Abstract:
A carriage assembly for use with an assembling apparatus is provided. The assembling apparatus is used to assemble operatively upper and lower portions of an integrated circuit carrier with co-operative upper and lower clamping members. The carriage assembly includes a linear carriageway in a working zone of the assembling apparatus and spaced from a support surface of the apparatus. Also included is a first holding mechanism movable along the linear carriageway and configured to hold the upper carrier portion and to displace said upper portion substantially orthogonally with respect to said linear carriageway towards and away from a support surface of the assembling apparatus, and a second holding mechanism movable along the linear carriage and configured to hold the upper clamping member and to displace the upper clamping member towards and away from the support surface. The carriage assembly also features a linear actuator configured to displace the holding mechanisms along the carriageway, and a control system to control operation of the holding mechanisms and the linear actuator.

Description:
FIELD OF THE INVENTION 
       [0001]    The invention relates to an assembler for assembling a carrier for supporting printhead integrated circuits, a method for assembling a carrier for integrated circuits, a safety system for an assembling apparatus for assembling a circuitry test support, a carriage assembly for use with an assembling apparatus of an integrated circuit carrier, and an adhesive application apparatus for use with an assembling machine for assembling a carrier for printhead integrated circuits. 
       CO-PENDING APPLICATIONS 
       [0002]    The following applications have been filed by the Applicant simultaneously with the present application: 
         [0000]                                                        MPN023US   MPN024US   MPN025US   MPN026US   MPN027US   MPN028US   MPN029US       MPN030US   MPN031US   MPN032US   MPN033US   MPN034US   MPN035US   MPN036US       MPN037US   MPN038US   MPN039US   MPN041US   MPN042US   MPN043US   MPN046US       MPN047US   MPN048US   MPN049US   MPN052US   MPN053US   MPN054US   MPN055US       MPN056US   MPN057US   MPN058US   MPN059US   MPN060US   MPN061US                    
The disclosures of these co-pending applications are incorporated herein by reference. The above applications have been identified by their filing docket number, which will be substituted with the corresponding application number, once assigned.
 
       CROSS REFERENCES 
       [0003]    The following patents or patent applications filed by the applicant or assignee of the present invention are hereby incorporated by cross-reference. 
         [0000]    
       
         
               
               
               
               
               
               
               
             
           
               
                   
               
             
             
               
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       BACKGROUND OF THE INVENTION 
       [0004]    Pagewidth printers that incorporate micro-electromechanical components generally have printhead integrated circuits that include a silicon substrate with a large number of densely arranged micro-electromechanical nozzle arrangements. Each nozzle arrangement is responsible for ejecting a stream of ink drops. 
         [0005]    In order for such printers to print accurately and maintain quality, it is important that the printhead integrated circuits be tested. This is particularly important during the design and development of such integrated circuits. 
         [0006]    Some form of carrier is generally required for testing such integrated circuits. 
       SUMMARY OF THE INVENTION 
       [0007]    According to one aspect of the invention there is provided an assembler for assembling a carrier for supporting printhead integrated circuits, said carrier having upper and lower parts that are operatively fastened together, said assembler comprising: 
         [0008]    a support structure configured to support the lower part in a pre-fastened position; 
         [0009]    a holding mechanism arranged on the support structure for holding the upper part in a pre-fastened position; 
         [0010]    a displacement mechanism arranged on the support structure for displacing the holding mechanisms to bring the parts into operative registration with each other; and 
         [0011]    a fastening apparatus for fastening the parts together. 
         [0012]    The support structure may include a support bed and a carriage assembly positioned on the support bed, the displacement and holding mechanisms being arranged on the carriage assembly. 
         [0013]    The carriage assembly may have a linear carriage spaced from the support bed and carriage actuators for linear displacement of the holding mechanisms with respect to the support bed. 
         [0014]    The fastening apparatus may include an operatively lower clamp and an operatively upper clamp, the clamps being configured to correspond with the lower part and the upper part respectively to clamp the parts together, the support bed being configured to support the lower clamp in a pre-clamped position. 
         [0015]    The fastening apparatus may include an upper clamp lifting and holding mechanism arranged on the carriage assembly and configured to lift the upper clamp from the support bed and to bring it into operative engagement with the lower clamp. 
         [0016]    The fastening apparatus may include an adhesive dispenser arranged on the support structure and configured to dispense an adhesive to be applied to one of the parts. 
         [0017]    The fastening apparatus may include an adhesive applicator positioned on the support bed to receive adhesive dispensed by the dispenser, the displacement mechanism being configured to displace the upper part into engagement with the applicator prior to positioning the upper part on the lower part. 
