Die Transfer Platform for Sensor-Based Pass/Fail Sorting
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Solution Overview
Problem
Modern manufacturing processes rely heavily on human skill and expertise for quality control, packaging, and maintenance, which can lead to inefficiencies and inconsistencies in processing and inspection of manufactured products.
Innovation Solution
A die transfer platform that utilizes an inspection sensor to determine whether a die is defective and automatically directs it to a pass or fail target lane based on inspection results, using conveyors and end effectors to move the die containers between different staging areas, allowing for efficient sorting and processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If automated die transfer systems are implemented, then productivity and inspection accuracy are improved, but device complexity increases
Solution Approach 1:
The die transfer system is divided into separate functional modules: source lane conveyor, target lane conveyors, inspection sensors, and control systems. Each module operates independently but coordinates through centralized control, allowing the complex system to be managed as discrete, maintainable units while achieving high productivity through parallel processing of multiple dies simultaneously
Solution Approach 2:
The conveyor system is designed with universal components that can handle different die container types and configurations. The same transfer mechanism serves multiple functions: moving dies from source to target lanes, positioning containers for inspection, and routing inspected dies to appropriate output lanes based on inspection results, thereby managing complexity through multi-functional design
2Manufacturing precision
If human operators perform quality control and inspection, then flexibility and adaptability are maintained, but manufacturing precision and consistency deteriorate
Solution Approach 1:
Manual inspection operations are replaced with automated optical sensors and imaging systems that detect die defects, measure dimensions, and classify products. The sensor system captures images and data that are processed by control algorithms to make sorting decisions, substituting human sensory and cognitive functions with automated detection and decision-making systems that provide consistent, high-precision inspection
Solution Approach 2:
The inspection system creates digital copies (images and measurement data) of each die being inspected. These digital representations are analyzed by the control system to determine pass/fail status and routing decisions, eliminating the need for physical handling and manual measurement while maintaining inspection accuracy through repeated, consistent digital capture and analysis
3Loss of time
If manual handling of die containers is used, then ease of operation is maintained, but loss of time in transfer and sorting operations increases
Solution Approach 1:
The conveyor system operates continuously to transfer dies from source lanes to target lanes without interruption. Multiple conveyors work in parallel, and the system maintains continuous motion during die transfer, inspection, and sorting operations. This eliminates idle time between operations and ensures that dies are constantly being processed rather than waiting for manual handling cycles to complete
Solution Approach 2:
Die containers are pre-positioned in source lanes and staged for inspection before the actual inspection and sorting process begins. The system prepares multiple containers in advance, so when one container is being inspected, others are already positioned and ready for immediate transfer, eliminating waiting time and maintaining continuous operational flow
Data Source
AI summary
In certain embodiments, a system includes: a source lane configured to move a first die container between a load port and a source lane staging area; an inspection sensor configured to produce a sensor result based on a die on the first die container; a pass target lane configured to move a second die container between a pass target lane out port and a pass target lane staging area; a fail target lane configured to move a third die container between a fail target lane out port and a fail target lane staging area; and a conveyor configured to move the die from the first die container at the source lane staging area to either the second die container at the pass target lane staging area or the fail target lane staging area based on the sensor result.