Abstract:
An apparatus and method of mounting components are provided. The apparatus for mounting components includes: a component supplying unit which supplies the components so that the components move in at least one line; and a plurality of suction nozzles disposed to approach to or retreat from the components, wherein intervals between the plurality of suction nozzles are changeable so that the suction nozzles correspond to positions of the components. The method of mounting components includes: disposing a plurality of suction nozzles corresponding to the positions of the components; picking up the components by using the suction nozzles adjusting intervals between the suction nozzles; moving the suction nozzles to an upper side of a substrate, on which the components are to be mounted; and putting the components down on the substrate.

Description:
CROSS-REFERENCE TO RELATED PATENT APPLICATION 
       [0001]    This application claims priority from Korean Patent Application No. 10-2010-0076969, filed on Aug. 10, 2010, in the Korean Intellectual Property Office, the disclosure of which is incorporated herein in its entirety by reference. 
       BACKGROUND 
       [0002]    1. Field 
         [0003]    Apparatuses and methods consistent with exemplary embodiments relate to mounting electric components on a substrate. 
         [0004]    2. Description of the Related Art 
         [0005]    An apparatus for mounting electric components installs electric components on a substrate, for example, a printed circuit board, and generally includes a nozzle spindle, which absorbs and moves components, and a component supplying unit, which supplies the component to the nozzle spindle, for example, a carrier tape reel feeder or a vibratory bowl feeder. 
         [0006]    Recently, in order to increase speed of installing components, an apparatus for mounting components including a plurality of nozzle spindles may be used. In the apparatus for mounting components including a plurality of nozzle spindles, components may be supplied to each of the plurality of nozzle spindles, and thus, a plurality of component supplying units such as carrier tape reel feeders or vibratory bowl feeders are needed according to the number of the nozzle spindles. 
       SUMMARY 
       [0007]    One or more exemplary embodiments provide an apparatus for mounting components which may supply the components to a plurality of nozzle spindles by using one component supplying unit and a method of mounting components using the apparatus. 
         [0008]    According to an aspect of an exemplary embodiment, there is provided an apparatus for mounting components, the apparatus including: a component supplying unit which supplies the components so that the components may move in at least one line; and a plurality of suction nozzles disposed to approach to or retreat from the components, wherein intervals between the plurality of suction nozzles are changeable so that the suction nozzles may correspond to positions of the components. 
         [0009]    According to an aspect of another exemplary embodiment, there is provided a method of mounting components, the method including: The method of mounting components includes: disposing a plurality of suction nozzles corresponding to positions of the components; picking up the components by using the suction nozzles; adjusting intervals between the suction nozzles; moving the suction nozzles to an upper side of a substrate, on which the components are to be mounted; and putting the components down on the substrate. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0010]    The above and other aspects will become more apparent by describing in detail exemplary embodiments thereof with reference to the attached drawings, in which: 
           [0011]      FIG. 1A  is a perspective view schematically illustrating an apparatus for mounting components according to an exemplary embodiment; 
           [0012]      FIG. 1B  is a perspective view schematically illustrating the apparatus for mounting components of  FIG. 1A  in more detail, according to an exemplary embodiment; 
           [0013]      FIG. 2  is an enlarged view of part II in the apparatus for mounting components of  FIG. 1A , according to an exemplary embodiment; 
           [0014]      FIGS. 3 through 5  are front views schematically illustrating partial operation states of the apparatus for mounting components of  FIG. 1A , according to exemplary embodiments; 
           [0015]      FIG. 6  is a perspective view schematically illustrating an apparatus for mounting components according to another exemplary embodiment; and 
           [0016]      FIG. 7  is a perspective view schematically illustrating an apparatus for mounting components according to another exemplary embodiment. 
       
    
    
     DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS 
       [0017]    Hereinafter, an apparatus for mounting components according to one or more exemplary embodiments will be described in detail with reference to the accompanying drawings. 
