ELECTRICAL COMPONENTS FEEDING AND DELIVERY SYSTEM
FIELD OF THE INVENTION This invention relates to an improved feeder for supplying electrical components to a pick up location. The invention is particularly useful for, but not necessarily limited to, supplying surface mountable electrical components, stored in hoppers, to pick up locations for subsequent mounting to a circuit board.
BACKGROUND ART Component feeding is a well-known process in Surface Mounting Technology (SMT). In general, a feeder is used to sequentially supply surface mountable electrical components to a pick up location for subsequent placing, by a pick-and-place machine, onto a Print d Circuit Board (PCB) which is pre-printed with solder paste.
One form of feeder is a tape and reel feeder in which the electrical components are packaged on a tape that is wound onto a reel. The tape comprises individual pockets each containing one of the electrical components that are individually sealed in the pockets by a covering of thin film. In use, the film is removed when the tape enters the pick up location therefore leaving a pocket containing one of the electrical components in a position accessible by the pick-and-place machine. Unfortunately, the tape is substantially wider than the components located in the pockets that increases the width of the feeder. Further, the reel and apparatus for removing the film also add to the width and overall size of the feeder.
Hopper feeders also known as bulk or tube feeders are an alternative to tape and reel feeders. Hopper feeders comprise a hopper in communication, along a downwardly sloping passage, with the pick up location. The downwardly sloping passage makes use of gravity for supplying the components to the pick up location. To further assist the supplying of the components to the pick up location a combination of gravity and air blasting has also been used. The pick up location has an abutment wall and an aperture. The abutment wall abuts the components supplied from the hopper before
they are removed, through the aperture, by the pick-and-place machine. The supply of components to the pick up location must be controlled, otherwise undesirable amounts of friction between the abutment wall and an abutting component can result. This friction is due to i mass of stacked components in the downwardly sloping passage pushing the abutting components into the abutment wall. Accordingly, this friction may cause problems when the pick-and-place machine attempts to remove the abutting component. Further, unnecessary friction between the abutting component and an adjacent component can further hinder the removal of the abutting component.
In order to reduce the friction described above, the supply of components to the pick up location is mechanically controlled to separate components in the downwardly sloping passage from a component in the pick up location. For example, one conventional approach is to use a pneumatically controlled slotted disk located horizontally in series between the pick up location and sloping passage. The slotted disk has two diametrically opposite slots for sequentially engaging a component. The disk rotates through 180 degrees in a timed sequence to thereby transport an individual component, engaged in one of the slots, from the passage to the pick up location.
The above conventional mechanically controlled component separation approach requires valuable limited space. This is primarily due to the disk being substantially larger than the components and for practical reasons it is located horizontally therefore increasing the width of the feeder.
In use, both conventional hopper feeders or tape and reel feeders are positioned on either sides of a conveyor track extending along a length of a pick-and-place machine. The conveyor track transports printed circuit boards into an area of the pick-and-place machine to allow components, fed from the hopper feeders or tape and reel feeders, to be mounted to the circuit boards. Such pick-and-place machines are expensive and their length is relatively short. Accordingly, there is typically less than 400 hopper or tape and reel feeders, or combinations of both, used per pick-and-place machine (200 either side of the track). As a result extra pick-and place machines may be required to complete the mounting of components to the circuit boards. This therefore can result
in increased manufacturing and maintenance costs. Further, both conventional bulk feeders and tape and reel feeders have moving parts that can also increase costs associated with maintenance.
SUMMARY OF THE INVENTION
It is an aim of this invention to overcome or alleviate at least one of the problems associated with prior art feeders.
According to one aspect of this invention there is provided a feeder for supplying electrical components to pick-and-place machine, the feeder comprising: at least one storage means for storing some of said components; a pick up location for supplying said components to said pick-and- place machine; a channel providing communication between said storage means and said pick up location, said channel comprising an upwardly inclined portion which is upwardly inclined towards said pick up location; and a movement means for moving said components up said upwardly inclined portion and towards said pick up location. Suitably, said movement means may include a fluid pushing means for assisting said components up said upwardly inclined portion. Suitably, an end of said upwardly inclined portion may be directly coupled to said pick up location.
In an alternative form there may be an intermediate portion of said channel between said pick up location and said upwardly inclined portion.
Suitably, said intermediate portion may have a component supporting surface angled relative to a component supporting surface of said upwardly inclined portion. The said component supporting surface of said intermediate portion may be substantially aligned in a horizontal plane.
Preferably, a component supporting surface of said pick up location can be angled relative to a component supporting surface of said upwardly inclined portion. The said component supporting surface of said pick up location may be substantially aligned in a horizontal plane.
Suitably, said channel may include a first portion providing communication between said storage means and upwardly inclined portion, wherein a length of said first portion is angled relative to said upwardly inclined portion. Preferably, there may be a fluid stopping means for stopping at least some of said components from sliding out of said upwardly inclined portion and into said first portion.
Suitably, said fluid stopping means and said fluid pushing means may each comprise at least one air jet operatively coupled to a compressed air supply, wherein said air supply is controllable to selectively supply air to either said air jet.
Preferably, said storage means may be a hopper having associated agitation means.
Preferably, a said air jet of said fluid pushing means may be located said hopper to thereby provide said agitation means.
