IC Forming Machine Separation for Jammed Component Mitigation
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Solution Overview
Problem
Integrated circuit (IC) production machines experience jams due to improperly formed ICs that fail to pass through designated openings, leading to shutdowns and reduced efficiency, as technicians manually clear these jams, increasing production costs and downtime.
Innovation Solution
A component forming machine with a separation system that automatically separates properly formed ICs from improperly formed ICs using aperture-based, pneumatic, or gate-based techniques, integrated or detachable to the forming machine, adjustable for varying dimensions and form factors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual jam clearing is performed, then machine shutdowns are resolved, but production efficiency decreases and downtime increases
Solution Approach 1:
The separation system performs preliminary action by automatically separating properly formed ICs from improperly formed ICs immediately after the forming process. This prevents improperly formed ICs from entering subsequent processing stages where they could cause jams, thereby maintaining machine operation continuity without requiring manual intervention and preserving production efficiency.
2Productivity
If automatic separation system is implemented, then production efficiency increases, but device complexity increases
Solution Approach 1:
The separation system replaces manual mechanical jam-clearing operations with an automated separation mechanism. The system uses a separation plate with openings that automatically directs properly formed ICs into a first collection container while diverting improperly formed ICs into a second collection container, eliminating the need for technicians to manually clear jams and thereby increasing production efficiency without requiring complex control systems.
3Reliability
If separation system is integrated to forming machine, then jam occurrence is reduced, but manufacturing complexity increases
Solution Approach 1:
The separation system is integrated with the forming machine by combining the collection containers and separation plate as a unified assembly. The first collection container receives properly formed ICs through openings in the separation plate, while the second collection container receives improperly formed ICs, creating a merged system that prevents jams without requiring separate standalone equipment and thereby maintaining ease of manufacture.
Data Source
AI summary
A component forming machine with jammed component mitigation. In some examples, the component forming machine can include a platform configured to receive a lower die that supports a plurality of components for forming and includes a void through which at least some of the plurality of components pass subsequent to the forming, a die press positioned above the lower die and configured to lower an upper die to exert downward pressure on the plurality of components to form unformed components and formed components, and a separation system. In some examples, the separation system is configured to interact with the lower die to permit the formed components to fall into the void and prevent the unformed components from falling into the void.