Diffraction Grating Orientation Sensing for Pick-and-Place Accuracy
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Solution Overview
Problem
Existing pick-and-place apparatuses face issues with inconsistent force application during electronic component placement, leading to variations in adhesive flow-out and component height/orientation, and difficulties in determining the orientation and position of the pickup unit due to its movement.
Innovation Solution
A system utilizing a diffraction grating on the device surface to emit collimated light, detecting multiple diffraction orders with sensors, and a processor to determine orientation and position, and a method to detect length changes in the pickup unit using diffraction gratings to adjust forces for consistent placement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If a pickup unit uses vacuum force for picking and placing electronic components, then the components can be automatically transferred, but the placement force becomes inconsistent leading to variations in adhesive flow-out and component height
Solution Approach 1:
The system uses optical sensors to detect the position and orientation of the pickup unit, feeding this information back to a control system that adjusts the placement force in real-time to maintain consistency despite variations in adhesive flow-out
Solution Approach 2:
The patent replaces direct mechanical force measurement and control with an optical measurement system using diffraction gratings and sensors to non-contactively determine pickup unit orientation and position, enabling more precise control
2Adaptability or versatility
If the pickup unit moves during operation to place components, then flexibility and adaptability are improved, but determining the orientation and position becomes complicated
Solution Approach 1:
The patent introduces diffraction gratings as intermediary elements attached to the pickup unit. These gratings interact with light sources to create measurable optical patterns that indirectly reveal the pickup unit's position and orientation without requiring direct mechanical sensors on the moving unit
Solution Approach 2:
The system creates an optical copy or representation of the pickup unit's spatial state through diffraction patterns. The position and orientation information is encoded in the light patterns, allowing measurement without physical contact with the moving component
3Productivity
If adhesive is applied in predefined quantities and components are pressed onto it, then assembly speed is improved, but variations in placement force cause inconsistent adhesive bonding
Solution Approach 1:
The control system uses real-time feedback from optical sensors to adjust placement force, ensuring consistent adhesive bonding while maintaining high assembly speed through automated force regulation
Solution Approach 2:
The system dynamically changes the placement force parameter based on detected pickup unit orientation and position, optimizing the bonding process for each individual component placement while maintaining overall process speed
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
Ensures consistent force application and accurate orientation/positioning of electronic components, reducing adhesive flow-out and height/orientation variations, and enabling precise placement through contactless measurement techniques.
Implementation Method 1
a diffraction grating is arranged on a surface of the device... creating, by means of diffraction by the diffraction grating, an m-th order light beam and an n-th order light beam
Data Source
AI summary
A system for determining an orientation of a device is provided that includes a diffraction grating arranged on a surface of the device. By impinging a collimated light beam onto the diffraction grating an m-th order light beam and an n-th order light beam are generated. By monitoring the positions on sensor surface at which these light beams are detected, orientation information concerning an orientation of the device can be determined.