Optical circuit pick and place machine

• US 20020168147A1
• Filed: 03/15/2002
• Published: 11/14/2002
• Est. Priority Date: 02/20/2001
• Status: Abandoned Application

• Current Assignee: CyberOptics Corporation (Nordson Corporation)
• Original Assignee: CyberOptics Corporation (Nordson Corporation)
• Inventors: Knighton, Craig D., Case, Steven K., Skunes, Timothy A., Mowry, Gregory S., Garfield, Patrick J., McElreath, John T.
• Application Number:
  US10/098,743
• Publication Number:
  US 20020168147A1
• Time in Patent Office: Days
• US Class Current: 385/53
• CPC Class Codes: G02B 6/255 Splicing of light guides, e.g. by fusion or bonding
• CPC Class Codes: G02B 6/2553 Splicing machines, e.g. optical fibre fusion splicer
• CPC Class Codes: G02B 6/2555 Alignment or adjustment devices for aligning prior to splicing
• CPC Class Codes: G02B 6/32 having lens focusing means positioned between opposed fibre ends with lens being an integral part of the single fibre end G02B6/262
• CPC Class Codes: G02B 6/362 Vacuum holders for optical elements
• CPC Class Codes: G02B 6/3636 the mechanical coupling means being grooves G02B6/3652 takes precedence
• CPC Class Codes: G02B 6/3652 the additional structures being prepositioning mounting areas, allowing only movement in one dimension, e.g. grooves, trenches or vias in the microbench surface, i.e. self aligning supporting carriers
• CPC Class Codes: G02B 6/3838 using grooves for light guides
• CPC Class Codes: G02B 6/3873 Connectors using guide surfaces for aligning ferrule ends, e.g. tubes, sleeves, V-grooves, rods, pins, balls
• CPC Class Codes: G02B 6/4207 with optical elements reducing the sensitivity to optical feedback anti-reflection devices specially adapted for lasers, see H01S3/0064
• CPC Class Codes: G02B 6/4221 involving a visual detection of the position of the elements, e.g. by using a microscope or a camera
• CPC Class Codes: G02B 6/4224 using visual alignment markings, e.g. index methods
• CPC Class Codes: G02B 6/4225 by a direct measurement of the degree of coupling, e.g. the amount of light power coupled to the fibre or the opto-electronic element
• CPC Class Codes: G02B 6/4226 Positioning means for moving the elements into alignment, e.g. alignment screws, deformation of the mount
• CPC Class Codes: G02B 6/4227 Active alignment methods, e.g. procedures and algorithms
• CPC Class Codes: G02B 6/4228 Passive alignment, i.e. without a detection of the degree of coupling or the position of the elements G02B6/4234 takes precedence
• CPC Class Codes: G02B 6/4231 with intermediate elements, e.g. rods and balls, between the elements
• CPC Class Codes: G02B 6/4232 using the surface tension of fluid solder to align the elements, e.g. solder bump techniques flip-chip mounting techniques in assembly of semiconductor devices H01L24/81
• CPC Class Codes: G02B 6/4236 Fixing or mounting methods of the aligned elements
• CPC Class Codes: G02B 6/4238 Soldering
• CPC Class Codes: G02B 6/4239 : Adhesive bonding; Encapsulation with polymer material

Abstract

A method and apparatus for automatically assembling an optical device is provided. Prealigned optical modules are mounted by a pick and place machine onto a fixed reference.

Claims

1. A method of assembling an optical device, comprising:

obtaining a plurality of prealigned optical modules, the modules having an optical components prealigned with respect to registration features on the modules;

obtaining a fixed reference having a plurality of registration features configured to mate with the registration features of prealigned optical modules;

initially aligning a registration feature of at least one of the prealigned optical modules with a registration feature of the fixed reference, the aligning performed with a first level of accuracy; and

urging the at least one prealigned optical module and the fixed reference together following the step of initially aligning and thereby passively aligning the registration features of the module and the fixed reference due to cooperation between the registration feature of the at least one prealigned optical module and the registration feature of the fixed reference to align the prealigned optical module with the registration feature of the fixed reference with a second level of accuracy, the second level of accuracy being greater than the first level of accuracy.

2. The method of claim 1 wherein initially aligning a registration feature of at least one of the optical modules including:

grasping the at least one prealigned optical module from a supply of the plurality of prealigned optical modules; and

transferring the at least one prealigned optical module from the supply to the fixed reference.

3. The method of claim 2 including identifying an orientation of the at least one prealigned optical module.

4. The method of claim 1 wherein initially aligning includes grasping at least one of the prealigned optical modules with a gripper, the gripper having limited compliance to allow relative movement of the module in at least one dimension.

5. The method of claim 1 including gripping the prealigned optical module.

6. The method of claim 5 wherein gripping includes applying a vacuum to a vacuum nozzle.

7. The method of claim 1 wherein the registration features comprise at least a portion of a kinematic registration feature.

