Carrier Tape Placement Alignment Using Vision Feedback
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Solution Overview
Problem
Existing placement systems for electronic devices on carrier tapes suffer from misplacement due to tolerances and mechanical inaccuracies, leading to jamming and reduced yield in high-speed electronics manufacturing.
Innovation Solution
A system comprising a taping head, cameras, and a processor that captures images of devices and tape pockets, determines size and orientation information, and adjusts the taping head's movements to accurately place devices into tape pockets using translational and rotational adjustments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a theoretical model is used to determine device placement positions, then the placement system operates at high speed, but placement accuracy deteriorates due to tolerances and mechanical inaccuracies
Solution Approach 1:
The system performs preliminary actions by capturing images of devices in tray pockets and tape pockets before the actual placement operation. The processor determines actual positions and dimensions from these images, creating a real-time reference model that compensates for tolerances and mechanical inaccuracies, enabling both high speed and high precision placement
Solution Approach 2:
The system implements feedback by using cameras to capture actual device and pocket positions, processing this visual information to determine real dimensions and locations, then using this feedback to dynamically adjust placement positions. This closed-loop approach eliminates the reliance on theoretical models while maintaining high-speed operation
2Device complexity
If the placement system operates without real-time position data, then the system complexity is reduced, but placement reliability deteriorates due to misplacement and jamming
Solution Approach 1:
The system introduces an intermediary visual measurement system (cameras and image processing) between the placement system and the physical components. This intermediary captures and processes position information non-invasively, providing real-time data without adding significant complexity to the mechanical placement system while dramatically improving reliability
Solution Approach 2:
The system replaces traditional mechanical measurement methods with optical measurement using cameras and image processing. This substitution eliminates the need for complex mechanical sensors and measurement devices, maintaining system simplicity while achieving high-precision position detection for reliable placement
Data Source
AI summary
The system includes a taping head configured to extract a plurality of devices from a plurality of tray pockets of a component tray and a first camera configured to capture one or more images of the plurality of devices extracted by the taping head. A processor is configured to determine size and orientation information of each of the plurality of devices extracted by the taping head based on the one or more images of the plurality of devices received from the first camera, determine a placement solution of the taping head to position each of the plurality of devices into the plurality of tape pockets of a carrier tape based on the size and orientation information of each of the plurality of devices, and control the taping head to place the plurality of devices into the plurality of tape pockets of the carrier tape according to the placement solution.