Component Mounting Machine Optical Path Refraction for Collision Prevention
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Solution Overview
Problem
Existing component-mounting machines face challenges in simultaneously capturing images of an imaging reference mark and a sucked component due to complex structures, collision risks, and limited focal depth, especially when the mounting head moves at high speeds, leading to difficulties in focusing and accurate position detection.
Innovation Solution
The implementation of refraction members that alter the focal positions of optical paths to allow simultaneous imaging of the reference mark and the component, positioned on the base rather than the mounting head, preventing collisions and simplifying the system, while also using a 2D image sensor for comprehensive visual field capture.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If the aperture of the camera is opened to increase light reception, then the amount of light received increases, 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 ground glass is introduced as an intermediary element in the optical path. The ground glass diffuses light to provide uniform illumination across the imaging plane, allowing the camera to capture both the imaging reference mark and the sucked component with sufficient brightness while maintaining an adequate depth of field. This mediator enables simultaneous clear imaging of objects at different heights without requiring a wide aperture.
2Productivity
If the component-mounting head moves at high speed to shorten mounting time, then productivity increases, but exposure time decreases making imaging difficult
Solution Approach 1:
The imaging operation is synchronized with the periodic motion of the component-mounting head. Imaging is performed at specific moments when the head passes through predetermined positions during its cyclic movement. This periodic timing allows sufficient exposure time to capture clear images of the imaging reference mark and sucked component even while the head moves at high speed, maintaining both productivity and imaging quality.
3Measurement precision
If the optical imaging device is provided on the mounting head side, then position detection is enabled, but the mounting head becomes complex and heavier increasing collision risk
Solution Approach 1:
The optical imaging device is extracted from the mounting head and relocated to a fixed position on the base. This separation removes the complexity and weight from the moving mounting head while preserving the position detection functionality. The ground glass is positioned in the optical path between the mounting head and the stationary camera, enabling the head to remain simple and lightweight while still allowing imaging of both the reference mark and sucked component.
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 configuration enables accurate and simultaneous focus on both the imaging reference mark and the sucked component, preventing collisions and reducing system complexity, allowing for precise position detection and mounting without the need for additional collision prevention mechanisms, thus downsizing and lightening the component-mounting head.
Implementation Method 1
is provided with a ground glass adjacent to the component. The position marking device is projected on the ground glass through the optical imaging device
Implementation Method 2
a refraction member that alters a focal position of a first optical path extending from the image sensor, through the lens, to the imaging reference mark
Data Source
Figure 1
Figure 2
Figure 3~4
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) .