Component Placement Unit Single Sensor Alignment
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Solution Overview
Problem
Existing component placement units require separate sensors for component alignment and board alignment, leading to increased costs and reduced accuracy due to the need for mutual calibration, and are sensitive to ambient light and dust, with limited ability to determine external dimensions.
Innovation Solution
A component placement unit that uses a single sensor to produce images of both the component and substrate, with a telecentric optical element and diffuser light source, allowing for accurate component alignment and board alignment without moving parts, reducing sensitivity to ambient light and dust, and enabling precise positioning of components of varying sizes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If separate sensors are used for component alignment and board alignment, then the functionality is complete, but the cost increases and accuracy decreases due to mutual calibration requirements
Solution Approach 1:
The patent combines component alignment sensing and board alignment sensing into a single sensor system. The sensor captures images of both the component held by the nozzle and the substrate, enabling both alignment functions with one device rather than requiring separate sensors that would need calibration relative to each other.
Solution Approach 2:
The single sensor serves multiple functions: it detects component orientation for component alignment, detects substrate features for board alignment, and provides imaging capability for both the component and substrate. This multi-functional approach eliminates the need for separate specialized sensors.
2Reliability
If traditional imaging systems are used, then the structure is simple, but the system is sensitive to ambient light and dust particles
Solution Approach 1:
The patent replaces traditional mechanical shadow-casting methods with optical imaging. Instead of using light sources that cast shadows of components onto detectors (which are sensitive to ambient light), the system uses an imaging sensor that directly captures light reflected from or transmitted through the component and substrate, making the system more robust to environmental conditions.
Solution Approach 2:
The patent introduces a telecentric optical element as an intermediary between the sensor and the component/substrate. This optical element creates telecentric lighting conditions that reduce sensitivity to dust particles and ambient light variations, while the deflection element redirects light paths to achieve the telecentric effect without requiring the sensor to be positioned directly above the component.
3Measurement precision
If a single sensor is used for both component and substrate imaging, then accuracy improves and cost decreases, but the optical system becomes more complex
Solution Approach 1:
The telecentric optical element acts as an intermediary that enables a single sensor to accurately image both the component and substrate simultaneously. The telecentric design ensures that light rays are parallel to the optical axis, eliminating perspective distortion and enabling accurate measurement of both objects at different positions and orientations.
Solution Approach 2:
The patent uses a deflection element to redirect light paths in a different spatial dimension. By deflecting light at 45 degrees, the system allows the sensor to capture images of the component and substrate that are arranged in different spatial planes, enabling both to be imaged by a single sensor without direct mechanical movement of the sensor itself.
4Manufacturing precision
If the optical axis intersects the central axis of the nozzle, then the image quality is sharp, but the system requires moving parts to adjust positioning
Solution Approach 1:
The patent separates the optical axis from the central axis of the nozzle by using a deflection element. Instead of requiring the sensor to be positioned directly on the central axis (which would require moving parts to adjust), the system deflects the optical path at 45 degrees, allowing the sensor to be positioned offset from the central axis while still achieving sharp images of the component and substrate.
Solution Approach 2:
The deflection element serves as an intermediary that redirects light paths between the component/substrate and the sensor. This deflection element enables the optical axis to be positioned independently from the nozzle's central axis, eliminating the need for moving parts to adjust sensor positioning while maintaining image sharpness through proper optical alignment.
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 eliminates the need for separate sensors, enhances accuracy by using a single sensor for both alignments, reduces sensitivity to environmental factors, and allows for faster image production and increased robustness, enabling precise and efficient component placement across different sizes.
Implementation Method 1
a telecentric optical element and diffuser light source, allowing for accurate component alignment and board alignment
Implementation Method 2
a first focus plane of the optical element at least substantially coincides with the central axis of the nozzle, whilst a second focus plane substantially coincides with the sensor
Implementation Method 3
diffuser light source, allowing for accurate component alignment and board alignment
Data Source
AI summary
A component placement unit for placing a component on a substrate, which component placement unit comprises at least one nozzle which is rotatable about a central axis, by means of which a component can be picked up and placed on the substrate. The component placement unit further comprises at least one sensor for determining the orientation of the component relative to the nozzle. At least one optical element is disposed between said sensor and said nozzle. A first focus plane of the optical element at least substantially coincides with the central axis of the nozzle, whilst a second focus plane substantially coincides with the sensor, wherein an image produced by means of the sensor is a contour image of the component.