Movable Cart Optical Alignment for SMT Replenishment
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Solution Overview
Problem
Stencil printers and dispensers in the manufacturing of surface-mount printed circuit boards require manual intervention for routine operations such as changing stencils, replacing solder paste cartridges, and replenishing other items, leading to inefficiencies and increased operational costs.
Innovation Solution
A system and method involving a movable cart with a docking station and sensors/lasers for automated alignment and communication with the assembly apparatus, enabling the automated changeover and replenishment of parts and materials, reducing the need for manual intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual intervention is used for changing stencils and replacing solder paste cartridges, then operational flexibility is maintained, but productivity decreases and labor costs increase
Solution Approach 1:
The system divides the replenishment function into separate mobile carts that can independently service multiple assembly apparatuses. Each cart is a self-contained unit with storage compartments for different items (stencils, solder paste cartridges, flux bottles), allowing flexible deployment without requiring integrated automated storage systems at each workstation.
Solution Approach 2:
The mobile cart system enables automated self-service replenishment through robotic arms that automatically transfer items between the cart and assembly apparatus. The system includes automatic identification of required items, automatic retrieval from the cart, and automatic placement at the correct location, eliminating the need for manual operator intervention.
2Loss of time
If manual operations are performed for routine tasks, then system complexity remains low, but loss of time increases due to manual intervention
Solution Approach 1:
The system replaces manual mechanical alignment operations with an optical alignment system using lasers and sensors. Lasers project alignment markers that are detected by sensors on the assembly apparatus, automatically calculating and adjusting positions. This optical system is also used for aligning circuit boards with stencils during the printing process, eliminating manual positioning errors and time consumption.
Solution Approach 2:
The mobile cart serves as an intermediary between centralized storage and multiple assembly apparatuses. It includes automated item identification systems that communicate with the control system to determine which items are needed at which apparatus, and robotic arms that physically transfer items, acting as a mediator that coordinates replenishment across the entire production line.
3Manufacturing precision
If automated alignment systems are implemented, then manufacturing precision improves, but device complexity increases
Solution Approach 1:
The mobile cart design incorporates universal interfaces and standardized storage compartments that can accommodate multiple types of items (stencils, cartridges, bottles) and service multiple different assembly apparatuses. The cart's robotic arm system and alignment system are designed to work with various item types and apparatus configurations, reducing the need for apparatus-specific customization and lowering overall system complexity.
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
The system automates the changeover process, enhancing efficiency and reducing manual labor, allowing for uninterrupted operation and improved production throughput by enabling the automated alignment and supply of replacement parts and materials.
Implementation Method 1
a laser associated with the other of the assembly apparatus and the movable cart. The sensor and the laser are configured to align the movable cart with the assembly apparatus
Data Source
AI summary
A system is provided to align a movable cart to an assembly apparatus. The assembly apparatus has at least one item of a plurality of items for replacement within the assembly apparatus. The assembly apparatus includes a docking station. The movable cart is configured to receive a used item and/or provide a new item to the assembly apparatus. The movable cart includes an interface configured to dock within the docking station of the assembly apparatus. The system includes a sensor associated with one of the assembly apparatus and the movable cart and a laser associated with the other of the assembly apparatus and the movable cart. The sensor and the laser are configured to align the movable cart with the assembly apparatus after an initial docking of the movable cart within the docking station of the assembly apparatus.