         [0018]    The upper clamp lifting and holding mechanism may be configured to bring the upper clamp into operative engagement with the lower clamp subsequent to positioning the upper part on the lower part. 
         [0019]    According to a second aspect of the invention, there is provided a method for assembling a carrier for integrated circuits, said carrier having upper and lower parts, the method comprising the steps of: 
         [0020]    positioning the lower part in a bottom clamp portion retained in a bottom clamp receptacle; 
         [0021]    positioning a top clamp portion in a top clamp receptacle, the clamp portions being configured to engage each other in a locking manner; 
         [0022]    positioning the upper part in a first gripper; 
         [0023]    applying adhesive to at least one of the parts; 
         [0024]    pressing said upper part onto the bottom part retained by the bottom clamp receptacle with the first gripper, whilst retrieving the top clamp portion with a second gripper; and 
         [0025]    locking the top clamp portion to the bottom clamp portion with the second gripper to clamp the parts together. 
         [0026]    The step of positioning the carrier parts may include positioning carrier parts molded from a liquid crystal polymer (LCP). The step of positioning the carrier parts may include receiving carrier parts which define a plurality of discrete fluid paths when operatively joined to form a fluid supply carrier for the printhead circuitry. 
         [0027]    The step of applying adhesive may include dispensing the adhesive with an adhesive dispenser onto a surface and dipping at least part of the gripped upper part in such dispensed adhesive with said first gripper. 
         [0028]    The method may be carried out with an apparatus that defines a single-user station and including the step of monitoring an operational status of the apparatus. 
         [0029]    The method may include the step of reading identifiers on the carrier parts and relaying data representing the identifiers to a control system of the apparatus. 
         [0030]    According to a third aspect of the invention there is provided a safety system for an assembling apparatus for assembling a circuitry test support having a number of components to be fastened together, the apparatus having moveable mechanisms displaceable within an operating zone, the system comprising: 
         [0031]    a sensor arrangement for sensing an operational status of the assembler; 
         [0032]    an emergency cut-off mechanism operatively connected to the sensor arrangement and configured to deactivate the assembler when an undesired operational status is sensed; and a control system for controlling operation of the sensor arrangement and the emergency cut-off mechanism. 
         [0033]    The control system may be configured such that the operational status includes aspects selected from the group consisting of: a position of the movable mechanisms; a presence of a foreign object proximate the movable mechanisms; a fluid pressure of hydraulic or pneumatic actuators of the movable mechanisms; a presence of the components; authenticity of the components; an electricity supply to the assembler; and an operator identifier of an operator operating the assembler. 
         [0034]    Accordingly, the sensor arrangement may include a plurality of micro-switches for sensing positions of the movable mechanisms. The sensor arrangement may include a light curtain connected to the control system to detect the ingress of a foreign object into the operating zone, a pressure sensor connected to the control system to detect a fluid pressure of hydraulic or pneumatic actuators for the movable mechanisms and proximity sensors connected to the control system to detect a position of the components. 
         [0035]    The sensor arrangement may include a barcode scanner connected to the control system and operable to scan a barcode of the components to enable verification of the authenticity of the components by the control system. 
         [0036]    The control system may be configured to communicate with a remote monitoring system. 
         [0037]    According to a fourth aspect of the invention, there is provided a carriage assembly for use with an assembling apparatus used to assemble operatively upper and lower portions of an integrated circuits carrier with co-operative upper and lower clamping members, the carriage assembly comprising: 
         [0038]    a linear carriageway in a working zone of the assembling apparatus and spaced from a support surface of the apparatus; 
         [0039]    a first holding mechanism movable along the linear carriageway and configured to hold the upper carrier portion and to displace said upper portion substantially orthogonally with respect to said linear carriageway towards and away from a support surface of the assembling apparatus; 
         [0040]    a second holding mechanism movable along the linear carriage and configured to hold the upper clamping member and to displace the upper clamping member towards and away from the support surface; 
         [0041]    a linear actuator configured to displace the holding mechanisms along the carriageway; and 
         [0042]    a control system to control operation of the holding mechanisms and the linear actuator. 
         [0043]    The control system may be configured to displace the first holding mechanism through an operative cycle that includes a first step towards the support surface, a second step away from the support surface, a third step along the carriageway, a fourth step towards the support surface and a fifth step away from the support surface. 
         [0044]    The control system may be configured to displace the second holding mechanism through an operative cycle that includes a first step along the carriageway, a second step towards the support surface, a third step away from the support surface, a fourth step along the carriageway in a direction opposite to the first step, a fifth step back towards the support surface and a sixth step away from the support surface. 
