Electronic Package Singulation Handling With Vacuum Buffer Transfer
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Solution Overview
Problem
Existing handler systems for electronic packages face challenges in efficiently singulating and handling small packages due to complex and costly setup requirements, unstable positioning, and high conversion kit costs, especially when package sizes decrease and density increases.
Innovation Solution
A singulation handler system comprising an onloader, cutting jig, buffer boat with vacuum holes, gang pick head, and offloader, which allows for precise singulation, stable orientation, and efficient transfer of packages using vacuum suction control and rotary turret devices, enabling cost-effective handling and processing of small packages.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If nesting jig sawing approach is used, then packages can be held during sawing, but device complexity and fabrication cost increase due to complex nests required for small packages
Solution Approach 1:
The patent extracts the nest structure from the sawing process entirely. Instead of using complex nesting jigs to hold packages during sawing, the invention allows packages to be sawn while loosely supported on a flat surface, then immediately picked up by vacuum after cutting. This eliminates the need for complex nest fabrication while maintaining package stability throughout the process.
Solution Approach 2:
The patent uses vacuum suction (pneumatics) to hold and transfer packages. The vacuum head picks up singulated packages directly after sawing and maintains holding during transfer to the buffer plate. This pneumatic holding method replaces complex mechanical nest structures with a simpler, more adaptable vacuum-based system that works effectively for small packages.
2Manufacturing precision
If buffer plate with guiding walls is used, then packages can be positioned on buffer plate, but fabrication cost and device complexity increase
Solution Approach 1:
The patent removes the guiding wall structure from the buffer plate entirely. Instead of using mechanical walls to position packages, the invention uses vacuum holes in the buffer plate that correspond to package positions. The vacuum suction holds packages in place without requiring physical guiding structures, significantly simplifying buffer plate fabrication.
Solution Approach 2:
The buffer plate uses an array of vacuum holes to hold packages in predetermined positions. By applying vacuum through specific holes, the system positions and secures packages without mechanical guiding walls. This pneumatic positioning system is simpler to fabricate and more adaptable to different package layouts.
3Manufacturing precision
If clearance between pocket walls and packages is small, then positioning accuracy improves, but package stability decreases due to unstable positioning
Solution Approach 1:
The patent uses vacuum suction to simultaneously achieve precise positioning and stable holding of packages. The vacuum force pulls packages into alignment with the vacuum holes (achieving precision) and then holds them firmly in place (achieving stability). This pneumatic mechanism resolves the contradiction by providing both accurate positioning and secure stabilization without requiring tight mechanical clearances.
4Adaptability or versatility
If conversion kits are fabricated for different package dimensions, then adaptability improves, but fabrication cost and setup time increase
Solution Approach 1:
The patent employs dynamically adjustable vacuum patterns rather than static mechanical conversion kits. The system can selectively activate different vacuum holes in the buffer plate and vacuum head to accommodate various package sizes and layouts. This dynamic control approach provides versatility for different package dimensions without requiring physical conversion components, reducing both fabrication cost and setup time.
Solution Approach 2:
The vacuum-based holding and positioning system serves multiple functions: it holds packages during transfer, positions them on the buffer plate, and secures them for inspection. This universal vacuum mechanism replaces multiple specialized conversion kits, providing adaptability for different package types through a single, multi-functional system that reduces overall device 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 improves handling efficiency and reduces costs by maintaining package stability and orientation, facilitating accurate processing and storage of small electronic packages with minimal conversion kit complexity, enhancing throughput and precision in handling and inspection processes.
Implementation Method 1
a buffer boat for holding singulated packages that have been removed from the cutting jig and which is operative to convey the singulated packages in a fixed relative orientation
Implementation Method 2
a gang pick head for transferring multiple singulated packages simultaneously from the buffer boat to a rotary turret device
Data Source
AI summary
A singulation handler system is provided for a strip of electronic packages, which comprises an onloader located adjacent to an onloading location for providing an unsingulated strip of packages for singulation and a cutting jig for mounting the strip of unsingulated packages. The cutting jig is movable between the onloading location and a singulation location at which the strip is singulated by a singulation engine. The system further includes a buffer boat for holding singulated packages that have been removed from the cutting jig and which is operative to convey the singulated packages in a fixed relative orientation. A gang pick head is operative to transfer multiple singulated packages simultaneously from the buffer boat to a rotary turret device and an offloader is provided for transferring singulated packages from the rotary turret device to containers in which the singulated packages are storable.