Inspection handler apparatus and method

Abstract

An apparatus for processing electronic circuit devices includes an infeed station, a first inspection station, an inverter station, a second inspection station, a sorting station, and an outfeed station. A linear transport mechanism having side edges transports a first work piece containing a plurality of electronic circuit devices through the stations along a linear path. The inverter station holds an empty second work piece above the transport mechanism in an inverted orientation. The inverter station also includes an elevator for lifting the first work piece vertically into an abutting relationship with the second work piece, and an inverting mechanism for inverting the first and second work pieces while maintaining them in the abutting relationship to position the electronic devices in the second work piece in the inverted orientation. The inverter station executes the work piece inverting action while maintaining the work pieces above the linear transport mechanism and between the side edges of the linear transport mechanism. Thus, the electronic circuit devices are inspected at the first inspection station in a first orientation in the first work piece, and are inspected at the second inspection station in an inverted orientation in the second work piece.

1. Apparatus for processing electronic circuit devices contained in a work piece comprising, in combination,
 an infeed station,  
 an outfeed station,  
 a work piece containing electronic circuit devices, 
 first transport mechanism extending from said infeed station to said outfeed station for transporting a  said work piece along a horizontal path from said infeed station to said outfeed station,  
 a plurality of additional stations serially arranged along said path between said infeed and outfeed stations,  
 a control unit operative to activate selective ones of said stations to perform predetermined operations on said work piece  electronic circuit devices and sequence said work piece through said stations under the influence of said transport mechanism in response to the initiation and completion of said predetermined operations in said stations,  
 one of said additional stations is a first inspection station positioned , said first inspection station with reference to the movement of said work piece by said first transfer mechanism being located downstream of said infeed station,  
 an inverter station positioned downstream of said first inspection station,  
 a second inspection station positioned downstream of said inverter station,  
 a sorting station positioned downstream of said second inspection station,  
 said work piece  electronic circuit devices having a top side to be inspected at said first inspection station and an underside to be inspected at said second inspection station, and  
 said inverter station includes an inversion unit for displacing said work piece and said electronic circuit devices contained therein vertically relative to  and displaced from said first transport mechanism and, when displaced vertically, turning said work piece and said electronic circuit devices contained therein to reverse the position of the top side and the underside of said work piece  electronic circuit devices, said inversion unit returning said work piece to said first transport mechanism after it has been so turned.  
 
     
     
       2. The apparatus of  claim 1  wherein said transport mechanism extends in a straight, linear direction so that said path is a straight, linear path. 
     
     
       3. The apparatus of  claim 2  wherein said inversion mechanism displaces said work piece vertically above said path while maintaining said work piece generally parallel to said path. 
     
     
       4. The apparatus of  claim 1  wherein said carrier  work piece is a tray and said work piece comprises  electronic circuit devices comprise a plurality of units arranged in a predetermined manner in said tray for inspection at said first and second inspection stations. 
     
     
       5. The apparatus of  claim 4  wherein said transport mechanism extends in a straight, linear direction so that said path is a straight, linear path. 
     
     
       6. The apparatus of  claim 5  wherein said inversion mechanism displaces said work piece vertically above said path. 
     
     
       7. The apparatus of  claim 6  wherein said inversion unit includes a frame for capturing and releasing a tray to be displaced by said inversion mechanism. 
     
     
       8. The apparatus of  claim 7  wherein
 said frame includes a pair of relatively spaced side members between which a tray is positioned when in said inversion unit and also includes a plurality of clamp sets arranged on both of said side members, and  
 each clamp set includes a pair of vertically spaced clamp members and each clamp member is movable relative to said frame between a first position in engagement with a tray in said frame and a second position spaced from and out of engagement with a tray.  
 
     
     
       9. The apparatus of  claim 8  wherein
 a first one of said clamp members of each set engages and holds a prepositioned tray in said frame as a carrier tray containing said units is being transported to said inversion station and the second of said clamp members of each clamp set engages said carrier tray when it is positioned in said inversion station, said prepositioned tray being empty of said units,  
 said trays having a predetermined thickness and the clamp members in each clamp set being spaced relative to said tray thickness to hold said prepositioned tray in engagement with said carrier tray,  
 said inversion mechanism rotates said frame and the trays held therein 180 degrees and transfers said units from said carrier tray to said prepositioned tray,  
 when said prepositioned tray is returned to said first transport mechanism said first one of said clamp members of each of said clamp sets releases said prepositioned tray for travel to said second inspection station, and  
 said second of said clamp members of each of said clamp sets maintains engagement of said carrier tray with said carrier tray replacing said prepositioned tray in said frame to function as said prepositioned tray as a subsequent carrier tray is transported to said inversion station.  
 