         [0045]    The first and second holding mechanisms may be fast with each other such that the third step of the first holding mechanism is simultaneous with the first step of the second holding mechanism. 
         [0046]    The control system may be configured to displace the first holding mechanism such that the upper portion is brought into and out of operative engagement with an adhesive station on the support surface in the first and second steps, into alignment with the lower portion positioned in the lower clamp member on the support surface in the third step and into adhesive engagement with the lower portion in the fourth step. 
         [0047]    The control system may be configured to displace the second holding mechanism into alignment with the upper clamp member in the first step, into engagement with the upper clamp member in the second step, away from the support surface, with the upper clamp member, in the third step, into alignment with the upper portion in the fourth step, to engage the upper clamp member with the lower clamp member in the fifth and to disengage from the upper clamp member in the sixth step. 
         [0048]    According to a fifth aspect of the invention, there is provided an adhesive application apparatus for use with an assembling machine for assembling operatively upper and lower components for carrying printhead integrated circuits, the application apparatus comprising: 
         [0049]    a plate; 
         [0050]    a dispensing mechanism which includes an adhesive reservoir, said mechanism being operatively engaged with said plate in a sealing and sliding manner, the mechanism configured to dispense adhesive onto the plate when sliding along the plate; 
         [0051]    a displacement mechanism to slide the dispensing mechanism along the plate; and 
         [0052]    a control system to control operation of the dispensing and displacement mechanisms. 
         [0053]    The dispensing mechanism may be configured to dispense adhesive according to a pad printing technique. The plate may define an etched channel shaped and dimensioned according to the upper component, so that a particular part of the upper component is covered in adhesive when the portion is placed on the plate. 
         [0054]    The displacement mechanism may include a linear carriage and actuator engaged with the dispensing mechanism. The dispensing mechanism may include a dispensing cup in which adhesive is stored, the dispensing cup being magnetically attracted to the plate to generate said operative engagement. 
         [0055]    According to a sixth aspect of the invention, there is provided a software product for execution by a processor of an assembler for assembling a carrier operatively supporting a printhead integrated circuit, said software product enabling the processor to perform the steps of: 
         [0056]    positioning a lower carrier part in a bottom clamp portion retained in a bottom clamp receptacle; 
         [0057]    positioning a top clamp portion in a top clamp receptacle, the clamp portions being configured to engage each other in a locking manner; 
         [0058]    positioning an upper carrier part in a first gripper; 
         [0059]    applying adhesive to at least one of the parts; 
         [0060]    pressing said upper part onto the bottom part retained by the bottom clamp receptacle with the first gripper, whilst retrieving the top clamp portion with a second gripper; and 
         [0061]    locking the top clamp portion to the bottom clamp portion with the second gripper to clamp the parts together. 
         [0062]    According to a seventh aspect of the invention, there is provided memory comprising a software product for execution by a processor of an assembler for assembling a carrier operatively supporting a printhead integrated circuit, said software product enabling the processor to perform the steps of: 
         [0063]    positioning a lower carrier part in a bottom clamp portion retained in a bottom clamp receptacle; 
         [0064]    positioning a top clamp portion in a top clamp receptacle, the clamp portions being configured to engage each other in a locking manner; 
         [0065]    positioning an upper carrier part in a first gripper; 
         [0066]    applying adhesive to at least one of the parts; 
         [0067]    pressing said upper part onto the bottom part retained by the bottom clamp receptacle with the first gripper, whilst retrieving the top clamp portion with a second gripper; and 
         [0068]    locking the top clamp portion to the bottom clamp portion with the second gripper to clamp the parts together. 
