Abstract:
A Tray input-output module, comprising a power unit, a clamp unit and a support unit, is capable of automatically retrieving a tray from a transport device and automatically delivering a tray to a transport device for facilitating automation in chip sorter operation, reducing manual work and raising productivity.

Description:
FIELD OF THE INVENTION 
     The present invention relates to a tray input-output module and in particular relates to a tray input-output module, capable of delivering a tray to a transport device and retrieving a tray from a transport device, automatically. Allowing full automation of chip sorter, the tray input-output module is able to save manpower, eliminate human error and elevate production efficiency. 
     BACKGROUND OF THE INVENTION 
     While automation has been the target of modern industry in the perpetual quest for efficiency and competitiveness, manual operation exists in certain processes and full automation remains a future goal. Efficiency and competitiveness continue to advance as more automatic processes replace manual operations. 
     a. Prior art 
     The chip sorter in the semiconductor industry is being used to illustrate the prior art. FIG. 1 shows the known chip sorter in the prior art, comprising a platform  10 , a robot arm  11  and a transport device  12 . A wafer is divided into a number of dies  21  and placed on a platform  10 . The main function of the chip sorter is to pick up a die  21  and place it onto a tray  3 . First, an operator sets a tray  3  on one end of transport device  12 , which then carries the tray  3  to a sorter position. Robot arm  11  of chip sorter picks up die  21  on platform  10  and loads it onto tray  3  until the tray  3  is full. The tray  3  is transferred by transport device  12  to a next stop before being removed by another operator. 
     It is clear from the above description that the chip sorter in the prior art is not capable of automatically delivering tray to transport device and retrieving tray from transport device. Requiring manual work, such operations are less efficient due to additional labor cost. 
     SUMMARY OF THE INVENTION 
     Aimed at resolving the above disadvantage, it is the object of the present invention to provide a tray input module, capable of delivering a tray to transport device and retrieving a tray from transport device. 
     It is another object of the present invention to provide a tray output module, capable of retrieving a tray from transport device. 
     The following Description and Designation of Drawings are provided in order to help understand the features and content of the present invention. 
    
    
     BRIEF DESCRIPTION OF DRAWINGS 
     The accompanying drawings form a material part of this description, in which: 
     FIG. 1 is a perspective view of a prior art chip sorter. 
     FIG. 2A is a perspective view of the first power unit of the tray input module in accordance with the first preferred embodiment of the present invention. 
     FIG. 2B is a perspective view of the clamp unit of the tray input module in accordance with the first preferred embodiment of the present invention. 
     FIG. 2C is a perspective view of the support unit of the tray input module in accordance with the first preferred embodiment of the present invention. 
     FIG. 3 is an exploded view of the tray input module in accordance with the first preferred embodiment of the present invention. 
     FIG. 4A is a perspective view of the first power unit of the tray output module in accordance with the second preferred embodiment of the present invention. 
     FIG. 4B is a perspective view of the clamp unit of the tray output module in accordance with the second preferred embodiment of the present invention. 
     FIG. 4C is a perspective view of the support unit of the tray output module in accordance with the second preferred embodiment of the present invention. 
     FIG. 4D is a perspective view of the second power unit of the tray output module in accordance with the second preferred embodiment of the present invention. 
     FIG. 5 is an exploded view of the tray output module in accordance with the second preferred embodiment of the present invention. 
     FIG. 6A is a perspective view of the first power unit of the tray input module in accordance with the third preferred embodiment of the present invention. 
     FIG. 6B is a perspective view of the clamp unit of the tray input module in accordance with the third preferred embodiment of the present invention. 
     FIG. 6C is a perspective view of the support unit of the tray input module in accordance with the third preferred embodiment of the present invention. 
     FIG. 6D is a perspective view of the second power unit of the tray input module in accordance with the third preferred embodiment of the present invention. 
     FIG. 7 is an exploded view of the tray input module in accordance with the third preferred embodiment of the present invention. 
     FIG. 8 is a three-dimensional view of the tray input module in accordance with the third preferred embodiment of the present invention. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     In the following description, the present invention is described in connection with specific and preferred embodiments. It will be understood that the present invention is not limited to these embodiments, but rather is to be construed as the spirit and scope defined by the appended claims. 
