Replacement Parts Container Mapping to Prevent Robot Collisions
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Solution Overview
Problem
Conventional mapping routines for substrate containers in electronics processing systems can cause damage when applied to containers holding replacement parts due to the mismatch in size and type, leading to potential collisions with robot arms and containers.
Innovation Solution
A detection system at the end effector of a robot arm uses an emitting and sensing component to identify the positions of replacement parts and determine regions without parts, employing distinct mapping patterns to accurately map and record the positions of replacement parts and wafers, avoiding damage by adapting to the specific characteristics of replacement part containers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a conventional mapping routine is used for substrate containers, then the mapping process can be completed, but damage may occur to the robot arm, container, or objects due to mismatch in size and type
Solution Approach 1:
The system performs preliminary detection of object positions and types before executing the mapping routine. The detection system scans the container to identify replacement parts and their locations, allowing the robot arm to adjust its movement pattern in advance to avoid collisions and damage.
Solution Approach 2:
The mapping routine is made dynamic by adapting the robot arm's movement pattern based on detected object characteristics. The system modifies the mapping trajectory in real-time according to the actual positions and types of replacement parts, rather than following a fixed conventional pattern designed for substrate containers.
2Measurement precision
If the detection system scans the entire container, then all objects can be identified, but system latency increases
Solution Approach 1:
The detection system performs partial scanning by focusing only on relevant regions of the container where replacement parts are likely to be located. Instead of scanning the entire container uniformly, the system identifies and scans specific areas of interest, reducing the total scanning time while maintaining sufficient detection accuracy for the mapping operation.
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
This approach reduces the likelihood of end effector and object damage, enhances retrieval success, decreases system latency, and minimizes operational costs by ensuring correct retrieval of replacement parts.
Implementation Method 1
The detection system detects an object responsive to a beam directed from the emitting component to the sensing component being broken by the object
Data Source
AI summary
A system includes a factory interface, a load port, and a controller. The controller detects when a container is received at the load port, where the container stores one or more parts. The controller directs a detection system, via one or more robot arms, to move according to one or more mapping patterns to obtain a mapping of the container, indicating regions and positions of detected parts. This mapping is recorded in a storage medium. Based on the mapping, the controller identifies any misalignment or misorientation of detected parts within the container. If such an issue is detected, the controller transmits an error message to a system controller associated with the manufacturing system, specifying the misalignment or misorientation of the affected part.