         [0069]    The invention is now described, by way of example, with reference to the accompanying drawings. The following description is intended to illustrate particular embodiments of the invention and to permit a person skilled in the art to put those embodiments of the invention into effect. Accordingly, the following description is not intended to limit the scope of the preceding paragraphs or the claims in any way. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0070]    In the drawings: 
           [0071]      FIG. 1  shows a frontal layout view of an embodiment, in accordance with the invention, of an assembler for a carrier for supporting printhead integrated circuits; 
           [0072]      FIG. 2  shows a perspective view of a holding mechanism for an upper carrier part of the assembler of  FIG. 1 ; 
           [0073]      FIG. 3  shows a perspective view of a holding mechanism for an upper clamp of the assembler of  FIG. 1 ; 
           [0074]      FIG. 4  shows an exploded perspective view of the upper part and a lower carrier part of the carrier for supporting printhead integrated circuits; 
           [0075]      FIG. 5  shows a perspective view of an embodiment, in accordance with the invention, of an adhesive application apparatus for use with an assembling machine for assembling operatively upper and lower components for carrying printhead integrated circuits, which can be the assembler of  FIG. 1 ; 
           [0076]      FIG. 6  shows a perspective view of a displacement mechanism of the assembler shown in  FIG. 1 ; 
           [0077]      FIG. 7  shows a perspective view of an upper clamp lifting and holding mechanism of the assembler shown in  FIG. 1 ; 
           [0078]      FIG. 8.1  shows electrical and pneumatic components in an enclosure for the assembler of claim  1 ; 
           [0079]      FIG. 8.2  shows a side view of the enclosure of  FIG. 8.1 , showing external connections for the electrical and pneumatic components; 
           [0080]      FIG. 9  shows an exploded detailed view of a fastening apparatus of the assembler of  FIG. 1  for fastening the upper and lower carrier parts together; 
           [0081]      FIG. 10  shows an embodiment of a user interface for the assembler of  FIG. 1 ; 
           [0082]      FIG. 11  shows an embodiment of a foot switch forming part of a user interface for the assembler of  FIG. 1 ; and 
           [0083]      FIG. 12  shows a flow diagram representing a method, in accordance with the invention, for assembling the carrier for integrated circuits. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0084]    With reference to the accompanying drawings, reference numeral  10  generally refers to an assembler or assembling machine for assembling a carrier for supporting printhead integrated circuits, in accordance with the invention. Throughout this description, like reference numerals indicate like components, unless otherwise specified. 
         [0085]    Referring now to  FIG. 1 , one embodiment of the assembler  10  is shown in broad overview. In the embodiment shown, the assembler  10  is a single-user workstation-type machine for assembling a carrier  14 , which is also a carrier for integrated circuits (see  FIG. 4 ). The assembler  10  includes a frame or support structure  16  which houses the necessary components, as described below. 
         [0086]    With reference to  FIG. 4 , the assembler  10  is used to assemble a carrier  14  for printhead circuitry. The carrier  14  comprises an upper part  14 . 1  and a lower part  14 . 2 . The carrier parts  14 . 1  and  14 . 2  are typically molded from a liquid crystal polymer to define a plurality of tortuous printing fluid paths therein. The carrier  14  is used to mount printhead integrated circuits (not shown) for testing purposes. 
         [0087]    The printhead integrated circuits is generally formed from micro-electromechanical systems (MEMS) manufacturing techniques and comprises a number of nozzle arrangements for operatively ejecting printing fluids onto a medium. However, prior to installing the printhead circuitry into a printer, it is important to test the circuitry to ensure acceptable levels of operation. The carrier  14  is used as a conduit for the supply of printing fluids to the printhead circuitry. 
         [0088]    As shown in  FIG. 4 , the carrier  14  has an upper part  14 . 1  onto which the circuitry is placed in operation. The upper part  14 . 1  defines a number of openings for ducting printing fluid to similar openings of the circuitry. The lower carrier part  14 . 2  defines a number of channels which form the fluid paths when the two parts  14 . 1  and  14 . 2  are bonded together. The assembler  10  is used to bond these parts together. The assembler  10  uses a fastening apparatus in the form of a clamp assembly  20 , described below. 
         [0089]    Referring now to  FIG. 1 , the assembler  10  includes the support bed  16  which locates a lower clamp receptacle or nest  12  and an upper clamp receptacle or nest  18 . A carriage assembly  26  is supported on the support bed and has a linear carriage defined by a rail  38  which supports, in a linearly displaceable manner, a first holding mechanism  22  and a second holding or displacement mechanism  28 , both linked and driven by a linear actuator to be displaceable together along the rail  38 . 
         [0090]    The first holding mechanism  22  includes a first gripper  24 , and the displacement mechanism  28  includes a second gripper  30 . In use, an operator (not shown) is responsible for loading the assembler  10  with four components, namely a lower clamp  20 . 1 , an upper clamp  20 . 2 , the upper carrier part  14 . 1  and the lower carrier part  14 . 2 . The clamp assembly  20  is shown in more detail in  FIG. 9  discussed below. 
         [0091]    In use, the operator loads the lower clamp  20 . 1  into the lower clamp nest  12 , and places the lower carrier part  14 . 2  into the lower clamp  20 . 1 . The upper carrier part  14 . 1  is placed into the first gripper  24  of the holding mechanism  22 , and the upper clamp  20 . 2  is placed into the top clamp nest  18 . 
         [0092]    The assembler  10  also includes an adhesive application apparatus having a glue dispenser apparatus  32 . The glue dispenser apparatus includes a dispensing mechanism  34 , a displacement mechanism  46 , and an etched plate  36 . The dispensing mechanism  34  is configured to dispense an adhesive onto the etched plate  36 . The etched plate  36  functions as an applicator when a carrier part  14  is brought into contact with the plate  36 . 
