Component Loading Apparatus with Integrated Impurity Removal
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Solution Overview
Problem
Current technologies face challenges in efficiently and quickly loading high-performance micro-components onto trays for packaging, often leaving defective components behind and lacking in automation for mass production.
Innovation Solution
A component loading apparatus comprising a work table, a component recognizer, a rotary head with nozzles, and an analyzer system for inspecting and sorting components, which includes impurity removers and a tray analyzer to ensure only good components are loaded onto trays, utilizing cameras and vacuum suction for accurate placement and inspection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If automated component loading is implemented, then productivity is improved, but device complexity increases
Solution Approach 1:
The head unit integrates multiple functions including component suction, impurity removal, and placement operations into a single device. The nozzle assembly can both suction components and discharge impurities through integrated channels, reducing the need for separate devices and improving loading efficiency while managing complexity
Solution Approach 2:
The apparatus is divided into functional modules: component provider, work table with recognizer, head unit with nozzles, impurity remover, and tray analyzer. Each module performs a specific function, allowing the system to achieve high productivity through coordinated automation while maintaining manageable complexity through modular design
2Manufacturing precision
If component inspection is performed, then manufacturing precision is improved, but loss of time increases
Solution Approach 1:
The component recognizer and analyzer inspect components before they are loaded onto the tray. Defective components are identified and excluded from loading in advance, ensuring only high-quality components are placed on the tray. This preliminary inspection approach maintains high manufacturing precision while optimizing the overall loading process efficiency
Solution Approach 2:
Optical recognition systems and automated analyzers replace manual inspection methods. The component recognizer uses optical fields to detect component characteristics, and the analyzer automatically determines quality, significantly reducing inspection time while maintaining or improving precision compared to human inspection
3Reliability
If impurity removal is implemented, then purity is improved, but device complexity increases
Solution Approach 1:
The impurity removal function is merged with the head unit that performs component suction and placement. The nozzle assembly includes integrated channels that allow impurities to be discharged through the same structure used for component handling. This consolidation improves component purity while minimizing the increase in device complexity by combining functions rather than adding separate systems
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
The apparatus effectively sorts and loads high-quality components onto trays, reducing defects and impurities, simplifying the manufacturing process, and enhancing the marketability of the packaged components by ensuring only good components are shipped or sold.
Implementation Method 1
a head configured to suck the components
Implementation Method 2
The impurity remover may have an air blow nozzle which discharges air and a vacuum suction which sucks impurities
Implementation Method 3
The impurity remover may have an air blow nozzle which discharges air and a vacuum suction which sucks impurities
Data Source
AI summary
Provided is a component loading apparatus which includes: a work table comprising a working plane; a component recognizer configured to recognize components placed on the working plane of the work table; a head configured to suck the components; and a tray support for supporting a tray on which the components sucked by the head are loaded. The component loading apparatus further includes: an impurity remover configured to remove impurities attached onto the components in at least one of a first state of being placed on the working plane of the work table and a second state of being sucked by the head; and a tray analyzer configured to inspect loading positions of the components on the tray.