Component Mounting Machine Backup Plate Segmentation for Setup Reduction
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The increasing demand for small quantity production of multiple types of products leads to a rise in production switches, resulting in prolonged setup changeover times and reduced productivity due to the need to adjust the arrangement pattern and quantity of backup pins on a backup plate for each production switch.
Innovation Solution
The component mounting method divides backup members into multiple arrangement areas on the backup plate, allowing for reduced setup changeover frequency and automation of the process, utilizing a stocker and chuck mechanism to efficiently arrange backup members during idle time, and adjusting conveyor width to accommodate different board widths, thereby shortening total setup changeover time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If setup changeover is performed manually or automatically for each production switch, then the backup pin arrangement can be adjusted according to different circuit board types, but the total setup changeover time increases and productivity decreases
Solution Approach 1:
The backup plate is divided into multiple arrangement areas, each capable of independently holding different backup pin configurations. This segmentation allows different circuit board types to be supported by selecting specific arrangement areas without requiring complete reconfiguration, thereby reducing setup changeover time while maintaining adaptability to various board types and sizes
Solution Approach 2:
Multiple arrangement areas are prepared in advance with different backup pin configurations. When a production switch occurs, the system can quickly switch between pre-prepared arrangements rather than performing manual reconfiguration, thus maintaining versatility while significantly reducing setup time and improving productivity
2Adaptability or versatility
If the number of production switches increases to meet demand for multiple product types, then product variety is satisfied, but total setup changeover time increases and operating rate decreases
Solution Approach 1:
The backup plate with multiple arrangement areas serves multiple functions by accommodating different circuit board types, sizes, and configurations within a single unified structure. This multi-functionality allows the system to handle diverse product types without requiring separate backup plates for each product, thereby reducing setup time while maintaining product flexibility
Solution Approach 2:
The system enables dynamic selection and switching between different arrangement areas on the backup plate based on production requirements. This dynamic capability allows rapid adaptation to different product types without physical reconfiguration, reducing setup changeover time while maintaining the ability to produce multiple product types
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A component mounting station (10) is divided into two component mounting areas (B1 and B2) in a board conveyance direction according to the size of circuit boards (A1 and A2) that are used in two types of production that are performed in order, and the area in which a backup pin (16) is arranged on a backup plate (15) is divided into two pin arrangement areas (C1 and C2) corresponding to the two component mounting areas. The quantity of backup pins that are necessary to support the component mounting board that is produced in each component mounting area in each pin arrangement area in advance are arranged in a predetermined arrangement pattern, the circuit boards that are transported using the conveyor (11) are stopped in the component mounting areas according to the type of component mounting board to be produced, the backup plate is lifted up, and the circuit boards are clamped by the clamp member (26), and the circuit boards are supported by the backup pins in the pin arrangement areas that are positioned below the circuit boards, and components are mounted on the circuit boards.