     In the present specification, the structure and process are described as comprising specific components and steps, respectively. It is within the contemplation of the present inventors that the structure and process can consist essentially of, or consist of, the disclosed components and steps, respectively. 
     In order to resolve the aforementioned disadvantages, the present invention discloses a novel tray input-output module comprising a tray input module and a tray output module, wherein the tray input module is capable of automatically converting a whole stack of trays into single trays, two stacked trays, a plurality of stacked trays, or their combination as programmed and place said trays on the transport device for transferring to a next station, and the tray output module is able to automatically remove, one at a time, from the transport device individual trays and pile them up as a single stack. 
     a. Tray input module: 
     The tray input module in accordance with the first preferred embodiment of the present invention comprises a power unit  4 , a clamp unit  5  and a support unit  6 . 
     FIG. 2A shows a perspective view of the first power unit  4  of the tray input module in accordance with the first preferred embodiment of the present invention. The first power unit  4  is a cylinder having a push rod  41 . A front stopper  43 , a back stopper  44  and a middle stopper  45  are provided in the front, back and middle of the push rod  41 , respectively. A first spring  46  is provided between the middle stopper  45  and the back stopper  44  and a second spring  47  provided between the middle stopper  45  and the front stopper  43 . 
     FIG. 2A shows a perspective view of a clamp unit  5  of the tray input module in accordance with the first preferred embodiment of the present invention. 
     The clamp unit  5  comprises an upper slider  51 , two connecting rods  52   a ,  52   b , and two levers  53   a ,  53   b . Situated between the first spring  46  and the middle stopper  45 , the upper slider  51  has a round hole  512  for accepting the push rod  41  (not shown). A container  514  having a shape that complements the middle stopper  45  is provided in front of the upper slider  51 . When the first spring  46  is not loaded, the middle stopper  45  is located in the container  514 . The two connecting rods  52   a  and  52   b  provide two first ends  521   a  and  521   b  and two second ends  522   a  and  522   b , respectively. The two levers  53   a  and  53   b  provide two support points  531   a  and  531   b , respectively, two load points  532   a  and  532   b , respectively, and two clamp parts  533   a  and  533   b , respectively. The two first ends  521   a  and  521   b  are connected with the sides of the upper slider  51 , symmetrically, and the two second ends  522   a  and  522   b  are linked to the two load points  532   a  and  532   b , respectively. The two connecting rods  52   a  and  52   b  drive the two levers  53   a  and  53   b  and cause the two clamp parts  533   a  and  533   b  to retract and clamp the tray  3  by the two sides. 
     FIG. 2C shows a perspective view of a support unit  6  of the tray input module in accordance with the first preferred embodiment of the present invention. The support unit  6  comprises a lower slider  61 , two connecting rods  62   a ,  62   b , and two levers  63   a ,  63   b . Situated between the second spring  47  and the middle stopper  45  and at a proper distance away from the middle stopper  45 , the lower slider  61  has a round hole  612  for accepting the push rod  41  (not shown). The two connecting rods  62   a  and  62   b  provide two first ends  621   a  and  621   b  and two second ends  622   a  and  622   b , respectively. The two levers  63   a  and  63   b  provide two support points  631   a  and  631   b , respectively, two load points  632   a  and  632   b , respectively, and two clamp parts  633   a  and  633   b , respectively. The two first ends  621   a  and  621   b  are connected with the sides of the lower slider  61 , symmetrically, and the two second ends  622   a  and  622   b  are linked to the two load points  632   a  and  632   b , respectively. The two connecting rods  62   a  and  62   b  drive the two levers  63   a  and  63   b  and cause the two support parts  633   a  and  633   b  to open up and let go of the tray  3 . 
     FIG. 3 is an exploded view of the tray input module in accordance with the first preferred embodiment of the present invention. The operation of the tray input module is as follows. Having a stack of empty trays  3  in the tray input module such that the bottom tray  3   a  rests on the two support parts  633   a  and  633   b  and the tray  3   b  above tray  3   a  lies on the two clamp parts  533   a  and  533   b , and being driven by first power unit  4  via the push rod  41 , the upper slider  51  of the clamp unit  5  moves forward by the expanding force of the first spring  46  and causes the two clamp parts  533   a  and  533   b  to retract and clamp hold of the tray  3   b . As the loaded first spring  46  shortens, the lower slider  61  of the support unit  6 , driven by the middle stopper  45 , moves forward and causes the two support parts  633   a  and  633   b  to open up and place the tray  3   a  on the transport device  12 . 
