Component Collection Sensing for Full Bin and Straddling Parts
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Solution Overview
Problem
Existing component collecting devices fail to accurately detect when a collecting container is close to full capacity or when an unsuitable component is straddling over the opening, leading to potential overflow or interference with machine components, and require manual intervention for capacity management.
Innovation Solution
A component collecting device equipped with a collecting state detector that spatially detects the collecting state using a light-blocking detection sensor, allowing for reliable detection of nearly full capacity and straddling components, and a control system to manage the collection process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the size of the collecting container is increased to accommodate more unsuitable components, then the capacity of the collecting container is improved, but the arrangement of devices in the machine is restricted and the size of the component mounting machine is increased
Solution Approach 1:
The patent applies a movable collecting container that can be dynamically repositioned between a component discarding position and a component collecting position. This dynamic configuration allows the same container to serve dual purposes, effectively increasing capacity without permanently occupying additional space that would restrict device arrangement.
Solution Approach 2:
The patent utilizes vertical space by positioning the collecting container above the board, allowing it to be moved in the vertical dimension between discarding and collecting positions. This dimensional approach increases functional capacity without expanding the horizontal footprint that would constrain device layout.
2Volume of stationary object
If the size of the collecting container is increased to avoid full capacity issues, then the empty space in the collecting container is improved, but the size of the component mounting machine is increased
Solution Approach 1:
The collecting container is designed to be movable rather than fixed, allowing it to be repositioned vertically between a discarding position (when full) and a collecting position (when space is needed). This dynamic design provides sufficient empty space functionality without permanently increasing the machine's overall size.
Solution Approach 2:
The same collecting container serves multiple functions: collecting unsuitable components at one position and discarding them at another. This multi-functionality eliminates the need for separate containers for each purpose, maintaining adequate capacity without expanding the machine footprint.
3Device complexity
If manual intervention is used to manage collecting container capacity, then the device complexity is reduced, but the productivity is decreased due to maintenance work
Solution Approach 1:
The patent incorporates a full capacity detector that automatically monitors the collecting container's capacity and provides feedback to the control unit. When the container is full, the system automatically stops the mounting operation and notifies the operator, eliminating the need for manual capacity checks and maintaining high productivity.
Solution Approach 2:
The system performs self-monitoring of the collecting container's capacity through the full capacity detector and control unit. This self-service capability automatically manages the container status without requiring operator intervention, thereby maintaining operational efficiency while using minimal additional device complexity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables precise detection of nearly full capacity and straddling components, reducing the risk of overflow and interference, and allows for automated management of unsuitable components, enhancing operational efficiency and reducing machine constraints.
Implementation Method 1
a light-blocking detection sensor detects that the level of discarded components has reached the level of the sensor
Data Source
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AI summary
The component collecting device comprises: a collecting container, provided in a component mounting machine for executing a mounting operation of components and having an opening opened upward, configured to collect unsuitable components determined to be unsuitable for the mounting operation; and a collecting state detection section configured to spatially detect the collecting state of unsuitable components collected in the collecting container.