Optical Referencing in Micro-Assembly for Automatic Drift Correction
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Solution Overview
Problem
Micro-assembly machines face challenges in achieving micrometer-level precision and flexibility due to structural variations, requiring lengthy setup times and manual adjustments, which impact profitability and production efficiency when switching between applications or machines.
Innovation Solution
A micro-assembly machine equipped with a referencing system using fixed and onboard optical devices to automatically correct misalignments and adjust parameters, allowing for automatic setup and transfer of applications between machines.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If mechanical referencing systems are used for positioning, then structural stability is maintained, but manufacturing precision deteriorates due to misalignment and requires lengthy manual adjustments
Solution Approach 1:
The patent replaces mechanical referencing systems with an optical referencing system. Optical devices (cameras, lasers) are used to detect and measure positions and misalignments of machine components, eliminating the need for mechanical probes and manual measurement. This substitution enables automatic correction of misalignments through software-based positioning calculations, dramatically reducing setup time while maintaining micrometer-level precision.
Solution Approach 2:
The optical referencing system enables the machine to automatically detect, measure, and correct its own misalignments without external intervention. The system captures images of reference targets, calculates positional deviations, and automatically adjusts positioning parameters through the control unit. This self-correction capability eliminates the need for operator intervention during setup, reducing setup time from days to minutes while maintaining precision.
2Adaptability or versatility
If manual adjustments are performed for application setup, then adaptability to different applications is achieved, but productivity deteriorates due to lengthy setup periods
Solution Approach 1:
The system performs preliminary automatic referencing and positioning calculations before production begins. Reference targets are positioned and measured in advance, and the control unit pre-calculates all necessary positioning parameters for the upcoming production run. This preliminary setup eliminates the need for time-consuming adjustments during production changes, maintaining adaptability while protecting productivity by reducing setup time to minutes rather than days.
Solution Approach 2:
The optical referencing system enables rapid changes in positioning parameters through software rather than physical adjustments. When switching applications, the control unit automatically loads different reference target configurations and calculates new positioning parameters based on optical measurements. This parameter-based adaptation maintains versatility for different applications while dramatically improving productivity by eliminating manual adjustment time.
3Reliability
If machine settings are transferred between identical machines, then consistency is improved, but manufacturing precision deteriorates due to structural variations requiring additional adjustments
Solution Approach 1:
The optical referencing system implements feedback by continuously measuring the actual positions of machine components relative to reference targets. When transferring applications between machines, the system captures optical data from each machine's specific structural configuration, compares it against the reference application parameters, and automatically calculates correction factors. This feedback loop ensures that application transfers maintain reliability while compensating for structural variations to preserve manufacturing precision.
Solution Approach 2:
The system adjusts positioning parameters dynamically based on optical measurements of each specific machine's structural characteristics. When transferring an application from one machine to another, the control unit modifies positioning parameters according to the measured differences in structural elements detected by the optical referencing system. This parameter adaptation maintains application transferability while compensating for structural variations to ensure positioning accuracy is preserved across different machines.
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
Reduces downtime and setup times, maintaining precision and profitability by enabling automatic correction of misalignments and facilitating machine changes with minimal loss of quality.
Implementation Method 1
a referencing system adapted to automatically correct any misalignment... an optical device arranged on a moving element of the micro-assembly machine... a reference target... positioned within the detection field of the optical device
Data Source
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AI summary
The present invention relates to a micro-assembly machine (1) equipped with a referencing system comprising a referencing base provided with a fixed optical device (31) and a fixed target (32), where the target (32) is positioned within the detection field of the fixed optical device (31), and an onboard optical device (151) for identifying the target (32), so as to detect any misalignment (D151) of the onboard optical device (151) relative to the target, any misalignment (D31) of the fixed optical device (31) relative to the target, or a combination of both. The machine is adapted to automatically correct any drifts. The present invention also covers a method or process of micro-assembly using the present machine.