Pickup Head Force Calibration via Gap Height Sensing
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Solution Overview
Problem
Conventional semiconductor component handling devices face challenges in precisely calibrating and monitoring the force exerted by pickup heads, leading to inconsistent and potentially damaging component retrieval, especially with fragile components, due to manual calibration processes that are time-consuming and prone to human error.
Innovation Solution
A system that automatically sets and adjusts the force exerted by pickup heads using a sensor and resilient member, with a detection structure and gate mechanism to correlate gap heights with compressive force thresholds, enabling real-time monitoring and calibration of pickup head travel to ensure consistent and safe component handling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If manual calibration processes are used to set pickup head force, then device complexity is reduced, but manufacturing precision and reliability deteriorate due to human error and time-consuming procedures
Solution Approach 1:
The system performs automatic calibration using a sensor to detect gap height and a controller to compute and adjust compressive force, eliminating the need for manual calibration operations. The pickup head assembly self-regulates force through feedback from the sensor and processing by the controller.
Solution Approach 2:
Manual mechanical calibration procedures are replaced with an automated system combining optical/electronic sensors, computational algorithms, and electronic control signals to the resonant member, substituting human-operated mechanical adjustment with automated sensing and control.
2Device complexity
If manual calibration is performed, then device complexity remains low, but loss of time increases due to time-consuming calibration procedures
Solution Approach 1:
The calibration process is automated through self-service operation where the sensor detects gap height, the controller computes the required compressive force, and the system automatically adjusts the resonant member position without requiring operator intervention or manual measurement procedures.
Solution Approach 2:
The calibration system enables continuous operation by eliminating idle calibration time between production cycles. The automatic sensing and adjustment allow the system to rapidly complete calibration and return to productive component handling operations.
3Reliability
If higher force is exerted by pickup head, then reliability of component holding improves, but object-affected harmful factors increase due to component damage risk
Solution Approach 1:
The sensor provides feedback on the actual gap height between the pickup head and component surface. The controller uses this feedback to compute the appropriate compressive force and adjust the resonant member position, ensuring sufficient holding force while preventing excessive force that could damage fragile components.
Solution Approach 2:
The system dynamically adjusts the compressive force parameter based on real-time gap height measurements. By changing the force parameter in response to detected variations in component position or pickup head wear, the system maintains optimal holding reliability while avoiding damage from excessive force.
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 solution automates the calibration and monitoring of pickup head forces, reducing the likelihood of component damage, improving handling precision, and increasing throughput by eliminating human error and manual calibration time.
Implementation Method 1
A sensor may be located within the variable second gap such that the sensor detects portions of the detection structure
Implementation Method 2
A resilient member may reside within the housing and the reference structure such that the spring guide holder and the housing are spaced from each other to define a variable first gap thereinbetween
Data Source
AI summary
A system is disclosed for calibrating the compressive forces exerted on a component during a component retrieval process from a carrier or support surface by a component handling device. The system includes a sensor, a component pickup assembly having a reference structure, a housing and a spring guide holder coupled to a suction tip. A resilient member may reside within the housing and the reference structure such that the spring guide holder and the housing are spaced from each other to define a variable first gap thereinbetween. A gate is formed by the reference structure and a sheath located on the housing whereby the reference structure is spaced from the housing to define a variable second gap thereinbetween. A detection structure is located within the variable second gap such that the sensor is able to detect portions of the detection structure. The detected portion of the detection structure or element at the second gap size is correlated to the height of the variable first gap and the height of the variable first gap is correlated to a reference predetermined threshold compressive force exerted on the component by the resilient member.