with the stencil or screen of the stencil printer using one or more small holes or marks (known as "fiducials") on the circuit board. In some systems, an optical alignment system that embodies a visual system is used to align the circuit board with the stencil. Once the circuit board is properly aligned with the stencil in the printer, the circuit board is raised to the stencil, solder paste is dispensed onto the stencil, and a wiper blade (or squeegee) crosses the stencil, pushing the solder paste onto the circuit board through the holes in the stencil. The stencil is then separated from the circuit board, and the majority of the material remains on the circuit board due to adhesion between the circuit board and the solder paste.

[0005] In the dispenser, a very small amount of viscous material or very small dots of viscous material are deposited onto the circuit board. The viscous material may include liquid epoxy or solder paste, or any other related material. Before the dispensing operation, the circuit board is aligned with the dispenser of the dispensing system, or otherwise aligned. In one known method, this can be achieved by using the visual system of the dispensing system to match the position of a landmark, also known as a reference point, or by locating the position of known components on the circuit board. Once aligned, the dispensing head of the dispenser dispenses the material onto the circuit board.

[0006] Modern stencil printers and dispensers require manual intervention to perform routine operations. For example, during changeovers, operators must perform numerous manual tasks, such as changing stencils for the stencil printer, replacing solder paste cartridges for the stencil printer and dispenser, and replacing or replenishing other items. Each of these tasks requires manual operation. [Overview of the project]

[0007] One aspect of the present disclosure relates to a system for aligning a movable cart with an assembly apparatus. In one embodiment, the assembly apparatus has at least one article from a plurality of articles for replacement within the assembly apparatus. The assembly apparatus includes a docking station. A movable cart is configured to receive used articles and / or provide new articles to the assembly apparatus. The movable cart includes an interface configured to dock within the docking station of the assembly apparatus. In one embodiment, the system includes a sensor associated with one of the assembly apparatus and the movable cart, and a laser associated with the other of the assembly apparatus and the movable cart. The sensor and the laser are configured to align the movable cart with the assembly apparatus after the initial docking of the movable cart within the docking station of the assembly apparatus.

[0008] Embodiments of this system may further include mounting a sensor on a support of an assembly apparatus, and a laser mounted on the frame of a movable cart. The assembly apparatus may include at least one sensor mounted on the support of the assembly apparatus. The sensor may be mounted on a stencil support configured to support a stencil in a stencil printer. The sensor may be mounted on a support configured to hold a substrate in a stencil printer. The position of the laser on the frame of the movable cart may be at the same height as the sensor of the assembly apparatus. The laser may be a low-power laser. The sensor may be configured to generate an output signal that can be connected to a subsystem of the assembly apparatus. The subsystem may be a controller, and the sensor may be configured to generate an output signal that is processed by the controller. The controller may include software configured to convert the output signal into relative or absolute coordinates of the x, y, and z axes.

[0009] Another aspect of the present disclosure relates to a method for aligning a movable cart with an assembly apparatus. The assembly apparatus has at least one article from a plurality of articles for replacement within the assembly apparatus. The assembly apparatus includes a docking station. The movable cart is configured to receive used articles and / or provide new articles to the assembly apparatus. The movable cart includes an interface configured to dock within the docking station of the assembly apparatus. In one embodiment, the method includes providing a sensor on one of the assembly apparatus and the movable cart, and directing a laser associated with the other of the assembly apparatus and the movable cart towards the sensor. The sensor and the laser are configured to align the movable cart with the assembly apparatus after the initial docking of the movable cart within the docking station of the assembly apparatus.

[0010] Embodiments of this method may further include configuring a sensor to generate an output signal that can be connected to a subsystem of the assembly apparatus. The subsystem may be a controller, and the sensor may generate an output signal that is processed by the controller. The controller may include software configured to convert the output signal into relative or absolute coordinates of the x, y, and z axes. This method may further include calibrating a laser. The laser may be calibrated to one side of the movable cart with respect to a target that would ensure the laser emits a beam aligned to the x, y, and z axis coordinates of the movable cart. A sensor may be mounted on the assembly apparatus such that, when all axes in the assembly apparatus are in their initial positions, the light beam emitted from the laser on the movable cart is in a nominal position that the assembly apparatus interprets as a 0,0 position for x-axis alignment and z-axis height. Information may inform the assembly apparatus that the movable cart is in the correct or appropriate position relative to the assembly apparatus and is capable of performing its function. If a reading other than 0,0 is detected, this is interpreted as a misalignment, and the assembly device or mobile cart can make the necessary adjustments to return to a 0,0 reading to indicate proper alignment of the mobile cart and assembly device when the mobile cart is docked. If there is a reading other than 0,0 during initialization, this can be interpreted as an offset from the home position and can be compensated for by the assembly device's controller software, the mobile cart's controller, or both.

[0011] The attached drawings are not intended to be drawn to scale. In the drawings, identical or nearly identical components shown in various figures are represented by the same reference numerals. For clarity, not all components may be referenced in all drawings. [Brief explanation of the drawing]

[0012] [Figure 1]This is a front view of an assembly apparatus of one embodiment used for depositing assembly material onto an electronic circuit board. [Figure 2] This is a front view of an assembly apparatus of another embodiment used for depositing assembly material onto an electronic circuit board. [Figure 3] Figure 1 is a front perspective view of the assembly device shown. [Figure 4] This is a plan view of the assembly device shown in Figure 3, with some parts removed. [Figure 5] Figure 2 is a schematic diagram of the assembly device shown. [Figure 6] Figure 2 is a front perspective view of a portion of the assembly device shown. [Figure 7] Figure 6 shows a front perspective view of the assembly apparatus, with a portion removed to allow viewing of the assembly apparatus gantry. [Figure 8] This is a schematic elevation view of an assembly apparatus and a movable cart according to an embodiment of the present disclosure. [Figure 9] This is a front perspective view of an assembly apparatus that has a system for aligning a movable cart with the assembly device. [Figure 10] Figure 9 is an enlarged front perspective view of a portion of the assembly device shown. [Figure 11] Figure 9 is an enlarged front perspective view of another part of the assembly device shown. [Figure 12] This is an elevation view of an assembly device and a movable cart, illustrating a system for aligning a movable cart with the assembly device. [Figure 13] This is an enlarged perspective view of the system, showing the system's sensors. [Figure 14] This is another enlarged perspective view of the system, showing the system's laser. [Figure 15] Another enlarged perspective view of the system, showing the mounting of the sensor onto the assembly device. [Figure 16] This is yet another enlarged perspective view of the system, showing the mounting of the laser on the movable cart. [Modes for carrying out the invention]

[0013] This disclosure broadly relates to material application machines (hereinafter referred to as "stencil printers," "screen printers," "printing machines," or "printers") and other equipment used in surface mount technology (SMT) process lines and configured to apply assembly materials (e.g., solder paste, conductive ink, or encapsulating materials) onto a substrate (e.g., hereafter referred to as "electronic substrates," "circuit boards," "boards," "PCBs," "PCB substrates," "substrates," or "PCB boards") or to perform other operations such as inspection, reworking, or placement of electronic components onto the substrate. Specifically, embodiments of this disclosure are described below with reference to stencil printers used to manufacture printed circuit boards.

