Integrated testing and handling mechanism

Abstract

An integrated testing and handler mechanism includes an input/output module including: an input section, an output section, a turret that includes a plurality of pickup heads, and a shuttle configured to move the carrier from the component loading location to a test module transfer location; and a test module including: a test head comprising an array of a plurality of test sockets, a plunger configured to plunge the components held by the carrier into the test sockets when the carrier is located on the plunger, and a rotary table that includes a plurality of grippers that rotate around the rotary table, the rotary table being configured to (i) transfer a carrier between the test module transfer location and an input/output module transfer location, (ii) rotate the carrier between the input/output module transfer location and a plunger transfer location, and (iii) transfer the carrier between the plunger transfer location and plunger.

1 .- 43 . (canceled) 
     
     
         44 . A method comprising:
 providing a carrier having a plurality of holes defined in a surface thereof, the carrier comprising a first vacuum interface in communication with the plurality of holes, and a second vacuum interface in communication with the plurality of holes;   connecting the first vacuum interface of the carrier to a first vacuum generator such that the first vacuum generator communicates with the plurality of holes;   applying a vacuum to the components through the plurality of holes using only the first vacuum generator;   placing a plurality of components on the surface of the carrier while the first vacuum generator applies the vacuum through the plurality of holes;   connecting the second vacuum interface of the carrier to a second vacuum generator such that the second vacuum generator communicates with the plurality of holes;   applying a vacuum to the components through the plurality of holes using the second vacuum generator, in addition to the first vacuum generator;   disconnecting the first vacuum interface of the carrier from the first vacuum generator, such that the first vacuum generator ceases application of the vacuum through the plurality of holes, and the vacuum is applied to the components through the plurality of holes using only the second vacuum generator.   
     
     
         45 . The method of  claim 44 , further comprising:
 transporting the carrier from a location at which the components were placed on the surface of the carrier, to another location, while the vacuum is applied to the components through the plurality of holes using only the first vacuum generator.   
     
     
         46 . The method of  claim 44 , wherein the step of placing the components on the surface of the carrier is performed using at least one component handling head disposed on a rotatable turret. 
     
     
         47 . The method of  claim 44 , wherein the step of connecting the second vacuum interface of the carrier to the second vacuum generator comprises receiving the carrier in a gripper such that, when the carrier is received in the gripper, the second vacuum generator communicates with the plurality of holes via the second vacuum interface. 
     
     
         48 . The method of  claim 47 , wherein the gripper is a part of rotary table, and the method further comprises transporting the carrier to a conductive soaking area, and adjusting a temperature of the carrier using a heating or cooling device while the carrier is in the conductive soaking area. 
     
     
         49 . A component handling assembly comprising:
 a first vacuum generator;   a second vacuum generator; and   at least one carrier comprising:
 a surface configured to support a plurality of components, the surface having a plurality of holes defined therein through which a vacuum can be applied to hold the components on the surface; 
 a first vacuum interface in communication with the plurality of holes, the first vacuum interface being connectable to the first vacuum generator such that the first vacuum generator can apply the vacuum to the components through the plurality of holes; 
 a second vacuum interface in communication with the plurality of holes, second first vacuum interface being connectable to the second vacuum generator such that the second vacuum generator can apply the vacuum to the components through the plurality of holes. 
   
     
     
         50 . The assembly of  claim 49 , further comprising:
 an input/output module including:
 an input section, 
 an output section, 
 a plurality of component handling heads, the component handling heads being configured to (i) move components from the input section to the carrier, and (ii) move components from the carrier to the output section, 
   wherein the first vacuum generator is configured to apply the vacuum to the components while the components are loaded and unloaded at the input/output section.   
     
     
         51 . The assembly of  claim 49 , further comprising:
 a transport device configured to move the carrier from the input/output module to another location;   wherein the first vacuum generator is configured to apply the vacuum to the components while the carrier is moved from the input/output module to the test module to the other location.   
     
     
         52 . The assembly of  claim 51 , further comprising a rotary table comprising a plurality of grippers configured to hold the carriers, each gripper being connected to the second vacuum generator such that, when the carrier is received in the gripper, the second vacuum generator communicates with the plurality of holes via the second vacuum interface. 
     
     
         53 . The assembly of  claim 51 , further comprising a conductive soaking module configured to adjust a temperature of the carrier using a heating or cooling device. 
     
     
         54 . A method comprising:
 aligning a component into a predefined orientation relative to a carrier using a vision alignment system;   placing the aligned component on the carrier;   capturing an image of the component on the carrier using a downward-looking camera, and using that image to determine if the component is correctly located on the carrier; and   if the component is not correctly located on the carrier, picking the component from the boat,   performing the step of aligning the component a second time.   
     
     
         55 . The method of  claim 54 ,
 wherein the step of aligning the component into a predefined orientation comprises:
 capturing an image of the component using a downward-looking camera while the contacts of the component face upwards, and using that image to determine a translational and angular offset between a contact pattern of the component and a package outline of the component. 
   
     
     
         56 . The method of  claim 55 ,
 wherein the step of aligning the component into a predefined orientation further comprises:
 picking up the component with a component handling head, 
 capturing an image of the component on the component handling head using an upward-looking camera, and using that image to determine a translational and angular offset between the package outline of the component and the component handling head. 
   
     
     
         57 . The method of  claim 56 ,
 wherein the step of aligning the component into a predefined orientation further comprises:
 placing the component on an alignment table using the component handling head, 
 moving the alignment table such that the component is aligned to the component handling head, based on the determined translational and angular offset between the package outline of the component and the component handing head, and 
 picking up the component using the component handling head. 
   
     
     
         58 . The method of  claim 57 ,
 wherein the step of aligning the component into a predefined orientation further comprises:
 capturing an image of the carrier with a downward looking camera, and using that image to determine a translational and angular offset between the carrier and the component handling head, and 
 moving the carrier such that the carrier is aligned to the pickup head, based on the determined translational and angular offset between the carrier and the component handling head. 
   
     
     
         59 . The method of  claim 58 , wherein the carrier includes a plurality of fiducials used to determine the translational and angular offset between the carrier and the component handling head. 
     
     
         60 . The method of  claim 59 ,
 wherein the step of aligning the component into a predefined orientation further comprises:
 determining an elongation of the carrier caused by heating, 
 wherein the carrier is aligned to the pickup head based on (i) the determined translational and angular offset between the carrier and the component handling head, and (ii) the determined elongation of the carrier. 
   
     
     
         61 . The method of  claim 54 , wherein, after a mislocated component is picked from the carrier, the component is cycled around a turret before the step of aligning the component is performed the second time. 
     
     
         62 . A component handling assembly comprising:
 a vision alignment system configured to align a component into a predefined orientation relative to a carrier;   a rotatable turret comprising at least one component handling head configured to place the aligned component on the carrier;   a downward looking camera configured to capture an image of the component on the carrier   a controller configured to use the image to determine if the component is correctly located on the carrier,   wherein the assembly is configured such that, if the component is not correctly located on the carrier, the component handling head picks up the component from the boat, and the component is cycled around the turret before the vision alignment system aligns the component a second time.