Tray Positioner for Robotic Workcells Using Optical Feedback
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Solution Overview
Problem
Current methods for loading components into pick-and-place machines are inefficient, particularly for small quantities, as they require significant effort and are not adaptable for varying component sizes and types, especially when using tape-and-reel or manual loading into trays.
Innovation Solution
A system that includes a light source, detector, and actuator coupled with a processor to automatically position features on a tray by evaluating light intensity and moving the tray to align components with designated locations, allowing for precise placement of components on a pick-and-place machine.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If manual loading methods are used for small quantities of components, then flexibility for different component types is maintained, but significant manual effort and time are required
Solution Approach 1:
The system enables self-service automation where the machine automatically detects component positions using optical sensors and adjusts tray positions without human intervention. The feedback control system continuously monitors and corrects positioning errors, allowing the system to serve itself in achieving precise component placement while eliminating manual loading operations.
Solution Approach 2:
The patent replaces manual mechanical loading operations with an automated optical-mechanical system. Optical detectors sense component positions and generate electrical signals that drive actuators to automatically adjust tray positions, substituting human manual manipulation with sensor-actuator systems that provide both automation and adaptability.
2Productivity
If automated positioning systems are implemented, then productivity and precision are improved, but device complexity increases
Solution Approach 1:
The system employs feedback control where optical detectors continuously monitor component positions and tray locations, compare them against target positions, and generate corrective signals to actuators. This closed-loop feedback mechanism automates the positioning process while maintaining simplicity through iterative error correction rather than complex open-loop control systems.
Solution Approach 2:
The patent introduces optical detectors as intermediary elements between the mechanical tray positioning system and the control system. These detectors convert physical position information into electrical signals that can be processed by the control system, serving as a simple intermediary that bridges the mechanical and control domains without requiring complex direct sensing mechanisms.
3Manufacturing precision
If precise positioning is achieved through manual adjustment, then placement accuracy is maintained, but operator skill and time are required
Solution Approach 1:
The patent substitutes manual visual inspection and adjustment with optical detection systems that automatically sense component positions and generate positioning commands. This replacement eliminates the need for operator skill in visual assessment while maintaining or improving precision through consistent optical measurement capabilities.
Solution Approach 2:
The system performs self-positioning by automatically detecting component locations and adjusting tray positions without human intervention. The feedback control mechanism enables the system to self-correct positioning errors, eliminating the need for manual adjustment operations while maintaining high placement accuracy.
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 efficient and adaptable loading of components onto trays, reducing manual effort and improving the alignment of components for pick-and-place machines, thereby enhancing the processing efficiency of small quantities and varying component sizes.
Implementation Method 1
a first detector coupled to the source and configured to sense the first type of light reflected from the surface of the tray
Data Source
AI summary
Methods and apparatus for the positioning of a feature of a tray such that a robot may place a component in the feature are disclosed.