[0014] For illustrative purposes only and not to limit its universality, the present disclosure is described in detail here with reference to the accompanying drawings. The present disclosure is not limited to the details of configurations and arrangements of components described below or shown in the drawings in terms of its applications. The principles described herein are also applicable to other embodiments and can be practiced or implemented in various ways. Furthermore, the expressions and terms used herein are for illustrative purposes only and should not be considered limiting. Any reference herein to an example, embodiment, component, element or operation of a system or method referred to singularly may also encompass embodiments containing multiple components, and any reference herein to any embodiment, component, element or operation as plural may also encompass embodiments containing only one component. References in singular or plural form are not intended to limit the systems or methods, their components, operations or elements disclosed herein. The use herein of the terms “including,” “equipped with,” “having,” “containing,” “accompanying,” and variations thereof means that the articles listed before them, their equivalents and additional articles, are included. A reference to “or / or” can be interpreted as comprehensive, such that any term described using “or / or” can refer to one, two or more, or all of the terms described. In addition, if there is inconsistency in the use of terms between this specification and any document that constitutes part of this specification by reference, the use of terms in the document that constitutes this specification is supplementary to the use in this specification, and the use of terms in this specification shall prevail if the inconsistency is contradictory.

[0015] For purposes of illustration, embodiments of the present disclosure will be described below with reference to a stencil printer used to print an assembly material, such as solder paste, onto a circuit board, and a dispenser used to deposit the assembly material onto the circuit board. However, those skilled in the art will understand that the embodiments of the present disclosure are not limited to stencil printers and dispensers that print and deposit solder paste onto a circuit board, but can be used in other applications that require the dispensing of other adhesive assembly materials, such as glue and encapsulation materials. For example, the apparatus can be used to print or deposit an epoxy used as an underfill for a chip scale package. Further, the stencil printer and dispenser according to embodiments of the present disclosure are not limited to those that print and deposit an assembly material onto a circuit board, but include those used to print other materials onto various substrates, such as semiconductor wafers. In certain embodiments, the stencil printer can include a Momentum™ or Edison™ series stencil printer platform provided by ITW Electronic Assembly Equipment of Hopkinton, Massachusetts. An exemplary stencil printer is generally designated by 5 in FIG. 1. In this embodiment, the stencil printer 5 is an Edison™ series stencil printer platform provided by ITW Electronic Assembly Equipment of Hopkinton, Massachusetts. Further, in certain embodiments, the dispenser can include a Prodigy™ series dispenser provided by ITW Electronic Assembly Equipment of Hopkinton, Massachusetts. An exemplary dispenser is generally designated by 7 in FIG. 2. In this embodiment, the dispenser 7 is a Prodigy™ dispenser platform provided by ITW Electronic Assembly Equipment of Hopkinton, Massachusetts.

[0016] Referring to Figure 3, the stencil printer of an embodiment of the present disclosure is generally shown as 10. As shown, the stencil printer 10 has a frame 12 that supports the components of the stencil printer. The components of the stencil printer may include, in part, a controller 14, a display 16, a stencil 18, and a print head or print head assembly. The print head or print head assembly is generally shown as 20 and is configured to apply solder paste in a manner that will be described in more detail below. In one embodiment, the controller 14 is positioned behind the panel of the stencil printer in a conventional manner.

[0017] As shown in Figure 2 and described below, the stencil and printhead assembly can be connected to the frame 12 as appropriate, or otherwise connected. In one embodiment, the printhead assembly 20 can be mounted on a printhead assembly gantry 22, which can be mounted on the frame 12. The printhead assembly gantry 22 allows the printhead assembly 20 to move in the y-axis direction under the control of the controller 14 and to apply pressure to the printhead assembly by engaging with the stencil 18. In a particular embodiment, the printhead assembly 20 can be placed above the stencil 18 and can be lowered in the z-axis direction to contact and seal with the stencil.

[0018] The stencil printer 10 can also have a conveyor system having rails (not shown) that transport a printed circuit board (which may be referred to herein as a "printed wiring board", "substrate", or "electronic substrate") to a printing position within the stencil printer. The rails may be referred to herein as a "tractor feed mechanism". The tractor feed mechanism is configured to feed, load, or otherwise deliver a circuit board to a work area of the stencil printer, which may be referred to herein as a "print nest", and to unload the circuit board from the print nest.

[0019] In addition, referring to FIG. 4, the stencil printer 10 has a support assembly 28 that supports a circuit board 29 (shown in phantom). The support assembly 28 raises and secures the circuit board so that the circuit board is stable during the printing operation. In certain embodiments, the substrate support assembly 28 can further have a particular substrate support system, such as a rigid support, a plurality of pins, or a flexible tool, and the substrate support system is positioned below the circuit board when the circuit board is in the printing position. The substrate support system can be used, in part, to support an internal region of the circuit board to prevent bending or warping of the circuit board during the printing operation.

[0020] In one embodiment, the printhead assembly 20 may be configured to receive solder paste from a supply source, such as a solder paste cartridge, which provides solder paste to the printhead assembly during printing operations. Other methods of supplying solder paste may be used instead of a cartridge. For example, solder paste can be manually deposited between blades or from an external supply source. In addition, in certain embodiments, the controller 14 may be configured to use a personal computer with a suitable operating system, such as the Microsoft Windows® operating system provided by Microsoft Corporation, and to control the operation of the stencil printer 10 using application-specific software. The controller 14 may be networked with a master controller used to control a production line for manufacturing circuit boards.

[0021] In one configuration, the stencil printer 10 operates as follows: The circuit board 29 is loaded into the stencil printer 10 using a conveyor rail. A support assembly 28 raises and secures the circuit board 29 to the printing position. The print head assembly 20 is then lowered in the z-axis direction until the blades of the print head assembly make contact with the stencil 18 with the desired pressure. The print head assembly 20 is then moved in the y-axis direction across the stencil 18 by the print head assembly gantry 22. The print head assembly 20 deposits solder paste onto the circuit board 29 through the holes in the stencil 18. Once the print head assembly has completely traversed the stencil 18 across the holes, the print head assembly is lifted out of the stencil, and the circuit board 29 is lowered back onto the conveyor rail. The circuit board 29 is released and transported from the stencil printer 10, allowing a second circuit board to be loaded into the stencil printer. To print on the second circuit board 29, the print head assembly is lowered in the z-axis direction to contact the stencil and moved across the stencil 18 in the opposite direction to that used for the first circuit board.

[0022] An imaging system 30 may be provided for the purpose of aligning the stencil 18 with the circuit board 29 before printing and for inspecting the circuit board after printing. In one embodiment, the imaging system 30 may be positioned between the stencil 18 and a support assembly 28 on which the circuit board is supported. The imaging system 30 is connected to an imaging gantry 32 for moving the imaging system. In one embodiment, the imaging gantry 32 may be connected to a frame 12 and has beams extending between the lateral rails of the frame 12, providing for the imaging system 30 to move back and forth above the circuit board 29 in the y-axis direction. The imaging gantry 32 may further include a carriage device housing the imaging system 30, configured to move along the length of the beams in the x-axis direction. The structure of the imaging gantry 32 used to move the imaging system 30 is known in solder paste printing technology. The arrangement allows the imaging system 30 to be positioned at any position below the stencil 18 and above the circuit board 29 to capture images of predetermined areas of the circuit board or stencil, respectively.

