Component Mounting Apparatus Optical Path Refraction
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Solution Overview
Problem
Existing component-mounting machines face challenges with complex structures, collision risks, and limited imaging capabilities when capturing images of both imaging reference marks and components, especially at high speeds, due to the placement of optical systems and the use of CCD linear sensors.
Innovation Solution
A component-mounting machine design featuring a sucked-component position detection device with refraction members that alter optical paths to focus on both the imaging reference mark and the component, positioned on the base side to prevent collisions and simplify the mounting head, while using a 2D image sensor for simultaneous two-dimensional imaging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If the aperture of the camera is opened to increase the amount of light received, then the amount of light received by the camera is improved, but the depth of field becomes shallow making it difficult to focus on both the imaging reference mark and the sucked component
Solution Approach 1:
A meniscus lens is introduced as an intermediary optical element between the camera and the imaging target. This lens has a positive optical power that extends the depth of field, allowing both the imaging reference mark and the sucked component to be in focus simultaneously without requiring a large aperture opening.
2Productivity
If the component-mounting head moves at high speed to shorten mounting time, then productivity is improved, but exposure time of imaging is shortened requiring larger aperture
Solution Approach 1:
The optical system parameters are changed by introducing a meniscus lens with specific optical power. This allows the system to maintain adequate exposure levels at high mounting speeds without requiring excessive aperture opening, thereby preserving both productivity and imaging quality.
3Difficulty of detecting and measuring
If the optical imaging device is provided on the mounting head side to capture images, then imaging capability is improved, but the mounting head becomes complex and heavier
Solution Approach 1:
The imaging function is extracted from the mounting head and relocated to a fixed position on the base. This eliminates the need for complex optical systems on the moving mounting head, simplifying its structure and reducing weight while maintaining full imaging capability through the base-mounted camera and meniscus lens combination.
4Difficulty of detecting and measuring
If the optical imaging device is provided on the mounting head side, then imaging capability is improved, but collision with the component occurs when the mounting head moves
Solution Approach 1:
The imaging device is extracted from the moving mounting head and fixed to the base. This eliminates the collision risk between optical components and the sucked component while the imaging function is preserved through the base-mounted camera system with extended depth of field.
5Measurement precision
If a CCD linear sensor is used to image the component, then one-dimensional imaging is achieved, but simultaneous two-dimensional imaging of reference mark and component is impossible
Solution Approach 1:
The imaging system transitions from one-dimensional linear sensor imaging to two-dimensional area sensor imaging. Combined with the meniscus lens that extends depth of field, this allows simultaneous capture of both the imaging reference mark and the sucked component in two dimensions, enabling comprehensive positional detection.
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 design allows for accurate focus on both the reference mark and the component without collision risks, simplifies the mounting head structure, and prevents ghosting in images, enabling precise positional detection and reduced manhours for component mounting.
Implementation Method 1
a first refraction member 62 which alters a focal position FP1 of a first optical path OP1 that connects the image sensor 611, the lens 612 and the imaging reference mark 5M
Data Source
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AI summary
To provide a component-mounting machine 1 which prevents collision of a sucked component PA with an optical system capturing images of an imaging reference mark 5M and the sucked component PA simultaneously when a component-mounting head 52 moves to capture images while lightening the component-mounting head 52. In the component-mounting machine 1 of the present invention, a sucked-component position detection device 6 includes an imaging unit 61, which is installed on a side of a base 8 (a side of the direction indicated by arrow Z1) of the component-mounting machine 1 and has an image sensor 611 and a lens 612; and a first refraction member 62 which alters a focal position FP1 of a first optical path OP1 that connects the image sensor 611, the lens 612 and the imaging reference mark 5M. The first refraction member 62 is installed on the side of the base 8 (a side of the direction indicated by arrow Z1) and at a position lower than a focal position FP2 of a second optical path OP2 that connects the image sensor 611, the lens 612 and the sucked component PA.