Adaptive Error Stoppage Control for Component Mounting Systems
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
In component mounting systems, frequent error stoppages due to recovery processing limits lead to reduced production efficiency, as the current systems do not adapt to the severity or duration of errors, resulting in inappropriate occurrence frequencies and prolonged operator intervention.
Innovation Solution
A component mounting system with a determination device to assess correct component holding, a recovery device for re-performing holding tasks, a counting device to track recovery attempts, an error stoppage device to halt operations when a defined count is reached, and a canceling device to resume operations based on operator input, along with a timekeeping device to update the defined count number based on elapsed time, allowing for adaptive error stoppage frequency and improved efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a uniform defined count number is set for all error types, then error stoppage control is simplified, but production efficiency is severely lowered due to inappropriate error stoppage frequency
Solution Approach 1:
The patent applies local quality by setting different defined count numbers for different error types. Instead of using a uniform count number for all errors, the system tailors the recovery processing limit to each specific error type based on its severity and characteristics. This allows minor errors to have higher recovery limits (reducing stoppages) while major errors have lower limits (maintaining quality control), thereby resolving the contradiction between simplified control and production efficiency.
Solution Approach 2:
The patent implements dynamics by making the defined count number adaptable rather than fixed. The system dynamically adjusts the recovery processing limit based on the specific error type that occurs. This dynamic approach enables the error stoppage control to be both simple (automatic adjustment) and efficient (appropriate limits for each error), resolving the contradiction between uniform control and customized error handling.
2Manufacturing precision
If error stoppage occurs frequently to ensure quality control, then manufacturing precision is maintained, but loss of time increases due to repeated operator intervention
Solution Approach 1:
The patent applies local quality by differentiating error handling based on error severity. For minor errors that do not significantly impact quality, the system allows more recovery attempts before stoppage, reducing operator intervention time. For major errors that could compromise manufacturing precision, the system sets stricter limits. This localized approach maintains quality control while minimizing unnecessary stoppages and time loss.
3Productivity
If recovery processing is allowed unlimited times, then production efficiency is improved by avoiding stoppages, but reliability decreases due to potential defect propagation
Solution Approach 1:
The patent applies local quality by setting appropriate defined count numbers for each error type based on its potential impact on reliability. For errors with low risk of defect propagation, the system allows more recovery attempts, improving production efficiency. For errors with high risk, the system imposes stricter limits to prevent reliability degradation. This localized control resolves the contradiction between unlimited recovery and reliability protection.
Data Source
AI summary
In a component mounting system, recovery processing is repeated until a recovery count number Nr is larger than or equal to a defined count number Nth in a case where a pickup defect of a component occurs, an elapsed time is measured from error stoppage of a component mounting machine to canceling of the error stoppage in which the component mounting machine is error-stopped when the recovery count number Nr is larger than or equal to the defined count number Nth, the defined count number Nth is increased within a range in which the defined count number does not exceed the upper limit value Nmax in a case where the elapsed time is shorter than a defined time Tth, and the defined count number Nth returns to an initial value in a case where the elapsed time is longer than or equal to the defined time Tth.