[0023] After applying solder paste to the circuit board one or more times, excess solder paste may accumulate at the bottom of the stencil 18, and the stencil wiper assembly, generally shown as 34, can move below the stencil to remove the excess solder paste. In other embodiments, the stencil 18 may move above the stencil wiper assembly.

[0024] Referring to Figure 5, an ejection system according to one embodiment of this disclosure is generally shown as 40. The ejection system 40 is used to eject viscous materials (e.g., adhesives, sealants, epoxy, solder paste, underfill materials, etc.) or semi-viscous materials (e.g., soldering flux, etc.) onto an electronic substrate 42 such as a printed circuit board or semiconductor wafer. The ejection system 40 may alternatively be used in other applications, such as for coating automotive gasket material, or in certain medical applications, or for coating conductive ink. It should be understood that references to viscous or semi-viscous materials used herein are illustrative and non-limiting. In one embodiment, the ejection system 40 includes a first ejection unit and a second ejection unit, generally shown as 44 and 46, respectively, and a controller 48 that controls the operation of the ejection system. It should be understood that the ejection units 44, 46 may also be referred to herein as an ejection pump and / or ejection head. Although two dispensing units 44 and 46 are shown, please understand that a single dispensing unit or multiple dispensing units (three or more) may be used.

[0025] The dispensing system 40 may also include a frame 50 having a base or support 52 for supporting the electronic substrate 42, a dispensing unit gantry 54 movably connected to the frame to support and move dispensing units 44, 46, and a weighing device or weighing scale 56 for weighing the amount of viscous material dispensed, for example as part of a calibration procedure, and providing weight data to the controller 48. A conveyor system (not shown) or other transfer mechanism such as a moving beam may be used in the dispensing system 40 to control the loading of the electronic substrate 42 into and out of the dispensing system. The gantry 54 can be moved using a motor under the control of the controller 48 to position the dispensing units 44, 46 in predetermined positions above the electronic substrate 42. The dispensing system 40 may include a display unit 58 connected to the controller 48 for displaying various information to the operator. An optional second controller for controlling the dispensing units 44, 46 may be provided. Furthermore, each discharge unit 44, 46 may be configured to have a z-axis sensor that detects the height at which the discharge unit is positioned above the electronic circuit board 42 or above a feature portion mounted on the electronic circuit board. The z-axis sensor is connected to the controller 48 and relays the information obtained by the sensor to the controller.

[0026] Before performing the ejection operation, as described above, the electronic substrate 42, for example, a printed circuit board, must be aligned with or otherwise matched with the ejection units 44, 46 of the ejection system. The ejection system 40 further includes a visual system 60, which in one embodiment is connected to a visual system gantry 62 that is movably connected to a frame 50 to support and move the visual system. In another embodiment, the visual system 60 may be located on an ejection unit gantry 54. As described above, the visual system 60 is used to match the position of a landmark or component known as a reference point on the electronic substrate 42. Once the position is determined, the controller 48 can be programmed to operate the movement of one or more of the ejection units 44, 46 to eject material onto the electronic substrate 42.

[0027] The systems and methods of this disclosure relate to dispensing material onto an electronic substrate, such as a printed circuit board. The descriptions of the systems and methods provided herein refer to exemplary electronic substrates (e.g., printed circuit boards) supported on a support 52 of an extrusion system 40. In one embodiment, the extrusion operation is controlled by a controller 48, which may include a computer system configured to control material extrusion units 44, 46. In another embodiment, the controller 48 may be operated by an operator. The controller 48 is configured to operate the movement of a visual system gantry 62 to move a visual system 60 and acquire one or more images of the electronic substrate 42. The controller 48 is further configured to operate the movement of an extrusion unit gantry 54 to move the extrusion units 44, 46 and perform the extrusion operation.

[0028] Referring to Figures 6 and 7, the dispensing system is generally shown as 70. As shown, the dispensing system 70 includes a frame 72 configured to support the main subassemblies of the dispensing system. The dispensing system 70 further includes a gantry system generally shown as 74, configured to move in the x-axis and y-axis directions. The dispensing system 70 further includes a dispensing unit assembly generally shown as 76, supported by the gantry system 74. Figure 6 shows the dispensing system 70 with the dispensing unit assembly 76, and Figure 7 shows the dispensing system with the dispensing unit assembly removed. As shown, the dispensing unit assembly includes a dispensing unit 78 configured to deposit material onto a substrate, for example, a substrate 42, as will be described below. A conveyor system (not shown) can be used in the dispensing system 70 to control the loading and unloading of substrates, for example, electronic substrates, onto and from the support 80 of the dispensing system. The gantry system 74 can be moved in the x-axis and y-axis directions using motors under the control of the controller, in a manner similar to that of the controller 48 of the ejection system 40, in order to position the ejection unit assembly 76 at a predetermined position above the electronic substrate provided on the support 80.

[0029] In one embodiment, as shown in Figures 6 and 7, the gantry system 74 may be configured to include a left lateral rail 82, a right lateral rail 84, and a beam 86 extending between the two lateral rails. The beam 86 is configured to move in the y-axis direction along the lateral rails 82, 84 to achieve y-axis movement of the dispensing unit assembly 76. The gantry system 74 further includes a carriage 88 connected to the beam 86 and configured to move along the length of the beam to provide x-axis movement of the dispensing unit assembly 76. Specifically, the carriage 88 supports the dispensing unit 78 of the dispensing unit assembly 76 and is configured to move in the x-axis direction along the length of the beam 86 to move the dispensing unit above a desired position on an electronic substrate positioned on the support 80 of the dispensing system 70. In a particular embodiment, the movement of the gantry system 74 in the xy plane (i.e., the movement of the beam 86 and the carriage 88) may be achieved by utilizing ball screw mechanisms driven by respective motors, as is known in the art.

[0030] The dispensing unit assembly 76 is configured to move the dispensing unit 78 in the z-axis direction by a z-axis drive mechanism 90 shown in Figure 7. The amount of z-axis movement can be determined by measuring the distance between the tip of the needle (not shown) of the dispensing unit 78 and the electronic substrate. When moving, the dispensing unit 78 can be positioned at a nominal clearance height above the electronic substrate. The clearance height can be maintained at a relatively consistent height above the electronic substrate when moving from one dispensing position to another. Once a predetermined dispensing position is reached, the z-axis drive mechanism 90 lowers the dispensing unit 78 to the electronic substrate so that material can be dispensed onto the electronic substrate.

[0031] Referring further to Figures 6 and 7, the ejection unit 78 moves above the electronic substrate to perform the ejection operation using the ejection unit. However, before ejection, the position of the electronic substrate relative to the ejection unit 78 is determined so that accurate ejection can be performed. Specifically, in one embodiment, the carriage 88 may be configured to include an optical element or camera designed to capture an image of the electronic substrate. The camera is described as being mounted on the carriage 88, but it should be understood that the camera may be mounted separately on the beam 86 or on an independent gantry. The camera may be referred to herein as the “visual system” or “imaging system”. Images of at least two reference points provided on the electronic substrate are captured by the camera in order to align the electronic substrate with the ejection unit 78 and gantry system 74 of the ejection unit assembly 76. If the electronic substrate is misaligned, the gantry system can be operated to take into account the actual position of the electronic substrate. In one embodiment, the camera can be calibrated to determine the offset distance from the camera to the needle of the ejection unit.

