Component Mounting System Group Exchange Control
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Solution Overview
Problem
In component mounting systems, the automatic exchange of multiple component supply units is time-consuming, leading to delays in the mounting process and decreased production efficiency.
Innovation Solution
A component mounting system that includes a unit exchange device capable of collectively exchanging a predetermined number of component supply units in one operation, with a control device performing preparatory and supply arrangement controls to efficiently manage and prioritize the exchange of supply units between the supply area and a preparation area, ensuring alignment with the required arrangement order.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the number of target component supply units for automatic exchange increases, then the exchange device can handle more units, but the exchange time increases and production efficiency decreases
Solution Approach 1:
The component supply units are divided into multiple groups, with each group containing a predetermined number of feeders. The exchange device exchanges one group at a time rather than all units simultaneously, breaking down the large-scale exchange into smaller, manageable segments that can be handled more efficiently.
Solution Approach 2:
The exchange device performs preliminary actions by pre-positioning component supply units in a preparation area before they are needed in the supply area. This advance preparation reduces the actual exchange time when units are needed, as the device can quickly transfer pre-positioned units rather than searching for or preparing them during the exchange process.
2Productivity
If multiple component supply units are exchanged simultaneously, then exchange efficiency improves, but the complexity of coordination and arrangement increases
Solution Approach 1:
By segmenting the exchange process into groups of predetermined size, the system manages complexity through division. Each group exchange is a coordinated unit with manageable complexity, avoiding the overwhelming coordination required for simultaneous exchange of all supply units.
Solution Approach 2:
The preparation area serves as an intermediary zone between the storage area and the supply area. Component supply units are first positioned in the preparation area, then transferred to the supply area as needed. This intermediary step simplifies coordination by decoupling the complex arrangements into two simpler, sequential operations.
3Device complexity
If component supply units are exchanged one by one, then the arrangement control is simple, but the total exchange time increases
Solution Approach 1:
Multiple individual exchange operations are merged into group exchanges. Instead of exchanging one component supply unit at a time, the exchange device transfers groups of units together, combining several simple operations into more complex but time-efficient batch operations.
Solution Approach 2:
Component supply units are preliminarily arranged in the preparation area in the correct sequence and position before being transferred to the supply area. This preliminary arrangement allows multiple units to be exchanged together without requiring complex real-time coordination during the transfer, reducing total exchange time while keeping control manageable.
Data Source
AI summary
A component mounting system that includes a component mounter in which multiple component supply units are detachably arranged in a supply area and mounts components on a board based on a job. The system performs: a preparatory arrangement control for dividing the component supply units required for the job into multiple groups in a unit with a priority of the predetermined number, and controlling the unit exchange device so as to make an arrangement of the component supply units in each group match an arrangement order in the supply area and to collectively arrange the component supply units in the preparation area for each group, and a supply arrangement control for controlling the unit exchange device so as to automatically exchange the component supply units arranged in the preparation area by the preparatory arrangement control and the component supply units already arranged in the supply area before switching the job in a unit with a priority of the predetermined number at the time of switching the job, and to arrange the component supply units required for the job after switching in the supply area.