Component Offset Classification in Automatic Placement
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Solution Overview
Problem
In the context of automatic placement machines, the increasing miniaturization of electronic components and tighter spacing on component carriers pose challenges for precise placement, leading to issues with component alignment and rejection due to pick-up accuracy and offset errors, where existing methods struggle to efficiently classify and correct offsets for reliable assembly.
Innovation Solution
A method involving a holding device that detects and classifies the offset of picked-up components using a sensor device and evaluation unit, comparing the offset to reference values to determine if the component is to be discarded or used for learning, allowing for improved pick-up position adjustments and reduced rejection rates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a learning algorithm is used to determine optimal pick-up position, then the rejection rate of components is reduced, but the initial pick-up accuracy is poor and components are discarded due to large offset
Solution Approach 1:
The patent applies preliminary action by performing offset detection and classification before the actual placement operation. The vision system detects the offset between the component and holding device, and the classification unit determines whether to discard or proceed with placement based on predetermined reference values. This preliminary classification prevents time-consuming learning trials that would result in component discarding, as the system proactively identifies suitable components before attempting placement.
Solution Approach 2:
The system applies self-service by using the detected offset information to automatically adjust and optimize the pick-up position without external intervention. The classification unit uses the offset data to improve subsequent pick-up operations, allowing the system to self-optimize the learning process and reduce rejection rates without requiring manual recalibration or external guidance.
2Measurement precision
If the holding device is rotated to determine offset, then the pick-up position can be optimized, but the axis of rotation does not exactly coincide with the axis of symmetry leading to measurement errors
Solution Approach 1:
The patent replaces the mechanical rotation method with an optical detection system. Instead of physically rotating the holding device and detecting eccentric movement, a vision system captures images of the component and holding device, and the evaluation unit calculates the offset based on image analysis. This substitution eliminates the need for precise mechanical alignment of the rotation axis with the symmetry axis, as the offset is determined optically rather than mechanically.
3Area of stationary object
If the minimum distance between components is reduced for miniaturization, then the component carrier is more compact, but the pick-up accuracy requirement increases and more components are discarded
Solution Approach 1:
The patent applies preliminary action by detecting the offset between the component and holding device before the placement operation. The vision system captures images, the evaluation unit determines the offset, and the classification unit decides whether to proceed with placement based on predetermined reference values. This preliminary detection and classification enable the system to handle miniaturized components with tighter spacing by proactively identifying suitable components and adjusting pick-up positions, thereby maintaining high placement accuracy without increasing the component carrier area.
Data Source
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Figure 2a~3
AI summary
The method involves receiving the component from a pick-up position (112) of a component loading device (110) by a holding device (120) and detection of received component by sensor device (150). The misalignment between the component and the holding device is determined by evaluation unit (151) downstream to sensor device. The two reference values of misalignments are compared and classification of the received component, if the misalignment is smaller than the reference value and is larger than the other reference value. The received component is classified as a component, which is rejected and the determined misalignment is used for a learning process concerning the pick-up positions, which are to be estimated, of future components. Independent claims are also included for the following: (1) assembly device for automatic assembly of component carrier (2) computer readable storage medium, in which a program is stored for classification of electronic component received by holding device (3) program element for classification of electronic component received by holding device.