Cyber-Physical Systems for Micro-/Nano-assembly Operations: a Survey

Abstract Purpose of Review Latest requirements of the global market force manufacturing systems to a change for a new production paradigm (Industry 4.0). Cyber-Physical Systems (CPS) appear as a solution to be deployed in different manufacturing fields, especially those with high added value and technological complexity, high product variants, and short time to market. In this sense, this paper aims at reviewing the introduction level of CPS technologies in micro/nano-manufacturing and how these technologies could cope with these challenging manufacturing requirements. Recent Findings The introduction of CPS is still in its infancy on many industrial applications, but it actually demonstrates its potential to support future manufacturing paradigm. However, only few research works in micro/nano-manufacturing considered CPS frameworks, since the concept barely appeared a decade ago. Summary Some contributions have revealed the potential of CPS technologies to improve manufacturing performance which may be scaled to the micro/nano-manufacturing. IoT-based frameworks with VR/AR technologies allow distributed and collaborative systems, or agent-based architectures with advance algorithm implementations that improve the flexibility and performance of micro-/nano-assembly operations. Future research of CPS in micro-/nano-assembly operations should be followed by more studies of its technical deployment showing its implications under other perspectives, i.e. sustainable, economic, and social point of views, to take full advance of all its features

Study of rheological behaviour of polymer melt in micro injection moulding with a miniaturized parallel plate rheometer

Abstract The study of the rheological behaviour of the polymer in micro cavities is one of the aspects related to the technology of micro injection moulding (μIM) still substantially unresolved. Even today, there are no databases on the rheological characteristics of the material specific for the μIM, which, therefore, takes into account a number of important differences compared to the conventional injection moulding. In this paper, the study of the rheological behaviour of the polymer melt in a thin plate cavity with variable thickness has been conducted. The use of a micro injection moulding machine, on which the prototype of a sensorized mould with pressure and temperature sensor has been mounted, allowed the rheological study of the material under high shear rate conditions. After preliminary tests on different thicknesses, it has been studied the viscosity of polymer melt for 400 μm thickness. The viscosity reduction observed meets the characteristics of a pseudoplastic fluid subject to shear thinning and the wall slip seems to play an important role in the apparent reduction of viscosity. The results suggest to increase injection speed, and consequently injection pressures, so that the reduced viscosity can help melt flow to overcome the extreme conditions due to the aspect ratio and to obtain greater efficiency from the filling phase against the high cooling rate typical of micro injection moulding.

A Novel Method and Mechanism for Micro-Sphere Singularization

The paper presents an innovative mechanism for the singularization of micro-spheres, which can be effectively employed in a diverse range of robotized applications in micro-electronics and micro-mechanics. Many miniaturized devices are currently being developed and consist of different micro-components to be precisely assembled. The demanding product and process requirements can be met by automating the assembly phases, which include sorting and feeding the micro-components. Therefore, accurate, high-throughput, and modular mechanisms and tools able to supply a number of micro-components, or even a single element for the subsequent operations, play a significant role. In this context, this work focused on the development of a novel strategy for separating a single component from an unstructured stock of identical parts, in particular of micro-spheres with diameters of 0.2–1 mm. Suitable expedients were considered to overcome the adhesive effects that can become significant at the micro-scale due to the very small size and low mass of the micro-spheres. The paper describes the operating principle and the actuation strategies of the mechanism. The design and the development of a prototype for singularizing micro-spheres with a diameter of 0.6 mm are thoroughly discussed. Finally, the results of experimental singularization tests demonstrate the method effectiveness and the mechanism performance

A Vacuum manipulation device and a method for manipulating a components by means of a vacuum

A vacuum manipulation device (1 ) comprising a tube (2) in communication with a vacuum generating system for gripping a component by suction at a gripper nozzle (3) of the tube itself and a mechanical release system (8) inserted at least partially inside the tube (2). The mechanical release system (8) is movable between a release position, in which a release portion thereof projects externally from the gripper nozzle (3), and a gripping position, in which the release portion (10a) returns into the tube (2). The mechanical release system (8) comprises a transverse extension (9) made up of a perforated disk and a needle (10) solidly joined to the perforated disk and having a diameter that is smaller than the internal diameter of the tube (2). The needle (10) is inserted at least partially inside the tube (2) and comprises the release portion