[0032] In another embodiment, visual alignment and clearance height detection may be achieved using a laser or another calibrated distance measuring device located within the dispensing system 70.

[0033] Both the stencil printer and the dispenser require manual intervention to replace and / or replenish certain parts. For example, in a stencil printer, a typical stencil needs to be replaced after a certain period, e.g., every four hours. Also, stencils need to be replaced for separate production runs. In addition, in both the stencil printer and the dispenser, the solder paste cartridges that supply temperature-controlled solder paste to the stencil printer and dispenser need to be replaced over time, e.g., every four hours. Different solder paste materials may be required for separate production runs. In the stencil printer, the squeegee blade and tools are subject to wear during use and need to be replaced periodically.

[0034] Embodiments of the present disclosure relate to a delivery system configured to automate the switching process of any other type of assembly processing equipment, including but not limited to stencil printers and dispensers, or pick-and-place machines, wave soldering machines and selective soldering machines, reflow ovens, washing machines, and inspection machines. In one embodiment, the delivery system includes a movable cart configured to engage with a stencil printer and / or dispenser, to supply replacement and replenishment parts and materials to the stencil printer and / or dispenser, and to receive them from the stencil printer and / or dispenser to perform the switching. For example, the stencil printer and / or dispenser may each include a docking station configured to receive the movable cart. The docking station may include an interface that allows the movable cart to communicate with the stencil printer and / or dispenser. A single movable cart may be configured to include a switching stencil, a replacement stencil, a replacement solder paste cartridge, a replenishment solder paste cartridge, a replacement squeegee blade, a replenishment squeegee blade, and a replacement support tool. During a changeover, for example, the stencil printer and / or dispenser must be reconfigured to produce different items. Therefore, for example, different types of solder paste can be used in the stencil printer and / or dispenser to produce different products.

[0035] The switching process described herein can be implemented by a single mobile cart configured to replace and / or replenish each item. In other embodiments, two or more mobile carts may be provided. For example, a mobile cart may be configured to support a predetermined number of paste cartridges selected for a production run scheduled for a particular day or period. The mobile cart and / or stencil printer or dispenser may be configured to identify paste cartridges, store them in a suitable environment, transport paste cartridges to and from the stencil printer and dispenser, inspect paste cartridges, and interface with the stencil printer. The mobile cart may also be configured to remove used parts such as paste cartridges from the stencil printer and dispenser. The mobile cart may also be configured to store paste cartridges for extended periods. In one embodiment, extended storage of solder paste can be achieved by refrigeration at 0°C to 10°C (32°F to 50°F). Paste cartridges can be stored in a location within the mobile cart that maintains this temperature range. In another embodiment, the mobile cart may be configured to preheat the paste cartridge before use in order to prepare it for use in the stencil printer.

[0036] Embodiments of the present disclosure further relate to a delivery system configured to automate the replenishment process of a stencil printer. In one embodiment, the delivery system includes a movable cart configured to engage with the stencil printer, supply replacement and replenishment parts and materials to the stencil printer, and receive them from the stencil printer. For example, the stencil printer may include a docking station configured to receive the movable cart. The docking station may include an interface that allows the movable cart to communicate with the stencil printer. A single movable cart may be configured to include a changeover stencil, a replacement stencil, a replacement solder paste cartridge, a replenishment solder paste cartridge, a replacement squeegee blade, a replenishment squeegee blade, and a replacement support tool. During replenishment, for example, critical consumables of the stencil printer must be replenished regularly. In one example, a solder paste cartridge needs to be replaced when it is depleted. Furthermore, other articles such as paper and solvents used in the stencil wiper may be replenished.

[0037] The replenishment process described herein can be implemented by a single mobile cart configured to replenish all refillable items. In other embodiments, two or more mobile carts may be provided. For example, for the replenishment of solder paste, the mobile cart may be configured to support several replacement solder paste cartridges. The mobile cart and / or stencil printer may be configured to identify replacement solder paste cartridges, store the cartridges, transport the cartridges to and from the stencil printer, inspect the cartridges, and interface with the stencil printer. The mobile cart may also be configured to remove used items, such as used cartridges, from the stencil printer.

[0038] Referring to Figure 8, in one embodiment, a movable cart, generally indicated by 100, is shown in a docked position relative to an assembly device, such as a stencil printer 10 or a dispensing system 70. As shown, the movable cart 100 includes a frame or housing 102 configured to support replacement and / or replenishment articles. As shown, the frame 102 of the movable cart 100 is generally rectangular and is supported on wheels or casters, each indicated by 104. In one embodiment, the movable cart 100 is configured to be moved manually by an operator by pushing the housing 102 of the movable cart. In this embodiment, the movable cart 100 may be configured to have a push bar or handle. In another embodiment, the movable cart 100 is configured to be moved automatically by remote or automatic control associated with the movable cart, the assembly device 10, 70, the production line, and / or some other dedicated control device. In this embodiment, the movable cart 100 may include wheels 104 driven by a suitable motor and drivetrain, and a control device 106 associated with the movable cart. Alternatively, in other embodiments, the control device may be associated with some other dedicated control device configured to control the assembly apparatus 10, 70, the production line, and / or the movable cart. The movable cart 100 may further include one or more sensors and / or a vision system, such as a camera, to guide the movable cart from the storage room to, for example, the assembly apparatus 10, 70.

[0039] In one embodiment, the movable cart 100 includes one or more shelves, each indicated by 108, configured to store articles for assembly devices 10, 70. For example, shelf 108 may be specifically designed to support new paste cartridges and consumed / used paste cartridges. One or more shelves 108 may be configured to move vertically within the housing 102 to achieve a height suitable for working with the assembly devices 10, 70. Some shelves 108 may be designated as “clean shelves” to support clean or new articles ready for use within the assembly devices 10, 70. Some shelves 108 may be designated as “unclean shelves” to support used articles to be removed from the assembly devices 10, 70. The shelves 108 may be spaced a certain distance apart from each other to accommodate a variety of articles. For example, shelves 108 may be spaced 3 / 8 inch to 1 1 / 2 inches apart from each other to accommodate the thickness of stencil frames.

[0040] The movable cart 100 can be configured to have an interface designed to dock within a docking station provided on the assembly devices 10, 70. In one embodiment shown in Figure 8, the movable cart 100 includes an interface 110 configured to dock within the docking station 112 of the assembly devices 10, 70 via both a mechanical interface and an electronic communication interface. In a particular embodiment, the movable cart 100 can be configured to have a unique mechanical interface that mates with a unique mechanical docking station of the assembly devices 10, 70. The unique mechanical interface / docking station may include geometric features. In another embodiment, the movable cart 100 can be configured to have a pin, which is received within a guide section associated with the assembly devices 10, 70, and the movable cart is aligned with the assembly device before the movable cart is fully docked. Other types of guide sections can be used, such as electrical / magnetic guides, visual guides, sensors, latches, etc. When the movable cart 100 is docked within the docking station 112 of the assembly devices 10, 70, it can be physically engaged with the assembly devices or separated from them.

