Component Mounting Machine Parallel Supply Control
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Solution Overview
Problem
In the mounting process using a bulk feeder, when the collectable quantity of components is less than the required quantity, it leads to incomplete scheduled mounting operations or waiting for the bulk feeder supply, resulting in decreased production efficiency.
Innovation Solution
A component mounting machine and method that include a mounting control section, a supply control section, and an order adjustment section. The supply control section initiates a parallel supply operation by the bulk feeder during a mounting cycle when the collectable quantity falls below a reference value, and the order adjustment section adjusts the execution order of the PP cycle to align with the supply operation timing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the bulk feeder supplies components in bulk state, then the mounting process can be executed efficiently, but the collectable quantity of components is indefinite and may be less than the required quantity
Solution Approach 1:
The supply control section performs preliminary actions by initiating supply operations in advance when the collectable quantity falls below a reference value. The system predicts future component needs and triggers supply operations before the bulk feeder runs out of components, ensuring continuous availability during the mounting process.
Solution Approach 2:
The system implements feedback mechanisms where the supply control section continuously monitors the collectable quantity of components in the bulk feeder. Based on this feedback, the system dynamically adjusts supply operation timing and parallel execution strategies to maintain reliable component supply.
2Reliability
If the supply operation waits for the bulk feeder to replenish components, then the component supply is reliable, but the mounting operations cannot be executed timely
Solution Approach 1:
The system performs preliminary supply operations when the collectable quantity approaches the reference value threshold. By initiating supply operations in advance rather than waiting for depletion, the system eliminates waiting time and ensures components are replenished before needed.
Solution Approach 2:
The supply control section enables continuous component supply by executing supply operations in parallel with mounting cycles. This ensures the bulk feeder is continuously replenished without interrupting the mounting process, maintaining uninterrupted production flow.
3Productivity
If the bulk feeder executes supply operation in parallel with mounting cycle, then the production efficiency is maintained, but the execution timing must be precisely controlled
Solution Approach 1:
The system implements dynamic control where the supply control section adjusts supply operation timing based on real-time monitoring of collectable quantity. The control strategy adapts to varying component levels and mounting cycle requirements, optimizing parallel execution without fixed rigid scheduling.
Solution Approach 2:
The supply control section autonomously manages the parallel supply operations by automatically detecting when collectable quantity falls below the reference value and initiating appropriate supply operations. This self-managed control reduces the need for external intervention and simplifies operational complexity.
4Productivity
If the mounting cycle executes multiple times in parallel, then the mounting throughput increases, but the required time for each cycle must be optimized
Solution Approach 1:
The system performs preliminary supply operations before mounting cycles begin, ensuring components are ready in advance. This eliminates waiting time during cycle execution and allows for optimized parallel processing of multiple mounting cycles without delays.
Solution Approach 2:
By executing supply operations in parallel with mounting cycles and maintaining continuous component availability, the system enables uninterrupted mounting throughput. The continuous supply ensures each mounting cycle can execute at full speed without waiting for component replenishment.
Data Source
AI summary
A component mounting machine includes a mounting control section to execute a mounting process based on a control program in which an execution order of a PP cycle including a collection operation of components and a mounting operation of mounting the components on a board is set, a supply control section to, when the collectable quantity of components in a bulk feeder to supply multiple components in a bulk state is less than a reference value, cause the bulk feeder to execute a supply operation of the components in parallel to a mounting cycle, and an order adjustment section to, when a required time for a mounting operation scheduled to be executed in parallel with the next supply operation scheduled based on the current collectable quantity is shorter than a required time for the supply operation, adjust an execution order of the PP cycle including the mounting operation.