Can A Low Cost Sensing System Be Exploited For High Precision Machining

Abstract The aim of the present study is the assessment of the integration of a low cost optical measurement device into a high-precision machine tool for micro manufacturing applications. The measurement system can be effectively integrated into the working volume of different types of machines allowing both tool and workpiece measurements and avoiding its disassembly from the machine stage for off-line measurements and, consequently, reference losses. The fast measurements of tool and workpiece during the machining contribute to increase the accuracy and reduce the overall machining-measurement iterations. The assessment is achieved by a test case where a low cost USB microscope is applied to a micro-EDM machine. The low cost device has been applied for tool electrode measurements and tool wear evaluation after an accuracy enhanced calibration procedure and high performance image processing algorithms, which effectively reduce the lack of the hardware performance. The measurement performance gives a feedback on the deviations of the machined features from nominal geometry and allows their compensations by an adequate machining strategy

robotic am system for plastic materials tuning and on line adjustment of process parameters

Abstract Additive Manufacturing (AM) techniques based on thermoplastic polymer extrusion allow the manufacture of complex parts, but their slow printing speed limits their use for mass production. To overcome this drawback, an industrial screw-based extruder has been mounted on an anthropomorphic robot, realizing a flexible AM platform for big objects. The most important process parameters have been set by a suitable experimental campaign, ensuring a regular deposited layer geometry. A closed-loop control has been implemented to further improve the process parameter setting based on data measured during the deposition, in this way compensating the material withdrawal or other unexpected defects

Simulation of Corona Electrostatic Separator for End-of-Life Management in Printed Circuit Boards

Printed circuit boards (PCBs) are made of several materials, including platinum, gold, silver, and rare earth elements, which are very valuable from a circular economy perspective. The PCB end of life management starts with the component removal, then the PCBs are shredded into small particles. Eventually, different separation methods are applied to the pulverized material to separate metals and non-metals. The corona electrostatic separation is one of the methods that can be used for this purpose since it is able to separate the conductive and non-conductive materials. However, the lack of knowledge to set the process parameters may affect the efficiency of the corona electrostatic separation process, ultimately resulting in the loss of valuable materials. The simulation of particle trajectory can be very helpful to identify the effective process parameters of the separation process. Thus, in this study, a simulation model to predict the particles trajectories in a belt type corona electrostatic separator is developed with the help of COMSOL Multiphysics and MATLAB software. The model simulates the particle behavior taking into account the electrostatic, gravitational, centrifugal, electric image, and air drag forces. Moreover, the predicted particles trajectories are used to analyze the effects of the roll electrode voltage, angular velocity of roll electrode, and size of the particles on the separation process

Towards the Automated Coverlay Assembly in FPCB Manufacturing: Concept and Preliminary Tests

AbstractIn modern electronics, flexible and rigid-flex PCBs are largely used due to their intrinsic versatility and performance, allowing to increase the available volume, or enabling connection between unconstrained components. Rigid-flex PCBs consists of rigid board portions with flexible interconnections and are commonly used in a wide variety of industrial applications. However, the assembly process of these devices still has some bottlenecks. Specifically, they require the application of cover layers (namely, coverlays), to provide insulation and protection of the flexible circuits. Due to the variability in planar shape and dimensions, the coverlay application is still performed manually, requiring troublesome manipulation steps and resulting in undetermined time-cycle and precision.This paper aims at the improvement of the industrial process currently performed, by proposing an approach for the automation of Kapton coverlay manipulation and application. Since these products are commercially provided as a film with a protective layer to be removed, the peeling issue is addressed, representing a challenging step of the automated process; the results of a systematic series of tests, performed in order to validate the peeling strategy, are reported in the paper. The overall assembly strategy relies on the development of a customized multi-hole vacuum gripper, whose concept is presented and contextualized in the proposed assembly process by outlining a suitable workcell architecture