[0041] Embodiments of the present disclosure relate to a system and method used to align a movable cart with an assembly apparatus after the initial positioning of the movable cart within a docking station of the assembly apparatus. In one embodiment, referring to Figures 9 to 11, the assembly apparatus, e.g., a stencil printer 10, includes one or more sensors configured to detect light generated from one or more lasers provided on the movable cart. As shown, in one embodiment, the system for aligning the movable cart with the assembly apparatus includes two sensors, each indicated by 120, preferably mounted on a support structure of the assembly apparatus 10. Although two sensors 120 are shown, the system may include only one sensor for aligning the movable cart with the assembly apparatus. In one embodiment shown in Figures 9 to 11, the sensor 120 is mounted on a stencil support 122 configured to support a stencil, e.g., a stencil 18. By providing the sensor 120 on the stencil support 122, the movable cart is positioned correctly when it is initially positioned in front of the assembly apparatus. Once the alignment is confirmed, the movable cart can be moved to fully dock it within the assembly apparatus.

[0042] In a dispenser, one or two sensors, for example, sensor 120, may be mounted on the dispenser frame in close proximity to the tool supporting the circuit board for processing. In another embodiment, the sensor may be mounted on the gantry supporting the dispenser's dispensing head(s). Although two sensors 120 are shown above, it should be understood that only one sensor is required to accurately position the movable cart with the assembly apparatus. In one embodiment, sensor 120 is a position-sensing diode.

[0043] Referring to Figures 12 to 14, and particularly Figure 14, the system further includes a laser 130, for example, a low-power laser, mounted on the frame of the movable cart. Although one laser 130 is shown in the drawings, the system may include two lasers, one for each sensor 120, to align the movable cart with the assembly apparatus. As shown, the laser 130 is configured to produce a light beam 132 directed towards the sensor 120 located on the assembly apparatus 10. The position of the laser 130 on the frame 102 of the movable cart 100 is at the same height as the sensor 120 on the sensor support 122 of the assembly apparatus 10. The laser 130 can be positioned at any suitable location on the frame 102 to align the movable cart 100 with the assembly apparatus 10.

[0044] Referring to Figures 15 and 16, Figure 15 shows how the sensor 120 is fixed to the assembly apparatus 10. As shown, the sensor 120 includes a PCB substrate having mounting holes configured to receive standoffs fixed to the frame of the apparatus 10. Figure 16 shows how the laser 130 is fixed to the movable cart 100. As shown, the laser 130 is mounted to the frame 102 of the movable cart 100 by an antistatic plastic housing 131 which is fixed to the frame by suitable fasteners.

[0045] During operation, when the movable cart is initially positioned in front of the assembly apparatus, the laser 130 emits a light beam 132 toward the assembly apparatus, which is directed toward and received by the sensor 120. Once aligned, the movable cart can be fully docked within the assembly apparatus.

[0046] In one embodiment, the sensor 120 is configured to generate an output signal that can be connected to a subsystem, for example, the controller of the assembly apparatus and / or the controller 106 of the movable cart 100. In the case of a stencil system, the sensor 120 can be connected to the controller 14 of the stencil printer 10 and generate an output signal that is processed by the controller 14. In the case of a dispenser, the sensor 120 can be connected to the controller 48 of the dispensing system 40 and generate an output signal that is processed by the controller 48. Suitable software associated with a subsystem of the assembly apparatus, for example, the controller of the assembly apparatus, is configured to convert the output signal into relative or absolute coordinates of the x, y, and z axes. As described above, subsystems can be associated in addition to, or instead of, the movable cart 100.

[0047] Furthermore, in one embodiment, the laser 130 is calibrated to one side of the movable cart 100, for example, to the shelf 108 of the movable cart, with respect to a target that will ensure the laser emits a light beam 132 aligned to the x, y, and z axis coordinates of the movable cart. The calibration ensures that the light beam 132 is sufficiently aligned when installed, which is important to ensure that the system works with all types of assembly equipment that utilize the sensor 120 and the laser 130 to align the movable cart 100 to the assembly equipment.

[0048] During operation, the sensor 120 is mounted on the assembly device at a position where the light beam 132 emitted from the laser 130 on the movable cart is nominally positioned, with respect to the x-axis alignment and z-axis height, for example, the height of the stencil on the assembly device, when all axes within the assembly device are in their initial positions. This information informs the assembly device that the movable cart is in the correct or appropriate position relative to the assembly device and is capable of performing functions such as transferring the stencil from the movable cart to the assembly device. In this case, the y-axis is used for measuring light intensity during calibration. If a reading other than 0,0 is detected, this is interpreted as a misalignment, and the assembly device or movable cart can make the necessary adjustments to return to a 0,0 reading to indicate proper alignment of the movable cart and the assembly device when the movable cart is docked.

[0049] If there is a reading other than 0,0 during initialization, this is interpreted as an offset from the home position and can be compensated by the assembly device controller software, the mobile cart controller, or both. In one embodiment, the mobile cart controller (including a laser) communicates with the assembly device controller (including a sensor) via a "CAN bus" system.

[0050] In one embodiment, the sensor is a DL100-7 PCBA3 sensing diode provided by First Sensor AG in Berlin, Germany. The sensor is configured to have a duolateral position sensing module comprising a 10 mm × 10 mm active area position sensing photodiode and associated circuitry. The sensing diode is configured to sense the position of a light spot on the surface of the photodiode and provides voltage analogs for both axes and laser spot intensity for both axes.

[0051] In one embodiment, the laser is the VLM-635 / 650-02 series supplied by Infiniter Laser of Diamond Bar, California. The laser is an industrial red dot laser with an adjustable focal range, e.g., 100 mm to infinity.

[0052] In one embodiment, the movable cart may be configured to have one or more devices used to transport articles from the movable cart to the assembly apparatus and from the assembly apparatus to the movable cart. For example, the devices may include grippers that engage with articles such as substrate tool trays, move tool trays from the assembly apparatus to trays on the movable cart, and move different tool trays from the movable cart to the assembly apparatus.

[0053] In one embodiment, the movable cart includes wheels driven by a suitable motor and drivetrain, and a control device configured to control the movement of the movable cart. The movable cart further includes a power source, such as a battery, that powers the movement of the movable cart via the motor and drivetrain.

[0054] In some embodiments, the movable cart includes a controller, which is adapted to control the operation of the movable cart based on operating parameters obtained by the controller. The controller may be configured to communicate with controllers in the assembly apparatus and / or controllers associated with the production line. In one embodiment having multiple movable carts, the controller may embody multiple controllers provided within each movable cart that communicate with each other via a Controller Area Network (CAN) bus or other type of network. In other embodiments, a master controller may be provided to control the operation of the controllers in the movable carts. Each movable cart may be provided with a display operably connected to the controller. The display may be adapted to show operating parameters of the movable cart, such as the number of full paste cartridges and the number of consumed / used paste cartridges, but is not limited to these. A suitable monitor may be provided to obtain such information. Alternatively, or in addition to the embodiments described above, the operating parameters may be displayed on a display provided in the assembly apparatus and / or a display associated with the production line.

[0055] In other embodiments, the controller may be dedicated to one or more mobile carts.

