Loose Component Supply Imaging for Replenishment Timing
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Solution Overview
Problem
Existing component supply systems face challenges in accurately determining the timing for replenishing components on a stage, leading to inefficiencies and reduced practicality, as they rely on complex estimation methods that struggle to account for the presence and quantity of components in scattered states.
Innovation Solution
A component supply system incorporating an imaging device to capture and compare pre-scattering and post-scattering imaging data, allowing for the determination of component presence and quantity by analyzing brightness and color differences across the stage, enabling more precise and timely replenishment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If complex estimation methods are used to determine component quantity on stage, then measurement precision may be improved, but device complexity increases
Solution Approach 1:
The patent creates a virtual copy of the stage component distribution state through image processing. The imaging device captures the actual component layout, and the determining device processes this visual information to generate a digital representation of component quantity and position, replacing complex physical estimation methods with simpler optical copying and analysis
Solution Approach 2:
The patent replaces complex mechanical or manual estimation mechanisms with an optical imaging system and digital processing. Instead of using sophisticated physical sensors or manual counting methods, the system uses imaging devices to capture component positions and determining devices to analyze the images, substituting mechanical complexity with optical and computational simplicity
2Productivity
If frequent component replenishment is performed, then productivity is maintained, but loss of time increases due to unnecessary replenishment operations
Solution Approach 1:
The patent implements a feedback mechanism where the imaging device continuously monitors component quantity on the stage, and the determining device processes this information to provide real-time feedback on component status. This feedback loop enables the system to make informed replenishment decisions based on actual component levels rather than fixed schedules, optimizing both productivity and time utilization
Solution Approach 2:
The patent enables preliminary detection of component quantity depletion by continuously imaging and analyzing component positions before complete exhaustion occurs. The determining device identifies when component quantity falls below thresholds, allowing replenishment to be initiated at optimal moments before productivity is impacted, rather than reacting to complete depletion
3Ease of operation
If simple component presence detection is used, then ease of operation is improved, but measurement precision deteriorates
Solution Approach 1:
The patent segments the stage into multiple detection regions and processes component presence information for each segment independently. The determining device divides the overall component detection task into smaller spatial units, analyzing component quantity and distribution in each segment separately, which maintains operational simplicity while improving overall measurement precision through systematic segmentation
Solution Approach 2:
The patent transitions from simple binary presence/absence detection to multi-dimensional analysis by examining component positions, quantities, and spatial distributions across different zones of the stage. The imaging and determining devices analyze not just whether components are present but their specific locations, orientations, and relative quantities, adding dimensional information to the detection process
Data Source
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AI summary
A loose component supply device in which a stage on which components are scattered is imaged by an imaging device and the area of the stage imaged by the imaging device is divided into 20 x 20 blocks. A difference value between first imaging data that is imaging data of the stage without any components loaded and second imaging data that is imaging data of the stage after component supply has been started and components replenished onto the stage is calculated for each block. If the difference value is equal to or greater than a threshold value, it is determined that a component is present in the block, and if it is determined that the quantity of blocks for which it is determined that a component is present is equal to or less than a set quantity, components are replenished to the stage. By this, it is possible to replenish components onto the stage at an appropriate time.