Test Head Manipulator with Belt-Driven Enhancement
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Solution Overview
Problem
Existing test head manipulator systems face challenges in providing sufficient vertical range of motion and compliance, especially with larger test heads, due to size constraints and the limitations of pneumatic cylinder arrangements, making it difficult for operators to manually manipulate test heads across different peripherals.
Innovation Solution
A test head manipulator system with a base structure, a main arm unit, and an enhancement mechanism that includes a lift carriage and strap, along with a fluid control system for precise positioning and a rotation unit for rotational output, allowing for enhanced vertical and rotational motion with reduced operational force.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If a pneumatic cylinder arrangement is used to position the test head vertically, then the system is compact and controllable, but the vertical stroke is limited and inadequate for docking with different peripherals
Solution Approach 1:
The patent introduces a belt-driven rotational mechanism that converts vertical linear motion into rotational movement. The test head manipulator rotates about a vertical axis while the test head docks with peripherals at different heights, effectively using rotational dimension to achieve vertical positioning capability without increasing vertical stroke
Solution Approach 2:
The manipulator system is designed to perform multiple functions: it can dock test heads with both device handlers and probers, accommodate different peripheral types, and provide both vertical positioning and rotational orientation. This multi-functionality allows a single system to handle various docking scenarios without requiring multiple specialized actuators
2Ease of operation
If the test head is made compliantly moveable in six degrees of freedom, then manual manipulation is easier, but the physical force required becomes difficult or impossible for certain operators to provide with larger test heads
Solution Approach 1:
The patent implements a compliant mechanism with spring elements that act as counterweights, providing force compensation in the vertical direction. The springs are pre-loaded to offset the weight of the test head, allowing operators to manipulate the test head with minimal force while maintaining six degrees of freedom compliance
Solution Approach 2:
The patent introduces a compliant mechanism as an intermediary between the operator and the test head. This compliant mechanism includes spring elements that mediate the force transmission, reducing the direct force requirement while maintaining controllability and compliance in all six degrees of freedom
3Adaptability or versatility
If the same test head is used to dock with various different peripherals, then cost is reduced, but the manipulator requires a long vertical stroke which is not always practical due to size constraints
Solution Approach 1:
The patent uses a rotational mechanism that allows the test head to be oriented at different angles and positions to accommodate various peripheral types. By rotating the test head about a vertical axis and using belt-driven motion, the system achieves adaptability to different peripherals without requiring a long vertical stroke
Solution Approach 2:
The manipulator system employs dynamic positioning capabilities with adjustable rotational angles and belt-driven vertical motion. This dynamic adjustment allows the same test head to dock with different peripheral types (device handlers, probers) by changing the orientation and position dynamically, rather than requiring fixed long-stroke positioning
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
The system enables compliant motion in six degrees of freedom, allowing for easier and more precise positioning of test heads across various peripherals with reduced manual force requirements, addressing the limitations of existing systems.
Implementation Method 1
certain test head manipulator systems utilize pneumatic cylinders to position and manipulate test heads in the vertical direction
Implementation Method 2
an enhancement mechanism positioned between the main arm unit and the actuator and configured such that movement of the actuator a first distance causes the main arm unit to move along the first axis a second distance that is greater than the first distance
Data Source
AI summary
A test head manipulator system comprising a base structure, a main arm unit configured to support a test head and to be moved relative to the base structure, an actuator having a range of motion of L, and an enhancement mechanism positioned between the main arm unit and the actuator and configured such that movement of the actuator a first distance causes the main arm unit to move a second distance that is greater than the first distance. Additionally, a fluid control system for controlling a test head manipulator system. The pneumatic control system includes a regulator configured to controllably provide an output pressure to the main fluid actuator, and a second fluidly controlled actuator configured to adjust the regulator to modify the output pressure provided to the main fluid actuator. The second actuator is configured to be positively positioned in at least four operating modes with each operating mode causing the regulator to provide a different output pressure to the main fluid actuator.