Method for accurate population of a circuit carrier

• US 9,992,920 B1
• Filed: 06/02/2016
• Issued: 06/05/2018
• Est. Priority Date: 06/09/2015
• Status: Active Grant

• Current Assignee: ZKW Group GmbH (LG Corporation)
• Original Assignee: ZKW Group GmbH (LG Corporation)
• Inventors: Zorn, Jrgen, Kieslinger, Dietmar
• Primary Examiner(s): Williams, Joseph L
• Assistant Examiner(s): Diaz, Jose M
• Application Number:
  US15/579,663
• Publication Number:
  US 20180153064A1
• Time in Patent Office: 733 Days
• CPC Class Codes: F21S 41/141 Light emitting diodes [LED]
• CPC Class Codes: F21S 41/657 by moving light sources
• CPC Class Codes: F21Y 2115/00 Light-generating elements of semiconductor light sources
• CPC Class Codes: G01B 11/14 for measuring distance or clearance between spaced objects or spaced apertures G01B11/26 takes precedence; rangefinders G01C3/00
• CPC Class Codes: H05K 1/181 associated with surface mounted components
• CPC Class Codes: H05K 13/046 Surface mounting surface mounted components H05K3/341
• CPC Class Codes: H05K 13/08 Monitoring manufacture of assemblages
• CPC Class Codes: H05K 13/0812 the monitoring devices being integrated in the mounting machine, e.g. for monitoring components, leads, component placement
• CPC Class Codes: H05K 13/0813 Controlling of single components prior to mounting, e.g. orientation, component geometry H05K13/0812 takes precedence
• CPC Class Codes: H05K 2201/10106 Light emitting diode [LED]
• CPC Class Codes: H05K 2203/166 Alignment or registration; Control of registration
• CPC Class Codes: H05K 3/303 Surface mounted components, e.g. affixing before soldering, aligning means, spacing means H05K3/32 takes precedence
• CPC Class Codes: Y02P 70/50 Manufacturing or production processes characterised by the final manufactured product

Abstract

A method for accurate population of a circuit carrier (2) with at least one electronic component (1) which comprises at least two separately controllable light-emitting surfaces (3a, 3b, 3c), having the following steps: a) optically detecting current positions of the at least two light-emitting surfaces (3a, 3b, 3c) of the electronic component (1); b) calculating at least one current variable (S_ist) characterizing the geometric location of the light-emitting surfaces (3a, 3b, 3c) according to the current positions of the at least two light-emitting surfaces (3a, 3b, 3c) of the electronic component (1); c) comparing the at least one current variable (S_ist) to at least one target variable (S_soll) for calculating at least one correction variable (k); d) populating the circuit carrier (2) with the at least one electronic component (1) according to the at least one correction variable (k).

Claims

1. A method for accurate population of a circuit carrier (2) with at least one electronic component (1) which comprises at least two separately controllable light-emitting surfaces (3a, 3b, 3c), by which position errors of the light-emitting surfaces (3a, 3b, 3c) on the electronic component are detected and compensated for by calculating a correction variable (k), the method comprising:

a) optically detecting current positions of the at least two light-emitting surfaces (3a, 3b, 3c) of the electronic component (1) with respect to a reference point;

b) calculating at least one current variable (S_ist) characterizing the geometric location of the light-emitting surfaces (3a, 3b, 3c) according to the current positions of the at least two light-emitting surfaces (3a, 3b, 3c) of the electronic component (1);

c) comparing the at least one current variable (S_ist) to at least one target variable (S_soll) for calculating at least one correction variable (k), wherein the target variable (S_soll) is represented by predefined values regarding the location and orientation of the light-emitting surfaces (3a, 3b, 3c) with respect to the reference point;

d) populating the circuit carrier (2) with the at least one electronic component (1) according to the at least one correction variable (k).

2. The method of claim 1, wherein the current variable (S_ist) and the target variable (S_soll) are supplied to, or detected by, a digital computation unit in which the correction variable (k) is calculated, wherein the correction variable (k) is transferred to a population device as a digital information signal for population according to step d).

3. The method of claim 1, wherein the correction variable (k) comprises at least one vector variable, wherein the direction of the vector variable is oriented in parallel to the population surface of the circuit carrier (2).

4. The method of claim 3, wherein the correction variable (k) also comprises an angular value for rotation about an axis of rotation (z), wherein the axis of rotation is oriented orthogonally to the population surface of the circuit carrier (2).

5. The method of claim 1, wherein the at least one current variable (S_ist) comprises information characterizing the profile, in particular the slope, of the visible edges of the light-emitting surfaces (3a, 3b, 3c).

6. The method of claim 1, wherein the at least one current variable (S_ist) comprises information characterizing a virtual centroid (S_g) of the light-emitting surfaces (3a, 3b, 3c), wherein the virtual centroid (S_g) is determined by determining the geometric centers (S₁, S₂, S₂) of the individual light-emitting surfaces (3a, 3b, 3c) by taking into account their current positions.

7. The method of claim 1, wherein the at least one current variable (S_ist) comprises information characterizing the dimensions and position of a fictitious rectangular surface, wherein the dimensions as well as the position and orientation of the fictitious rectangle (R) are selected such that the ratio between overlap and size of the surface is optimized.

8. The method of claim 1, wherein the target variable (S_soll) comprises a position information with respect to a reference point, wherein the reference point is disposed on the electronic component (1) or the circuit carrier (2) of the electronic component (1).

9. The method of claim 1, wherein the light-emitting surfaces (3a, 3b, 3c) are spaced from one another.

10. The method of claim 1, wherein the at least one electronic component (1) has a plurality of at least three, four or five light-emitting surfaces (3a, 3b, 3c) which are preferably disposed in a row.

11. The method of claim 1, wherein the electronic component (1) is an LED, preferably an SMD-LED.

12. The method of claim 1, wherein the light-emitting surfaces (3a, 3b, 3c) are illuminated by an external light source during step a).

13. The method of claim 1, wherein the light-emitting surfaces (3a, 3b, 3c) are excited to emit light during step a).

14. A circuit carrier (2) with at least one electronic component (1), wherein the electronic component (1) has at least two separately controllable light-emitting surfaces (3a, 3b, 3c), wherein populating the circuit carrier (2) with the at least one electronic component (1) according to the current positions of the at least two light-emitting surfaces (3a, 3b, 3c) of the electronic component (1) is performed according to the method of claim 1.

15. A motor vehicle headlamp with a circuit carrier (2) of claim 14.