Automated Multi-Head Needle Cleaner for Dispensing Systems
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Solution Overview
Problem
Existing dispensing systems face challenges in efficiently cleaning multiple nozzles or needles, particularly in systems with continuous drive for lowering cycle time in circuit board assembly, due to the difficulty in manual intervention and adjustment for cleaning nozzles.
Innovation Solution
A material deposition system with a multiple needle cleaner assembly and a controller that automates the cleaning process, using a gantry system to move deposition heads and needle cleaners, and a vision system to verify and adjust needle positions, allowing simultaneous cleaning of multiple heads without manual intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If manual cleaning of nozzles is performed in multi-head dispensing systems, then cleaning can be accomplished, but operator intervention is required and cycle time increases
Solution Approach 1:
The dispensing heads are equipped with self-diagnostic capabilities that automatically detect nozzle clogging conditions and initiate cleaning operations without operator intervention. The system monitors its own state and performs maintenance functions autonomously, transforming manual cleaning into an automated self-service process.
Solution Approach 2:
The patent replaces manual mechanical cleaning operations with automated mechanical systems. A robotic mechanism automatically positions cleaning tools relative to the nozzles and performs cleaning actions, substituting human operators with automated mechanical systems that can operate continuously without intervention.
2Productivity
If multiple nozzles are cleaned simultaneously, then cycle time is reduced, but positioning accuracy and cleaning precision become more difficult to maintain
Solution Approach 1:
The system incorporates sensors and vision systems that continuously monitor the positions of multiple nozzles and the cleaning mechanism. Real-time feedback data is used to dynamically adjust positioning, ensuring that each nozzle is accurately located and cleaned with the same precision as single-nozzle cleaning, even when multiple nozzles are processed simultaneously.
Solution Approach 2:
The cleaning mechanism is designed as a universal system capable of handling multiple nozzle types and configurations through a single integrated apparatus. The system can adapt to different nozzle arrangements and automatically adjusts its positioning and cleaning parameters to maintain precision across all nozzles being cleaned simultaneously.
3Productivity
If continuous drive for lowering cycle time is implemented, then productivity increases, but the ability to sufficiently clean nozzles deteriorates
Solution Approach 1:
The system performs preliminary cleaning actions during idle periods between dispensing operations or during substrate transfer times. By utilizing non-productive time for maintenance functions, the system maintains effective nozzle cleaning without extending the overall assembly cycle time, thus preserving both productivity and cleaning effectiveness.
Solution Approach 2:
The cleaning system operates continuously throughout the dispensing process rather than as intermittent manual interventions. The automated cleaning mechanism runs continuously at optimized intervals, ensuring nozzles are consistently clean without stopping the main production flow, thereby maintaining both high productivity and reliable cleaning effectiveness.
Data Source
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AI summary
A material deposition system is configured to deposit material on an electronic substrate, such as a printed circuit board. The material deposition system includes a frame (20), a support (22) coupled to the frame (20) and configured to support an electronic substrate during a deposit operation, a gantry (24) coupled to the frame (20), and two deposition heads (14, 16) coupled to the gantry (24). Each deposition head includes a needle, with the deposition heads (14, 16) being movable over the support (22) by movement of the gantry (24). The material deposition system further includes a needle cleaner assembly movable on a needle cleaner gantry (24), with the needle cleaner assembly being configured to clean needles of the deposition heads (14, 16). The material deposition system further includes a controller (18) configured to control the operation of the needle cleaner assembly to perform a needle cleaning operation.