Dual-Track PCB Assembly Setup for Synchronous Placement Planning
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Solution Overview
Problem
Existing component placement lines with dual transport systems for printed circuit boards face inefficiencies due to unproductive downtime and uneven head utilization, particularly in synchronous operations, leading to suboptimal production times and equipment underutilization.
Innovation Solution
A method and control device for determining a fixed setup for a dual-transport printed circuit board system, optimizing component assignment to maximize production time savings by using mixed integer programming to ensure consistent board width and component availability, thereby enabling synchronous operation without variable setups.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If asynchronous operation is used to populate one side of PCBs at a time, then component setup flexibility is maintained, but production time increases due to unproductive waiting time
Solution Approach 1:
The system dynamically switches between asynchronous and synchronous operation modes based on real-time conditions. The control device monitors component availability, board width constraints, and setup family assignments to determine when synchronous operation can be implemented, thereby optimizing production time while maintaining flexibility when conditions don't permit synchronization.
Solution Approach 2:
The invention changes the operational parameter from fixed asynchronous mode to variable mode that can switch between asynchronous and synchronous operation. By adjusting this operational parameter based on component setup conditions, board width consistency, and setup family assignments, the system achieves reduced production time without sacrificing necessary flexibility.
2Productivity
If synchronous operation is implemented to reduce production time, then productivity increases, but device complexity increases due to requirements for fixed setups and consistent board widths
Solution Approach 1:
The system performs preliminary assignment of PCB types to setup families and pre-configures component setups before production begins. The control device identifies suitable setup families and assigns PCB types in advance, ensuring that all boards in a setup family have consistent widths and that components are available, thereby enabling synchronous operation without adding operational complexity.
Solution Approach 2:
The control device automatically manages the complexity of synchronous operation by self-determining setup families, assigning PCB types, and monitoring conditions for synchronous vs. asynchronous operation. This automation eliminates the need for manual configuration and reduces the operational burden despite the increased system capabilities.
3Adaptability or versatility
If variable setups are used to accommodate different PCB types, then adaptability improves, but equipment utilization becomes uneven with some heads waiting unproductively
Solution Approach 1:
The invention creates universal setup families that can accommodate multiple PCB types with consistent widths using the same component setup. By designing setup families with universal component configurations that work across different PCB variants, the system maintains adaptability while ensuring all placement heads remain productive during synchronous operation.
4Productivity
If fixed setups are implemented for synchronous operation, then production time decreases, but the number of components that can be accommodated is limited by track space
Solution Approach 1:
The system segments PCB types into different setup families based on their component requirements and board widths. By dividing the production portfolio into multiple specialized setup families, each optimized for specific component combinations, the system can accommodate diverse component quantities across different families while maintaining fixed setups within each family for efficient synchronous production.
Data Source
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AI summary
The invention relates to a method for identifying at least one fixed setup (165) for an assembly line (110) comprising a circuit board double transport system (125) of which the first transport track (201) and second transport track (202) transport double-sided circuit boards (120) of a circuit board type (122). The method comprises the following steps: - acquiring a quantity of circuit board types which are each associated with double-sided circuit boards intended to be populated on the assembly line within the planning horizon; - acquiring a quantity of component types together with their space requirement in tracks in at least one component feed device (150); - acquiring a production time for synchronous population of the first and second side of each associated double-sided circuit board on the first and second transport track; - acquiring a production time for asynchronous population of the first and second side of each associated double-sided circuit board on the first and second transport track; - acquiring a number of fixed setup clusters, wherein each fixed setup cluster comprises a quantity of circuit board types of which the circuit boards can be populated with the components of the component types of the fixed setup on the assembly line; - assigning circuit board types to each fixed setup cluster, wherein all the components for populating a circuit board of a circuit board type of the assigned circuit board types have the space they require in the tracks available in the fixed setup and are mounted in the fixed setup; and - optimising the assignment process in such a way that the production time saving identified from the acquired production times of the synchronous and asynchronous population over all associated double-sided circuit boards is maximised.