Component-Mounting Machine Illumination with Dual-Brightness LED Control
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Solution Overview
Problem
Conventional LED lighting devices for component-mounting machines face challenges in simultaneously increasing illumination light amount and achieving finer adjustment widths while reducing costs and device size, due to the need for multiple LED drivers and high-brightness LEDs, which increase costs and occupy space.
Innovation Solution
The solution involves using a combination of high-brightness and low-brightness LED elements, adjusting current through low-brightness LEDs in steps with specified gradations, and maintaining a specified illumination level with high-brightness LEDs, allowing for fine adjustment of illumination beyond the required minimum without increasing the number of LED elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If the quantity of LED elements is increased to increase illumination light amount, then the illumination light amount is improved, but the mounting area must be increased making the device larger
Solution Approach 1:
The patent changes the parameter of LED brightness by using both high-brightness and low-brightness LED elements. This allows increasing illumination light amount without increasing the quantity of LED elements, thereby avoiding expansion of the mounting area. The control device adjusts the balance between high-brightness and low-brightness LEDs to achieve desired illumination levels within the same physical space.
2Illumination intensity
If high-brightness LEDs are used to increase illumination light amount, then the illumination light amount is improved, but the adjustment width of current value becomes coarse reducing fine adjustment capability
Solution Approach 1:
The patent segments the LED lighting device into two functional groups: high-brightness LED elements for providing base illumination and low-brightness LED elements for fine adjustment. The control device independently controls the current values of both groups, allowing coarse illumination provision by high-brightness LEDs and precise fine adjustment by low-brightness LEDs with finer current gradation steps.
Solution Approach 2:
The patent utilizes different brightness parameters of LED elements to achieve both high illumination and fine adjustment. By switching between or combining high-brightness and low-brightness LEDs, the system can maintain fine adjustment capability while achieving high illumination light amounts, overcoming the limitation of using high-brightness LEDs alone.
3Manufacturing precision
If the quantity of LED drivers is increased to adjust illumination light amount with finer gradation, then the adjustment precision is improved, but the cost increases
Solution Approach 1:
The patent makes the LED drivers universal by enabling them to control both high-brightness and low-brightness LED elements. This multi-functionality allows a single LED driver to handle different brightness levels and adjustment requirements, reducing the total number of LED drivers needed while maintaining fine adjustment precision, thereby lowering manufacturing costs.
4Illumination intensity
If the number of LED elements is increased to maintain required illumination level, then the illumination light amount is improved, but the device becomes larger occupying more space
Solution Approach 1:
The patent changes the brightness parameter of individual LED elements by incorporating both high-brightness and low-brightness types. This allows achieving the required illumination light amount with fewer LED elements, thereby keeping the device compact and occupying less space while maintaining adequate illumination for imaging.
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 approach enables fine adjustment of illumination light amount while maintaining the required level, reduces costs by minimizing the number of LED drivers, and keeps the device compact, thus addressing the limitations of conventional systems.
Implementation Method 1
an LED lighting device (61) configured by using a plurality of LED elements (62, 63)
Data Source
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AI summary
A component-mounting machine (10) including: an LED lighting device (61) configured to illuminate an imaging target that is to be imaged by a camera (55) loaded on the component-mounting machine; and an illumination light amount adjusting device (71) configured to adjust in steps with a specified gradation quantity an illumination light amount of the LED lighting device. The LED lighting device uses two types of LED elements (72, 73) with different brightness levels, and the illumination light amount adjusting device is configured to adjust in steps with a specified gradation quantity a pulse width or a current value of a current flowing through low-brightness LED elements (72) that are the LED elements with a lower brightness level out of the two types of LED elements so as to adjust in steps with a specified gradation quantity an emitted light amount of the low-brightness LED elements while maintaining a specified level of illumination light amount by making a specified current flow through high-brightness LED elements (73) that are the LED elements with a higher brightness level out of the two types of LED elements, in order to adjust the illumination light amount in steps with the specified gradation quantity in a region that exceeds the specified level while maintaining a required illumination light amount required for imaging the imaging target.