         [0093]    The assembler  10  further includes a control system or controller having an operator interface in the form of a panel  42  and a touch-screen display  40 . The operator interface is used to permit an operator to control operation of the assembler  10 . The control system also has a barcode scanner  44 , which is used to scan identifiers in the form of barcodes from the clamp and carrier parts. 
         [0094]    During operation of the assembler  10  and after the respective parts have been loaded into the different clamp nests and grippers, as described above, the process is as follows. Upon activation of the assembler  10  via the operator interface, the mechanisms  22  and  28  are positioned as shown in  FIG. 1 . The glue dispenser  32  is activated so that the dispensing mechanism  34  is displaced across the etched plate  36  by the displacement mechanism  46 , dispensing glue over the plate  36 . The displacement mechanism  28  then lowers the second gripper  30 , which grips the upper carrier part  14 . 1  ( FIG. 4 ), onto the etched plate  36 . 
         [0095]    The etched plate  36  has adhesive spread thereon by the action of the dispensing mechanism  34 , so that dipping the upper carrier part  14 . 1  therein coats a bottom surface of the carrier part  14 . 1  with adhesive. The second gripper  30  then raises the carrier part  14 . 1 , whereafter the displacement mechanism  28  is displaced along the rail  38  so that the second gripper  30  can place the upper carrier part  14 . 1  onto the lower carrier part  14 . 2 . When the first holding and the displacement mechanisms  22 ,  28  are in a predetermined position, the first gripper  24  and the second gripper  30  are lowered simultaneously. 
         [0096]    The first gripper  24  retrieves the top clamp  20 . 2  from the top clamp nest  18 , whilst the second gripper  30  presses the upper carrier part  14 . 1  onto the lower part  14 . 2  which is held by the bottom clamp in the lower clamp nest  12 . Thereafter both grippers  24  and  30  are retracted upwards towards the rail  38 , and the first holding and displacement mechanisms  22 ,  28  are moved so that the first gripper  24  is above the lower clamp nest  12 . Once in position, the first gripper  24  locks the top clamp  20 . 2  to the lower clamp  20 . 1 , so that the carrier parts  14  are clamped together. This clamped assembly may then be subjected to a heat curing process, or the like. 
         [0097]    Prior to the operator loading the parts into their respective grippers and/or clamp nests, the parts  14  and clamps  20  can be scanned with the barcode scanner  44 . The barcode scanner  44  is in signal communication with the control system or controller of the assembler  10 , which can be configured to log and keep track of discrete clamps and parts. 
         [0098]      FIG. 2  shows a more detailed view of the lower clamp nest  12 . The nest  12  is affixed to the supporting bed of the structure  16  by means of fasteners  54 . In the embodiment shown, these fasteners are Allen screws, but any suitable fastener may be used. The nest  12  includes locating tabs  52  to locate the lower clamp  20 . 1  therein, as well as proximity sensors  50  to sense when the clamp is correctly positioned and secured. In one embodiment the sensors  50  are short-barrel inductive proximity sensors. The sensors  50  are linked to the controller by means of wires  56 , as shown. 
         [0099]    The Inventor has found that pre-wired miniature sensors from the Omron™ E2E range are suitable for the sensors  50 . The nest  12  also includes an orientation spigot  58  for complementarily engaging a corresponding aperture in the lower clamp  20 . 2  to ensure that the clamp is correctly in position. 
         [0100]      FIG. 3  shows a more detailed view of the top clamp nest  18 . The nest  18  is fastened to the support bed  16  with fasteners  66 . In the embodiment shown, the fasteners are Allen screws, but any suitable fastener may be used. The nest  18  defines locating channels  60  for receiving the top clamp  20 . 2 . The channels  60  include proximity sensors  62  linked to the controller by wires  64 . The sensors  62  are used to sense when the top clamp is correctly in position. As above, the Inventor has found that pre-wired miniature sensors from the Omron™ E2E range are suitable for sensors  62 . 
         [0101]    It is to be appreciated that sensors  50  and  62  are linked to the controller so that operation of the assembler  10  can be interrupted if the clamps are removed from the nests  12  and  18 . For example, should the top clamp  20 . 2  be accidentally or erroneously removed during operation, a safety system of the assembler (described in more detail below) may interrupt the assembler to prevent damage to components and/or injury to the operator. 
         [0102]    The adhesive dispenser apparatus  32  is shown in more detail in  FIG. 5 . As shown, the apparatus  32  comprises a dispensing mechanism  34  in the form of a glue cup or adhesive reservoir  34  with an accompanying glue cup lid  74  which is removable for refilling said cup with adhesive. The glue cup  34  also includes a sealing member  76  which provides a reduced friction surface to facilitate displacement of the glue cup  34  across the etched plate  36 . 