     
     
       10. The apparatus of  claim 9  wherein
 said inversion mechanism includes a support fixture engaging said frame and including a second transport mechanism for raising and lowering said frame relative to said first transport mechanism and said path,  
 said prepositioned tray being held by said support fixture above said path as said carrier tray is being transported to said inversion station,  
 activating means at said inversion station responsive to the presence of said carrier tray in said inversion station to activate said second transport mechanism to lower said frame into engagement with said carrier tray and for engagement by said first one of said clamp members with said carrier tray and said activating means further operative in response to engagement of said clamp members with said tray to activate said second transport mechanism to raise said frame for rotation of said trays.  
 
     
     
       11. The combination of  claim 10  wherein said first transport mechanism includes
 elongated guide members arranged on opposite side of and parallel to said path and engageable with said carrier tray,  
 and drive members selectively engageable with said carrier tray when said carrier tray is engaged with said guide members to propel said tray along said guide members and said path.  
 
     
     
       12. The apparatus of  claim 10  wherein said sorting station includes
 a pick and place station downstream of said inversion station,  
 a tray station offset from said path,  
 a taper station offset from said path, and  
 selector means for selectively activating said pick and place assembly alternatively 
 to displace units to said tray station, and  
 to displace units to said taper station.  
 
 
     
     
       13. The apparatus of  claim 1  including
 a pick and place device in said sorting station operative to remove selected ones of said units  electronic circuit devices from said carrier tray  work piece as it passes through said sorting station, and  
 third transport means for means for  moving said pick and place device with the selected unit  electronic circuit device laterally of said path.  
 
     
     
       14. The apparatus of  claim 13  wherein said work piece is a tray and including
 a tray station at said pick and place station but spaced laterally of said path,  
 said tray station including a tray and a support for that tray, and  
 said third transport device moving said pick and place device laterally to said tray at said tray station after said pick and place device has selected a unit  an electronic circuit device from said tray in said pick and place station for deposit of said selected unit  electronic circuit device in said tray at said tray station.  
 
     
     
       15. The apparatus of  claim 9  wherein
 said clamp members of each set have a first position relative to said frame and in said first positing  position being engageable with a tray in said frame,  
 said clamp members have a second position displaced from said first position and in which they are not engageable with a tray in said frame, and  
 a sensor at said clamp members sensing the position of said clamp members and operatively connected to said second transport mechanism to disable said second transport mechanism if said clamp members are not in their first position.  
 
     
     
       16. The apparatus of  claim 15  wherein said sensor includes
 a light source,  
 a light receiving mechanism,  
 elongated light transmitting members extending from said light source to said clamp members and from said clamp members to said light receiving mechanism,  
 said clamp members including a channel there aligning with said light transmitting members when said clamp members are in said first position and out of alignment with said light transmitting members when said clamp members are in said second position,  
 said clamp members having light interrupting surfaces surrounding said channels and said light interrupting surfaces being aligned with said light transmitting members when said clamp members are in said second position, and  
 said light receiving mechanism operatively connected to said second transport mechanism operative to disable said second transport mechanism when light is not transmitted thereto.  
 
     
     
       17. A method of inspection for electronic circuit devices comprising the steps of
 introducing a plurality of units  electronic circuit devices to be inspected into an input station,  
 transporting said units  electronic circuit devices from said input station to a first inspection station along a generally horizontal path,  
 inspecting said units  electronic circuit devices at said first inspection station,  
 transporting said units  electronic circuit devices from said first inspection station to an inverter station,  
 moving said units  electronic circuit devices at said inverter station vertically from said horizontal path to an inversion location directly above said path and rotating said units  electronic circuit devices while said units  electronic circuit devices are in said inversion location,  
 returning said inverted units  electronic circuit devices to said horizontal path after said rotation,  
 transporting said units  electronic circuit devices from said inverter station to a second inspection station,  
 transporting said units  electronic circuit devices to a sorting station from said second inspection station, and  
 sorting said units  electronic circuit devices at said sorting station based on the inspection conducted at said first and second inspection stations.  
 
     
     
       18. The method of  claim 17  wherein the transport of said units  electronic circuit devices through said stations is along a straight, linear path. 
     
     
       19. The method of  claim 18  including the steps of said units  electronic circuit devices being loaded into a carrier tray,
 positioning a prepositioned tray in said inverter station prior to the transport of said carrier tray to said inverter station,  
 bringing said trays into engagement in said inversion location and rotating said trays simultaneously in said inversion location thereby transferring said units  electronic circuit devices from said carrier tray to said prepositioned tray,  
 transporting said prepositioned tray to said path and leaving said carrier tray in said inverter station to then become a prepositioned tray to cooperate with a subsequent carrier tray transported to said inverter station, and  
 said prepositioned tray to which said units  electronic circuit devices were transferred at said inverter station being transported through said second inspection station to said sorting station.  
 