[0056] In some embodiments, material identification of articles on a mobile cart may include a device for manipulating the articles and a scanner for scanning and identifying the articles. For example, for a paste cartridge, the mobile cart may be configured to have a pinch wheel that rotates the paste cartridge and aligns a code or predetermined identification mark on the paste cartridge with a scanner provided on the mobile cart. The system may be configured to associate the material identification associated with the paste cartridge with the recipe and production time of an assembly device, etc. In one embodiment, a barcode can be implemented to identify the articles. For example, the barcode may include a 1D scanner for UPC codes, a 2D scanner for QRC codes, a printed label affixed to the article, or a laser-etched label etched onto the article. In another embodiment, an RFID system can be implemented to identify the articles. For example, the RFID system may include an RFID tag affixed to the article and an RFID reader associated with the mobile cart. Using an RFID system eliminates the need for a line of sight between the reader and the article, and also eliminates the need to scan all articles in the mobile cart to identify them. In another embodiment, an imaging or visual system can be implemented to identify the articles. The visual system may be an imaging system similar to an imaging system associated with a stencil printer or dispenser, or an imaging system on a mobile cart.

[0057] In some embodiments, a database is provided to track items stocked on the mobile cart. In one embodiment, the database may include an open application (App) architecture and may be configured to push data to the assembly equipment. The mobile cart may be configured to communicate with the assembly equipment to push / pull data to the assembly equipment and / or the production line, or to communicate directly with the production line. The database may include job information or material information. The database may further communicate with a manufacturing execution system (MES) associated with the production line, the assembly equipment, or both. The MES system may be configured to know which materials are needed for production operation. The mobile cart may be configured to communicate with the MES system to coordinate the delivery of items to the assembly equipment.

[0058] The database can be further configured to retrieve information about an item based on identification information, such as a barcode number. In one embodiment, a central management system can be provided in which the assembly apparatus and / or the mobile cart is programmed to receive materials coming from the mobile cart. The mobile cart is programmed to update the database to identify the materials on the mobile cart and to load information from the network into a database associated with the mobile cart and / or the assembly apparatus, and the information is further associated with the MES system.

[0059] The database can be further configured to store additional information such as usage and consumption. The database can be configured to store information locally or remotely, and can be configured to store data associated with one or more production runs. For example, the database can be configured to retrieve and store data including, but is not limited to, the traceability of stencils, paste cartridges, squeegee blades, and tools, paste usage, cycles, etc.

[0060] The database can be configured to share predictive data when replacement / replenishment is needed. For example, for storing information about paste cartridges, the database can be configured to store information about when replenishment of paste cartridges is needed, perform specific functions when paste cartridges are low on paste, trigger alarms and / or reports about low paste cartridges, signal to inventory management systems associated with assembly equipment and / or production lines, perform analysis of consumable usage based on operating parameters and actual usage and upstream / downstream equipment activity, predict replacement or maintenance (for assembly equipment and / or mobile carts), and predict when to switch paste cartridges by correlating across multiple locations. The database can be configured to share predictive data for other changeable / consumable items such as stencils, paste cartridges, squeegee blades, and tools.

[0061] The database can be configured to store data associated with lot traceability. In addition, RFID or mechanical keying or stencil frames are provided on the substrate to ensure that the alignment, orientation, direction, front / back, and top / bottom are correct when these articles are inserted into the assembly machine. This information can be used to verify the correct orientation and / or fit before the articles are transported from the warehouse and / or before they are installed in the assembly machine. This function can be performed by a low-cost reader.

[0062] In one embodiment, the remote control device may be configured to communicate with a database via a cloud or ISP to provide the functions described above. In another embodiment, the database may be part of a computer control system for an assembly device, a mobile cart, or a production line.

[0063] In some embodiments, the mobile cart can be configured to store materials. The mobile cart can be configured to have the flexibility to adapt to where the materials come from and where they go. In addition, the mobile cart can be configured to identify where a particular material is located on the mobile cart. In certain embodiments, the location is remote, local, on the mobile cart, and / or on the assembly equipment, whether the delivery is automated or manual. As described above, the mobile cart can be configured to control environmental parameters. For example, the mobile cart can be configured to control the temperature of paste contained within paste cartridges by cooling stored paste cartridges, heating paste cartridges that are ready for use, and cooling paste cartridges that have been used but still hold paste. In one embodiment, the housing can be insulated, and a cooling / heating unit can be provided to cool or heat the inside of the housing and thus the paste cartridges. The mobile cart can be further configured to predict when to heat / cool paste cartridges based on upcoming production, track time for storage life, and individually control each paste cartridge to the appropriate temperature in the correct time. In other embodiments, the movable cart may include a cartridge chute for moving paste cartridges. The movable cart may be further configured to control humidity to avoid condensation. The movable cart may be further configured to operate in a clean environment, for example, a standard mechanical interface (SMIF) environment.

[0064] In some embodiments, the mobile cart can be configured to perform inventory management. Specifically, the mobile cart can be configured to identify where materials are located, how much of the materials are used, how the materials are used, and when the materials are used, to associate information about the materials with a customer inventory management system, and to track the types of materials consumed per substrate or per lot of substrates.

[0065] In some embodiments, the movable cart may be configured to organize the articles stored on the movable cart. As described above, in one embodiment, a single movable cart may be provided for storing, transporting, and delivering multiple resources, including, but not limited to, paste cartridges. In another embodiment, the movable cart may be configured to store a single resource or article and transport and deliver it to an assembly apparatus. The movable cart may be configured for use in multiple production lines. In another embodiment, the movable cart may be configured for use in a single assembly apparatus.

[0066] In some embodiments, the mobile cart can be configured to transport articles from the mobile cart to an assembly device and from the assembly device to the mobile cart, and can be configured to take into account the difference in elevation between the mobile cart and the assembly device. Transportation can be automated or manual. In one embodiment, the mobile cart can be moved by an automated guided vehicle (AVG) technology associated with the mobile cart, or it can be remotely controlled. In another embodiment, the mobile cart can be configured to move autonomously. In yet another embodiment, the mobile cart can be configured to be moved manually. In yet another embodiment, the mobile cart can be configured to move articles stored on the mobile cart automatically and / or manually. For example, the mobile cart can be configured to move articles automatically and to accommodate interruptions to pre-planned activities in which articles are moved manually.

[0067] In some embodiments, the timing associated with the execution of the transport function of the mobile cart can be programmed to take into account shift changes, e.g., worker shifts, scheduled maintenance, on-demand activities, e.g., recipe changes, and precursory events (just-in-time exchanges). The timing can be programmed to meet multi-line balancing control requirements using one or more mobile carts, as well as to meet the real-time on-demand material supply demand on the production line.

[0068] In some embodiments, the mobile cart is configured to perform inspections. For example, the mobile cart can inspect articles on and outside the cart, including stencils, paste cartridges, squeegee blades, and tools. In one embodiment, a visual system associated with the mobile cart can be configured to obtain images of the articles. The visual system, in conjunction with a controller, can be configured to inspect for cleanliness, damage, wear, and readability of identification information, for example, whether a barcode label is worn, dirty, or torn. The visual system can embody any type of 2D, 3D, or color camera.