         [0103]    The dispensing mechanism  34  is configured to dispense the adhesive according to a pad printing technique. The glue cup  34  is displaced across the plate  36  by the displacement mechanism  46 , which includes a pneumatic actuator sliding along a dispenser rail  70  actuated with air via pneumatic tubing  72 . The cup  34  is magnetically attracted to the plate  36  to form a tight seal. 
         [0104]    The plate  36  includes an etched channel  68  which is shaped so that a particular portion of the upper carrier part  14 . 1  is covered in glue when the second gripper  30  places said particular portion in the channel  68 . By displacing the glue cup  34  across the plate  36 , a layer of glue is deposited on the plate and collects in the channel  68 . The apparatus  32  is controlled by the controller or control system described below. 
         [0105]    The displacement mechanism  28  is shown in more detail in  FIG. 6 . The mechanism  28  is used to dip the upper carrier part  14 . 1  onto the etched plate  36  of the glue dispenser  32 , and subsequently to place the upper part  14 . 1  onto the lower carrier part  14 . 2  held in the bottom clamp nest  12 . 
         [0106]    The mechanism  28  has a micro-motor housing  80  housing a micro-motor to raise and lower the second gripper  30 . This motor can include a DC motor with precision screw mechanism to gently place and lift the carrier part  14 . 1  onto the etched plate  36 . The mechanism  28  can be configured to lift the carrier part  14 . 1  with an initial relatively slow movement to prevent “stringing” of the adhesive. The Inventor has found that the Maxon® 24V DC motor from the F2140 range is suitable for this application. The motor typically includes safety switches to interrupt power to the mechanism  28  if it exceeds its normal extent of travel. The Inventor has found that two Cherry® sub-miniature DC1C-C3LC sealed switches are adequate for this purpose. 
         [0107]    The mechanism  28  also has actuator cylinders  82  to actuate the second gripper  30 . The cylinders  82  are connected to pneumatic components under control of the controller via pneumatic connections  88 . The cylinders  82  include position sensors  86  to sense the position of the mechanism  28 , which is relayed to the controller via wires  84 . 
         [0108]    A more detailed view of the holding mechanism  22  is shown in  FIG. 7 . The mechanism  22  includes the first gripper  24  and is attached to the rail  38  of the carriage assembly  26 . Actuator cylinders  90  are controlled by the controller to actuate the first gripper  24  to retrieve and place the top clamp onto the bottom clamp. The cylinders  90  are pneumatically operated via pneumatic connections  92 . The cylinders  90  can include a load cell (not shown) for measuring the amount of pressure applied when the top clamp is placed or pressed onto the bottom clamp. It is to be appreciated that the mechanism  22  generally applies a predetermined amount of pressure to clamp the clamps  20  together. 
         [0109]    Accordingly, the first gripper  24  includes clamp lock proximity sensors  94  configured to determine when the clamps  20  are locked together. Typically, the clamps  20  have locking levers which are displaced proximate these sensors  94  when said clamps  20  are locked together. The sensors  94  are operatively linked to the controller via wires  98 . The cylinders  90  can also include position sensors  96  to sense and relay the position of the mechanism  22  to the controller. 
         [0110]    An embodiment of the controller  100  is shown in  FIG. 8 , housed in an enclosure  102  of the assembler  10 . The enclosure  102  houses the required electrical and pneumatic components for operating the assembler  12 . The controller  100  includes a programmable logic controller (PLC). The Inventor has found that the Mitsubishi FX3U-48MR PLC is suitable. The PLC generally includes an RS232 interface module (Mitsubishi FX3U-232BD), and Ethernet interface module  104  (Mitsubishi FX3U-ENET) and a 2-channel analog function module (Mitsubishi FX3U-2AD). 
         [0111]    The RS232 module is used to perform data transfer between the PLC  100  and the barcode scanner  44 . The RS232 module may also be used to upgrade PLC software via an 8-way DIN connector. In general, the RS232 module is used to connect the PLC  100  with the display panel  40 . A Monitouch® V606eC20 display has been found to be suitable, as it offers a 16-colour 320×240 dots display incorporating an analog switch and a SRAM/built-in clock function. The Ethernet interface module  104  is used to connect the controller or PLC  100  to a remote monitoring system. The analog function module is used to convert analog measurements from the load cell in the holding mechanism  22  into digital signals for interpretation by the controller  100 . 
