Rotating Dispensing Pump Arrays for Multi-Substrate Alignment
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Solution Overview
Problem
Existing dispensing systems for viscous materials on substrates, such as printed circuit boards, face limitations in production rate due to the rate of accurate and controlled dispensing, part loading/unloading, and process requirements like substrate heating and material flow time.
Innovation Solution
A dispensing system with multiple dispensing pumps configured to simultaneously dispense material on multiple substrates, featuring an adjustable pump array that can rotate in the X-Y plane to match substrate patterns, and an X-Y adjustment mechanism to align pumps with substrate features.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple dispensing units are used to increase production rate, then productivity is improved, but device complexity increases due to mechanical and electrical complexities
Solution Approach 1:
The system divides the dispensing task into multiple independent dispensing units, each capable of operating autonomously on different substrates or different locations. This segmentation allows parallel processing while keeping each unit relatively simple in design, avoiding the need for a single complex multi-functional unit.
Solution Approach 2:
The dispensing units are designed with universal capabilities to perform the same dispensing function across multiple substrates. The system can handle various substrate types and dispensing patterns using the same basic unit architecture, reducing overall system complexity while maintaining versatility.
2Manufacturing precision
If adjustable brackets and X-Y position control are used to align dispensing units, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The dispensing units incorporate self-alignment capabilities through standardized mounting interfaces and self-calibrating mechanisms. The units can automatically adjust their positions and orientations to match substrate patterns without requiring complex external adjustment mechanisms, reducing both complexity and improving precision.
Solution Approach 2:
The system replaces complex mechanical adjustment mechanisms with computer-controlled positioning systems. Digital control algorithms calculate and execute precise positioning commands, substituting mechanical complexity with computational simplicity while achieving higher precision through software-based adjustment.
3Manufacturing precision
If the spacing between dispensing units is adjusted to match substrate patterns, then manufacturing precision is improved, but ease of operation deteriorates due to complex adjustment requirements
Solution Approach 1:
The system incorporates feedback mechanisms that automatically detect substrate patterns and calculate optimal dispensing unit spacing. Sensors and vision systems provide real-time information about substrate positions and orientations, allowing the control system to automatically adjust spacing without requiring manual measurement and adjustment by operators.
Solution Approach 2:
The system performs preliminary alignment calculations and spacing adjustments before the actual dispensing operation begins. Substrate patterns are scanned and analyzed in advance, and dispensing unit positions are pre-configured to match the detected patterns, eliminating the need for complex adjustments during operation.
Data Source
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AI summary
A method of dispensing material includes delivering an electronic substrate to a dispense position. The electronic substrate has at least two identical patterns and at least two fiducial marks. The method further includes capturing at least one image of the at least two fiducial marks provided on the electronic substrate, analyzing the at least one image to determine a position of the electronic substrate in X axis, Y axis and theta directions, calculating a rotational angle of the electronic substrate, and rotating a dispensing pump array to match an angle of the electronic substrate. Alternatively, the electronic substrate can be rotated to match an angle of the dispensing pump array.