Component Supply Unit Conveyance for Faster SMT Setup Change
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Solution Overview
Problem
Existing substrate production systems face inefficiencies in component replenishment and setup change work due to increased work time and potential bottlenecks in conveyance operations, particularly when kitting work is automated.
Innovation Solution
A substrate production system that includes a component mounter, a kitting station, and a conveyance device. The kitting station sets component containers in the component supply unit, and the conveyance device efficiently moves the component supply unit from the kitting station to the component mounter, minimizing conveyance distance and time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If a tape reel supply robot is used to automatically load tape reels into tape feeders, then the kitting work can be automated, but the work time increases due to sequential loading of each tape reel
Solution Approach 1:
The system divides the kitting process into two independent segments: (1) a kitting station that prepares component supply units by loading component containers onto carrier tapes, and (2) a conveyance device that transports the prepared units to component mounters. This segmentation allows parallel processing where multiple component supply units can be prepared simultaneously at the kitting station while others are being conveyed or installed, eliminating the sequential bottleneck.
Solution Approach 2:
The kitting station performs preliminary preparation of component supply units in advance, loading component containers onto carrier tapes and securing them with adhesive tapes before conveyance. This preliminary action ensures that when component supply units are needed at component mounters, they are already fully prepared and ready for immediate installation, eliminating on-the-spot preparation delays.
2Ease of operation
If a unit storage warehouse and conveyance vehicle are used to store and convey component supply units, then the unit storage warehouse can provide excellent usability, but the work time may be extended due to conveyance operation restrictions
Solution Approach 1:
The conveyance device transitions from conventional ground-level or distant warehouse conveyance to an overhead three-dimensional space utilization approach. By routing the conveyance device through vertical and horizontal spaces above the production line, the system achieves both compact integration and rapid access to multiple component mounters without being constrained by ground-level layout limitations.
3Quantity of substance
If the kitting station and unit storage warehouse are disposed at a distance, then the unit storage warehouse can store multiple component supply units, but the conveyance operation is restricted and work time increases
Solution Approach 1:
The kitting station is nested within or integrated into the overhead structure of the production line, with the conveyance device operating in the same three-dimensional space. This nesting arrangement allows the system to maintain compact footprint while providing rapid conveyance between the kitting station and multiple component mounters, eliminating the need for distant warehouse placement.
Data Source
AI summary
A substrate production system includes a component mounter having a component supply area in which a component supply unit is disposed, and configured to pick up a component from the component supply unit and mount the picked up component on a substrate, a kitting station provided in a substrate production line in which multiple substrate production machines including the component mounter are arranged, and configured to set a component container containing multiple components in the component supply unit, and a conveyance device configured to convey the component supply unit in which the component container is set by the kitting station to the component mounter.