         [0112]    The assembler  10  includes two DC power supply modules  110  and  116  for supplying the PLC  100  and related components, along with a motor controller  114  and solenoid components discussed below, respectively with power. The Inventor has found that the Phoenix Contact MINI-PS-100-240AC/24DC/4 and MINI-PS-100-240AC/5DC/3, respectively, are suitable for the application. 
         [0113]    The assembler  10  has a safety system, in accordance with an embodiment of the invention. The safety system includes an emergency cut off mechanism having two safety relays  134  in the form of a primary safety relay and a relay for a light curtain  150  (shown in  FIG. 1 ) of the safety system discussed in more detail below. The Inventor has found that the Wieland SNO 4003K Safety Relay is adequate for the primary relay, with the Omron G7S-4A2B DC24 Plug-In Safety Relay appropriate for the light curtain relay. A flare relay  108  is also included between the power supply  110  and the PLC  100 , in the form of a Wieland 24V DC terminal relay. 
         [0114]    A signal conditioning unit  106  is included which provides signal conditioning for the load cell in the holding mechanism  22 . Gain selection and gross offset correction are allowed by this unit to match load cell signals to input requirements of the PLC  100 . An Applied Measurement RM044 unit has been found to be appropriate. 
         [0115]    Overcurrent and earth leakage protection are provided by a Hager AD 810T residual current circuit breaker  130 . The unit  130  is a single pole unit with a switched neutral to detect sinusoidal residual current, and offers earth fault detection and incorporates a trip free mechanism. 
         [0116]    Ventilation and cooling for the enclosure  102  is provided by a Sunon 24V DC brushless fan  132 . The fan unit  132  can include a filter to keep dust out of the enclosure  102 . 
         [0117]    The light curtain  150  forms a sensor arrangement and comprises transmitter and receiver units located on opposite sides of the support structure  16  to create an invisible light curtain between the sides. The safety system, forming part of the control system includes a light curtain controller  136  that is configured to shut the assembler  10  down when a foreign object pierces the light curtain. The Inventor has found that a Keyence® SL-C32H Light Curtain is able to fulfill this task. The light curtain  150  is configured to interrupt electrical power and to release air pressure in the pneumatic components when a foreign object is detected. 
         [0118]    The controller  100  is configured to regulate and control the pneumatic components such as the grippers  24  and  30 , the carriage  26 , the glue dispenser  32 , the mechanisms  22  and  28 . To this end, and for safety purposes, the enclosure  102  includes solenoid valves  120  and  112 , pressure sensor  122 , and isolation valve  126 . For electrical protection, a number of fuses  118  and  128  are also included, as shown. 
         [0119]    A side view of the enclosure  102  of  FIG. 8.1  is shown in  FIG. 8.2 . An air connector  140  is shown via which the assembler  10  is connected to an air supply for the pneumatic components controlled by the controller  100 . The connector  140  includes a pressure regulator  144  and the air supply isolation valve  126  can be seen. The pneumatic connector  140  includes a micro-mist separator to trap and drain moisture from an incoming air supply. A main AC power isolation switch  124  is also included. 
         [0120]    As discussed above, the clamps  20  are shown in more detail in  FIG. 9 . The lower clamp  20 . 1  includes a bottom bar  151  with a silicone sheet  152 , which is attached to the bottom bar  151  by means of a rubber retainer  156  and retainer screws  158 . Dowel pins  154  are also included, as shown. Clamp pins  160  are affixed to bottom bar  151  by means of pin nuts  162 . 
         [0121]    Accordingly, top clamp  20 . 2  has a top bar  164  having a glass layer  166  attached to the bar  164  by means of glass clips  168  and clip screws  170 . Clamp pin latches  172  operatively receive the clamp pins  160 , whereafter the second gripper  30  displaces dowel pins  174  outwards to lock the clamps  20  together. The top clamp  20 . 2  further includes cover  176  and cover screws attaching said cover  176  to the top bar  164 , as shown. 
         [0122]      FIGS. 10 and 11  show embodiments of the user interface panel  42  and a foot switch  192 . The interface panel  42  includes a wipe button  180  which is connected to the PLC  100  such that, on actuation, the controller to displace the adhesive dispenser mechanism  34  across the etched plate  36  to wipe excess glue from the plate  36 . A reset button  182  is also provided which resets the assembler  10  to a ready state. The interface  42  includes two start buttons  184  and  188  as a safety feature. Both these buttons  184  and  188  must be pressed simultaneously to activate the assembler  10 . An emergency stop button  186  is also included, along with a scanner connection  190  for connecting the scanner  44  to the PLC  100 . 
         [0123]    In the embodiment shown, the foot switch  192  is used to instruct the PLC  100  so that the upper carrier part  14 . 1  is gripped in the second gripper  30 , which frees up the operator&#39;s hands for the interface panel and touch screen display  40 . 
