Camera-Guided Robotic Arm Control for Stepper Motor Slippage
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Solution Overview
Problem
Current robotic systems are not cost-effective for automating the replacement of integrated circuits during characterization, as they either require expensive precision motors or are unsafe due to slippage issues with low-cost stepper motors, making them unsuitable for automating chip replacement.
Innovation Solution
A low-cost robotic integrated circuit placement system using a robotic arm with stepper motors, equipped with cameras and image processing, to accurately move and place integrated circuits by compensating for slippage through image processing pipelines, ensuring safe and precise operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If low-cost stepper motors are used in robotic arm systems, then cost is reduced and safety is improved, but movement precision deteriorates due to slippage
Solution Approach 1:
The system continuously captures images of the reference point during robotic arm movement and uses image processing to determine actual position. This feedback loop allows the system to detect and compensate for stepper motor slippage in real-time, maintaining precision despite using low-cost motors.
Solution Approach 2:
The patent replaces reliance on mechanical precision of stepper motors with an optical measurement system. Instead of depending on the motor's inherent precision, the system uses camera-based optical feedback to detect position and compensate for mechanical imperfections through software control.
2Manufacturing precision
If sophisticated motors and electronic control systems are used, then movement precision is improved, but cost increases
Solution Approach 1:
The system replaces expensive precision motors with inexpensive stepper motors that are acceptable to use and replace if needed. The investment is shifted from expensive mechanical components to a software-based image processing system that provides the necessary precision.
Solution Approach 2:
The patent substitutes sophisticated mechanical control systems with a software-based optical control system. Instead of using expensive motors with advanced electronic control, the system uses simple stepper motors controlled by image processing algorithms that calculate and compensate for positioning errors.
3Productivity
If automated robotic systems are implemented, then productivity is improved, but device complexity increases
Solution Approach 1:
The robotic arm system is designed to perform multiple functions: moving the integrated circuit, positioning it on the socket, and the image processing system serves both for feedback control and for verification. This multi-functionality reduces the need for separate specialized components, simplifying the overall system.
Data Source
AI summary
A robotic arm system includes a robotic arm having at least one stepper motor and operable to move an end of the robotic arm in X-, Y-, and Z-dimensions, a camera attached to the robotic arm, and a controller coupled to the robotic arm and to the camera. During configuration, the controller moves the end of the robotic arm to a reference point to obtain initial reference coordinates and a reference image, and to a target location to obtain initial target coordinates. During operation, the controller moves the robotic arm according to the initial reference coordinates, adjusts a position of the robotic arm to an actual reference location using the camera to determine actual reference coordinates, and moves the robotic arm to an actual target location using the initial target coordinates and a difference between the initial reference coordinates and the actual reference coordinates.