Two-Stage Robotic Module Insertion with Compliance Element
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Solution Overview
Problem
Robotic assembly systems face challenges in accurately inserting modules, such as DIMMs, into sockets due to real-world variations in pitch, yaw, and rotation, leading to potential damage and board-level failures, especially after the board has entered service life.
Innovation Solution
A two-stage insertion system that includes a compliance element for accommodating positioning disparities, with a first stage for verifying alignment and a second stage for applying sufficient force to seat the module correctly, using a rocker for central insertion force and a floating double disk for flexibility, and incorporating sensors and cameras for precise alignment and force measurement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a robotic assembly system uses high precision positioning to insert modules into sockets, then insertion accuracy is improved, but the system complexity and cost increase due to the need for sophisticated control mechanisms
Solution Approach 1:
The insertion process is divided into multiple discrete stages: approach stage, contact stage, insertion stage, and seating stage. Each stage has specific force thresholds and displacement criteria that must be met before transitioning to the next stage. This segmentation allows the system to achieve high precision through a series of simple, controlled movements rather than requiring complex continuous positioning control.
Solution Approach 2:
The system continuously monitors insertion force and displacement during the insertion process, using this feedback to determine when to transition between stages and when insertion is complete. Force sensors detect the characteristic force curves at each stage (approach, contact, insertion, seating), allowing the controller to automatically adjust the insertion process in real-time without requiring pre-programmed precise positioning.
2Reliability
If the robotic system applies high insertion force to ensure proper module seating, then insertion reliability is improved, but the risk of damaging the module or socket increases
Solution Approach 1:
The system performs preliminary actions at each stage before the final insertion: first establishing contact with the module, then gradually applying force through the insertion stage, and finally completing the seating stage with controlled force. This preliminary progression allows the system to prepare both the robotic mechanism and the module-socket interface for the final high-force seating action, ensuring proper alignment and reducing the risk of damage when maximum insertion force is applied.
Solution Approach 2:
The system uses force monitoring and controlled deceleration to cushion the insertion process. As the module approaches the socket and during insertion, the system detects force increases and automatically reduces insertion speed, preventing impact damage. The controlled seating stage applies force gradually until the module is properly seated, then stops immediately, avoiding excessive force that could damage the module or socket.
3Productivity
If the system uses a single-stage insertion process, then the manufacturing speed is improved, but the accuracy and reliability of module insertion deteriorate due to inability to accommodate positioning variations
Solution Approach 1:
The system dynamically adjusts the insertion process based on real-time conditions. The multi-stage approach allows the system to spend more time on precision-critical stages (contact and insertion) while maintaining speed on less critical stages (approach and seating). The force monitoring and automatic stage transitions create a dynamic process that adapts to each specific insertion event, accommodating positioning variations without requiring excessive overall cycle time.
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
Ensures accurate and damage-free insertion of modules, reducing the risk of board-level failures and enabling reliable assembly processes by accommodating small imperfections and misalignments, thereby improving manufacturing efficiency and reducing rework.
Implementation Method 1
The compliance element provides flexibility enabling the module to shift slightly to accept small misalignments during insertion
Implementation Method 2
a force sensor for detecting an insertion force exerted on the first member by the robot
Data Source
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AI summary
A two-stage insertion system including a gripper to grip a module, a compliance element to provide movement in the XY axis, a first stage insertion control to insert the module into a socket, to a first level, and a second stage insertion control to complete the insertion of the module into the socket, when the first stage insertion control indicates that the module is aligned to the socket, the second level insertion control exerting enough force to complete the insertion of the module into the socket.