         [0124]    The invention extends to a method  198  for assembling the carrier or carrier  14  for the printhead circuitry. An overview of these method steps are shown in  FIG. 12 , individual steps generally represented by the blocks referenced from numeral  200  to  240 . 
         [0125]    Blocks  204  and  220  refer to steps generally performed by the PLC  100  transmitting data via the Ethernet module  104  to the remote monitoring system, such as a control network linked to a production or testing assembly, or the like. Steps indicated by blocks  200 ,  202 ,  206 ,  208 ,  214 ,  212 ,  210 ,  216 ,  218 ,  222 ,  224 ,  226 ,  236  and  240  are generally performed by the operator. Blocks  228 ,  230 ,  232  and  234  represent steps typically performed by the assembler  10  under control of the operator. 
         [0126]    In preparation of bonding the carrier parts  14  together, the operator typically commences the process  198  by retrieving the clamps  20  from storage, as indicated by block  200 . The barcode scanner  44  is used to scan barcodes of the clamps (shown by block  202 ), and these barcodes are sent to the remote monitoring system during block  204 . 
         [0127]    The clamps  20  are then placed in their respective clamp nests  12  and  18  located on the support bed  16  of the assembler  10 . Similarly, the carrier parts  14  are removed from a clean storage environment (shown in block  212 ) and their barcodes are scanned in block  214 , data representing the barcodes being communicated to the remote monitoring system in block  220 . The method can include the step of scanning a batch barcode (block  222 ) of the parts and communicating data representing the batch barcode to the remote monitoring system. The carrier parts  14  are loaded by placing the top carrier part  14 . 1  into the second gripper  30 , and placing the bottom carrier part  14 . 2  into the bottom clamp  20 . 1  in the bottom clamp nest  12  (blocks  208  and  224 , respectively). 
         [0128]    In anticipation of the bonding process, it might be necessary to fill the glue cup  34  with glue prior to bonding. This process is shown by blocks  210  (retrieving the glue),  216  (scanning a barcode of the glue batch), and  218  (filling the glue cup). Once the above steps have been completed, where necessary, the operator can press the start buttons  184  and  188  (block  226 ) on the panel  42  to commence a process performed by the assembler  10 . 
         [0129]    The PLC  100  then manages the steps of dipping the upper carrier part  14 . 1  in the glue dispensed on the plate  36 , and placing the upper part  14 . 2  on the bottom part  14 . 2  (blocks  228  and  230 , respectively). The top clamp  20 . 2  is retrieved by the first gripper  24 , and pressed onto the bottom clamp  20 . 1  (block  232 ). The mechanism  22  then locks the clamps  20  together, as described above, shown in block  234 . 
         [0130]    The operator is then able to remove the bonded and clamped assembly (block  236 ) from the bottom clamp nest  12 , whereafter it can be transferred to a curing oven (block  240 ). 
         [0131]    As mentioned above, the assembler  10  includes a safety system represented by the respective sensors, described above, and the light curtain  150  as controlled by the PLC  100 . The safety system monitors an operating zone within the support structure  16 , generally as demarcated by the light curtain  150 . If a foreign object is sensed by the light curtain, or any sensor senses an undesired position of a mechanism, the PLC  100  deactivates the assembler  10 . 
         [0132]    Accordingly, the PLC  100  is configured to deactivate the assembler when any undesirable operational status, as monitored by the PLC  100 , is detected. The PLC  100  generally monitors positions of the movable mechanisms, such as mechanisms  22  or  28 , carriage  26 , glue dispenser  32 , gripper  24  and  30 , etc. The fluid pressure of the pneumatic components, as described above, is also monitored. Similarly, the presence and correct placement of the carrier parts and clamps  20  in their respective nests or grippers can be monitored, along with the authenticity of the components as identified by their barcodes. 
         [0133]    As discussed above, the PLC  100  also monitors the electricity supply to the assembler  10 . In one embodiment, the operator may have to provide identification prior to operating the machine. This may include keying in a code via the display  40 , or the like. Should any of the monitored aspects not be complied with, the PLC  100  can be programmed not to activate the assembler  10 . Accordingly, the PLC  100  can be connected to any suitable sensors for monitoring the above aspects, such as pressure sensors, proximity sensors, etc. 
         [0134]    The above examples are merely to guide the skilled person in implementing the invention, and are not meant to unduly restrict the scope thereof. It is to be appreciated that any reference to particular components specific to particular manufacturers does not limit the invention to the use of these components. As such, the skilled person will appreciate that similar functionality is achievable by different components or even different configurations without detracting from the scope of the invention.