Component Replenishment Timing From Board Arrival Prediction
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Solution Overview
Problem
Existing component management systems struggle to accurately predict component exhaustion in component mounting devices, especially when upstream devices interrupt the workflow, leading to inefficiencies in replenishment timing and potential delays.
Innovation Solution
A component management system that includes a specifying section to track board locations, an arrival predicting section to forecast arrival times, a component-exhaustion predicting section to calculate exhaustion times based on remaining components and arrival times, and a notification section to report critical replenishment times, allowing for timely and efficient replenishment even during upstream interruptions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If component exhaustion is predicted using periodic sampling at fixed intervals, then the prediction method is simple to implement, but the prediction accuracy is insufficient when upstream devices interrupt workflow
Solution Approach 1:
The patent transitions from static periodic sampling to dynamic prediction that adapts to real-time system state changes. The prediction mechanism continuously updates based on current board locations, upstream device status, and conveyance conditions, making the prediction interval and timing dynamic rather than fixed.
Solution Approach 2:
The system implements feedback by continuously monitoring board locations from specifying sections, upstream device operational status, and conveyance information. This feedback loop allows the prediction mechanism to adjust its estimates based on actual system state, improving accuracy when interruptions occur.
2Stability of the object's composition
If the component mounting device waits for board conveyance before replenishment, then the mounting workflow is maintained, but the replenishment time period is extended
Solution Approach 1:
The system performs preliminary action by predicting component exhaustion in advance and providing early warnings to operators. This allows replenishment preparation to begin before the device actually stops, reducing the effective replenishment time while maintaining workflow continuity.
Solution Approach 2:
The prediction mechanism acts as a cushion by providing advance notice of component exhaustion, creating a time buffer that allows operators to prepare replenishment materials and plan interventions without causing workflow interruptions.
3Measurement precision
If multiple board locations and arrival times are tracked to improve prediction accuracy, then the prediction reflects the entire system state, but the system complexity increases
Solution Approach 1:
The system segments the tracking function into modular components: specifying sections at each device location independently track their local board status, and these segment results are aggregated by the prediction mechanism. This modular approach maintains accuracy while managing complexity through division of functions.
Solution Approach 2:
The prediction mechanism serves multiple functions simultaneously: it tracks board locations, predicts arrival times, estimates component exhaustion, and provides warnings. This multi-functionality consolidates what would otherwise require separate systems into a single integrated mechanism, managing overall system complexity.
4Measurement precision
If real-time board location tracking is implemented to predict arrival times accurately, then the component exhaustion prediction is improved, but the measurement and detection difficulty increases
Solution Approach 1:
The patent introduces intermediary components (specifying sections) at each device location that act as local sensors and reporters. These intermediaries simplify the measurement task by locally detecting board presence and status, then reporting to the central prediction mechanism, reducing the overall detection difficulty.
Solution Approach 2:
The system uses information copying by having specifying sections create local representations of board status and location data. These copied data elements are then transmitted to the prediction mechanism, allowing accurate tracking without requiring complex direct monitoring of all boards throughout the entire system.
Data Source
AI summary
It is an object of the present invention to provide a component management system or the like that can accurately predict component exhaustion in a component mounting device that performs work at a line. Specifying section updates the time table based on the arrival time point or the unloading time point in each of component mounting devices. Arrival predicting section predicts the arrival time point in each component mounting device based on the time table and updates a prediction table. Since component-exhaustion predicting section acquires the arrival time point of a circuit board for which a component will be exhausted from the prediction table and calculates a component exhaustion time point, it is possible to predict the component exhaustion time point with high accuracy. An operator can perform a replenishment work based on the component exhaustion time point.