         [0018]      FIG. 1A  is a perspective view schematically illustrating an apparatus  1  for mounting components according to an exemplary embodiment,  FIG. 1B  is a perspective view schematically illustrating the apparatus  1  for mounting components in more detail, according to an exemplary embodiment,  FIG. 2  is an enlarged view of part II in the apparatus  1  for mounting components as shown in  FIG. 1 , according to an exemplary embodiment, and  FIGS. 3 through 5  are front views schematically illustrating partial operation states of the apparatus  1  for mounting components, according to exemplary embodiments. 
         [0019]    Referring to  FIGS. 1 through 5 , the apparatus  1  for mounting components includes a component transfer guide  100 , a component supplying unit, suction nozzles  312 , substrate supporters  400 , and a camera  500 . 
         [0020]    The component transfer guide  100  guides components C to move in one direction A 1  so that the components C are transferred in a line. In the current exemplary embodiment, the components C are contained in component containing spaces TH of a carrier tape T, and the component transfer guide  100  guides transfer of the carrier tape T so as to guide transfer of the components C. 
         [0021]    As illustrated in  FIG. 2 , the component transfer guide  100  is fixed to an upper side of a base unit  600 , and an opening  110  is formed on the component transfer guide  100 . 
         [0022]    When the carrier tape T is disposed in the opening  110  of the component transfer guide  100 , a protective film on the carrier tape T is removed before the carrier tape T reaches the opening  110  of the component transfer guide  100  so that the components C may be exposed to the outside. 
         [0023]    Although not illustrated in the drawings, the removed protective film and the carrier film T that passes the opening  110  of the component transfer guide  100  are discharged outside of the component transfer guide  100 . 
         [0024]    The component transfer guide  100  is manufactured so that transfer speed of the carrier tape T may be controlled. 
         [0025]    The detailed structure of the component transfer guide  100  is disclosed in various prior arts including KR 2009-0030476 filed by the applicant of the present invention, and thus, detailed descriptions thereof are omitted. 
         [0026]    The component supplying unit supplies the components C to the component transfer guide  100 . In the current exemplary embodiment, a reel  200 , onto the carrier tape T is rolled, is disposed as the component supplying unit. The reel  200  supplies the carrier tape T, in which the components C are contained, to the component transfer guide  100 , thereby supplying the components C to the component transfer guide  100 . 
         [0027]    The suction nozzles  312  suck and grab the components C, and transfers the components C to the substrate S. A plurality of suction nozzles  312  are disposed in a transferring direction A 1  of the components C, that is, a direction parallel to an x-axis direction. 
         [0028]    The suction nozzles  312  are disposed on the lower ends of nozzle spindles  310 , wherein the nozzle spindles  310  are coupled to spindle bodies  320  so as to move up and down. Accordingly, the suction nozzles  312  may move up and down along with the nozzle spindles  310 , and approach to or retreat from the components C disposed in the opening  110 . 
         [0029]    The plurality of spindle bodies  320  are coupled to a spindle holder  350  and arranged in the x-axis direction. The plurality of spindle bodies  320  may move relatively to each other so that an interval between the spindle bodies  320  may change. Referring to  FIG. 2 , guide rails  330  are disposed on the spindle holder  350 , and extend in an x-axis direction. Sliders  340  are coupled to the guide rails  330 , and slide along the guide rails  330 . The spindle bodies  320  are fixed to the sliders  340  and thus may move relatively to each other in an x-axis direction. Therefore, intervals between each of the spindle bodies  320  may be changed. Accordingly, intervals between each of the suction nozzles  312  may be also changed. 
         [0030]    The nozzle spindles  320 , the spindle bodies  320 , and the spindle holder  350  combined altogether are referred to as a mounter head  300 . The mounter head  300  is coupled to a guiding member  620 , which extends in the x-axis direction, may move along the guiding member  620 . Also, the guiding member  620  may be coupled to rails  612  of a rail support unit  610  formed on the base unit  600 . Since the rails  612  extend in a y-axis direction, the guiding member  620  may move in the y-axis direction. Accordingly, the mounter head  300 , which is attached to the guiding member  620 , may move along both the x-axis direction and the y-axis direction. 