8. The method of claim 1 including adhering the prealigned optical module to the fixed reference.

9. The method of claim 8 wherein adhering includes soldering.

10. The method of claim 1 including applying an adhesive to secure the optical modules to the fixed reference.

11. The method of claim 1 including applying an adhesive which provides an optical index match between optical components.

12. The method of claim 1 including identifying an orientation of the optical module.

13. The method of claim 12 wherein identifying an orientation includes optically imaging the prealigned optical module.

14. The method of claim 1 including obtaining a serial number for a prealigned optical module.

15. The method of claim 14 wherein obtaining a serial number is through an optical inspection of the prealigned optical module.

16. The method of claim 1 including grasping the prealigned optical module and grasping an optical fiber pigtail coupled to the prealigned optical module.

17. The method of claim 16 wherein grasping the optical fiber pigtail comprises grasping a cassette which carries the pigtail.

18. The method of claim 16 including grasping a distal end of the optical fiber pigtail.

19. The method of claim 4 including fixing the gripper to eliminate the limited compliance prior to the initially aligning.

20. The method of claim 1 including selecting a tool on a placement head from a plurality of tools.

21. The method of claim 1 including providing an electrical connection to at least one of the prealigned optical module and fixed reference.

22. The method of claim 1 including providing a prealigned optical module through a component feeder mechanism.

23. The method of claim 1 including providing a laminar air flow.

24. The method of claim 1 including inspecting an alignment of a prealigned optical module following the step of releasing.

25. The method of claim 1 wherein urging comprises performing a kinematic registration.

26. The method of claim 25 wherein the registration features comprise a protrusion and a recess and performing a kinematic registration comprises seating the protrusions in the recesses.

27. The method of claim 25 wherein the urging is performed with sufficient compliance to allow the kinematic registration.

28. The method of claim 1 wherein urging comprises urging the optical module through a compliance wrist.

29. A pick and place machine configured to operate in accordance with the method of claim 1.

30. An optical device made in accordance with the method of claim 1.

31. The method of claim 9 including preheating a pad prior to soldering.

32. The method of claim 9 including heating the solder with a resistive heater, or laser.

33. The method of claim 9 wherein the soldering is performed in an atmosphere other than air to prevent or remove oxidation during bonding.

34. The method of claim 1 including gripping the at least one optical module at a fiber loop.

35. The method of claim 7 including verifying kinematic seating.

37. The apparatus of claim 36 wherein the actuator is coupled to the fiber optical pigtail gripper.

38. The apparatus of claim 36 wherein the optical module gripper comprises a vacuum nozzle.

39. The apparatus of claim 36 wherein the fiber optic pigtail gripper comprises a vacuum nozzle.

40. The apparatus of claim 36 including a distal end gripper configured to couple to a distal end of the fiber optic pigtail.

41. The apparatus of claim 40 wherein the distal end gripper comprises a vacuum nozzle.

42. The apparatus of claim 40 wherein the distal end gripper is coupled to the actuator.

43. The apparatus of claim 36 wherein the fiber optic pigtail is carried in a cassette.

44. The apparatus of claim 36 including a camera coupled to the controller to identify an orientation of the prealigned optical module.

45. The apparatus of claim 36 wherein the optical module gripper comprises a compliance wrist.

46. The apparatus of claim 36 including electrical probes configured to couple to electrical contacts on the prealigned optical module to provide an electrical connection to heating elements configured to heat solder.

47. The apparatus of claim 36 including electrical probes configured to couple to the fixed reference to provide an electrical connection to heating elements configured to heat solder.

48. The apparatus of claim 36 including a source of laminar air flow.

49. The apparatus of claim 44 wherein the camera is mounted on the actuator.

50. The apparatus of claim 46 wherein electrical contacts are carried on the actuator.

51. The apparatus of claim 36 including a bar code reader configured to read a bar code carried on the prealigned optical module.

52. The apparatus of claim 51 wherein the bar code reader is mounted on the actuator.

53. The apparatus of claim 36 including a plurality of interchangeable tools selectively coupleable to the actuator.

54. The apparatus of claim 36 wherein the optical module gripper comprises a vacuum nozzle having a vacuum nozzle and a push rod, the push rod configured to provide a downward force against the optical module.

55. The apparatus of claim 54 wherein the push rod allows limited lateral and/or angular movement of the optical module.

56. The apparatus of claim 43 wherein the pigtail is spooled.

57. The apparatus of claim 36 wherein the optical module is carried in a cradle and the optical module gripper is configured to grip the cradle.

58. The apparatus of claim 57 including a cassette configured to carry the fiber pigtail and wherein the cradle is loosely coupled to the cassette.

59. The apparatus of claim 36 wherein the optical module couples to the fixed reference through a kinematic mount.

97. The apparatus of claim 36 or 66 including a laser to heat solder.

98. The apparatus of claim 36 or 66 including a source of a nitrogen atmosphere or a forming gas for use during soldering.

