Inclined Component Mounting with Dual Light Source Alignment
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Solution Overview
Problem
Existing mounting apparatuses struggle to accurately align and mount components with inclined surfaces onto substrates due to complications in controlling light irradiation and achieving desired contrast, leading to inaccurate position detection and mounting.
Innovation Solution
A mounting apparatus equipped with a first light source orthogonal to the substrate's surface, an image pickup section, a second light source that irradiates the inclined surface of the component, and a moving mechanism to adjust the component or substrate in a plane parallel to the contact surface, allowing for precise alignment and image identification by varying the light intensity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If one light source is used to irradiate both substrate and component, then the alignment process is simplified, but the image contrast and detection accuracy deteriorate due to insufficient differentiation between substrate and component surfaces
Solution Approach 1:
The single light source is segmented into two distinct light sources: a first light source for irradiating the substrate and a second light source for irradiating the component. This segmentation allows independent optimization of lighting conditions for each object, improving image contrast and detection accuracy while maintaining system simplicity through dedicated functional assignment.
Solution Approach 2:
Different lighting qualities are applied to different regions: the first light source provides orthogonal illumination for the substrate surface, while the second light source provides directional illumination at a specific angle for the inclined component surface. This local quality differentiation enhances the reflectivity and image contrast specific to each surface type, enabling accurate position detection.
2Measurement precision
If complex control systems are used to achieve desired image contrast, then position detection accuracy improves, but the system complexity and cost increase
Solution Approach 1:
The system uses the inherent optical properties of the component's inclined surface to achieve self-illumination and self-detection. The second light source is positioned to exploit the inclined surface's reflectivity characteristics, allowing the component to serve its own detection function without requiring complex external control mechanisms. This self-service approach achieves high detection accuracy while maintaining system simplicity.
Solution Approach 2:
The system exploits optical property changes (reflectivity variations) of the inclined surface under specific illumination angles. By positioning the second light source at a predetermined angle relative to the inclined surface, the system achieves optimal reflectivity and image contrast automatically, eliminating the need for complex real-time control adjustments.
3Illumination intensity
If light irradiation is optimized for flat surfaces, then substrate imaging is clear, but inclined surface imaging suffers from insufficient contrast and reflection
Solution Approach 1:
The solution introduces a spatial dimension change by positioning the second light source at a specific angle relative to the inclined surface, rather than using orthogonal illumination. This angular positioning exploits the three-dimensional geometry of the inclined surface to maximize reflectivity toward the image pickup device, thereby achieving high contrast imaging of the inclined component surface.
Solution Approach 2:
Asymmetric illumination geometry is employed: the first light source illuminates the substrate orthogonally, while the second light source illuminates the component at a predetermined non-orthogonal angle. This asymmetric arrangement matches the asymmetric geometry of the inclined surface, optimizing light reflection and image contrast for the component while maintaining clear substrate imaging.
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 setup enables accurate image identification and position detection of both the substrate and component, even with inclined surfaces, resulting in high-precision mounting without complex control systems, making the process simpler and more cost-effective.
Implementation Method 1
a first light source having an optical path orthogonal to the surface of contact... reflected light which is irradiated from the second light source, and which is reflected by the inclined surface is incident on the image pickup section
Implementation Method 2
a second light source which irradiates light on the inclined surface... reflected light which is irradiated from the second light source, and which is reflected by the inclined surface is incident on the image pickup section
Data Source
AI summary
A mounting apparatus which mounts on a substrate, a component having an inclined surface which intersects with a contact surface of the substrate and the component, at an acute angle, includes a first light source having an optical path orthogonal to the contact surface, and a camera which picks up an image of the component and an image of the substrate, a second light source which irradiates light on the inclined surface, and a moving means which moves at least one of the component and the substrate relatively, in a plane parallel to the surface of contact, and reflected light which is irradiated from the second light source, and reflected by the inclined surface is incident on the image pickup section.