         [0031]    The nozzle spindles  310  may move upward and downward, that is, in a z-axis direction, and thus, the suction nozzles  312  formed on the nozzle spindles  310  may move in the x-axis, the y-axis, and the z-axis directions. 
         [0032]    Although not illustrated, a driving unit for moving the spindle bodies  320  with respect to the spindle holder  350  may be further included in the mounter head  300 . 
         [0033]    The substrate supporters  400  support the substrate S, on which the components C are installed, and are interposed between the base unit  600  and the mounter head  300 . The substrate supporters  400  are positioned to be spaced apart from the component transfer guide  100  in the transferring direction A 1  of the components C. The substrate S is placed on the substrate supporters  400 , and the substrate supporters  400  may move in the y-axis direction in order to move the substrate S in the y-axis direction. 
         [0034]    The camera  500  is disposed below the mounter head  300 , captures images of components C grabbed by the suction nozzles  312 , and is interposed between the component transfer guide  100  and the substrate supporters  400 . 
         [0035]    As illustrated in  FIGS. 3 through 5 , the camera  500  includes a camera module  510  facing upward. Thus, when the suction nozzles  312  pass above the camera  500  while the suction nozzles  312  grab the components C, the camera  500  may capture the images of the components C thereabove. The captured images of the components C may be used in estimating the state of the grabbed components C. 
         [0036]    Then, a method of mounting the components C by using the apparatus  1  for mounting components according to the current exemplary embodiment is described. 
         [0037]    The carrier tape T rolled to the reel  200  is inserted into the component transfer guide  100 , and is transferred to a direction A 1  to reach the substrate supporters  400  so that the components C contained in the carrier tape T are transferred in a line. 
         [0038]    While the carrier tape T passes the component transfer guide  100 , a protective film on the carrier tape T is removed and the carrier tape T is disposed in the opening  110  so that the components C are exposed to the outside through the opening  110  of the component transfer guide  100 . 
         [0039]    Then, transfer of the carrier tape T is stopped, the mounter head  300  is disposed above the opening  110  of the component transfer guide  100 , and then, the nozzle spindles  310  descend. Here, in order to match the intervals between the nozzle spindles  310  with intervals d 1  between the components C disposed on the carrier tape T, the nozzle spindles  310  are moved relative to the spindle holder  350 . 
         [0040]    As illustrated in  FIG. 3 , when the nozzle spindles  310  descend, the components C are sucked and grabbed by the suction nozzles  312 . When the components C are grabbed by the suction nozzles  312 , the nozzle spindles  310  are raised to lift the components C. 
         [0041]    Then, the mounter head  300  is moved and positioned above the substrate S while the components C are grabbed by the suction nozzles  312 . 
         [0042]    While the mounter head  300  moves from the component transfer guide  100  to the substrate S, the camera  500  is used to capture the image of the components C grabbed by the suction nozzles  312 . 
         [0043]    When the mounter head  300  is disposed above the substrate S, the intervals between the suction nozzles  312  are changed to be matched with intervals d 2  of portions CL, on which the components C are disposed, on the substrate S. In the current exemplary embodiment, as illustrated in  FIG. 2 , the intervals d 2  between the portions CL, on which the components C are disposed, on the substrate S are greater than the intervals d 1  between the components C contained in the carrier tape T. Therefore, the nozzle spindles  310  are moved relative to the spindle holder  350  in order to widen the intervals between the suction nozzles  312 . 
         [0044]    When the intervals between the nozzle spindles  310  are changed according to the intervals d 2  of the portions CL, on which the components C are disposed, on the substrate S, information contained in the image obtained from the camera  500  may be used to minutely control the location of the nozzle spindles  310 . 
         [0045]    Then, the nozzle spindles  310  are moved downward. 
         [0046]    As illustrated in  FIG. 5 , when the nozzle spindles  310  move down, the components C are disposed on the portions CL on the substrate S. When the components C are disposed on the substrate S, suction power of the suction nozzles  312  is cleared, and the components C are remained on the substrate S. Then, the nozzle spindles  310  are raised again. 
