Vision-Guided Fluid Dispenser for Precise Solder Paste Application
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Solution Overview
Problem
Existing fluid dispensing technologies, both manual and automated, face challenges in dimensional control and quality control, leading to inefficiencies and increased costs due to overcompensation in material application, particularly when connecting electrical components like soldering wires to circuit boards.
Innovation Solution
A fluid dispensing machine equipped with a camera-guided positioning system and controller that dynamically adjusts the fluid dispenser's position based on real-time imaging, allowing for precise dispensing of fluids like solder paste onto substrates with varying layouts, and updates its motion profile to ensure accurate application without excess material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If automated preprogrammed control is used for fluid dispensing, then productivity is improved, but manufacturing precision deteriorates due to inability to account for actual component position variations
Solution Approach 1:
The system uses a camera to capture images of the substrate and components, processes these images to determine actual positions, and feeds this information back to the controller which adjusts the fluid dispenser position accordingly. This closed-loop feedback mechanism enables the automated system to adapt to actual position variations, resolving the contradiction between high-speed automated dispensing and precise dimensional control.
Solution Approach 2:
The system transitions from static preprogrammed control to dynamic adaptive control by using real-time image processing to determine component positions and dynamically adjusting the dispensing parameters. The controller modifies the motion profile based on actual substrate and component positions, enabling the system to maintain precision while operating at high speed.
2Reliability
If automated preprogrammed control overcompensates to ensure connection, then reliability is improved, but loss of substance increases due to extra material application
Solution Approach 1:
The camera-based vision system provides real-time feedback on the actual positions of substrate and components, allowing the controller to calculate precise dispensing parameters without overcompensation. The system determines the exact amount and location of material needed based on measured positions, ensuring reliable connections while minimizing material waste by eliminating the need for excessive material application.
Solution Approach 2:
The system dynamically changes dispensing parameters (position, amount, speed) based on real-time image processing results. By adjusting these parameters according to actual component positions, the system achieves reliable connections with precise material control, avoiding both under-dispensing and over-dispensing conditions that would compromise reliability or waste material.
3Adaptability or versatility
If manual fluid application is used, then adaptability to position variations is improved, but productivity deteriorates due to time consumption
Solution Approach 1:
The system replaces manual mechanical positioning with an automated vision-guided positioning system. The camera captures substrate and component positions, image processing algorithms determine optimal dispensing parameters, and the controller automatically positions the fluid dispenser. This substitution of manual operations with automated vision-based control maintains adaptability to position variations while dramatically increasing dispensing speed and productivity.
Solution Approach 2:
The system performs self-positioning and self-adjustment by using its own camera to detect substrate and component positions, processing these images to determine dispensing parameters, and automatically adjusting its operation without external intervention. This self-service capability enables the system to adapt to position variations as quickly as image processing allows, far exceeding manual adjustment speeds.
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 cost-effective, precise, and efficient fluid dispensing on substrates by using vision guidance to accurately position the fluid dispenser, reducing material waste and enhancing quality control, thereby optimizing the connection process between electrical components.
Implementation Method 1
A guidance system has a camera viewing the fixture that is movable relative to the fixture
Data Source
AI summary
A fluid dispensing machine includes a frame and a fixture held by the frame. The fixture is configured to support a substrate. A positioning system is supported by the frame. A guidance system is supported by the positioning system. The guidance system has a camera viewing the fixture that is movable relative to the fixture. A fluid dispenser is supported by the positioning system and is moved by the positioning system relative to the fixture. The fluid dispenser is configured to dispense fluid onto the substrate. A controller communicates with the positioning system and the guidance system. The controller operates the positing system to control a position of the fluid dispenser relative to the fixture based on an image obtained by the camera.