     Since the middle stopper  45  and the lower slider  61  are separated at a proper distance in the first preferred embodiment of the present invention, a time differential exists between the operations of the clamp unit  5  and the support unit  6 . That is, the support unit  6  will let go of the tray  3   a  only after the clamp unit  5  clamps hold of the tray  3   b  so as to ensure that only one tray  3  is being released in a single operation. 
     As the first power unit  4  drives the push rod  41 , the lower slider  61  of the support unit  6  moves backward by the recovery force of the first spring  46  and causes the two support parts  633   a  and  633   b  to return to the support position. Then the recovery force of the first spring  46  moves the upper slider  51  of the clamp unit  5  backward and causes the two clamp parts  533   a  and  533   b  to open up so as to let go of the tray  3   b  and place it on the two support parts  633   a  and  633   b . The tray input module can automatically deliver the tray  3  by repeating the above procedures. 
     b. Tray output module: 
     The tray output module in accordance with the second preferred embodiment of the present invention includes a first power unit  7 , a clamp unit  8 , a support unit  9 , and a second power unit  7   a.    
     FIG. 4A is a perspective view of the first power unit  7  of the tray output module in accordance with the second preferred embodiment of the present invention. The first power unit  7  is a cylinder having a first push rod  71 . A front stopper  73 , a back stopper  74  and a middle stopper  75  are provided in the front, back and middle of the first push rod  71 , respectively. A first spring  76  is provided between the middle stopper  75  and the back stopper  74  and a second spring  77  provided between the middle stopper  75  and the front stopper  73 . 
     FIG. 4B is a perspective view of the clamp unit  8  of the tray output module in accordance with the second preferred embodiment of the present invention. The clamp unit  8  comprises an upper slider  81 , two connecting rods  82   a ,  82   b , and two levers  83   a ,  83   b . Situated between the first spring  76  and the middle stopper  75 , the upper slider  81  has a round hole  812  for accepting the first push rod  71  (not shown). A container  814  having a shape that complements the middle stopper  75  is provided in front of the upper slider  81 . When the first spring  76  is not loaded, the middle stopper  75  is located in the container  814 . The two connecting rods  82   a  and  82   b  provide two first ends  821   a  and  821   b  and two second ends  822   a  and  822   b , respectively. The two levers  83   a  and  83   b  provides two support points  831   a  and  831   b , respectively, two load points  832   a  and  832   b , respectively, and two clamp parts  833   a  and  833   b , respectively. The two connecting rods  82   a  and  82   b  drive the two levers  83   a  and  83   b  and cause the two clamp parts  833   a  and  833   b  to retract and clamp hold of the tray  3  by the two sides. 
     FIG. 4C is a perspective view of the support unit  9  of the tray output module in accordance with the second preferred embodiment of the present invention. The support unit  9  comprises a lower slider  91 , two connecting rods  92   a ,  92   b , and two levers  93   a ,  93   b . Situated between the second spring  77  and the middle stopper  75  and at a proper distance away from the middle stopper  45 , the lower slider  61  has a round hole  912  for accepting the first push rod  71  (not shown). The two connecting rods  92   a  and  92   b  provide two first ends  921   a  and  921   b  and two second ends  922   a  and  922   b , respectively. The two levers  93   a  and  93   b  provides two support points  931   a  and  931   b , respectively, two load points  932   a  and  932   b , respectively, and two clamp parts  933   a  and  933   b , respectively. The two first ends  921   a  and  921   b  are connected with the sides of the lower slider  91 , symmetrically, and the two second ends  922   a  and  922   b  are linked to the two load points  932   a  and  932   b , respectively. The two connecting rods  92   a  and  92   b  drive the two levers  93   a  and  93   b  and cause the two support parts  933   a  and  933   b  to open up and let go of the tray  3 . 
     FIG. 4D is a perspective view of the second power unit  7   a  of the tray output module in accordance with the second preferred embodiment of the present invention. Located below the support unit  9 , the second power unit  7   a  is a cylinder having a second push rod  71   a.    
