Phased Automation Strategy for Emerging Technology

Owens Design’s phased approach to factory equipment development starts with modular architecture definition, followed by high risk module proof-of-concept, culminating in a fully automated production line. In one example, the completed line consisted of over 36 process stations, 24 robots, 29 inspection & alignment cameras, and 19 computers.

• Precision optical assembly and alignment
  • Alignment tolerances less than 25 µm.
  • Pressure sensitive adhesive application while preventing air gaps
• Machine vision - pre and post inspection
  • Micron level alignment tolerances achieved despite difficult to image parts
  • Off-axis illumination, on robot end effector vision, long working distance objectives
• Precision adhesive dispense
  • Adhesive dispense volume controlled to milligrams
  • Corona cleaning prior to bonding
  • Oven bake out integrated into line
• System software, controls, data tracking
  • Individual part tracking thru 46 part processing stations
  • Over 400 data values and inspection images logged per part in real time to multiple distributed SQL databases
  • Tool recipes contain over 2200 individual recipe parameters
  • CC-link field bus connecting 24 robots and 4 PLCs for real time control and data collection
  • OPC-UA communications linking 19 computers and 4 PLCs for real time HMI updates
  • In-line process quality control with automatic part rejection
• Functional testing
  • Automated calibration
  • Complete module test including optical parameters
• Pre-production benchtop robotic workstations
  • Single robot with swappable end effectors
  • Standard programming interface
  • Suitable for engineering development and pre-production prototypes