Vision Alignment System Guiding Rings IC Testing

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Solution Overview

Problem

Existing IC device testing handlers face challenges with inaccurate and expensive vision alignment systems that lack precision and repeatability, particularly due to space limitations and the need for multiple rotation stages.

Innovation Solution

A vision alignment system comprising a head guiding ring, a socket apparatus with moveable guiding rings and actuators, and visualization devices to accurately align device contact arrays with contactor pin arrays, utilizing actuators like shape memory alloy wires and air bearings for precise adjustments.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If traditional mechanical alignment is used without cameras, then the system is simpler and less expensive, but the alignment accuracy and precision are limited by manufacturing tolerances

Engineering Contradiction:

Improvealignment accuracyVSAvoidsystem complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The patent replaces traditional mechanical alignment systems with a vision-based alignment system that uses cameras to capture images of alignment features and calculates precise positioning data, eliminating reliance on mechanical tolerances for alignment accuracy

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces guiding rings with fiducial markers as intermediary alignment features that facilitate precise positioning by providing visual reference points for the camera system to capture and process

Inventive Principle:

Principle #24Intermediary (Mediator)

2Measurement precision

If vision alignment systems with x, y, and rotation stages are used, then alignment accuracy improves, but space limitations and system cost increase

Engineering Contradiction:

Improvealignment accuracyVSAvoidspace requirements

Core Design Contradiction:

Measurement precisionVSArea of stationary object

Solution Approach 1:

The patent extracts and eliminates the rotation stage component from traditional vision alignment systems by implementing rotation directly on the pick-and-place head, thereby reducing space requirements while maintaining alignment capabilities

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The pick-and-place head is designed with multi-functionality, incorporating both picking/placing operations and rotation capabilities in a single integrated component, eliminating the need for separate rotation stages

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Adaptability or versatility

If individual device pick-and-place mechanisms with one rotation stage per head are used, then device handling flexibility improves, but accuracy and repeatability decrease while cost increases

Engineering Contradiction:

Improvedevice handling flexibilityVSAvoidaccuracy and repeatability

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The patent merges the rotation functionality into the pick-and-place head itself, creating an integrated mechanism that maintains device handling flexibility while improving accuracy and repeatability through unified control of positioning and rotation operations

Inventive Principle:

Principle #5Merging (Combining)

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 achieves high accuracy and repeatability in aligning IC device contact arrays with contactor pin arrays, overcoming space limitations and reducing costs by using linear actuators and vision alignment, enabling multiple plunges and parallel testing.

Implementation Method 1

the precising mechanism is a spring-loaded shape memory alloy wire based precising mechanism

Methodology Applied

Scientific EffectShape memory alloy: Shape Memory Alloy

Implementation Method 2

the floating mechanism includes a plurality of air bearings

Methodology Applied

Scientific EffectAir lubrication: Air Lubrication

Data Source

PatentUS9857419B2Micro-vision alignment system with guiding rings for IC testing

Publication Date: 2018.01.02 DELTA DESIGN INC

AI summary

A vision alignment system for an integrated circuit device testing handler includes a head guiding ring configured to be attached to a pick-and-place device, the head guiding ring having an opening in which a device-under-test having a device contact array is locatable; a socket apparatus including: a fixed mounting frame, a moveable socket guiding ring, and a plurality of actuators configured to move the moveable socket guiding ring relative to the fixed mounting frame; and a visualization device configured to provide data relating to a position of the device contact array relative to the contactor pin array. The socket apparatus is configured to adjust a position of the head guiding ring by moving the moveable socket guiding ring while the head guiding ring is located in an opening of the moveable socket guiding ring to align the device contact array to the contactor pin array.