Adjustable Force Contactor for Consistent Electronic Component Testing
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Solution Overview
Problem
Existing testing equipment for miniature electronic components faces challenges in applying consistent contact force without damaging the components, as the resilience of metal terminations diminishes with smaller sizes, and current solutions either require hardware changes or decrease productivity due to mechanical limitations.
Innovation Solution
An adjustable force applicator system that supplies a substantially constant force over a large range of travel, using various contactor types and force applicators such as air cylinders, pneumatic bladders, or piezoelectric actuators, allowing dynamic force adjustment without hardware changes, and minimizing lateral movement to prevent component damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a contact roller is preloaded to a constant spring force of 50 grams, then stable testing is achieved, but smaller electronic components with diminished resilience are damaged
Solution Approach 1:
The patent applies dynamics by replacing the constant spring force with a dynamically controllable force application mechanism. The contactor uses an actuator (such as a voice coil motor, piezoelectric actuator, or pneumatic cylinder) that can adjust the contact force in real-time based on the specific component being tested. This allows the system to apply exactly the right amount of force needed for stable testing without exceeding the resilience limits of smaller components.
Solution Approach 2:
The patent implements parameter changes by making the contact force a variable parameter rather than a fixed value. The system can modify the contact force parameter dynamically based on component size, material properties, and testing requirements. This is achieved through programmable control of the actuator, allowing the force parameter to be adjusted within a specified range to match the specific needs of each component being tested.
2Object-affected harmful factors
If the contact roller is retracted and extended using a solenoid coil, then component damage is eliminated, but productivity decreases by 5% to 13%
Solution Approach 1:
The patent applies continuity of useful action by maintaining continuous contact between the contactor and the component throughout the testing process. Unlike the solenoid-based system that requires retraction and extension cycles, this contactor remains in continuous contact with the component, eliminating the productivity loss associated with repeated engagement and disengagement. The continuous contact is maintained while the force parameter is dynamically adjusted to prevent damage.
Solution Approach 2:
The patent replaces the mechanical solenoid actuation system with an alternative force generation mechanism such as electromagnetic actuators, piezoelectric actuators, or pneumatic cylinders. These systems can apply and adjust force more efficiently without the need for mechanical retraction and extension movements, thereby maintaining productivity while preventing component damage through controlled force application.
3Force
If spring force sources are used to provide contact force, then contact force is supplied, but the spring force sources fatigue over time and require replacement
Solution Approach 1:
The patent replaces mechanical spring force sources with non-mechanical or electronically controlled force generation systems such as electromagnetic actuators, piezoelectric actuators, or pneumatic cylinders. These systems do not suffer from the same fatigue limitations as metal springs and can maintain consistent force output over extended periods. The electronic or pneumatic systems can be precisely controlled and monitored, extending the operational duration without requiring replacement.
Solution Approach 2:
The patent implements self-service through programmable control systems that automatically adjust and maintain the contact force without manual intervention. The system includes sensors and control algorithms that monitor the contact force and make real-time adjustments to compensate for any drift or changes in operating conditions, eliminating the need for periodic manual recalibration or replacement that would be required with mechanical spring systems.
4Manufacturing precision
If multiple contacts are co-planarized to produce roughly the same contact force, then consistent force distribution is achieved, but device complexity and calibration requirements increase
Solution Approach 1:
The patent applies universality by using a single programmable actuator system that can control the contact force for multiple contacts simultaneously. Instead of requiring separate mechanical adjustment mechanisms for each contact to achieve co-planarity, the system uses a unified control algorithm that distributes force evenly across all contacts through software control. This reduces mechanical complexity while maintaining force uniformity.
Solution Approach 2:
The patent implements feedback through sensors that monitor the contact force at each contact point and feed this information back to the control system. The control algorithm uses this feedback to automatically adjust the actuator positions or forces to achieve uniform contact force distribution across all contacts. This closed-loop control eliminates the need for precise mechanical co-planarity while maintaining manufacturing precision.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables precise and consistent contact force application across a wide range of components, reduces productivity losses, and simplifies maintenance by automating force adjustments and reducing the need for recalibration, while allowing lower tolerance parts to be used, thus lowering costs and improving system efficiency.
Implementation Method 1
The adjustable force applicator can be selected from a group of force applicators consisting of an air cylinder, a bladder cylinder, a pneumatic bladder, an electroformed bellows, a voice coil motor, a solenoid, a piezoelectric actuator, and a muscle wire beam
Implementation Method 2
The adjustable force applicator can be selected from a group of force applicators consisting of an air cylinder, a bladder cylinder, a pneumatic bladder, an electroformed bellows, a voice coil motor, a solenoid, a piezoelectric actuator, and a muscle wire beam
Implementation Method 3
The adjustable force applicator can be selected from a group of force applicators consisting of an air cylinder, a bladder cylinder, a pneumatic bladder, an electroformed bellows, a voice coil motor, a solenoid, a piezoelectric actuator, and a muscle wire beam
Implementation Method 4
The adjustable force applicator can be selected from a group of force applicators consisting of an air cylinder, a bladder cylinder, a pneumatic bladder, an electroformed bellows, a voice coil motor, a solenoid, a piezoelectric actuator, and a muscle wire beam
Data Source
AI summary
An apparatus for testing electric components supported on a test plate for transport along a of travel path through a test station includes an electrical contactor at the station for contacting the plate surface and at least one electronic component transported to the test station by the test plate for testing. An adjustable force applicator supplies contact pressure to the contactor to apply a substantially constant force over a large working travel range. The applicator can include an air cylinder having a force applying pin applying force to a position located between a working point of the contactor and the pivot point such that the applied force variation is reduced as a result of a lever reduction ratio between the working point and the pin position.