Selective Illumination for Manual Component Sorting
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Solution Overview
Problem
In manufacturing processes, particularly after wafer dicing, there is a need for efficient and cost-effective methods to manually sort microscopic components on a component holder, as existing ink dot mechanisms and pick-and-place equipment are expensive and challenging to operate due to the small size and varied characteristics of the components.
Innovation Solution
An illumination system comprising an array of lights and a control module that receives component information for sorting and location, selectively illuminating identified components on a component holder to facilitate manual sorting, using reference points for precise illumination and minimizing overlap between light areas to ensure accurate identification.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If expensive ink dot mechanisms or pick and place equipment are used to locate and sort components, then sorting accuracy is improved, but equipment cost and operational complexity increase
Solution Approach 1:
The patent introduces an illumination apparatus as an intermediary tool between the inspection system and the operator. The apparatus receives component location information from the inspection system and uses selective illumination to guide the operator's eye to the exact location of components requiring sorting, eliminating the need for complex mechanical location mechanisms
Solution Approach 2:
The patent replaces complex mechanical location systems (ink dot mechanisms, pick and place equipment) with an optical illumination system. Instead of using mechanical means to mark or physically manipulate components, the system uses light to indicate component locations, simplifying the overall system while maintaining accuracy
2Device complexity
If manual sorting is used to reduce equipment cost, then equipment cost decreases, but sorting efficiency and accuracy deteriorate due to difficulty in locating small components
Solution Approach 1:
The illumination apparatus serves as an intermediary that bridges the gap between the inspection system's digital information and the operator's physical sorting task. By providing visual guidance through selective illumination, it enables manual operators to work as efficiently as automated systems would
Solution Approach 2:
The patent employs different colors of light to indicate different sorting criteria or component states. The illumination apparatus can highlight components based on their inspection results, allowing operators to quickly identify and sort components according to multiple criteria simultaneously, thereby improving sorting efficiency
3Measurement precision
If comprehensive inspection of all components is performed, then component identification accuracy is improved, but inspection time increases
Solution Approach 1:
The inspection system applies the principle of local quality by focusing inspection resources on specific areas or components that require sorting. Rather than uniformly inspecting all components with equal detail, the system identifies and concentrates on components that meet sorting criteria, reducing overall inspection time while maintaining accuracy for relevant components
Solution Approach 2:
The system performs partial inspection by focusing only on components that require sorting rather than conducting exhaustive inspection of all components. The illumination apparatus then highlights these identified components for sorting, achieving sufficient accuracy for the sorting task without the time cost of complete inspection of every component
Data Source
AI summary
An illumination apparatus, method and system to facilitate manual sorting of components. The illumination apparatus can include an array of lights and a component holder receptacle configured to receive a component holder retaining components. The illumination apparatus can further include a control module configured to receive information identifying components for sorting and location information for locating the one or more components on the component holder, and to selectively control activation of individual lights of the array of lights to illuminate the one or more components.