Component Mounter Error Handling for Pickup Retry and Part Rescue
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Solution Overview
Problem
Component mounters often wastefully discard components due to pickup errors during production model changes or initial production phases, leading to inefficiencies and component wastage.
Innovation Solution
A component mounter with error handling processing that stops production to confirm error causes when few boards are produced and performs retry operations when more boards are produced, allowing for component rescue and maintaining production efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If retry operation is performed to handle pickup errors, then production efficiency is maintained, but component wastage increases
Solution Approach 1:
The patent dynamically adjusts the error handling strategy based on the production phase. During the initial phase (first board or within tolerance period), the system uses a conservative approach that stops production to prevent wastage. During the stable phase (after tolerance period), the system switches to a retry operation approach that prioritizes productivity. This dynamic switching resolves the contradiction by adapting the handling method to the current production state.
Solution Approach 2:
The patent introduces a tolerance period parameter that changes the system's behavior. When the number of boards produced exceeds the tolerance period, the system transitions from stop-production mode to retry operation mode. This parameter-based approach allows the system to balance between preventing wastage during initial instability and maintaining productivity during stable operation.
2Loss of substance
If production stops to confirm error causes, then component wastage is prevented, but productivity decreases
Solution Approach 1:
The patent segments the production process into two distinct phases: an initial phase (first board or within tolerance period) where production stops to confirm error causes and prevent wastage, and a stable phase (after tolerance period) where retry operations are performed to maintain productivity. This segmentation allows the system to apply different error handling strategies appropriate to each phase, resolving the contradiction between preventing wastage and maintaining productivity.
3Productivity
If retry operation is performed immediately after model change, then productivity is maintained, but component wastage increases due to unstable production
Solution Approach 1:
The patent implements a preliminary action by setting a tolerance period (e.g., first board or within a specified number of boards) after model change or production start. During this preliminary phase, the system prioritizes confirming error causes and stabilizing production over maintaining immediate productivity. This preliminary conservative approach prevents the system from entering unstable retry operations that would cause component wastage, while still allowing productivity to be maintained once stability is confirmed.
Data Source
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.