[0069] In some embodiments, the movable cart is configured to interface with the assembly device via both a mechanical interface and an electronic communication interface. In one embodiment, the movable cart may be configured to have a unique mechanical interface that mates with the assembly device's unique mechanical interface. The unique mechanical interface may be a geometric feature. In another embodiment, the movable cart may be configured to have a pin, which is received within a guide section associated with the assembly device, and the movable cart is aligned with the assembly device before the movable cart is fully docked. The pin and guide section may be reversed, with the pin provided on the assembly device and the guide on the movable cart. Other types of guide sections may be used, such as electrical / magnetic guides, visual guides, sensors, and latches.

[0070] In some embodiments, the interface and docking station may be configured to include a clamping system for holding the movable cart in place relative to the assembly device. For example, a magnetic clamping system may be used.

[0071] In some embodiments, the assembly apparatus may be configured to have a plurality of docking stations, for example, five docking stations. The docking stations may be located at the front or rear of the assembly apparatus.

[0072] A mobile cart and / or assembly apparatus can be configured to verify whether the mobile cart can dock with and interface with the assembly apparatus. In one embodiment, verification can be provided to confirm whether the mobile cart is in the correct position and ready to interface with the assembly apparatus. This verification process can further determine whether the correct material is on the mobile cart and whether mobile cart material information can be received from the MES system or identified locally. If incorrect, the mobile cart can be configured to activate an alarm and / or warn the operator if the wrong or damaged material is on the mobile cart.

[0073] In some embodiments, the movable cart may be configured to have an actuation device or actuator that moves articles onto and off the movable cart when the movable cart is docked to an assembly device. Embodiments of the actuator can be implemented on the movable cart, the assembly device, or both. In another embodiment, articles can be loaded onto and unloaded from the movable cart manually.

[0074] In some embodiments, the movable cart can be configured to interface with a production line. According to this embodiment, workers on the production line can confirm the correct location of the movable cart on the assembly equipment and be notified of its acceptance.

[0075] In some embodiments, the mobile cart can be configured to communicate with assembly equipment, production lines, and / or selected machines within the production lines via an open platform. The communication system may include wired systems, wireless systems (via common networks, mesh, Bluetooth®, Wi-Fi, Zigbee®, WAN, Nodes, Li-Fi, etc.), combinations of wired and wireless systems, and infrared (IR) systems.

[0076] In some embodiments, the mobile cart may be configured to have a dedicated power supply. In one embodiment, the mobile cart has a battery configured to power automated components located within the mobile cart, such as a mechanism used to move stencils in and out of the mobile cart, a mechanism used to move paste cartridges in and out of the mobile cart, a mechanism used to move squeegee blades in and out of the mobile cart, and a mechanism used to move tools in and out of the mobile cart. In other embodiments, the mobile cart may be configured to have an uninterruptible power supply. The power supply may be configured to support operation while “docked” (high voltage from the assembly device when docked, and low voltage when undocked). The power supply may be configured to recharge for autonomous operation, for example, by recharging the battery from power provided by the assembly device.

[0077] In some embodiments, the mobile cart can be configured to function with an assembly device. For example, the mobile cart can be configured to provide a handshake function with the assembly device before transferring articles, for example, "Give me paste cartridge #1234." The mobile cart and assembly device can be configured to have a communication protocol and / or a library reference of what is consumable. The mobile cart can be configured to determine whether the mobile cart has the correct articles. The handshake function can be configured to ensure the correct transfer of articles, for example, "Here is paste cartridge #1234," and / or to ensure the subsequent transfer of articles, for example, "I have paste cartridge #1234." In one embodiment, a mobile device can be configured to scan and identify articles in the mobile cart and to determine, for example, whether the articles are ready for use, whether they need cleaning, etc.

[0078] In some embodiments, the mobile cart can be configured to address errors associated with the handling and retrieval of items within the mobile cart. For example, the mobile cart can be configured to detect incomplete actions by one party, incomplete transfer of items, e.g., items stuck or jammed, items dropped during transfer, e.g., "I handed you paste cartridge #1234, don't you have it?", and manual intervention or override, e.g., "Here, let me help." In one embodiment, a controller associated with the mobile cart can be configured to perform electrostatic discharge control, data recovery, and / or protection.

[0079] In some embodiments, the movable cart can be configured to have higher capacity. In addition to indexing all equipment to the correct height, the movable cart may require pushing / pushing all equipment into the machine gantry for mounting.

[0080] In some embodiments, the existing machine gantry, rails, and print heads of the assembly apparatus can be configured to reciprocate articles in and out.

[0081] In some embodiments, the mobile cart may be configured to have a paste cartridge indexer for loading / unloading paste cartridges.

[0082] In some embodiments, the mobile cart can be configured to communicate with assembly equipment, production lines, and warehouses associated with the production lines.

[0083] In some embodiments, the mobile cart may be configured to have an electrical / pneumatic interface.

[0084] In some embodiments, the mobile cart can be configured to track new and used consumables on the mobile cart, such as solder paste cartridges, including location, temperature, and other data.

[0085] In some embodiments, the mobile cart can be configured to scan all consumables using a suitable scanning device such as a barcode reader or RFID reader.

[0086] In some embodiments, the movable cart may be configured to have an indexing mechanism for properly positioning consumables.

[0087] In some embodiments, the movable cart may be configured to have a bypass switch that disconnects the movable cart from the assembly device in the event of a problem with the movable cart.

[0088] In some embodiments, the mobile cart can be configured to be actively or passively controlled by the environment.

[0089] In some embodiments, the mobile cart can be configured to be controlled by a smartphone-integrable application (App).

[0090] As used herein, “automated” or “fully automated” switching refers to the exchange or replenishment of items without human intervention.

[0091] As used herein, “partially automated” switching refers to the exchange or replenishment of items with some or limited human intervention.

[0092] As used herein, “transport” or “transporting” refers to moving an article from one location to another, either manually or by machine.

[0093] As used herein, “install” or “installing” describes the process of placing an article in a position where it is ready for use.

[0094] The concepts disclosed herein may be applied to other types of equipment used to manufacture electronic circuit boards, including pick-and-place machines, reflow ovens, wave soldering machines, selective soldering machines, inspection stations, and cleaning stations. For example, a concept directed towards tool replacement can be applied to a pick-and-place machine used to mount electronic components onto an electronic circuit board. In another example, a concept directed towards item replacement can be applied to solder replacement in wave soldering machines and selective soldering machines, and to cleaning products in a cleaning station.

