Electronic Component Allocation for Mounting Accuracy

Solution Overview

Problem

In electronic component mounting systems, new components without a past usage record may have inaccurate shape data, leading to errors, delays, and discarding due to incorrect allocation to nozzle holders, as existing methods rely on estimated dimensions rather than actual measurements.

Innovation Solution

Allocate new electronic components or test targets to nozzle holders without operation restrictions, allowing for temporary reallocation and ensuring they can be mounted without interference, even if errors occur, by managing usage records based on type, imaging device resolution, and production lots.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If new electronic components are allocated to nozzle holders based on estimated shape data from CAD diagrams, then the mounting process can proceed without delays for components with usage records, but errors occur when the estimated shape data does not accurately reflect the actual component shape

Engineering Contradiction:

Improvemounting work efficiencyVSAvoidaccuracy of shape data

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The system performs preliminary image processing on newly fed electronic components to obtain accurate shape data before mounting. By capturing images of the actual components and processing them to extract precise dimensional information, the system ensures that allocation decisions are based on real component characteristics rather than estimated CAD data, thereby preventing mounting errors while maintaining productivity

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system implements feedback by comparing the actual component shape obtained through image processing with the allocated nozzle holder requirements. The image processing results provide feedback on the true component dimensions, allowing the system to verify whether the allocated nozzle holder is appropriate and to make real-time adjustments if necessary, thus ensuring both accuracy and efficiency

Inventive Principle:

Principle #23Feedback

2Manufacturing precision

If shape data is confirmed through image processing for components with usage records, then mounting accuracy is ensured, but new components without usage records cannot benefit from this verification process

Engineering Contradiction:

Improvemounting accuracyVSAvoidabsence of usage record

Core Design Contradiction:

Manufacturing precisionVSLoss of information

Solution Approach 1:

The system performs preliminary image processing on newly fed electronic components to obtain accurate shape data before mounting. By capturing images of the actual components and processing them to extract precise dimensional information, the system ensures that allocation decisions are based on real component characteristics rather than estimated CAD data, thereby preventing mounting errors while maintaining productivity

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system enables new components to self-verify their shape characteristics through automatic image processing. When a new component is fed, the imaging device automatically captures its image and the image processing unit extracts its shape data, allowing the component to effectively 'prove' its dimensions without requiring external verification or manual measurement, thus achieving mounting accuracy independent of usage records

Inventive Principle:

Principle #25Self-service

3Reliability

If a new electronic component is picked up by a suction nozzle and an error is detected, then the component would need to be discarded or re-allocation would be required, but this causes adjustment work delays

Engineering Contradiction:

Improvecorrectness of component allocationVSAvoidadjustment work delay

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The system performs preliminary image processing on newly fed electronic components to obtain accurate shape data before mounting. By capturing images of the actual components and processing them to extract precise dimensional information, the system ensures that allocation decisions are based on real component characteristics rather than estimated CAD data, thereby preventing mounting errors while maintaining productivity

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system converts the potential harm of picking up a component with potentially incorrect shape data into a benefit by implementing a verification mechanism. When a new component is picked up, the system checks the image processing results against the actual mounting requirements. If an error is detected, rather than causing delays through re-allocation or discarding, the system has already prepared accurate shape data that enables immediate correction or confirmation, thus turning a potential problem into a streamlined verification process

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Data Source

PatentUS10334769B2Method for allocating electronic component and electronic component mounting system

Publication Date: 2019.06.25 FUJI CORP

AI summary

A method of allocating electronic components to be mounted to each of a plurality of nozzle holders provided on a mounting head is provided, in which the electronic component which does not have a usage record or the electronic component which is a test target is allocated to a nozzle holder which does not have operation restrictions. An electronic component mounting system is provided with a mounting head which is provided with a plurality of nozzle holders, each of which holds a suction nozzle, and a control device which allocates electronic components to be mounted to each of the plurality of nozzle holders. The control device includes an electronic component allocation section which allocates an electronic component which does not have a usage record or an electronic component which is a test target to a nozzle holder which does not have operation restrictions.