DEVICE FOR PRE-POSITIONING COMPONENTS IN A ROW FOR SUBSEQUENT PROCESSING AS WELL AS SUCH A METHOD

Abstract: Device and method for pre-positioning components in a row for subsequent processing. The device comprises at least one template having several component receiving segments lying at initial predetermined positions on a row. The segments are moveable with respect to the template and each other in at least one direction parallel to said row. Furthermore the device comprises at least one component mounting tool to pre-position a component on an empty segment. The tool comprises means to relatively move the segments adjacent to said empty segment in a direction away from said empty segments.

Description: Device for pre-positioning components in a row for subsequent processing as well as such a method. The invention relates to a device for pre-positioning components in a row for subsequent processing. The invention also relates to a method for pre- positioning components in a row for subsequent processing. This invention relates to pre-positioning of components for mechanical or robotic pick-up and for subsequent processing like insertion into a printed circuit board, die stamping, molding, assembly or plating. It has particular applicability to application equipment for placing and inserting electrical connectors onto printed circuit boards, especially by means of the connector application equipment disclosed in the provisional application filed in the name of Paul Friederichs entitled Single Head Application Machine and filed on July 19, 1997 under US serial number 60/050,256 and the corresponding international patent application, the disclosure of which is herein incorporated by reference. The objective of said above-identified application equipment is to locate accurately several connector modules on a tool, subsequently accurately measure the true-position of press-fit tails as related to a tooling index point and accurately position this assembly with the measured true-position of board holes prior to press-fit application of the connector modules in a single application step. However, to reduce the time necessary for fitting of the connector modules to the tool, such modules need to be removed from the tube-unloader or other product source and positioned for subsequent pick-up by the tool . For efficient production, the swiftness and accuracy of product placement is important. Often with products, such as modular connectors, that are end-to-end stackable, customer requirements dictate arrangements of several such connector modules being placed adjacent to each other. Also, some customers dictate placement of, for example, two such modules adjacent to each other, followed by an air gap of 1 mm, e.g., to insert metal shield plates, to be followed by another two adjacently located modules. In some applications, this gap may be larger, to locate such products on either side of a component, for example a transformer, previously located on the printed circuit board. In all of these situations, the programmed placement needs to be accurate and without application of extraneous forces that might result in damage or loss in production. Surface mount placement devices have some of these capabilities. These devices have three degrees of movement being horizontal, vertical and rotation, with a placement accuracy of ± 0,1 mm. However, such units are very costly. Consequently, a less expensive positioning means is desirable. If components which need to be placed end to end on the printed circuit board are pre-positioned in a row, problems occur when one component must be located between two components which are already located at their predetermined positions in the row. Because the space between these components (for example 12 mm) is nearly the same as the dimension (for example 11,8 mm) of the component to be placed therebetween, the tool mounting the component in the row must be very accurate to avoid damaging of the components. By the known devices the accurate mounting results in a relatively slow mounting of the component in the rows. The object of the invention is to provide a device whereby components can be pre-positioned on a predetermined position in a row in a relatively fast and accurate manner. This objective is achieved by the device according to the invention in that the device comprising at least one template having several component receiving segments lying at initial predetermined positions on a row which segments are moveable with respect to the template and each other in at least one direction parallel to said row, whilst furthermore the device comprises at least one component mounting tool to pre-position a component on an empty segment, which tool comprises means to relatively move the segments adjacent to said empty segment in a direction away from said empty segments. Because the segments on which the components are mounted can be moved away from the empty segment, the space to mount the component becomes relatively large and the accuracy of the tool can be relatively low. The segment on which the component needs to be placed is being aligned with respect to the tool by movement of the segment by the tool . Therefore the accuracy by which the component is put on the segment is still very high. After removal of the tool , the segments return to their predetermined initial positions in which the distance between adjacent components can be very small . The invention also relates to a method for pre- positioning components in a row for subsequent