Ultrasonic Bonding Tooling Alignment via Optical Overlay
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Solution Overview
Problem
The existing methods for aligning tooling elements in ultrasonic bonding systems are time-consuming and costly, particularly when multiple clamping fingers are involved, and are often limited to specific workpieces and bonding systems.
Innovation Solution
A method using an overlay to define the relative position of tooling elements, which involves imaging and adjusting the position of support structures and clamping fingers based on reference locations, allowing for precise alignment and portability across different systems and workpieces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional mechanical dies/gauges are used for aligning tooling elements, then alignment precision can be achieved, but the process becomes expensive and time-consuming
Solution Approach 1:
The patent replaces mechanical dies and gauges with an optical imaging system that captures images of tooling elements and workpieces. The system uses visual field overlays and coordinate transformations to achieve alignment, eliminating the need for physical mechanical alignment tools and significantly reducing alignment time while maintaining precision.
Solution Approach 2:
The patent creates a visual copy of the tooling elements and workpiece positions through imaging. By generating an overlay that represents the desired alignment configuration and comparing it with the actual captured image, the system enables precise alignment without requiring physical alignment fixtures, thus reducing both time and cost.
2Measurement precision
If conventional mechanical dies/gauges are used for aligning tooling elements, then alignment precision can be achieved, but the cost increases due to expensive manufacturing
Solution Approach 1:
The patent replaces expensive mechanical alignment dies and gauges with a software-based optical alignment system. The imaging system and coordinate transformation algorithms provide a cost-effective alternative to manufacturing custom mechanical fixtures for each alignment task.
Solution Approach 2:
The patent creates a universal alignment system that can handle multiple workpiece types and tooling configurations through software programming. Instead of manufacturing separate mechanical dies for each application, the system uses a single imaging system with programmable alignment criteria, reducing manufacturing costs while maintaining precision.
3Measurement precision
If conventional alignment methods are used, then alignment can be achieved for specific workpieces, but the system becomes limited to single workpiece type
Solution Approach 1:
The patent implements a universal alignment system that can accommodate multiple workpiece types and tooling configurations. The imaging system captures various configurations, and the coordinate transformation software adapts the alignment criteria programmatically, enabling the same system to align different workpieces without requiring dedicated mechanical fixtures for each type.
Solution Approach 2:
The patent employs dynamic and adjustable alignment criteria that can be programmed for different workpiece types. The system adapts its alignment parameters and overlay generation based on the specific workpiece being processed, providing versatility while maintaining alignment accuracy across different applications.
4Reliability
If multiple clamping fingers are included in the clamping structure, then workpiece securing capability is improved, but the alignment process becomes more complex and time-consuming
Solution Approach 1:
The patent merges the alignment process for multiple clamping fingers into a single unified imaging and overlay process. Instead of aligning each finger separately using individual mechanical gauges, the system captures an image of all fingers and workpiece positions simultaneously and generates a comprehensive overlay that displays alignment criteria for all elements, significantly reducing alignment time while ensuring proper workpiece securing.
Data Source
AI summary
A method of aligning a subject tooling element of a material handling system of an ultrasonic bonding system is provided. The method includes the steps of: a) providing an overlay defining a relative position of at least a portion of a reference tooling element; b) viewing an image of at least a portion of the subject tooling element combined with a corresponding portion of the overlay; and c) adjusting a position of at least a portion of the subject tooling element by referring to the overlay in the image.