IC Placement Robot Using Vision Feedback for Stepper Slippage
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Solution Overview
Problem
Current robotic systems are not cost-effective for automating the replacement of integrated circuits during characterization, as they either require expensive precision motors or are unsafe due to slippage from low-cost stepper motors, and neither type is suitable for automating chip replacement in a low-cost manner.
Innovation Solution
A robotic integrated circuit placement system using a low-cost robotic arm with stepper motors, equipped with cameras and image processing, to accurately move and place integrated circuits between a chip tray and a test board, compensating for slippage through image processing pipelines.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If low-cost stepper motors are used in robotic arm systems, then cost is reduced and safety is improved, but movement precision deteriorates due to slippage
Solution Approach 1:
The system uses cameras to capture images of fiducial markers on the circuit board and chip tray, processes these images to determine actual positions, and feeds this information back to calculate compensation values for stepper motor slippage, thereby restoring positioning accuracy without sacrificing the cost benefits of stepper motors
Solution Approach 2:
The system changes the parameter of position accuracy by introducing image processing-based position detection and compensation calculations, transforming the positioning mechanism from purely motor-driven to a hybrid system that corrects for motor slippage through computational adjustment of position parameters
2Manufacturing precision
If sophisticated motors and electronic control systems are used, then movement precision is improved, but cost increases and system complexity increases
Solution Approach 1:
The system replaces sophisticated precision motors with simpler stepper motors, and substitutes the mechanical precision function with an image processing and compensation-based control system, thereby achieving similar positioning accuracy through a different technical approach that reduces cost and complexity
Solution Approach 2:
The system introduces cameras and image processing algorithms as intermediary components between the stepper motors and the positioning task, using these intermediaries to detect positions and calculate compensations that enable accurate placement without requiring expensive precision motors
3Productivity
If automated robotic systems are implemented, then productivity is improved by enabling operation during overnight hours, but system cost increases
Solution Approach 1:
The system employs inexpensive stepper motors and standard USB cameras instead of expensive industrial-grade components, accepting that these are consumer-grade parts with shorter lifespans but achieving the primary goal of cost-effective automation for overnight operation
Data Source
AI summary
A robotic integrated circuit placement system includes a test board comprising a socket for holding an integrated circuit, a tester coupled to the test board, a chip tray having a plurality of slots for storing respective integrated circuits including the integrated circuit, and a robotic arm system. The robotic arm system includes a robotic arm having a stepper motor for controlling a position of an end of the robotic arm, a camera, and a controller coupled to the robotic arm and adapted to operate the robotic arm automatically. The controller performs image processing on images acquired by the camera, and moves the integrated circuit between the chip tray and the socket using the robotic arm in response to the image processing.