Component Mounting Method for Continuous PCB Fabrication
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Solution Overview
Problem
Existing component mounting devices face challenges in continuing printed circuit board fabrication when components run out during the mounting process, especially in alternating mounting modes, leading to production halts and increased line lengths due to the need for separate feeders for each substrate carrying line.
Innovation Solution
A component mounting method and device that utilize two substrate carrying lines to alternate substrate positioning and determine if each mounting turn can be completed, shifting the process to the opposite carrying line if components are depleted, allowing continuous fabrication without increasing the line length.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If the component mounting process is executed in the alternating mounting mode with two substrate carrying lines, then the number of parts feeders can be reduced and the base table width can be narrowed, but when components run out during the mounting process, the entire printed circuit board fabrication line must be stopped until the parts feeder is refilled
Solution Approach 1:
The patent merges the substrate carrying functions into a single integrated line that can carry multiple substrates simultaneously at different positions. This allows the mounting head to service multiple substrates sequentially without requiring separate carrying lines for each substrate, thereby reducing the base table width while maintaining continuous production capability.
Solution Approach 2:
The substrate carrying line pre-positions multiple substrates in advance along its path before the mounting process begins. This preliminary positioning allows the mounting head to continuously pick and place components on different substrates in sequence without waiting for substrate changes, eliminating production stoppages when components run out on one substrate.
2Productivity
If separate parts feeders are provided for each substrate carrying line to enable independent mounting mode, then continuous fabrication can be maintained when components run out on one line, but the number of parts feeders increases and the base table width must be increased
Solution Approach 1:
The single substrate carrying line is designed with multi-functionality to serve multiple substrates simultaneously at different positions along its path. This universal carrying line replaces the need for separate dedicated carrying lines and parts feeders for each substrate, achieving continuous production without increasing base table width.
Solution Approach 2:
The mounting head continuously performs picking and placing operations on multiple substrates in sequence as they are conveyed along the single carrying line. This continuous action eliminates idle time and production stoppages, maintaining constant productive output without requiring redundant parts feeders.
3Area of stationary object
If a single substrate carrying line is used to carry multiple substrates, then the base table width can be reduced, but it becomes difficult to maintain continuous production when components run out during the mounting process
Solution Approach 1:
Multiple substrates are pre-positioned along the single carrying line before mounting begins. When components run out on one substrate, the mounting head can immediately switch to the next pre-positioned substrate without stopping production, thereby maintaining reliability and continuous output while using compact single-line configuration.
Solution Approach 2:
The system dynamically switches between multiple substrates mounted on the single carrying line based on component availability. The mounting head can adaptively change its target substrate in real-time, transitioning from a static single-substrate approach to a dynamic multi-substrate strategy that maintains production continuity.
Data Source
AI summary
When a component mounting process by mounting heads is executed on substrates which are positioned alternately by two substrate carrying lines, a determination is made on whether or not a mounting turn can be completed every time the mounting heads perform the mounting turn, and when it is determined that one of the mounting turns performed by the mounting head cannot be completed, a component mounting process is executed on the substrate which is positioned by the substrate carrying line which is opposite to the substrate carrying line.