Component Mounter Error Handling via Dynamic Retry Logic
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Solution Overview
Problem
In component mounting processes, wasteful consumption of components occurs due to retry operations when errors occur, especially during production model changes, as components are discarded without confirming normal production performance.
Innovation Solution
A component mounter system that includes a control device and management device, which allows for error handling by stopping production and retaining components with errors when the number of produced boards is low, and performing retry operations when the number of boards exceeds a predetermined amount, thereby preventing wasteful component disposal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If retry operations are performed when pickup errors occur, then production continuity is maintained, but components are wastefully consumed
Solution Approach 1:
The system changes the error handling parameter (retry operation execution) based on the production stage parameter (number of boards produced). When the number of boards is within the predetermined range, retry operations are suppressed. When the number exceeds the range, retry operations are enabled. This dynamic parameter adjustment resolves the contradiction by adapting the error handling strategy to the production context.
2Loss of substance
If retry operations are suppressed to prevent component waste, then component consumption is reduced, but production efficiency deteriorates
Solution Approach 1:
The error handling strategy is made dynamic by adjusting it according to the production stage. The system transitions from a static retry suppression policy to a dynamic policy that enables retries after a predetermined number of boards are produced. This dynamic adaptation allows the system to optimize both component conservation and production efficiency at different stages.
3Productivity
If retry operations are always enabled, then production efficiency is maintained, but component waste increases during model changes
Solution Approach 1:
The system applies different error handling qualities to different production stages. During the initial production stage (within predetermined number of boards), retry operations are suppressed to conserve components. After exceeding the predetermined stage, retry operations are enabled to maintain efficiency. This localized quality adjustment resolves the contradiction by tailoring the error handling approach to the specific production context.
Data Source
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AI summary
A component mounter includes a pickup member configured to pick up a component, and a control device. When a predetermined error occurs after a pickup operation that picks up the component is performed by the pickup member, the control device stops production in a state where the component, which is a target of an error, is held by the pickup member, in a case where a number of boards produced from a start of production is within a predetermined number of the boards, performs a retry operation that discards the component picked up by the pickup member and picks up a new component, in a case where the number of the boards produced from the start of production exceeds the predetermined number of the boards, and stops production when the error is not resolved even if the retry operation is performed.