processing. This method is characterized in that the components are positioned on segments lying at initial predetermined positions on a row, whereby to mount a component on an empty segment, the adjacent segments together with the components already mounted thereon are relatively moved away from the empty segments against spring force and after mounting of the component on the empty segment, the adjacent segments are moved back to their initial position. Due to this method components can be pre-positioned in a efficient and accurate manner. Brief description of the drawings Fig. 1 is a top view of a product configuration unit. Fig. 2 is an end view of a product configuration unit. Fig. 3 is a side view of the product configuration unit shown in fig. 1. Fig. 4 is a top view of the product configuration unit shown in fig. 2, partially disassembled. Figs.5a and 5b are plan views of segments of a conveyor used in the equipment depicted in figs. 1 and 2. Figs. 6a, 6b and 6c are plan views of individual parts in unassembled and assembled views of the conveyor sections shown in figs. 3a and 3b. Figs. 7a and 7b are front and side views, respectively, of a product locating tool for locating connectors on a conveyor of the structure shown in figs. 5a, 5b and 6a, 6b and 6c. Fig. 8 is an isometric view of a product positioning tool as shown in figs. 5a and 5b cooperating to place parts on a conveyor. Fig. 9a is a top view of three adjacent plates of the conveyor with the middle position being empty. Fig. 9b is essentially the same view as fig. 9a, with the middle position loaded with product. Fig. 10a shows a top view of a second embodiment of a product configuration unit according to the invention. Fig. 10b shows a side view of the product configuration unit as shown in fig. 10a along lines XB-XB. Fig. 10c is an enlarged detail indicated by XC of the product configuration unit as shown in fig. 10b. Fig. lOd is an enlarged detail indicated by XD of the product configuration unit as shown in fig. 10a. Fig. 11 shows a cross section of the product configuration unit as shown in fig. 10a along lines XI-XI. Fig. 12a shows a top view of two segments of the product configuration unit as shown in fig. 10a. Fig. 12b shows a side view of the segment as shown in fig. 12a. Figs. 13a en 13c shows on a top view of two segments of the product configuration unit as shown in fig. 10a respectively in the initial position and the position in which a component may be placed. Figs. 13b and 13d show enlarged views of fig. 13a and fig. 13c respectively. Like parts are numbered alike in the figures. Description of preferred embodiments Figs. 1-4 show the product configuration station C located adjacent to pick-up tooling head 1 attached to a robot arm 2. The tooling head 1 releasably holds reusable tools (not shown) on which are received one or more connector modules. The tools are of a type for locating and inserting press-fit connector modules 13 into a printed circuit board according to the method for example as described in the above-mentioned US serial number 60/050,256. The connector modules 13 are located in an orientated fashion at the end of tube unloaders 3 on either side of a centrally located conveyor 5. A placer 4 has the function to pick up a connector module 13 at the end of the tube unloader and locate these modules at a programmed location in one of the segments 7 of the templates 8 (see fig. 5a, 5b) of the conveyor 5. The tube unloader units 3 comprise a magazine 3a of tubes for containing product and a movable rack unit 3b. Fig. 4 shows a right hand unloader unit 3 about to be positioned along side conveyor 5. The placer 4 comprises a positioning tool 14 movable in directions indicated by double arrow PI transversely across the conveyor 5 and vertically toward and away from the conveyor 5. A product placer 4 may be associated with each tube unloading station 3. The sequence of the product placer 4 is pre-programmed for each product. By appropriate programming, a different array of connector modules 13 can be assembled across the conveyor 5. The conveyor 5 is program indexed in a direction indicated by arrow P2 from the first tube unloading station to the next, finally delivering all products located in one of the templates 8 at the end station 6, where a tool mounted in tooling head 1 of robot arm 2 is loaded with the assembled row of connector modules 13 from the template 8. Template/segment build-up Figs. 5a and 5b illustrate a template 8 of the conveyor 5, the conveyor 5 being formed of a plurality of templates 8 jointed together preferable to form an endless loop, and moved in the direction of arrow P2. The configuration in fig. 5b is the standard configuration, in which several straight modules, for example, plug connectors, can be positioned adjacent to each other at a pitch of Dl, for example of 12 mm. The configuration of fig. 5a is used for a product configuration in which two modules with a width of Dl are located adjacent to each other, followed by an air-gap space G of 1 mm, to be followed by another group of two modules. Each module is for example 12 mm wide (= Dl) whilst the distance D2 between one module of one group to the first module of the next group is 13 mm (D2 = Dl + G). Several individually, transversely movable segments 7 are located in a template 8 over the width of the conveyor 5. The recessed sides 8a of the template are accurately ground along a special contour. In each of figs. 5a and 5b, only the first six segments 7 are shown for purposes of