Dynamic Suction Nozzle Height Control for Interference Avoidance
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Solution Overview
Problem
In component mounting machines with parallel conveyors, the existing lifting mechanisms for suction nozzles face a trade-off between speed and productivity, as increasing the lifting stroke to avoid interference prolongs the lifting operation, while decreasing it may result in interference with components on higher circuit boards, necessitating stopped movements and reduced productivity.
Innovation Solution
A component mounting machine with a control device that adjusts the lifting stroke and height position of suction nozzles dynamically, using a combination of XY moving and head lifting mechanisms to avoid interference, allowing for faster operation and improved productivity by minimizing the lifting stroke and enabling continuous movement across conveyors without waiting for component transport.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If the lifting stroke of the suction nozzle is increased and the height position at the time of the rise of the suction nozzle is increased to avoid interference with mounted components, then interference avoidance is achieved, but the lifting operation time is prolonged
Solution Approach 1:
The patent applies dynamics by making the mounting head height position adjustable and controllable during operation. The mounting head can be dynamically raised to a higher position when crossing over conveyors to avoid interference, and lowered to a normal position when performing mounting operations. This dynamic height adjustment resolves the contradiction by allowing the system to adapt its lifting stroke based on operational context, avoiding both interference and excessive lifting time.
Solution Approach 2:
The patent changes the parameter of mounting head height position from fixed to variable. By controlling the mounting head to switch between a higher position (when crossing conveyors) and a normal position (when mounting), the system optimizes both interference avoidance and operational speed. The control device manages these parameter changes based on the operational phase, resolving the trade-off between lifting stroke and lifting time.
2Speed
If the lifting stroke of the suction nozzle is decreased and the height position at the time of the rise of the suction nozzle is decreased to achieve higher speed, then lifting operation time is reduced, but interference with mounted components occurs
Solution Approach 1:
The system dynamically adjusts the mounting head height based on operational requirements. When crossing over conveyors, the mounting head is raised to a higher position to avoid interference. When performing suction and mounting operations, it is lowered to a normal position for precise component placement. This dynamic adjustment enables high-speed operation without causing interference.
Solution Approach 2:
The mounting head height position parameter is changed from a fixed low position to a variable parameter that switches between high and normal positions. The control device manages this parameter change based on the operational phase, allowing the system to achieve high speed during mounting while preventing interference during conveyor crossing operations.
3Object-affected harmful factors
If the mounting head is stopped to wait for the component mounted circuit board on the front side conveyor to be transported outward to avoid interference, then interference is avoided, but productivity decreases
Solution Approach 1:
The patent applies dynamics by enabling continuous movement of the mounting head through dynamic height adjustment. Instead of stopping the mounting head to wait for conveyor clearance, the system raises the mounting head to a higher position when crossing over the front side conveyor, allowing continuous operation without interruption. This eliminates waiting time and maintains high productivity while avoiding interference.
Solution Approach 2:
The control device performs preliminary action by raising the mounting head to a higher position before crossing over the conveyor, preventing potential interference in advance. This allows the mounting head to move continuously over the conveyor without stopping, as the elevated position pre-empts any possible collision with mounted components, thereby maintaining productivity.
Data Source
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AI summary
When a mounting head 22 is moved upward of a rear side conveyor 15b across and over a front side conveyor 15a after a component suction operation, it is determined whether or not there is a possibility that a component sucked by a suction nozzle 21 may interfere with a component mounted on a circuit board A on the front side conveyor 15a. When it is determined that there is the possibility that the component sucked by the suction nozzle 21 interferes with the mounted component, a head lifting mechanism 29 is caused to lift up the mounting head 22 to a position where the component sucked by the suction nozzle 21 does not interfere with the mounted component. Thereafter, the mounting head 22 is moved upward of the rear side conveyor 15b, and the head lifting mechanism 29 is caused to lift down the mounting head 22 to an initial height position. Thereafter, the component is mounted on a circuit board B on the rear side conveyor 15.