Component Mounting Device Posture Detection via Side Imaging
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Solution Overview
Problem
Existing component mounting devices fail to accurately detect posture changes of components during conveyance, leading to potential mounting defects due to vertical suction, positional deviations, and rotation issues, especially with non-flat suction surfaces and reduced component sizes.
Innovation Solution
A component mounting device equipped with a rotary head, side imaging means, and determination means that captures post-suction and pre-mounting images to detect posture changes, allowing for real-time correction of positional and rotational deviations, ensuring stable component mounting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If only a lower image is acquired during conveyance to set correction values, then the device complexity is reduced, but the measurement precision of component posture is insufficient to detect posture changes during conveyance
Solution Approach 1:
The imaging process is segmented into two distinct phases: post-suction imaging and pre-mounting imaging. The post-suction image captures component posture immediately after suction, while the pre-mounting image captures posture before mounting. By comparing these two segmented images, the system can detect posture changes during conveyance without requiring continuous complex imaging throughout the entire process.
Solution Approach 2:
The system performs preliminary imaging action by capturing the post-suction image before the component is conveyed to the mounting position. This preliminary image serves as a reference to compare against the pre-mounting image, enabling detection of any posture changes that occur during conveyance without adding complex real-time tracking systems.
2Measurement precision
If imaging is performed continuously throughout conveyance to detect posture changes, then the measurement precision improves, but the productivity decreases due to increased imaging time
Solution Approach 1:
Instead of continuous imaging, the system uses periodic action by capturing images at two specific moments: immediately after suction (post-suction image) and immediately before mounting (pre-mounting image). This periodic sampling approach provides sufficient data to detect posture changes while minimizing the time spent on imaging operations, thus maintaining high mounting speed.
Solution Approach 2:
The system skips the intermediate conveyance period without imaging, rushing through the conveyance phase using only the initial post-suction image as reference. This allows the component to be conveyed and positioned quickly, with imaging only performed at critical checkpoints, thereby maintaining productivity while ensuring detection accuracy.
3Reliability
If correction values are set based on lower image only, then the ease of operation is improved, but the reliability of mounting decreases when posture changes occur during conveyance
Solution Approach 1:
The system implements feedback by comparing the post-suction image with the pre-mounting image to detect any posture changes during conveyance. When a posture change is detected, the control system provides feedback to adjust the correction values accordingly, ensuring that the mounting operation accounts for the actual component posture rather than relying solely on the initial lower image correction values.
Solution Approach 2:
The control system performs preliminary correction value setting based on the post-suction image before conveyance occurs. This preliminary correction is then refined by comparing with the pre-mounting image, allowing the system to prepare correction values in advance while still accommodating any posture changes that occur during conveyance, thus maintaining reliability without requiring complex real-time control adjustments.
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
The device effectively detects and corrects posture changes, preventing mounting defects by setting and resetting correction values based on acquired images, ensuring accurate component placement even with unstable suction conditions.
Implementation Method 1
a plurality of nozzles that are able to suck a component
Implementation Method 2
side imaging means for acquiring an post-suction image by imaging the nozzle from the side after suction of the component
Data Source
AI summary
The component mounting device determines suction deviation (posture change) of the component from after suction of the component until prior to mounting of the component based on an immediately post-suction image which is acquired by imaging the suction nozzle from the side immediately after suction of the component and an immediately pre-mounting image that is acquired by imaging the suction nozzle from the side immediately prior to mounting of the component.