     
     
       20. The method of  claim 19  wherein said units  electronic circuit devices are displaced vertically above said path. 
     
     
       21. The method of  claim 20  wherein the path of movement of said carrier tray is a straight, linear path. 
     
     
       22. The method of  claim 17  including
 prepositioning a tray in said frame prior to an  a carrier tray containing said units  electronic circuit devices being transported to said inversion station,  
 moving said prepositioned tray into engagement with said carrier tray when said carrier tray is in said inversion station,  
 displacing said prepositioned tray and carrier tray simultaneously above said path and rotating said trays to reverse the position of said tray  trays so that one assumes the position of the other,  
 lowering said trays toward said path and positioning said prepositioned tray on said path, and  
 releasing said prepositioned tray for movement along said path to said second inspection station and raising said carrier tray above said path to the position vacated by the prepositioned trays  tray.  
 
     
     
       23. The method of  claim 22  wherein said inversion mechanism rotates said trays and the units  electronic circuit devices therein 180 degrees to transfers  transfer said units  electronic circuit devices from said carrier tray to said prepositioned tray. 
     
     
       24. The method of  claim 22  wherein said carrier tray left in said inverter station is rotated after the transfer of said units  electronic circuit devices. 
     
     
       25. The method of  claim 19  wherein
 said sorting station includes a pick and place device removing selected ones of said units  electronic circuit devices from said carrier tray as it passes through said sorting station, and  
 said pick and place device selecting units  electronic circuit devices and moving them laterally of said path.  
 
     
     
       26. The method of  claim 25  including
 positioning a tray adjacent said sorting station but spaced laterally of said path, and  
 moving said pick and place device laterally to said tray spaced laterally of said path after said pick and place device has selected a unit  an electronic circuit device from said tray in said sorting station and depositing said selected unit  electronic circuit device in said laterally spaced tray.  
 
     
     
       27. An apparatus for processing a work piece having first and second oppositely-facing surfaces, the apparatus comprising:
 an infeed station;  
 an outfeed station;  
 a first tray adapted to bold the work piece;  
 a transport mechanism for transporting said first tray in a downstream direction from said infeed station to said outfeed station, said transport mechanism receiving said tray from said infeed station with the first surface of the work piece facing away from the transport mechanism;  
 a first inspection station positioned downstream of said infeed station, said first inspection station adapted to inspect the first surface of the work piece;  
 an inverter station positioned downstream of said first inspection station and including 
 a second tray substantially identical to said first tray and positioned in an upside-down orientation above said transport mechanism,  
 a plurality of clamp members movable to selectively engage and disengage said first and second trays and to lift said first tray into a sandwiched engagement with said second tray, and  
 an inversion mechanism rotating said clamp members and trays 180 degrees to transfer the work piece from said first tray to said second tray, wherein said second tray containing the work piece is returned to said transport mechanism by said clamp members and said first tray is held in an upside-down orientation above said transport mechanism; and  
 
 a second inspection station positioned downstream of said inverter station and upstream of said outfeed station, said second inspection station receiving the second tray on the transport mechanism to inspect the second surface of said work piece.  
 
     
     
       28. The apparatus of  claim 27 , wherein said transport mechanism includes first and second side edges extending the length of said transport mechanism within the inverter station, wherein first and second vertical planes include said first and second side edges, respectively, and wherein said first tray is lifted and said first and second trays are inverted between said first and second vertical planes. 
     
     
       29. The apparatus of  claim 27 , further comprising a sorting station positioned downstream of said second inspection station and upstream of said outfeed station. 
     
     
       30. The apparatus of  claim 27 , wherein said inversion station includes a frame supporting said clamping members, said first and second trays having a predetermined thickness and the clamp members being spaced relative to said tray thickness to avoid interference between said clamp members when holding said first and second trays in sandwiched engagement with each other. 
     
     
       31. The apparatus of  claim 27 , wherein said inversion mechanism includes a support fixture engaging said frame and an elevator for raising and lowering said frame relative to said transport mechanism, said second tray being held by said support fixture above said transport mechanism as said first tray is being transported to said inversion station, said apparatus further comprising activating means at said inversion station responsive to the presence of said first tray in said inversion station to activate said elevator to lower said frame into engagement with said first tray and for engagement by at least one of said clamp members with said first tray, said activating means further operative in response to engagement of said clamp members with said first tray to activate said elevator to raise said frame to sandwich said first and second trays together.