Pickup Head Rack Gear Drives Passive Feeder Cartridge
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Solution Overview
Problem
Existing pick-and-place mechanisms face challenges in accurately monitoring spindle position and are bulky, especially when handling small components, due to their pneumatic operation, which limits precise placement on printed circuit boards.
Innovation Solution
A pick-and-place machine with a pickup head that includes a vacuum nozzle system, a rack gear mechanism, and a computer-controlled system for precise linear and angular corrections, using a component camera and collimated light to project a shadow image onto a diffuser screen for accurate component placement, and a modular feeder system that allows for quick setup and interchangeability of feeder cartridges without onboard power.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If pneumatic cylinder is used to drive spindle mounting vacuum head, then pickup and placement function is achieved, but device size becomes excessive and position monitoring becomes difficult
Solution Approach 1:
The patent replaces the pneumatic cylinder system with a mechanical rack and pinion drive system. The pickup head contains a pinion gear that engages with a rack on the spindle, converting rotational motion of the pinion into linear motion of the spindle. This mechanical substitution eliminates the need for pneumatic components, reducing device size while maintaining the pickup and placement function.
Solution Approach 2:
The pickup head is designed to perform multiple functions: it contains both the vacuum generation system for picking up components and the rack-pinion mechanism for spindle actuation. By integrating these functions into a single multi-functional unit, the overall device size is reduced compared to having separate pneumatic systems for each function.
2Ease of operation
If pneumatic cylinder is used to drive spindle, then pickup function is achieved, but manufacturing precision for small components deteriorates
Solution Approach 1:
The patent replaces pneumatic actuation with a mechanical rack and pinion system that provides more precise control over spindle position. The engagement between the pinion gear teeth and rack teeth creates discrete, controllable positioning steps, enabling more accurate placement of small components compared to pneumatic positioning which suffers from monitoring difficulties.
Solution Approach 2:
The patent incorporates position feedback mechanisms to monitor and control the spindle position along its axis. This feedback system allows for precise control of the pickup head's movement, ensuring accurate placement of small components by continuously monitoring and adjusting the position based on actual measurements.
3Extent of automation
If feeder cartridge has onboard power components, then autonomous operation is achieved, but device complexity increases
Solution Approach 1:
The feeder cartridge is designed as a passive component that does not require onboard power sources. Instead, it is driven by the pickup head's pinion gear engaging with the cartridge's rack, allowing the feeder cartridge to be driven by the main system rather than having its own power and control systems. This self-service approach reduces complexity while maintaining functionality.
Solution Approach 2:
The pickup head serves as a universal driving mechanism for multiple feeder cartridges. The same pinion gear on the pickup head can engage with racks on different feeder cartridges, allowing a single multi-functional component to drive multiple passive feeders, thereby reducing overall system 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
Enables precise and efficient placement of small components on printed circuit boards with reduced setup time and increased flexibility, as the machine can accurately correct for linear and angular misalignments and quickly switch between different component configurations.
Implementation Method 1
a component camera cooperating with a collimated light source arranged to project collimated light towards a component held by the pickup device and a diffuser screen disposed between the component and the component camera such that a shadow image of the held component is projected onto the diffuser screen
Implementation Method 2
a vacuum source in fluid communication with the hollow portion
Data Source
AI summary
A pick-and-place machine and method includes use of a passive component feeder cartridge including a feeder gear. Rotation of the feeder gear causes a component-bearing tape to be fed through the feeder cartridge. A pickup head includes a vacuum nozzle to pick up the components from the tape and a rack gear to engage and drive the feeder gear of the feeder cartridge via translational motion of the pickup head when operatively disposed with respect to a selected feeder cartridge.