         [0047]    As such, when the components C are disposed on the substrate S, the mounter head  300  moves again to the upper side of the transfer guide  100 , and the carrier tape T is again transferred so that the components C are again disposed on the opening  110  of the component transfer guide  100 . Also, at the same time, the substrate supporters  400  move to the y-axis direction so that subsequent portions CL where other components C are installed, on the substrate, may be disposed on an extension line of a transferring path of the components C. 
         [0048]    As the above operations are repeated, the components C are installed on the substrate S continuously. 
         [0049]    In the apparatus  1  for mounting components according to the current exemplary embodiment, even if one reel  200  is used, the plurality of components C may be simultaneously installed on the substrate S. Accordingly, speed of installing the components C on the substrate S may be efficiently increased without using a plurality of reels. 
         [0050]    Even if the components C are the same kind, deviations in performance of the components C may exist. In general, the deviations in the components contained in different reels are larger than the deviations in the components contained in a same reel. Accordingly, in order to reduce the performance deviations of the components C installed on the substrate S, it is desirable to use only one reel to supply the components C to the nozzle spindles  310  as the current exemplary embodiment. 
         [0051]    In particular, when a plurality of light emitting diode packages are installed on a printed circuit board so as to manufacture a backlight unit, deviations in brightness of the light emitting diode packages need to be suppressed in order to make brightness of the backlight unit to be entirely uniform. Accordingly, in order to manufacture a backlight unit, the light emitting diode packages supplied from only one reel may be installed on a printed circuit board. 
         [0052]    In this regard, when the apparatus  1  for mounting components according to the current exemplary embodiment is used, a plurality of light emitting diodes supplied from one reel  200  may be simultaneously installed on a printed circuit board, and thus, a backlight unit having entirely uniform brightness may be rapidly manufactured. 
         [0053]    Also, in the apparatus  1  for mounting components according to the current exemplary embodiment, the intervals between the nozzle spindles  310  may be changed so that even if sizes of the components C or the type of the substrate S is changed, such a change may be easily managed. 
         [0054]    Next, an apparatus  2  for mounting components according to another exemplary embodiment is described with reference to  FIG. 6 . 
         [0055]    Referring to  FIG. 6 , the apparatus  2  for mounting components according to the current exemplary embodiment includes the component transfer guide  100 , the component supplying unit, the suction nozzles  312 , and the substrate supporters  400 . 
         [0056]    The component transfer guide  100  according to the current exemplary embodiment is different from the component transfer guide  100  in the apparatus  1  for mounting components according to the previous exemplary embodiment in terms of arrangement of the component transfer guide  100  and the substrate supporters  400 . Other structures and functions of the component transfer guide  100 , the component supplying unit, the suction nozzles  312 , and the substrate supporters  400  are similar to those in the apparatus  1  for mounting components of  FIG. 1A . 
         [0057]    As illustrated in  FIG. 6 , the component transfer guide  100  is disposed to extend in the x-axis direction and the substrate supporters  400  are disposed to be parallel to the component transfer guide  100 . That is, the substrate supporters  400  are spaced apart from the component transfer guide  100  in a direction intercrossing the transferring direction A 1  of the components C. 
         [0058]    In this case, a transfer path of the mounter head  300  may be reduced compared with when the substrate supporters  400  is spaced apart from the component transfer guide  100  in the transferring direction A 1  of the components C. Accordingly, time for installing the components C on the substrate S may be reduced, and thus, speed of installing the components C on the substrate S may be efficiently increased. 
         [0059]    In the apparatus  2  for mounting components according to the current exemplary embodiment, the plurality of components C may be supplied from one reel  200 , and thus, may be simultaneously installed on the substrate S, and the intervals between the suction nozzles  312  may be changed. Accordingly, even if the intervals d 1  between the components C in the component transfer guide  100  are different from the intervals d 2  between the portions CL, on which the components C are installed, on the substrate S, such a difference may be efficiently managed. 
         [0060]    Next, an apparatus for mounting components according to still another exemplary embodiment is described with reference to  FIG. 7 . 
         [0061]      FIG. 7  is a perspective view schematically illustrating an apparatus  3  for mounting components according to still another exemplary embodiment. 