     FIG. 5 is an exploded view of the tray output module in accordance with the second preferred embodiment of the present invention. A plurality of trays  3  is placed on the support unit  9  of the tray output module wherein a bottom tray  3   c  is situated between the two clamp parts  833   a  and  833   b  and on top of the two support parts  933   a  and  933   b . When a tray  3   d  full of dies  21  is being transferred by a transport device  12  to a location below the support unit  9 , a first push rod  71  of a first power unit  7  drives forward a first spring  76  to move an upper slider  81  of a clamp unit  8  and causes two clamp parts  833   a  and  833   b  to retract and clamp hold of the tray  3   c . As the loaded first spring  76  shortens, the lower slider  91  of the support unit  9 , driven by the middle stopper  75 , moves forward and causes the two support parts  933   a  and  933   b  to open up and let go of the tray  3   c . When the tray  3   d  lies beneath the tray  3   c , a second push rod  71   a  of a second power unit  7  pushes the tray  3   d  up. Being thin elastic material, the two connecting rods  82   a  and  82   b  are capable of curving up under load such that the tray  3   d  originally under the support unit  9  will be pushed to a location above the two support parts  933   a  and  933   b.    
     As the first power unit  7  drives the first push rod  71 , the lower slider  91  of the support unit  6  moves backward by the recovery force of the second spring  77  and causes the two support parts  933   a  and  933   b  to return to the support position. Meanwhile, the upper slider  81  of the clamp unit  8  moves backward by the recovery force of the first spring  76  and causes the two clamp parts  833   a  and  833   b  to let go of the tray  3   c.    
     The second power unit  7   a  drives downward the first push rod  71   a  to cause the tray  3   d  to be placed on the two support parts  933   a  and  933   b . By repeating the above procedures, the tray output module can automatically deliver the tray  3  from the 12-transport device. 
     c. Tray input module: 
     FIG.  7  and FIG. 8 show an exploded view and a three-dimensional view of the tray input module, respectively, in accordance with the third preferred embodiment of the present invention, wherein said tray input module comprises a first power unit  13 , a clamp unit  14 , a support unit  15  and a second power unit  16 . 
     FIG. 6A shows a perspective view of the first power unit  13  of the tray input module in accordance with the third preferred embodiment of the present invention, wherein the first power unit  13  includes a cylinder  131 , a cylinder connector  132 , a push rod base  134 , a push rod  135 , a compression spring  137 . One end of the cylinder connector  132  is secured to the cylinder  131  and the other end secured to the push rod base  134 . The push rod  135  is provided in front of the push rod base  134 . A front protrusion  136  is provided on the front end of said push rod  135 . Disposed around the push rod  135 , a compression spring  137  is provided between the front protrusion  136  and the push rod base  134 . 
     FIG. 6B shows a perspective view of the clamp unit  14  of the tray input module in accordance with the third preferred embodiment of the present invention, wherein the clamp unit  14  has two tray supporters  141 , a stopper spring  142 , a tray stopper  1421 , a base  144 , two rollers  145 , two sliders  146   a  and  146   b , two slider rod bases  1461   a  and  1461   b , two push rod bases  1462   a  and  1462   b , two spring pins  1463   a  and  1463   b  and an extension spring  1464 . 
     Providing one of the rectangular openings  1411   a  and  1411   b  respectively on each of the lower part, the two tray supporters  141   a  and  141   b  are secured to the base  144  in symmetrical fashion for containing a stack of trays  3 . Being T-shaped or any other suitable shape, the stopper spring  142  has the tray supporters  141   a  and  141   b  secured to its upper end and the tray stopper  1421  to its lower end, respectively. The slider rod bases  1461   a  and  1461   b  are secured to the base  144  symmetrically. The two sliders  146   a  and  146   b  are provided symmetrically between the slider rod bases  1461   a  and  1461   b . The two push rod bases  1462   a  and  1462   b  are provided, respectively, in two through holes that are supplied through the two slider rod bases  1461   a  and  1461   b  and the two sliders  146   a  and  146   b . The two rollers  145   a ,  145   b  are provided above the two sliders  146   a ,  146   b  and the two spring pins  1463   a ,  1463   b  are secured to the two sliders  146   a ,  146   b . The extension spring  1464  is disposed between the two spring pins  1463   a  and  1463   b.    
     FIG. 6C shows a perspective view of the support unit  15  of the tray input module in accordance with the third preferred embodiment of the present invention. The support unit  15  has two tray holders  151   a  and  151   b , being secured to the sliders  146   a  and  146   b , respectively. 
