Module placement device and method

1. A module placement device for securing a module having an LED light source and a reflector on a mirror substrate, the module placement device comprising:

a mirror substrate fixture for at least partially securing the mirror substrate;

a module fixture positionable by a plurality of repositioning actuators, the module fixture being moveable by the repositioning actuators with respect to the mirror substrate fixture, the module fixture capable of holding the module, pressing the module against the mirror substrate at a location thereof having a portion ablated so as to permit light to pass therethrough, and releasing the module;

an adhesive situated on at least one of the module and the mirror substrate for securement of the module to the mirror substrate when pressed in place;

a controller connected to the plurality of repositioning actuators for controlling the movement of the repositioning actuators, wherein the controller includes a processor, a memory, and a program in communication with the controller memory, wherein the program includes the geometry of the module and the mirror substrate, and wherein the controller is configured for controlling movement of the repositioning actuators based at least in part by the geometry provided by the program;

a camera in communication with the controller and in line of sight position with respect to at least a portion of the mirror substrate and at least a portion of the module, wherein the camera is configured to capture one or more images of the at least a portion of the mirror substrate and the at least a portion of the module when the module has been moved by the module fixture along a Z-axis to the height of the substrate; and

wherein the controller is configured to receive and process the images to determine the relative position of the module and the mirror substrate through visual identification of landmarks on the mirror substrate and module, and to compare the relative position of the module and the mirror substrate to a desired relative position, and calculate the necessary actuation of the repositioning actuators along an X-axis, a Y-axis, a Z-axis, and a rotational axis around the Z-axis in order to obtain the desired relative position, and wherein the controller is programmed to lower the module fixture along the Z-axis and actuate the repositioning actuators so as to move the module into the desired relative position by adjustment of the module along the X-axis, the Y-axis, and the rotational axis around the Z-axis, and to raise the module along the Z-axis a subsequent time in order to press the module against the mirror substrate.

2. A method of securing a module having a light source and a reflector on a mirror substrate comprising:

at least partially securing the mirror substrate to a mirror substrate fixture;

securing the module to a module fixture, wherein the module fixture is capable of securing the module, pressing the module against the mirror substrate, so as to secure the module to the mirror substrate by direct securement of the module to the mirror substrate with an adhesive, and releasing the module, and wherein the module fixture is positionable by a plurality of repositioning actuators;

controlling the movement of the repositioning actuators, via a controller in communication with the plurality of repositioning actuators, wherein the controller includes a processor, a memory, and a program, wherein the program includes the geometry of the module and the mirror substrate, and wherein the controller is configured for controlling movement of the repositioning actuators based at least in part by the geometry provided by the program;

raising the module via the module fixture along a Z-axis to the height of the substrate;

capturing one or more images of at least a portion of the mirror substrate and at least a portion of the module;

receiving and processing the images to determine the relative position of the module and the mirror substrate through visual identification of landmarks on the mirror substrate and module, and comparing the relative position of the module and the mirror substrate to a desired relative position;

calculating the necessary actuation of the repositioning actuators along an X-axis, a Y-axis, a Z-axis, and a rotational axis around the Z-axis in order to obtain the desired relative position;

lowering the module fixture along the Z-axis using the repositioning actuators and further actuating the repositioning actuators so as to move the module into the desired relative position along the X-axis, the Y-axis, and the rotational axis around the Z-axis; and

raising the module along the Z-axis to the desired relative position in order to press the module against the mirror substrate.