Robotic processing system and method

• US 8,934,999 B2
• Filed: 02/13/2012
• Issued: 01/13/2015
• Est. Priority Date: 02/13/2012
• Status: Active Grant

• Current Assignee: Tesla Inc.
• Original Assignee: Tesla Motors Incorporated (Tesla Inc.)
• Inventors: Kalayjian, Nicholas R.
• Primary Examiner(s): PATEL, RAMESH B
• Application Number:
  US13/372,472
• Publication Number:
  US 20130211579A1
• Time in Patent Office: 1,065 Days
• Field of Search: 700/160, 700/186, 700192-195, 700/212, 700/245, 700258-259, 257/779, 219/616, 228/180.1
• US Class Current: 700/160
• CPC Class Codes: B23K 3/0653 with wave generating means, e.g. nozzles, jets, fountains

Abstract

A robotic processing system includes a microprocessor-controlled workpiece processor having a mobile processing element to be positioned independently in three orthogonal dimensions with respect to each of a plurality of target locations on a workpiece, with each particular target location of the plurality of target locations including an element to be processed, the mobile processing element processing the element at each particular target location by first moving to an initial location that is offset from the particular target location in a single dimension and then second moving along the single dimension towards the element at the particular target location until a contact signal is detected; and a control, coupled to the workpiece and to the mobile processing element, communicating the contact signal to the workpiece processor when the processing element makes physical contact with the element at the particular target location.

Claims

1. A robotic processing system, comprising:

a microprocessor-controlled workpiece processor including a mobile processing element to be positioned independently in three orthogonal dimensions with respect to each of a plurality of target locations on a workpiece, with each particular target location of said plurality of target locations including an element to be processed, said mobile processing element processing said element at each particular target location by first moving to an initial location that is offset from said particular target location in a single dimension and then second moving along said single dimension towards said element at said particular target location until a contact signal is detected; and

a controller, coupled to said workpiece and to said mobile processing element, communicating said contact signal to said workpiece processor when said processing element makes a physical contact with said element at said particular target location.

2. The robotic processing system of claim 1 wherein said contact signal is generated by a current flowing through said workpiece including said element to be processed and said mobile processing element.

3. The robotic processing system of claim 2 wherein a first element at a first particular target location is coupled to a first node of said workpiece and wherein a second element at a second particular target location is coupled to a second node of said workpiece.

4. The robotic processing system of claim 3 wherein said nodes are temporarily electrically shorted during processing of said first element and said second element.

5. The robotic processing system of claim 3 wherein a third element at a third particular target location is coupled to a third node of said workpiece and wherein said nodes are temporarily electrically shorted during processing of said first element, said second element, and said third element.

6. The robotic processing system of claim 5 wherein said workpiece includes a plurality of active semiconductor devices, wherein each said active semiconductor device includes three active connections with each active connection corresponding to an element at a particular target location, a first active connection coupled to said first node, a second active connection coupled to said second node, and a third active connection coupled to said third node.

7. The robotic processing system of claim 6 wherein said workpiece processor includes a selective wave solder station, wherein said mobile processing element includes a wave solder nozzle, and wherein said plane includes a horizontal plane disposed beneath said workpiece and said third dimension includes a vertical axis.

8. The robotic processing system of claim 1 wherein said controller advances said mobile processing element a predetermined distance along said single dimension towards said element after said physical contact.

9. The robotic processing system of claim 1 wherein said workpiece processor includes a selective wave solder station, wherein said mobile processing element includes a wave solder nozzle, and wherein said plane includes a horizontal plane disposed beneath said workpiece and said third dimension includes a vertical axis.

10. The robotic processing system of claim 9 wherein said controller advances said wave solder nozzle a predetermined distance along said single dimension towards said element after said physical contact.

11. The robotic processing system of claim 9 wherein said selective wave solder station includes a solder pump generating a solder wave for said solder wave nozzle wherein said solder pump is responsive to a pump speed control signal to control a height of said solder wave above said solder wave nozzle and wherein said controller advances said wave solder height a first predetermined distance towards said element after said physical contact.

