PCB Through-Hole Component Mounting via Force Sensor Feedback
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Solution Overview
Problem
Manual mounting of through-hole electronic components on printed circuit boards is time-consuming and lacks automation, leading to inefficiencies in production.
Innovation Solution
A method utilizing an industrial robot with a force and/or moment sensor, along with a grasping mechanism, to automate the mounting process by recognizing component positions and adjusting movement based on sensor data to accurately place components within board openings, simulating human-like precision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual mounting of through-hole components is used, then flexibility in handling different components is maintained, but productivity is low and the process is time-consuming
Solution Approach 1:
The force sensor enables the robot to self-adjust its insertion depth by detecting resistance forces during the mounting process, eliminating the need for external vision systems or complex control algorithms. The system serves itself by using tactile feedback to automatically compensate for variations in component and board characteristics.
Solution Approach 2:
The patent replaces traditional mechanical positioning systems with force-based tactile sensing. Instead of using complex mechanical guides or vision-guided positioning, the system uses force sensors to detect and adapt to the mechanical characteristics of the PCB and components during insertion, substituting mechanical precision with force-based control.
2Adaptability or versatility
If fixed insertion depth is used, then manufacturing precision is simplified, but adaptability to different components and board rigidities is reduced
Solution Approach 1:
The force sensor provides real-time feedback during the insertion process, allowing the system to detect resistance changes and automatically adjust insertion depth. This feedback mechanism enables the robot to adapt to different component types and board rigidities without requiring complex pre-programming or external measurement systems.
Solution Approach 2:
The system dynamically changes the insertion depth parameter based on force sensor readings during the mounting process. Instead of using fixed insertion depths, the robot adjusts this parameter in real-time according to the resistance encountered, allowing adaptation to various component and board characteristics through simple parameter modification rather than complex system changes.
3Manufacturing precision
If force sensor with real-time adjustment is used, then adaptability to different board rigidities is improved, but device complexity increases
Solution Approach 1:
The force sensor enables the robot to self-adjust its insertion depth by detecting resistance forces during the mounting process, eliminating the need for external vision systems or complex control algorithms. The system serves itself by using tactile feedback to automatically compensate for variations in component and board characteristics.
Solution Approach 2:
The force sensor acts as an intermediary between the robot and the mounting process, translating physical resistance into actionable control signals. This intermediary device simplifies the overall system by providing direct tactile feedback that the robot can use to adjust its actions, avoiding the need for complex external measurement and control systems.
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 method accelerates the mounting process, automates manual operations, and facilitates short batch production by ensuring precise placement of through-hole electronic elements on PCBs, enhancing production efficiency and reducing manual errors.
Implementation Method 1
with the use of an industrial robot with a force and/or moment sensor
Data Source
AI summary
The invention provides a method of mounting, suitable for placing components on a PCB, by means of an industrial robot that comprises a force and/or moment sensor and means for gripping and transporting a component, said method comprising the steps of drawing a component, transporting the component to a predetermined starting position, taring the force and/or moment sensor, moving the sensor in Z-axis defined as a height over the surface of the board, towards the board, until the component contacts the board surface, activating the regulator with determined parameters, transmitting from the regulator, when output data are stabilized, a signal to means for gripping and transporting of the industrial robot as Z-axis offset, releasing the components from the means for gripping and transporting of the industrial robot if the Z-axis offset is greater than or equal to a preset parameter and establishing the current position of the component as a starting point, moving the component if the Z-axis offset is less than the preset parameter, along a predetermined path, beginning from the current position point, arresting the movement of the component when the force and/or moment sensor detects an opening edge in the board, moving the component away from the opening edge based on data from the force and/or moment sensor, repeating steps g.-j, while a change in the component movement is executed.