Dual Tray Feeder Setup During Production
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Solution Overview
Problem
In high-mix low-volume production systems, existing electronic component mounting methods require device stop times for setup changes when switching product types, as they cannot execute setup changes in advance due to component stock issues, leading to inefficiencies.
Innovation Solution
The method employs a dual tray feeder system with independent tray supply mechanisms and a controller that allows advanced setup changes by prohibiting mounting head access to a tray supply mechanism when components are low, enabling operator access and reducing device stop times by allowing setup changes during ongoing production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If components are supplied from a single tray feeder, then the device structure is simple, but the flexibility for switching product types is reduced
Solution Approach 1:
The tray feeder is divided into multiple independent tray supply mechanisms (first tray supply mechanism and second tray supply mechanism), each capable of supplying different component types. This segmentation allows the system to handle multiple product types simultaneously while maintaining operational independence of each tray supply mechanism.
Solution Approach 2:
Each tray supply mechanism is designed to be multi-functional, capable of supplying different types of electronic components to different substrate transport lanes. The tray feeders can be configured to supply components for various product types, enabling the same device structure to handle diverse production requirements.
2Productivity
If setup change operation is executed during production, then production continuity is maintained, but device stop time increases
Solution Approach 1:
The system enables setup change operations to be performed in advance on idle tray supply mechanisms while other mechanisms continue producing. Operators can prepare trays for future product types during periods when other tray supply mechanisms are not needed, so that when product type switching is required, the setup change has already been completed or can be executed quickly.
Solution Approach 2:
While one tray supply mechanism undergoes setup change, other tray supply mechanisms continue to supply components for current product types, maintaining continuous production. The system ensures that useful production action continues uninterrupted while setup changes are performed on non-critical mechanisms.
3Quantity of substance
If tray supply mechanisms share the same component supply, then component inventory is optimized, but access control during setup changes becomes difficult
Solution Approach 1:
The controller dynamically adjusts access permissions for each tray supply mechanism based on its operational state. When a tray supply mechanism is actively supplying components, access is restricted to prevent interference. When a mechanism is idle or undergoing setup change, access is permitted. This dynamic access control ensures both inventory optimization through shared components and operational ease during setup changes.
Data Source
AI summary
In an electronic component mounting method, electronic components are picked up from a component supply unit in which first and second tray supply mechanisms are arranged, and mounted on substrates. In the method, a first substrate and a second substrate different in type from the first substrate are transported by first and second substrate transport lanes, respectively, and a first component to be mounted on the first substrate and a second component to be mounted on the second substrate are supplied by the first and second tray supply mechanisms, respectively. If use stop setting indicating that the pickup of the electronic components is no longer conducted is enabled in one tray supply mechanism, the controller prohibits an access of a mounting head to the one tray supply mechanism, and permits an operation access of an operator to a tray housing unit of the one tray supply mechanism.