12. The robotic processing system of claim 11 wherein said controller advances said wave solder nozzle a second predetermined distance along said vertical axis towards said element after said physical contact.

13. A robotic processing method, the method comprising the steps of:

(a) moving a mobile processing element to an initial location with respect to a particular target location of a workpiece including a plurality of target locations, each particular target location including an element to be processed wherein said initial location is offset from said target location in a single dimension; and

thereafter

(b) moving said mobile processing element along said single dimension towards said element at said particular target location; and

thereafter

(c) communicating a contact signal to a controller when said mobile processing element makes a physical contact with said element at said particular target location, wherein said mobile processing element is moved until said contact signal is received at said controller.

14. The robotic processing method of claim 13 wherein said contact signal is generated by a current flowing through said workpiece including said element to be processed and said mobile processing element.

15. The robotic processing method of claim 14 wherein a first element at a first particular target location is coupled to a first node of said workpiece and wherein a second element at a second particular target location is coupled to a second node of said workpiece.

16. The robotic processing method of claim 15 wherein said nodes are temporarily electrically shorted during processing of said first element and said second element.

17. The robotic processing method of claim 15 wherein a third element at a third particular target location is coupled to a third node of said workpiece and wherein said nodes are temporarily electrically shorted during processing of said first element, said second element, and said third element.

18. The robotic processing method of claim 17 wherein said workpiece includes a plurality of active semiconductor devices, wherein each said active semiconductor device includes three active connections each active connection corresponding to an element at a particular target location, a first active connection coupled to said first node, a second active connection coupled to said second node, and a third active connection coupled to said third node.

19. The robotic processing method of claim 18 wherein said workpiece processor includes a selective wave solder station, wherein said mobile processing element includes a wave solder nozzle, and wherein said plane includes a horizontal plane disposed beneath said workpiece and said third dimension includes a vertical axis.

20. The robotic processing method of claim 13 further comprising the step of:

d) advancing said mobile processing element a predetermined distance along said single dimension towards said element after said physical contact.

21. The robotic processing method of claim 13 wherein said workpiece processor includes a selective wave solder station, wherein said mobile processing element includes a wave solder nozzle, and wherein said plane includes a horizontal plane disposed beneath said workpiece and said third dimension includes a vertical axis.

22. The robotic processing method of claim 21 further comprising the step of:

d) advancing said mobile processing element a predetermined distance along said single dimension towards said element after said physical contact.

23. The robotic processing method of claim 21 wherein said selective wave solder station includes a solder pump generating a solder wave for said solder wave nozzle wherein said solder pump is responsive to a pump speed control signal to control a height of said solder wave above said solder wave nozzle and further comprising:

d) advancing said height of said wave solder a first predetermined distance along said single dimension towards said element after said physical contact.

24. The robotic processing method of claim 23 further comprising the step of:

e) advancing said mobile processing element a second predetermined distance along said single dimension towards said element after said physical contact.

25. A computer program product comprising a non-transitory tangible computer readable medium carrying program instructions for operating a system when executed using a computing system, the executed program instructions executing a robotic processing method, the method comprising:

(a) moving a mobile processing element to an initial location with respect to a particular target location of a workpiece including a plurality of target locations, each particular target location including an element to be processed wherein said initial location is offset from said target location in a single dimension; and

thereafter

(b) moving said mobile processing element along said single dimension towards said element at said particular target location until a contact signal is received; and

thereafter

(c) stopping said movement of said mobile processing element in step (b) responsive to a generation of said contact signal when said mobile processing element makes physical contact with said element at said particular target location.

26. The computer program product of claim 25 wherein said contact signal is generated by a current flowing through said workpiece including said element to be processed and said mobile processing element.

27. The computer program product of claim 26 wherein a first element at a first particular target location is coupled to a first node of said workpiece and wherein a second element at a second particular target location is coupled to a second node of said workpiece.

28. The computer program product of claim 27 wherein said nodes are temporarily electrically shorted during processing of said first element and said second element.