Electromagnetic Assembly Head for Precise Component Placement
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Solution Overview
Problem
Existing assembly heads face challenges in precisely controlling placement forces for components on substrates, particularly with small and sensitive components requiring low forces and large components needing higher forces, while also dealing with high mass forces and inertia that impair accuracy and control complexity.
Innovation Solution
The assembly head employs a lifting actuator with a ferromagnetic counterpart and an electric holding magnet to create a defined magnetic connection, allowing precise control of placement force by adjusting the magnetic adhesive force, which decouples from the actuator's mass and weight forces, enabling faster cycles and precise placement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a powerful placement head with large number of holders is used to assemble small components in high numbers, then productivity is improved, but the mass forces and inertia of moving parts increase which delays control cycles and impairs accuracy
Solution Approach 1:
The lifting actuator is divided into two independent mass regions: a stationary upper mass region (coil part) and a movable lower mass region (holder with ferromagnetic counterpart). This segmentation allows the coil part to remain fixed while only the holder moves, significantly reducing the moving mass and improving control accuracy while maintaining the ability to lift multiple holders simultaneously for high productivity
Solution Approach 2:
A ferromagnetic counterpart is introduced as an intermediary element between the holder and the coil part. This counterpart enables electromagnetic coupling to transmit lifting force while allowing the holder to be accelerated and then decoupled during the placement process, reducing the impact of actuator mass on placement precision
2Productivity
If high spring force and high dead weight of lifting actuator are used to accelerate holders, then productivity is improved, but placement force control becomes difficult and precision is impaired
Solution Approach 1:
The system transitions from a static spring-based force application to a dynamic electromagnetic force application. The coil part can be selectively energized to provide controlled lifting force, and the magnetic coupling can be dynamically adjusted or released during the placement process, enabling precise control of placement force while maintaining high acceleration capability
Solution Approach 2:
The traditional mechanical spring-based lifting mechanism is replaced with an electromagnetic lifting system. The electromagnetic force can be precisely controlled through current regulation, allowing independent control of lifting force and placement force, eliminating the constraint where high dead weight and spring force made precise placement force control difficult
3Manufacturing precision
If pneumatic device with cylinder, control valve and pressure sensor is used to limit placement force, then placement force control is achieved, but device complexity increases and control response is delayed
Solution Approach 1:
The complex pneumatic control system (cylinder, control valve, pressure sensor) is replaced with a simplified electromagnetic control system. The coil part can be selectively energized to provide controlled magnetic attraction force, and the force can be rapidly adjusted or released by controlling the electrical current, achieving placement force control with much lower device complexity and faster response time
Solution Approach 2:
The system uses periodic or pulsed electromagnetic activation of the coil part to control the holder placement. The coil can be energized in controlled pulses to provide lifting force during approach, then deactivated or reduced to allow controlled placement, enabling precise force control through temporal modulation rather than complex mechanical regulation
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
This solution allows for precise control of placement forces within a narrow tolerance range, reducing measurement and control effort, achieving higher impact velocity and shorter cycle times with minimal residual mass, and enabling quick and accurate component placement on substrates.
Implementation Method 1
the holder being able to be electromagnetically coupled to a lifting actuator which can be displaced in the vertical direction in such a way that a lifting force directed downwards onto the holder can be transmitted via a magnetic adhesive force
Implementation Method 2
a ferromagnetic counterpart which can be placed on the front face or can be lifted off the front face
Data Source
AI summary
Fitting head for fitting substrates with electrical components in a fitting device, fitting device, method of operating the fitting head in the fitting device A fitting head (2) for fitting substrates (38) with electrical components (4) in a fitting device has a guide body for at least one holder (5) for the components (4), the holder (5) being mounted on said guide body so as to be movable in a stroke direction (z) perpendicular to the substrate (38). The holder (5) is movable downwardly in the direction of the substrate from an upper holding position. The holder (5) is electromagnetically couplable to a stroke actuator that is movable in the perpendicular direction (z), such that a stroke force directed downwardly onto the holder (5) is transmissible via a magnetic adhering force. The adhering force acts on an end face (46) of a connectable electromagnetic coil part (34, 34') which is movable in the stroke direction by the stroke actuator. A ferromagnetic counterpart is placeable on the end face (46) and liftable from the end face (46). The power supply to the coil part (34, 34') is variable such that, before the component (4) is deposited on the substrate (38), the magnetic adhering force generated by the coil part (34, 34') is settable to a value that corresponds to a specified depositing force. Directly after the deposition and the reaching of the preset depositing force, the ferromagnetic counterpart lifts off the end face (46). In the process, the inertia forces of the stroke actuator are fully decoupled and the fitting procedure can be correspondingly accelerated.