BRIEF DESCRIPTION OF THE DRAWINGS In order that the invention may be readily understood and put into practical effect, reference will now be made to a preferred embodiment illustrated in the accompanying drawings in which:
Fig. 1 is a side view of a preferred embodiment of a feeder in accordance with this invention;
Fig. 2 is a plan view of the feeder of Fig. 1; Fig. 3 illustrates the feeder of Fig. 1 in operation; and Fig. 4 is a plan view of a plurality of feeders of Fig. 1 when mounted adjacent a conveyor track of a pick-and-place machine.
DETAILED DESCRIPTION OF THE
PREFERRED EMBODIMENT OF THE INVENTION Referring to Figs. 1 to 3 there is illustrated a feeder 1 for supplying electrical components to pick-and-place machine. The feeder 1 comprises a storage means in the form of a hopper 2, a pick up location
3 and a channel 4. The channel 4 provides communication between the hopper 2 and the pick up location 3 so that electrical components 20 in hopper 2 can transferred to the pick up location 3.
The channel 4 comprises an upwardly inclined portion 5 that is upwardly inclined towards the pick up location 3. There is a fluid stopping means in the form of an air jet nozzle 6 located in the first portion 12. The channel 4 has an intermediate portion 7 between the pick up location 3 and the upwardly inclined portion 5. The intermediate portion 7 has a component supporting surface 8b in a horizontal plane. Accordingly, the supporting surface is angled relative to a component supporting surface 8a of the upwardly inclined portion 5.
The pick up location 3 has a component supporting surface 9 that is aligned with surface 8b. There is also an abutment wall 10 for stopping and positioning the components 20 and access aperture 11 for allowing removal of the components 20, by a pick-and-place machine (not shown), from pick up location 3.
The channel 4 also has a first portion 12 and second portion 13 angled relative to each other. The second portion 13 is coupled at one end to an outlet 21 of the hopper 2 and at the other end to an end of the second portion 12. The other end of the second portion 12 is coupled to an end of the upwardly inclined portion 5 and the first portion 12 is angled relative to the upwardly inclined portion 5. There is a combined agitator and fluid pushing means in the form of an air jet nozzle 14 located in hopper 2, adjacent the outlet 21, for pushing the components 20 up the upwardly inclined portion 5 towards the pick up location 3. An air conduit 17 allows for air to be supplied to nozzle 14 and another air conduit 18 allows for air to be supplied to nozzle 6.
The channel 4, pick up location 3, hopper 2 and air conduits 17, 18 are machined into a surface of a block 15 and enclosed by a transparent plate 16 that is glued and bolted to the block 15 (bolts not shown).
In use, the conduits 17 and 18 are operatively coupled to a controlled pulsed compressed air supply. The air supply provides a blast of air through nozzle 14 that agitates the components 20 in hopper 2. Accordingly, after each air blast through nozzle 14 one or more components 20 may drop through the outlet 21 into the second portion 13. The components 20 in the second portion will usually slide in the direction of arrow A into the first portion 12 and form a queue.
If there is available space in the upwardly inclined portion 5, a subsequent air blast through nozzle 14 will push the components 20 in the portions 13 or 14 up the upwardly inclined portion 5 (in the direction of arrow B). Further, if there is available space, a leading one of the components 20 in the queue will be pushed into the intermediate portion 7. However, if there is no available space in the intermediate portion 7, upon completion of an air blast the components 20 will slide down the inclined portion 5 in the direction of arrow C due to the effects of gravity. To stop the components located in the inclined portion 5 from sliding into first portion 12, the controlled pulsed compressed air supply is supplied through nozzle 6 at intervals between the air blasts through nozzle 14.
When there is no component located in pick up location 3, the next air blast will push the leading one of the components into location 3. This leading component will abut wall 10 and be positioned underneath the access aperture 11 ready for removal by a pick-and-place machine. Further, if there is a component 20 located in the intermediate portion 7, this will push against, and assist in, maintaining abutment of the leading component against the wall 10.
Referring to Fig. 4 there is illustrated a plan view of a plurality of feeders 1 mounted adjacent a conveyor track 22 of a pick-and-place machine. The conveyor track 22 is used to transport a printed circuit board 24 to a position near the pick up locations 3 so that a robot arm 25 can remove the components in the locations 3 via the access apertures 11. The robot arm 25 then places the components onto the board 24 in their required positions.
As illustrated, there is only one transparent plate 16 that is glued and bolted to an end block 15. All other blocks 15 abut a surface of an adjacent block 15 that advantageously reduces the overall width of the feeders 1. Accordingly, more feeders 1 can be positioned along a length of the conveyor track 22. Further, there are flexible conduits 26, 27 respectively coupling each of conduits 18,17 to a controlled pulsed pressurized air supply 28. The flexible conduits 26,27 are connected to respective outlets of conduits 18,17 located on an underside surface of each feeder 1 that also reduces the overall width of the feeders 1.
The present invention as described above advantageously limits the amount of friction of components 20 against the abutment wall 10 without the need for slotted disks and the like.
Another advantage of the present invention is that there are no mechanical parts for controlling the supply of components 20 to the pick up location 3 of each feeder. This advantageously also reduces the width of each feeder 1 and therefore improves space utilization. As a result, this can lead to a reduced number of pick-and-place machines being required to manufacture products when compared with prior art feeders. Further, because the present invention does not require moving parts or sensors to supply the components 20 to the pick up locations 3, maintenance costs can be reduced.
Although this invention has been described with reference to a preferred embodiment, it is to be understood that the invention is not limited to the specific embodiment described herein.