Test Handler Orientation Correction for LED Throughput
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Solution Overview
Problem
Existing test handlers for electronic devices, such as LEDs, face inefficiencies in orientation correction, leading to high rejection rates and reduced throughput due to the need for multiple pick-and-place steps and reliance on electrical polarity checks, which are ineffective for certain devices.
Innovation Solution
A test handler with an integrated orientation correction unit that includes a package support and an actuable orientation correction device capable of rotating the package support to correct the orientation of electronic devices along their transport path to a testing station, utilizing optical inspection and a movable insert with a locking mechanism for efficient orientation adjustment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If electrical polarity checking is used to determine LED orientation, then orientation can be verified, but the process requires multiple pick-and-place steps and reduces throughput
Solution Approach 1:
The patent replaces the mechanical pick-and-place system with an optical sensing system. Optical sensors detect LED orientation directly on the linear track without requiring physical manipulation, eliminating multiple indexing motions and maintaining continuous feed rate while achieving accurate orientation detection.
Solution Approach 2:
The patent extracts the orientation detection function from the mechanical handling process. By using optical sensors to detect orientation on the linear track, the system separates detection from manipulation, allowing LEDs to be indexed directly to the turret handler without rejection and return to the bowl feeder.
2Reliability
If LEDs are rejected and returned to the bowl feeder for re-orientation, then incorrect orientations can be corrected, but the feed rate is reduced by approximately half
Solution Approach 1:
The patent performs preliminary orientation correction by integrating an orientation correction unit on the linear track that adjusts LED orientation before indexing to the turret handler. This preliminary action ensures correct orientation is achieved during the initial feed, eliminating the need for rejection and return trips to the bowl feeder.
Solution Approach 2:
The patent merges the orientation correction function with the linear track transport system. The orientation correction unit is integrated into the linear track, combining transport and correction functions in one continuous process, thereby eliminating the separate rejection and re-feeding cycles.
3Ease of operation
If multiple indexing motions are used for orientation correction, then orientation can be adjusted, but device handling time increases
Solution Approach 1:
The patent creates a universal linear track system that handles multiple functions: transport, optical sensing, and orientation correction. This multi-functional integration eliminates the need for separate indexing motions dedicated solely to orientation adjustment, maintaining high throughput while providing comprehensive device handling capability.
Data Source
AI summary
A test handler comprises a package support for holding an electronic device in a certain orientation and for transporting the electronic device to a testing station for testing the electronic device. An orientation correction device is actuable and operative to engage the package support and to rotate the package support so as to change the orientation of the electronic device.