         [0062]    Referring to  FIG. 7 , the apparatus  3  for mounting components according to the current exemplary embodiment includes the component transfer guide  100 , the component supplying unit, the suction nozzles  312 , the substrate supporters  400 , and the camera  500 . 
         [0063]    The structures and functions of the suction nozzles  312 , the substrate supporters  400 , and the camera  500  are similar to those in the apparatus  1  for mounting components of  FIG. 1A , and thus, detailed description thereof is omitted. 
         [0064]    As illustrated in  FIG. 7 , the component transfer guide  100  is disposed to extend in the x-axis direction and sidewalls are formed at both sides of the component transfer guide  100  so that the components C are guided and moved to the x-axis direction. An interval between the sidewalls is set to slightly greater than widths of the components C so that the components C may be transferred in a line. 
         [0065]    In the current exemplary embodiment, the component supplying unit includes a vibratory bowl feeder  250 . The components C are arranged in a bulk form on the vibratory bowl feeder  250 . When the vibratory bowl feeder  250  vibrates, the components C are moved to the component transfer guide  100 . The vibratory bowl feeder  250  is well-known to one of ordinary skill in the art, and thus, detailed description thereof is omitted. 
         [0066]    In the apparatus  3  for mounting components according to the current exemplary embodiment, the components C arranged in a bulk form may be put into the vibratory bowl feeder  250  without using the carrier tape T containing the components C, and thus, costs for manufacturing the carrier tape T may be saved. 
         [0067]    Also, a plurality of the bulk components C may be installed simultaneously using only one vibratory bowl feeder  250 , and thus, speed for installing the components C on the substrate S may be increased. In addition, a manufacturing cost of the apparatus  3  for mounting components may be lower than when the apparatus for mounting components comprises a plurality of vibratory bowl feeders. 
         [0068]    In the apparatus  3  for mounting components according to the current exemplary embodiment, the intervals between the suction nozzles  312  may be controlled. Accordingly, even if the intervals d 1  between the components C in the component transfer guide  100  are different from the intervals d 2  between the portions CL, on which the components C are installed, on the substrate S, such a difference may be efficiently managed. Also, even if sizes of the components C or the type of the substrate S are changed, such a change may be easily managed 
         [0069]    In the above exemplary embodiments, the nozzle spindles  310  may be moved by a driving unit (not illustrated). However, the nozzle spindles  310  may be moved by manual operation. In particular, when the intervals d 1  between the components C in the component transfer guide  100  are the same as the intervals d 2  between the portions CL, on which the components C are installed, on the substrate S, the locations of the nozzle spindles  310  are controlled manually so as to match the intervals between the nozzle spindles  310  with the intervals d 1  between the components C. In this case, when the components C or the substrate S are changed, the intervals between the nozzle spindles  310  may be reset manually according to intervals between the components C. 
         [0070]    Also, in the above exemplary embodiments, in order to change the intervals between the nozzle spindles  310 , the spindle bodies  320  are combined to the guide rails  330  so as to slidably move; however, a mechanical structure to change the intervals between the nozzle spindles  310  is not limited thereto. For example, a mechanical mechanism for changing the intervals between the nozzle spindles  310  may include a gear system, a belt, and a pulley system. 
         [0071]    In addition, in the above exemplary embodiments, the components C are transferred in a line by the component transfer guide  100 ; however, the components C may be transferred in a plurality of lines by the component transfer guide  100 . In this case, the suction nozzles  312  may alternately install the components C in each line on the substrate S. 
         [0072]    According to the exemplary embodiments, in the apparatus and method of mounting components, one component supplying unit may be used to supply components to a plurality of nozzle spindles. 
         [0073]    According to the exemplary embodiments, in the apparatus and method of mounting components, even if sizes of the components or installation locations of the components on the substrate are changed, such a change may be easily managed. 
         [0074]    While the inventive concept has been particularly shown and described with reference to the exemplary embodiments thereof, it will be understood by those of ordinary skill in the art that various changes in form and details may be made therein without departing from the spirit and scope of the inventive concept as defined by the following claims.