System and method for locating components on a tray

Abstract

A system and method for precisely locating the position of a component in a tray. The tray is a unitary structure having a plurality of protrusions on at least one side. A robot relies on the protrusions to locate pockets adjacent to each protrusion. An end effector reaches for a component in each pocket. The degree of accuracy of locating a component in a tray is enhanced by employing the plurality of protrusions and by following the method of the present invention.

1 . A method for moving a component from a pocket of a tray, the method comprising: 
 (a) providing a plurality of datums on the tray;    (b) providing a pocket cluster around each datum;    (c) moving an end effector to a first datum on the tray;    (d) manipulating the end effector to reach for a component from one or more pockets in the cluster surrounding the first datum;    (e) manipulating the end effector to locate a supplemental datum on the tray;    (f) resetting the end effector at the supplemental datum to zero; and    (g) manipulating the end effector to reach for a component from one or more pockets in a cluster surrounding the supplemental datum.    
   
   
       2 . The method of  claim 1 , further comprising repeating steps (e)-(g) until the end effector has attempted to move a component from each pocket in the tray.  
   
   
       3 . The method of  claim 1 , wherein the location of a component is determined within 0.0030-0.010 inches of accuracy.  
   
   
       4 . The method of  claim 1 , wherein the step of reaching for a component comprises retrieving the component and inserting it into hardware.  
   
   
       5 . The method of  claim 1 , wherein the datum is located by a touch or vision sensor.  
   
   
       6 . The method of  claim 1 , wherein the tray is advanced to a stacking area after the robot has targeted all of the pocket clusters in the tray.  
   
   
       7 . A system for locating a component position on a tray in an assembly line, the system comprising: 
 a. a mechanical member that is programmed to move a predetermined distance from a first datum on a tray to a new datum on the same tray;    b. a sensor on the mechanical member that detects the new datum;    c. a reset mechanism within the mechanical member for establishing the new datum as a zero point on the tray;    d) a lever arm connected to the mechanical member that reaches for a component in one or more pockets of a cluster associated with the datum when a sensor detects a new datum.    
   
   
       8 . The system of  claim 7 , wherein the datums comprise a protrusion having an x- and a y-axis.  
   
   
       9 . The system of  claim 8 , wherein the datums comprise a protrusion shaped in the form of an L, an X, or a +.  
   
   
       10 . The system of  claim 8 , wherein each datum is surrounded by a cluster of pockets.  
   
   
       11 . A tray for storing components in an automation assembly line, said tray comprising: 
 a) a unitary structure having more than one pocket for storing components;    b) a first datum on the tray and external to the pockets; and    c) additional datums external to the pockets, distributed throughout the tray, wherein each datum enables a detector to precisely identify the location of components stored within the tray.    
   
   
       12 . The tray of  claim 11 , wherein the additional datums surround the central datum,  
   
   
       13 . The tray of  claim 11 , wherein each datum is a protrusion.  
   
   
       14 . The tray of  claim 13 , wherein the protrusion comprises an L, an X or a + shape that is molded together with the tray.