[0095] Thus, while several aspects of at least one embodiment have been described, it will be understood that various variations, modifications, and improvements will be readily conceivable to those skilled in the art. Such variations, modifications, and improvements are intended to be part of and within the scope of this disclosure. Accordingly, the foregoing description and drawings are merely illustrative. The inventions disclosed herein include the following: [Item 1] A system for aligning a movable cart with an assembly device, The assembly device has at least one article from a plurality of articles for replacement within the assembly device, The assembly apparatus includes a docking station, The movable cart is configured to receive used articles and / or provide new articles to the assembly device. The movable cart includes an interface configured to dock within the docking station of the assembly apparatus, and the system is A sensor associated with one of the assembly apparatus and the movable cart, A laser associated with the other of the assembly apparatus and the movable cart, Equipped with, A system in which the sensor and the laser are configured to align the movable cart with the assembly apparatus before the first docking of the movable cart within the docking station of the assembly apparatus. [Item 2] The system according to item 1, wherein the sensor is mounted on a support of the assembly apparatus, and the laser is mounted on the frame of the movable cart. [Item 3] The assembly apparatus includes at least one sensor mounted on the support of the assembly apparatus, as described in item 2. [Item 4] The system according to item 3, wherein the sensor is mounted on a stencil support configured to support a stencil within a stencil printer. [Item 5] The system according to item 3, wherein the sensor is mounted on a support configured to hold a substrate within a dispenser. [Item 6] The system according to item 2, wherein the laser is positioned on the frame of the movable cart at the same height as the sensor of the assembly device. [Item 7] The laser is a low-power laser, as described in item 1. [Item 8] The system according to item 1, wherein the sensor is configured to generate an output signal that can be connected to the subsystem of the assembly apparatus. [Item 9] The system according to item 8, wherein the subsystem is a controller, and the sensor generates an output signal to be processed by the controller. [Item 10] The system according to item 9, wherein the controller includes software configured to convert the output signals into relative or absolute coordinates of the x and z axes. [Item 11] A method for aligning a movable cart with an assembly device, The assembly device has at least one article from a plurality of articles for replacement within the assembly device, The assembly apparatus includes a docking station, The movable cart is configured to receive used articles and / or provide new articles to the assembly device. The movable cart includes an interface configured to dock within the docking station of the assembly apparatus, and the method is A sensor is provided on either the assembly device or the movable cart. Directing the laser associated with the other of the assembly apparatus and the movable cart towards the sensor, Includes, A method wherein the sensor and the laser are configured to align the movable cart with the assembly apparatus before the first docking of the movable cart within the docking station of the assembly apparatus. [Item 12] The method according to item 11, wherein the sensor is configured to generate an output signal that can be connected to the subsystem of the assembly apparatus. [Item 13] The method according to item 12, wherein the subsystem is a controller, and the sensor generates an output signal to be processed by the controller. [Item 14] The method according to item 13, wherein the controller includes software configured to convert the output signals into relative or absolute coordinates for the x and z axes. [Item 15] The method according to item 14, further comprising calibrating the laser. [Item 16] The method according to item 15, wherein the laser is calibrated to one side of the movable cart with respect to a target that will ensure the laser emits a beam aligned to the x, y, and z axis coordinates of the movable cart. [Item 17] The method according to item 16, wherein the sensor is mounted on the assembly apparatus such that when all axes in the assembly apparatus are in their initial positions, the beam of light emitted from the laser on the movable cart is in a nominal position which the assembly apparatus interprets as a 0,0 position with respect to x-axis alignment and z-axis height. [Item 18] The method of item 17, wherein the assembly device is notified that the movable cart is in the correct or appropriate position relative to the assembly device and is capable of performing its function. [Item 19] The method according to item 18, wherein if a reading other than 0,0 is detected, this is interpreted as a misalignment, and the assembly apparatus or the movable cart may make the necessary adjustments to return to a reading of 0,0 to indicate proper alignment of the movable cart and the assembly apparatus when the movable cart is docked. [Item 20] The method according to item 19, wherein if there is a reading other than 0,0 at initialization, this is interpreted as an offset from the home position and can be compensated by the controller of the assembly apparatus, or by the controller of the movable cart, or both.

Claims

1. A system for aligning a movable cart with an assembly device, The assembly device has at least one article from a plurality of articles for replacement within the assembly device, The assembly apparatus includes a docking station, The movable cart is configured to receive used articles and / or provide new articles to the assembly device. The movable cart includes an interface configured to dock within the docking station of the assembly apparatus, and the system is A sensor associated with one of the assembly apparatus and the movable cart, A laser associated with the other of the assembly apparatus and the movable cart, Equipped with, The sensor and the laser are configured to align the movable cart with the assembly apparatus before the first docking of the movable cart within the docking station of the assembly apparatus. The system comprises a sensor mounted on a support of the assembly apparatus and a laser mounted on the frame of the movable cart.

2. The system according to claim 1, wherein the assembly apparatus includes at least one sensor mounted on the support of the assembly apparatus.

3. The system according to claim 2, wherein the sensor is mounted on a stencil support configured to support a stencil within a stencil printer.

4. The system according to claim 2, wherein the sensor is mounted on a support configured to hold a substrate within a dispenser.

5. The system according to claim 1, wherein the laser on the frame of the movable cart is at the same height as the sensor of the assembly device.

6. The system according to claim 1, wherein the laser is a low-power laser.

7. The system according to claim 1, wherein the sensor is configured to generate an output signal that can be connected to the subsystem of the assembly apparatus.

8. The system according to claim 7, wherein the subsystem is a controller, and the sensor generates an output signal to be processed by the controller.

9. The system according to claim 8, wherein the controller includes software configured to convert the output signals into relative or absolute coordinates of the x and z axes.

10. A method for aligning a movable cart with an assembly device, The assembly device has at least one article from a plurality of articles for replacement within the assembly device, The assembly apparatus includes a docking station, The movable cart is configured to receive used articles and / or provide new articles to the assembly device. The movable cart includes an interface configured to dock within the docking station of the assembly apparatus, and the method is A sensor is provided on either the assembly device or the movable cart. Directing the laser associated with the other of the assembly apparatus and the movable cart towards the sensor, Includes, The sensor and the laser are configured to align the movable cart with the assembly apparatus before the first docking of the movable cart within the docking station of the assembly apparatus. A method wherein the sensor is mounted on a support of the assembly apparatus, and the laser is mounted on the frame of the movable cart.

11. The method according to claim 10, wherein the sensor is configured to generate an output signal that can be connected to the subsystem of the assembly apparatus.

12. The method according to claim 11, wherein the subsystem is a controller, and the sensor generates an output signal to be processed by the controller.

13. The method according to claim 12, wherein the controller includes software configured to convert the output signals into relative or absolute coordinates of the x and z axes.

14. The method according to claim 13, further comprising calibrating the laser.

15. The method according to claim 14, wherein the laser is calibrated to one side of the movable cart with respect to a target that will ensure the laser emits a beam aligned to the x, y, and z axis coordinates of the movable cart.

16. The method according to claim 15, wherein the sensor is mounted on the assembly apparatus such that, when all axes in the assembly apparatus are in their initial positions, the beam of light emitted from the laser on the movable cart is in a nominal position which the assembly apparatus interprets as a 0,0 position with respect to x-axis alignment and z-axis height.

17. The method according to claim 16, wherein the assembly device is notified that the movable cart is in the correct or appropriate position relative to the assembly device and is capable of performing its function.

18. The method according to claim 17, wherein if a reading other than 0,0 is detected, this is interpreted as a misalignment, and the assembly apparatus or the movable cart can make the necessary adjustments to return to a reading of 0,0 in order to indicate proper alignment of the movable cart and the assembly apparatus when the movable cart is docked.

19. The method according to claim 18, wherein if there is a reading other than 0,0 at initialization, this is interpreted as an offset from the home position and can be compensated by the controller of the assembly apparatus, or by the controller of the movable cart, or both.

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