drawing simplicity. As previously noted, the templates 8 of conveyor 5 advance stepwise to end station 6 in the direction of arrow P2. Fig.6a shows a segment 7. Each segment 7 has two spring members 9 located at each end of a base portion 12. As shown in fig. 6a, each segment 7 has an array of holes 11, the diameter of which is slightly larger than the outer periphery of the press-fit pins of the connector module 13, as depicted by hole 11a. The configuration of the holes 11 is governed by the pin configuration of the connector module 13. For example, the segment 7 can be for a 4 or 5 row product, in which case the segment will have five rows of holes as standard. Fig. 6b shows opposed portions of the contour 8a for receiving one of the segments 7. The template 8 has recessed zones 10 preventing the segments 7 from falling out of the template. Outside edge portions of the base portion 12 and springs 9 are slidably received in the recesses 10 of the template 8 to allow transverse movement in the direction of arrow P3 of the segment with respect to the template 8. Fig. 6c shows the segment 7 with such edges received in the recessed zones 10. The recessed zone 10 can be formed by machining or by clamping two plates together to form the recessed area. The template 8 can be molded plastic or machined or stamped metal. The springs 9 may be integrally insert molded in a plastic segment 7 or the segment 7 may be stamped or molded unitary element of plastic or metal. Position tooling/segment operation Figs. 7a and 7b show front and side views of the position tool 14 which has a contoured gripping section 14a to fit the product 13 being placed. Such a position tool 14 is connected to the product placer 4 shown in figs. 1-3 to pick up and locate a connector module 13 in one segment 7 on the template 8 of conveyor 5. As shown in the figs. 7a, 7b and 8, the positioning tool 14 has four legs 15 of a specific width and thickness. The distal portion of each leg 15 has a lead-in nose 16 to pre-position and accurately enter a recess 17 positioned opposite to it in the template 8. The combined function of the position tool 14 with each segment 7 located in the template 8 is shown by the example in fig. 9a and 9b. In an application requiring end-to-end connector stacking, connector modules 13 have been positioned at the first and third segment positions SI, D3 on template 8. A third module 13 must be located in the second segment position S2 of the template 8. In this case, the position tool 14 with the product 13 is moved towards a specific segment 7 of the template 8. During the downward travel of the position tool 14 loaded with a connector module 13, the four legs 15 with lead-in noses 16 enter four of the openings 17 at two horizontally displaced locations formed between the side edges 19 of the segment 7 and the projections 21 of the template, as shown in fig. 9a. The press-fit terminals 30 enter the holes 11 in the segment 7. The outside edges of legs 15 engage the adjacent segments 7 at the first and third stations SI, S3. This results in a relative movement of the first and second segments 7 and relative movement of both with respect to the third segment 7, in the illustrated case in the direction indicated by arrow P3, to define the desired space to accommodate the plug at the intermediary second location S2 as shown in fig. 9. The distance between the inside and outside edges of each leg 15, i.e., the width of the leg, is dimensioned to be slightly greater than the normal length L (fig. 5b) of the opening 17. As a result, insertion of the legs 15 into the openings 17 move the segments at the first and second locations SI, S2 to create the spaces of dimensions Tl and T2 (fig. 9a). At the same time, the intermediary segment 7 has been precisely positioned with respect to tool 14 by the opposed inside edges of legs 15, that are spaced apart by a distance just slightly greater than the dimension W of the base 12. When the position tool 14 reaches the end of its downward travel, the module 13 has been properly located in the second intermediary space S2, resulting in an arrangement as shown in fig. 9b. With the position tool 14 removed, segments 7 are then free to move back toward each other in a direction opposite to arrow P3 under the action of springs 9. The products 13 can be easily located with relatively inexpensive tooling, at a desired position tolerance, for example, of within ± 0,2 mm at a speed of 1 to 2 sec/product. The movement of segments 7 accommodates side-by- side stacked tolerances of the assembled row of connector modules 13. Fig. lOa-d, 11, 12a-b, 13a-d show a second embodiment of a device 30 according to the invention. The device 30 comprises a template 31 built up out of several layers 32-37 which are kept together by means of bolts 38. The layers 32-37 bound an open inner area 39 in which several segments 40 are located in a row at predetermined initial positions. The segments 40 are located between the layers 32, 35 (see fig. 11) preventing the segments 40 from dropping out of the template 30. Each segment 40 comprises an area 41 with the array of holes 11. On both sides of this area 41 the segment 40 has one hole 42 and one opening 43. Near each opening 43 the segment 40 comprises two flanges 44 extending in the direction of the opening 43 of adjacent segment 40. The template 30 is provided with plate springs 45 supporting balls 46 which extend through openings in layer 35. Each segment 40 is located with the holes 42 around the balls 46. The balls 