There are several reasons why I am so far behind on my blog, but one of the two major factors is this machine. It's a machine that automates a soldering process currently done by hand at a solar company in California. It has two lasers, a robotic arm, and a vision system so the robot can "see." It also has two solder paste dispensers that extrude solder paste onto the target then the lasers heat the solder and it metalizes. The good news. . . this machine shipped on Monday morning this week.
Believe it or not, this little "bowtie" as we call it, is the finished product. It's two strips of tin plated copper, .003" thick, soldered together with a tiny diode in the middle.
This is "Thumper" the robot, made by Epson. He costs a cool $20K. He earned his name because one day one of our team was working near him and tripped a sensor that set the robot into motion knocking his arm with austacious force. Robots are extremely strong, in fact, bones will break before they stop in their path, so they demand safety and caution.
Here is a view of the "Dial Table." It's 30 inches in diameter, 3/4" thick aluminum plate that rotates 30° at a time. Each time it rotates, it places one of the little white blocks underneath a work station where some function is performed to help solder the bowtie.
Each of these little white blocks has a blue tube running into it that creates vacuum to hold the parts in place during soldering. The white block is a ceramic, the brown part is made of a plastic material called Ultem. I spent significant time designing, testing, and redesigning these two blocks until they worked just right. There are six pins sticking up that hold the bowtie in place, the third pin back is actually spring loaded - a very cool feature that allows the bowtie to be removed from the ceramic after it's soldered.
These black trays are loaded with bowties and then fed into the system. There are two different tracks, one is where the machine offloads finished bowties, the other is for onloading new parts that need to be soldered. You can see the finished bowties being placed into the pins in the black trays.