Pick-and-Place Head With Integrated X-Y Pitch Conversion
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Solution Overview
Problem
Conventional pick-and-place devices are slow and cannot meet the desired machine throughput targets due to the need for sequential pitch conversion at external stations, limiting their efficiency in handling components of varied sizes and formats.
Innovation Solution
A pick-and-place system with multiple self-contained stations and devices capable of automatic X and Y coordinate pitch conversions, utilizing drive motors, movement transfer elements, and engagement arms to simultaneously adjust the pitch of pickup tips, enabling flexible and simultaneous pitch adjustments across multiple devices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple pickup heads are utilized to increase machine throughput, then productivity is improved, but device complexity increases due to the need for multiple pitch conversion mechanisms
Solution Approach 1:
The system divides the pitch conversion function into separate modular units, with each pickup head having its own integrated pitch conversion mechanism. This segmentation allows each unit to operate independently, enabling multiple pickup heads to process components simultaneously without interfering with each other, thus maintaining high productivity while managing complexity through modularity.
Solution Approach 2:
Each pickup head is designed as a universal module that can handle different component types and pitches through its integrated pitch conversion mechanism. This multi-functionality allows a single standardized pickup head design to serve multiple purposes across different product configurations, increasing productivity without proportionally increasing overall system complexity.
2Adaptability or versatility
If external auto pitch stations are used for pitch conversion, then adaptability is improved, but productivity deteriorates due to sequential processing requirements
Solution Approach 1:
The pitch conversion mechanism is merged directly into each pickup head, combining the pitch adjustment function with the component pickup function in a single integrated unit. This eliminates the need for separate external pitch conversion stations and sequential processing, allowing adaptability to different pitches while maintaining continuous parallel operation across multiple pickup heads.
Solution Approach 2:
The system transitions from a centralized external pitch conversion approach to a distributed integrated approach, adding the pitch conversion capability as an intrinsic dimension of each pickup head rather than as a separate external process. This dimensional integration enables simultaneous pitch conversion and component handling, resolving the contradiction between adaptability and productivity.
3Device complexity
If sequential pitch conversion at external stations is implemented, then device complexity is reduced, but loss of time increases due to sequential movement and processing
Solution Approach 1:
The pitch conversion mechanism is prepared and integrated within each pickup head in advance, so that pitch adjustment can be performed immediately when needed without requiring movement to external stations. This preliminary integration eliminates the time loss associated with sequential transport and conversion operations.
Solution Approach 2:
The integrated pitch conversion mechanism enables continuous pitch adjustment operations to be performed alongside component pickup and placement operations. This continuity eliminates idle time and sequential processing delays, maintaining constant productive action across all pickup heads simultaneously.
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
Enhances machine throughput by allowing simultaneous pitch conversions across multiple devices, accommodating varied component sizes and formats without the need for sequential movement to external stations, thereby optimizing operational efficiency.
Implementation Method 1
a first drive motor, a plurality of movement transfer elements for transferring rotary motions of the first drive motor to cause a pair of X-pitch bands to move in a linear direction
Implementation Method 2
a second drive motor, a plurality of movement transfer elements for transferring rotary movements of the second drive motor to a pair of Y-pitch arms to cause a pair of Y-pitch rods to move in a linear direction
Implementation Method 3
a plurality of movement transfer elements for transferring rotary motions of the first drive motor to cause a pair of X-pitch bands to move in a linear direction
Data Source
AI summary
There is a component pick-and-place system having a control unit, at least one transport line for transporting a plurality of component trays; and at least one transfer line for transferring a plurality of pick-and-place (PnP) devices. Each of the plurality of PnP devices has a control and valve unit, an automatic pitch conversion unit having at least one column/module and at least one row of pickup tips positional at a parking area and an active area. The automatic pitch conversion unit has a X-pitch conversion mechanism and a Y-pitch conversion mechanism. The X-pitch conversion mechanism has a first drive motor, a plurality of movement transfer elements for transferring rotary motions of the first drive motor to cause a pair of X-pitch bands to move in a linear direction, and a pair of engagement arms that are slidably engaged to the pair of X-pitch bands for sequentially engaging a column of pickup tips to move to a desired X-pitch position. The Y-pitch conversion mechanism has a second drive motor, a plurality of movement transfer elements for transferring rotary movements of the second drive motor to a pair of Y-pitch arms to cause a pair of Y-pitch rods to move in a linear direction, and a pair of pickup tip holders slidably engaged to the pair of Y-pitch rods for simultaneously moving the plurality of rows of pickup tips to a desired Y-pitch position.