Exchange Feeder Mounting Control for Predicted Component Depletion
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing mounting devices face inefficiencies in component pickup due to increased time required from alternate positions and frequent feeder depletions, leading to potential operation stoppages.
Innovation Solution
A mounting system with a supply section, mounting section, and moving work device that predicts feeder depletion, moves exchange feeders to spare loading sections, and executes spare component pickup processes to maintain continuous operation by shortening pickup times and preventing stoppages.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If components are picked up from a feeder at a position different from the original position (spare loading section), then the mounting process can continue without stopping, but the efficiency of the mounting process is reduced due to increased pickup time
Solution Approach 1:
The system predicts component depletion before it occurs and proactively moves exchange feeders to spare loading sections in advance. This preliminary action ensures that when depletion occurs, the mounting section can immediately switch to the pre-positioned exchange feeder without waiting for feeder replacement, thus maintaining continuous operation while minimizing efficiency loss.
Solution Approach 2:
The spare loading section acts as an intermediary buffer between the main loading section and the mounting section. Exchange feeders are positioned in this intermediate zone, allowing the mounting section to access alternative components without directly interrupting the main feeding process, thereby reducing the impact on mounting efficiency.
2Reliability
If multiple feeders are depleted at the same time, then feeder exchange operations become frequent and complex, but the mounting device stops operating
Solution Approach 1:
The system performs preliminary depletion prediction for multiple feeders simultaneously and prepares exchange feeders in advance. When multiple feeders are predicted to deplete around the same time, the system has already positioned the necessary exchange feeders in spare loading sections, preventing operation stoppages and simplifying the exchange process.
Solution Approach 2:
The mounting control section continuously monitors component inventory levels in real-time and uses this feedback to predict future depletion events. This feedback mechanism allows the system to proactively manage multiple feeders, switching to exchange feeders before depletion occurs and preventing the complexity of simultaneous exchanges.
3Reliability
If the mounting section frequently switches between different feeder positions, then component depletion can be managed, but the time required to pick up components increases
Solution Approach 1:
Exchange feeders are moved to spare loading sections in advance based on depletion prediction, so that when switching is needed, the mounting section can immediately access the pre-positioned exchange feeder without time-consuming movements, thus minimizing pickup time loss.
Solution Approach 2:
The system extracts the exchange feeder preparation process from the critical mounting path by using separate spare loading sections. This allows feeder exchanges to occur in parallel with mounting operations, removing the time penalty from the main mounting process and reducing overall component pickup time.
Data Source
AI summary
A mounting control section of a mounting device causes a mounting section to pick up a component from a feeder at a position designated in mounting condition information. When component depletion of the feeder for which component depletion is predicted occurs, the mounting control section executes a spare component pickup process in which the mounting section is caused to pick up the component from the exchange feeder loaded to the spare loading section at a position not designated in the mounting condition information. Then, when component depletion of the feeder for which component depletion is predicted occurs, the moving control section collects the component depleted feeder in the accommodation section while moving and loading the exchange feeder, on which the spare component pickup process corresponding to the collected component depleted feeder is being performed, to the loading section from which the component depleted feeder was collected.