46 determine the initial predetermined position of each segment 40. By the template 30 as shown in fig. lOa-d segments 40 are positioned in sets of two whereby the distance LI between segments 40 in a set is slightly larger than the dimension of the component to be placed on the segment. The distance L2 between segments 40 of adjacent sets is for example 1 mm larger than the distance LI causing an air gap G of 1 mm between the segments 40. The flanges 44 of the segments are dimensioned such that by segments 40 lying at a distance LI of each other the ends 47 of the flanges 44 of one segment 40 extend partly across the opening 43 of the adjacent segment 40 (see fig. lOd). The device also comprises a separate tool (not shown) having two pins 50 (figs. 13c, d) with lead-in sections. The pins 50 are insertable into the two openings 43 of an empty segment 40 into which a component must be placed. If the pins are inserted into these openings 43, the pins will force the flanges 44 of the adjacent segments into opposite directions P4, P5 away from the empty segments 40 making spaces (fig. 13c) for the component to be placed. When the segments 40 are moved into the directions P4 or P5 respectively the balls 46 will be pressed against spring force of the plate 45 into a direction P6. After the component is placed, the tool is removed and under the spring force of the plate springs 45 the balls 46 will be moved back to their initial position whereby also the segments 40 return to their initial predetermined position. The conveyor 5 comprises a sequential, endless array of templates 8, 31 that are advanced step-wise to the end station 6. Thus each group of connector modules 13 to be received at tool station 6 is pre-assembled on one of the templates 8, 31 of conveyor 5. The positioning tool 14 is a part of the unloading and placing assembly 4 and is movable transversely of the conveyor 5 to position modules at the positions defined by each template 8, 31. The tooling head 1 at the end station of the configurator C can accurately pick up this array of products for further handling to insert to the printed circuit boards. The use of a configuration as disclosed lowers product costs by allowing the assembly of standard-sized modules instead of larger mono-block connectors. The configuration can also increase the through-put of application equipment by providing pre-positioned assemblies of connector modules. The device according to the invention is also suitable for components not having press-fit pins but other means to accurately position them on the segments 40.

Claims: CLAIMS. 1. Device for pre-positioning components in a row for subsequent processing, characterized in that a device comprising at least one template having several component receiving segments lying at initial predetermined positions on a row which segments are moveable with respect to the template and each other in at least one direction parallel to said row, whilst furthermore the device comprises at least one component mounting tool to pre-position a component on an empty segment, which tool comprises means to relatively move the segments adjacent to said empty segment in a direction away from said empty segments. 2. Device according to claim 1, characterized in that each segment is moveable against spring force in two opposite directions. 3. Device according to claim 1 of 2, characterized in that each segment is provided with two holes in each of which a ball is located which determine the initial position of the segments, each segment is moveable against spring force in the two opposite directions with respect to said balls. 4. Device according to claim 3, characterized in that the balls are moveable in a direction extending perpendicular to the direction in which the segments are moveable against spring force. 5. Device according to one of the preceding claims, characterized in that several templates are connected to each other to form an endless belt being moveable in a direction perpendicular to the rows of the templates. 6. Device according to one of the preceding claims, characterized in that each segment is provided with at least one pin receiving opening and at least one flange extending partly over a pin receiving opening of an adjacent segment, whilst the tool is provided with at least one pin being insertable into the opening of the segment. 7. Device according to claim 6, characterized in that the pin is provided with a lead-in portion at one end thereof. 8. Device according to claim 1, characterized in that from the initial position in which the segment lies against one edge of the template, the segment is moveable against spring force in one direction away from said edge. 9. Method for pre-positioning components in a row for subsequent processing, characterized in that the components are positioned on segments lying at initial predetermined positions on a row, whereby to mount a component on an empty segment, the adjacent segments together with the components already mounted thereon are relatively moved away from the empty segments against spring force and after mounting of the component on the empty segment, the adjacent segments are moved back to their initial position.

Inventors: VAN DEN AKER CORNELIS GUALTHER, VAN DEN AKER, CORNELIS, GUALTHERUS, JOSEPHUS
Applicants: BERG ELECTRONICS MFG, DEN AKER CORNELIS GUALTHERUS J, BERG ELECTRONICS MANUFACTURING B.V., VAN DEN AKER, CORNELIS, GUALTHERUS, JOSEPHUS
Application year: 1998
Main classification: H01R43
IPC codes: B23P19, H01R43, H05K13