Component Height Measurement Using Segmented Sensors
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Solution Overview
Problem
Existing mounter technologies face challenges in accurately measuring the height of electronic components ranging from tiny to larger sizes due to the limitations of detectors, which can lead to measurement errors and human errors, especially when using large detectors that burden the transfer head and affect positioning accuracy.
Innovation Solution
A method involving a sensor with a small measurement range is used to measure component height by lowering the component within the sensor's high-accuracy range, utilizing tentative and definitive measurements based on the nozzle's lowering amount and sensor signals, allowing for accurate measurement of various component sizes without significantly impacting the transfer head's accuracy or increasing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a large-sized detector is attached to the transfer head to detect the height of larger components, then the measurement range is improved, but the positioning accuracy of the transfer head deteriorates due to increased size and weight
Solution Approach 1:
The measurement process is divided into two distinct phases: a first measurement using a large-sized detector to capture the overall height of larger components, and a second measurement using a small-sized detector to capture the height of smaller components with high precision. This segmentation allows each detector to be optimized for its specific measurement range without compromising the other.
Solution Approach 2:
The system dynamically switches between different measurement modes based on component size. The control unit determines whether to perform the first measurement, second measurement, or both, depending on the detected component characteristics. This dynamic approach allows the system to adapt its measurement strategy to maintain both range and precision.
2Adaptability or versatility
If a large-sized detector is used to measure larger components, then the measurement range is improved, but the measurement error for tiny components increases due to low resolution
Solution Approach 1:
The detection system is segmented into two detector types with different characteristics: a large-sized detector for capturing overall component dimensions and a small-sized detector for high-precision measurement of tiny components. This segmentation resolves the contradiction by assigning each detector to its optimal measurement range.
Solution Approach 2:
Different measurement precision requirements are addressed by applying different detector characteristics to different component sizes. The small-sized detector provides high local precision for tiny components, while the large-sized detector provides broad coverage for larger components, optimizing the measurement quality for each specific case.
3Measurement precision
If a small-sized detector with high resolution is used to measure tiny components, then the measurement precision is improved, but the measurement range for larger components is reduced
Solution Approach 1:
The system segments the measurement function across two detector types, allowing the small-sized high-resolution detector to specialize in tiny component measurement while the large-sized detector handles larger components, thereby achieving both precision and broad measurement range through functional division.
4Adaptability or versatility
If a large-sized detector is attached to the transfer head, then the measurement capability for larger components is improved, but the cost increases due to unnecessary high resolution for tiny components
Solution Approach 1:
The detection system is segmented into two specialized detectors rather than using one large expensive detector for all measurements. This allows the system to pay for high resolution only where needed (small detector for tiny components) while using a more economical large detector for larger components, optimizing the cost-performance ratio.
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
This approach enables precise measurement of component heights from tiny to larger sizes using a small sensor, reducing measurement errors and maintaining high accuracy while minimizing the impact on the transfer head's positioning and reducing costs.
Implementation Method 1
a nozzle for sucking and holding an electronic component
Data Source
AI summary
A method by which the height of an electronic component sucked and held by a nozzle can be detected with high accuracy and high efficiency is a component height measurement method applied to a mounter (100) equipped with a transfer head (8) having a component-sucking-and-holding nozzle (21), for transferring a component P and mounting the component P onto a board (3), and includes: lowering the component P to within the high-accuracy range of a first line sensor (13) for measuring the height of the component P; and measuring the height of the component P using the first line sensor (13).