Automatic Feeder Device Fixed Position Optimization
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Solution Overview
Problem
Existing methods for optimizing component type arrangement in board production, such as those involving feeder devices, are inefficient due to cumbersome setup changes and high facility costs, especially when producing small quantities of various types, as they often require exchanging entire feeder devices rather than just component storage tapes, leading to increased setup changing work time and costs.
Innovation Solution
A method and apparatus that utilize a combination of automatic and manual feeder devices, where automatic feeder devices are fixed in position and manual feeder devices can be moved without relocating the automatic ones, allowing for optimized component type arrangement by simulating the placement of components to minimize setup changing work and mounting cycle time, while reducing the need for frequent feeder device exchanges.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the entire feeder device is exchanged to change component types, then the mounting cycle time is shortened, but the setup changing work time increases significantly
Solution Approach 1:
The feeder device is divided into two independent parts: the automatic feeder body (which remains fixed) and the reel holding device with component storage tape (which can be exchanged). This segmentation allows the automatic feeder mechanism to be reused while only replacing the component supply portion, thereby reducing setup time while maintaining mounting efficiency.
Solution Approach 2:
The reel holding device and component storage tape are extracted as separable components from the feeder device. This extraction enables independent replacement of the component supply module without affecting the automatic feeding mechanism, resolving the contradiction between maintaining short mounting cycles and reducing setup time.
2Productivity
If the entire feeder device is exchanged to change component types, then the mounting cycle time is optimized, but the facility cost increases due to requiring more feeder devices
Solution Approach 1:
The automatic feeder device is designed with universal compatibility to accept different reel holding devices and component storage tapes for various component types. This multi-functionality allows a single automatic feeder body to serve multiple component types by simply changing the reel holding device, eliminating the need for multiple dedicated feeder devices and reducing facility costs.
3Loss of time
If manual feeder devices are used to allow component storage tape exchange, then the setup changing work time is reduced, but the mounting cycle time increases due to slower feeding speed
Solution Approach 1:
The automatic feeder device performs the component feeding operation automatically without requiring manual intervention during mounting. By combining the automatic feeding mechanism with exchangeable reel holding devices, the system achieves both fast mounting cycles (through automation) and quick setup changes (through component exchangeability), resolving the contradiction between speed and flexibility.
Data Source
AI summary
A method for optimizing component type arrangement in which multiple component types are optimally disposed on multiple installation positions when an automatic feeder device which automatically loads the component storage tape, a manual feeder device which does not automatically load the component storage tape, and a reel holding device are installed into the installation positions on a common pallet, the method includes a step of determining a portion of the multiple installation positions as a fixed position and fixing the determined automatic feeder device to the fixed position; and an optimizing step of performing a simulation optimally disposing the multiple component types on the multiple installation positions under a condition that the manual feeder device can be moved to an arbitrary installation position other than the fixed position without moving the automatic feeder device from the fixed position.