99. The apparatus of claim 36 or 66 wherein the controller verifies a kinematic seating.

36. An apparatus for assembling optical devices, comprising:

an optical module gripper configured to selectively grasp a prealigned optical module;

a fiber optic pigtail gripper configured to selectively grasp a fiber optic pigtail coupled to prealigned optical module;

an actuator configured to move the optical module gripper between a source of prealigned optical modules and a fixed reference; and

a controller configured to control the actuator and the optical module gripper to cause the actuator to position the optical module gripper proximate the source of prealigned optical modules where the optical module gripper grasps a prealigned optical module, moves the prealigned optical module proximate the fixed reference and places the prealigned optical module in registration features of the fixed reference.

60. An apparatus configured to carry a prealigned optical module, comprising:

a cassette configured to support an optical fiber pigtail coupled to the prealigned optical module; and

a cradle configured to hold the prealigned optical module, the cradle loosely coupled to the cassette to allow limited relative movement between the cradle and the cassette.

61. The apparatus of claim 60 wherein the cradle is configured to be grasped by a pick and place machine.

62. The apparatus of claim 60 wherein the cassette is configured to be grasped by a pick and place machine.

63. The apparatus of claim 60 including a distal cradle configured to hold an optical module coupled to a distal end of the fiber optic pigtail, the distal cradle loosely coupled to the cassette.

64. The apparatus of claim 60 wherein the prealigned optical module includes an indentation and wherein the cradle includes a protrusion configured to fit into the indentation to thereby secure the prealigned optical module in the cradle.

65. The apparatus of claim 60 wherein the cassette is configured to hold a spool of optical fiber.

66. An apparatus for assembling an optical device, comprising:

a source of prealigned optical modules;

an optical module gripper configured to compliantly grip a prealigned optical module;

an actuator configured to move the optical module gripper between the source of prealigned optical modules and a fixed reference; and

a controller configured to control the actuator and the gripper whereby the gripper grasps a prealigned optical module from the source of optical modules, aligns registration features on the optical module with registration features on the fixed reference and urges the registration features together.

67. The apparatus of claim 66 wherein the controller identifies an orientation of the at least one prealigned optical module.

68. The apparatus of claim 66 wherein the gripper has limited compliance to allow limited relative movement of the module relative to the gripper in at least one dimension.

69. The apparatus of claim 66 wherein gripper applies a vacuum to a vacuum nozzle.

70. The apparatus of claim 66 wherein the registration features comprise a kinematic registration.

71. The apparatus of claim 66 including a source of adhesive to adhere the prealigned optical module to the fixed reference.

72. The apparatus of claim 66 wherein the controller heats solder to secure components and/or provide an electrical connection.

73. The apparatus of claim 66 wherein the gripper has a controllable compliance.

74. The apparatus of claim 66 including a camera to optically image the prealigned optical module.

75. The apparatus of claim 66 wherein the controller identifies a serial number of the prealigned optical module.

76. The apparatus of claim 66 including a second gripper to grasp an optical fiber pigtail coupled to the prealigned optical module.

77. The apparatus of claim 76 wherein second gripper grasps a cassette which carries the pigtail.

78. The apparatus of claim 76 including a third gripper to grasp a distal end of the optical fiber pigtail.

79. The apparatus of claim 66 including a plurality of selectable tools coupled to the actuator.

80. The apparatus of claim 66 wherein the source includes a component feeder mechanism.

81. The apparatus of claim 66 including a source of laminar air flow.

82. The apparatus of claim 66 wherein the controller releases the prealigned optical module from the gripper and subsequently inspects an alignment of a prealigned optical module.

83. The apparatus of claim 66 wherein the registration features comprise a protrusion and a recess.

84. The apparatus of claim 66 wherein gripper comprises a compliance wrist.

85. The apparatus of claim 66 wherein the controller is further configured to place an electrical component on the fixed reference.

86. The apparatus of claim 66 including electrical probes configured to electrically contact the prealigned optical module.

87. The apparatus of claim 66 including electrical probes configured to electrically contact the fixed reference.

88. The apparatus of claim 66 including electrical probes configured to melt solder to secure the prealigned optical module.

89. The apparatus of claim 66 including electrical probes configured to melt solder to provide an electrical connection to the prealigned optical module.

90. The apparatus of claim 66 including an adhesive dispenser configured to dispense an adhesive.

91. The apparatus of claim 90 wherein the adhesive secures the prealigned optical module to the fixed reference.

92. The apparatus of claim 90 wherein the adhesive encapsulates the prealigned optical module.

93. The apparatus of claim 69 including a push rod to urge the prealigned optical module from the vacuum nozzle.

94. The apparatus of claim 66 wherein the optical module gripper has a controllable compliance.

95. The apparatus of claim 66 including a functional inspection module configured to test operation of the optical module.

96. The apparatus of claim 95 wherein the functional inspection module is configured to test the optical module after the optical module is placed in the fixed reference.