Cut-and-Clinch Unit Calibration Using Image-Based Position Detection
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Solution Overview
Problem
The existing substrate working machines face productivity decreases due to the need for frequent calibration of the bending device, which is necessary for accurately positioning the bending member relative to the lead of a leaded component inserted into a through-hole in a board.
Innovation Solution
A substrate working machine equipped with a bending device that includes a contacting section for bending the lead via contact and a main body section, along with an imaging device and control device to capture images, calculate position information, and perform calibration only when the attachment position deviation exceeds a threshold, thereby minimizing unnecessary calibration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If calibration is performed frequently to ensure positioning accuracy, then manufacturing precision is improved, but productivity deteriorates due to time loss
Solution Approach 1:
The patent replaces manual calibration operations with an automated imaging system that captures images of the contacting section, calculates its position automatically, and performs calibration only when deviations are detected. This substitution of mechanical/manual calibration with optical detection and automated processing resolves the contradiction by eliminating time-consuming manual operations while maintaining positioning accuracy through image-based position verification.
Solution Approach 2:
The system performs self-calibration by automatically detecting the position of the contacting section through imaging, calculating position information, and adjusting itself only when necessary. This self-service mechanism eliminates the need for frequent manual calibration operations, thereby maintaining manufacturing precision without sacrificing productivity.
2Manufacturing precision
If manual calibration is performed to correct attachment position deviations, then manufacturing precision is improved, but loss of time increases due to human intervention
Solution Approach 1:
The patent replaces manual calibration with an automated system that uses an imaging device to capture images of the contacting section, automatically calculates its position, and performs calibration only when position deviations exceed a threshold. This automation eliminates human intervention time while maintaining attachment position accuracy through systematic image-based detection and correction.
Solution Approach 2:
The system implements feedback by continuously monitoring the position of the contacting section through imaging, comparing detected positions with target positions, and performing calibration only when deviations are detected. This feedback mechanism ensures manufacturing precision is maintained while minimizing calibration time by acting only when necessary rather than through continuous manual intervention.
3Adaptability or versatility
If the contacting section is removably attached to allow flexibility, then adaptability is improved, but reliability deteriorates due to potential position deviations from reattachment
Solution Approach 1:
The patent replaces manual inspection and adjustment methods with an automated imaging system that objectively detects the position of the removably attached contacting section. This substitution ensures that even though the contacting section can be removed and reattached for adaptability, the imaging-based position detection and automated calibration maintain consistent and reliable attachment positions across multiple assembly cycles.
Solution Approach 2:
The system monitors and adjusts the position parameters of the contacting section after reattachment by capturing images, calculating position information, and performing calibration when deviations are detected. This parameter-based control approach ensures that the removably attached contacting section maintains reliable positioning despite repeated attachment and detachment operations.
Data Source
AI summary
Movable section of a cut and clinch unit includes exchange section in which is formed second insertion hole for cutting and bending a lead, and main body section to which exchange section is removably attached. An opening position of the second insertion hole is calculated as an attachment position of the exchange section on the main body section based on image data. It is determined whether a difference between the calculated opening position and a standard position of the second insertion hole that is set in advance exceeds a threshold value. If the difference between the calculated opening position and the standard position exceeds the threshold value, calibration is performed based on the assumption that the exchange section has been exchanged.