Modular Pick-and-Place Head for Variable Tray Capacity
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Solution Overview
Problem
Conventional pick-and-place modules for test handlers are not adaptable to customer trays with varying semiconductor device loads, requiring replacement when the number of devices changes, leading to increased manufacturing costs and resource wastage.
Innovation Solution
A modular design where a detachable kit with adjustable vacuum passages and pickers can be mounted to a main body, allowing for easy adaptation to different customer tray capacities without replacing the entire module.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the number of pickers is increased to handle customer trays with more semiconductor devices, then the productivity is improved, but the device complexity increases
Solution Approach 1:
The pick-and-place module is divided into a main body and a detachable kit. The kit contains a specific number of pickers (e.g., 8 pickers) that can be attached to or detached from the main body. This segmentation allows the system to handle different tray configurations by simply changing the kit rather than redesigning the entire module, thus maintaining productivity while controlling complexity.
Solution Approach 2:
The main body is designed with a universal interface that can accommodate different kits. The kit structure allows it to be used across multiple configurations and customer tray types. This multi-functionality enables a single main body to support various productivity requirements by swapping kits, avoiding the need to increase overall device complexity.
2Adaptability or versatility
If the entire pick-and-place module is replaced to adapt to different customer tray capacities, then the adaptability is improved, but the manufacturing cost increases
Solution Approach 1:
By segmenting the module into a permanent main body and replaceable kits, the invention avoids the need to manufacture entirely new modules for different tray capacities. Only the kits need to be manufactured in different configurations (different numbers of pickers), significantly reducing manufacturing costs while maintaining high adaptability.
Solution Approach 2:
The variable component (kit with pickers) is extracted from the fixed component (main body). This extraction allows the main body to remain a single standardized design, reducing manufacturing complexity and cost, while the extracted kits can be customized for different tray capacities without affecting the main body production.
3Adaptability or versatility
If the entire pick-and-place module is replaced to change the number of pickers, then the adaptability is improved, but the loss of time increases
Solution Approach 1:
The segmentation into detachable kits allows only the necessary component (the kit) to be replaced rather than the entire module. This reduces replacement time significantly as the main body remains in place and only the kit needs to be attached or detached.
Solution Approach 2:
The kit is designed with dynamic attach/detach capabilities through hook coupling mechanisms. This allows rapid configuration changes without permanent installation or complex assembly procedures, minimizing the time lost when adapting to different customer tray capacities.
4Ease of manufacture
If resources are fully utilized in conventional modules, then the manufacturing cost is reduced, but the adaptability worsens
Solution Approach 1:
The segmentation strategy allows standardization of the main body (achieving economies of scale in manufacturing) while enabling customization of kits for different applications. This resolves the contradiction by maintaining low manufacturing costs through repeated production of the same main body design while achieving high adaptability through varied kit configurations.
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
Enables the pick-and-place module to be universally applicable to customer trays with different loading capacities, reducing manufacturing costs and resource wastage by allowing only the kit to be replaced, thus minimizing replacement time and costs.
Implementation Method 1
a plurality of pickers, arranged in a line, for sucking-picking semiconductor devices or placing them using vacuum pressure
Data Source
AI summary
A pick-and-place module for test handlers is disclosed that includes a main body and a kit. The main body forms vacuum paths therein and the kit also forms vacuum passages therein. The kit is detachably mounted to the main body in a hook coupling manner. The pick-and-place module can be applied to all customer trays having different loading capabilities when only the kit of the pick-and-place module needs to be replaced, so there is no need to manufacture the entire pick-and-place module and this reduces manufacturing costs. The pick-and-place module can reduce the amount of resources to be replaced and reduce the replacement time since the kit can be easily removed from the main body of the pick-and-place module in a hook manner.