     FIG. 6D shows a perspective view of the second power unit  16  of the tray input module in accordance with the third preferred embodiment of the present invention. Provided below the support unit  15 , the second power unit  16  is a cylinder  16   a  having a push rod  161   a.    
     FIG.  7  and FIG. 8 are an exploded view and a three-dimensional view of the tray input module in accordance with the third preferred embodiment of the present invention. A plurality of trays  3  are provided on the support unit  15  wherein a bottom tray  3   c  is disposed on the same height as the tray stopper  1421  and the tray  3   c  is arranged above two tray holders  151   a  and  151   b  of the support unit  15 . The operation in accordance with the third embodiment is as follows. As a stack of trays  3  is provided horizontally in a clamp unit  14 , the two tray holders  151   a  and  151   b  of the support unit  15  enter the rectangular openings  1411   a  and  1411   b , respectively, and hold the stack  3  by the lower sides. When the input module in accordance with the third embodiment is scheduled to deliver a single tray in a single operation, the cylinder  131  as shown in FIG. 6A provides the driving force for the tray stopper  1421  to move forward and the elastic deflection of the stopper spring  142  allows the tray stopper  1421  to advance and move the whole stack of trays except the bottom tray until the stack is up against the wall of the tray supporters  141 . Still driven horizontally by the cylinder  131 , the tray stopper  1421  firmly clamps the stack of trays, being above and separated from the bottom tray, against the vertical wall of the tray supporters  141 . When the cylinder  131  continues to drive in sliding fashion the cylinder connector  132  and the push rod base  134 , the push rod base  134  advances as it presses against the compression spring  137 . Meanwhile, the slope on both sides of the push rod base  134  starts to press and cause the rollers  145   a  and  145   b  to move away in opposite directions. Being attached to the rollers  145   a  and  145   b , the sliders  146   a  and  146   b  move accordingly as the rollers  145   a  and  145   b  move away in opposite directions, thus causing the tray holders  151   a  and  151   b  (See FIG. 6C) to move away from each other. When the distance between the tray holders  151   a  and  151   b  exceeds the width of the tray, the bottom tray falls through between the tray holders  151   a  and  151   b  and lands onto the base  144  while said stack of trays, already above and separated from the bottom tray, are still being clamped in place between the tray stopper  1421  and the tray supporters  141 . After the bottom tray lands onto the base  144 , the push rod  161   a  driven by cylinder  16   a  pushes the bottom tray onto the transport device  12  for transporting to a next station. At the same time, the push rod base  134  stops and the cylinder  131  also ceases to drive. Since the compression spring  137  is loaded, its elastic tension now pushes back the push rod base  134  in the absence of the cylinder  131 &#39;s driving force. Meanwhile, the extension spring  1464 , being in an expansion state, now pulls the sliders  146   a  and  146   b  to move towards each other. As the push rod base  134  retreats, the rollers  145   a  and  145   b  slide along the slope on the sides of the push rod base  134  move towards each other and bring the sliders  146   a  and  146   b  towards each other accordingly, thereby causing the tray holders  151   a  and  151   b  to move towards each other. When the distance between the tray holders  151  reaches a point of being able to support the tray, the tray holders  151  stop to move and cause the rollers  145  to stop as well. At this point, the compression spring  137  is no longer under compression and thus gradually losses its elastic expansion. When the compression spring  137  gradually stops to push back said push rod base  134  and the tray stopper  1421 , and, at the same time, the stopper spring  142  also gradually pushes the tray stopper  1421  back to its original vertical position, the stack of trays is no longer being clamped so that it falls through between the tray stopper  1421  and the tray supporters  141 , and is immediately being supported by the tray holders  151 , thus completing the first cycle of converting a whole stack of trays into single trays for transferring to the next station. By the same token, two stacked trays, a plurality of stacked trays, or their combination can be accomplished as programmed. 
     By repeating the above procedures, the tray input module is capable of converting a whole stack of trays to single trays, two stacked trays or a plurality of stacked trays, or their combination to be transferred away by the transport device. 
     While the invention has been described in terms of a preferred embodiment, various alternatives and modifications can be devised by those skilled in the art without departing from the invention. Accordingly, the present invention is intended to embrace all such alternatives that fall within the scope of the claims.