Automatic Exchanger Control for Component Mounting Lines
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Solution Overview
Problem
Automatic exchanging devices in component mounting lines can interfere with operator work when errors occur, and may cause unnecessary interruptions by moving into the work area before operator tasks are completed, especially when other machines continue production and generate feeder exchange requests.
Innovation Solution
A component mounting line with an automatic exchanging device that moves alongside the machines and a control device to set a movement prohibited area around the affected machine until operator work is finished, preventing interference and allowing efficient operator access, and optionally includes a monitoring system to prevent emergency stops by shutting off power when intrusions are detected.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the automatic exchanging device moves to the front of a component mounting machine to perform feeder exchange, then feeder exchange efficiency is improved, but the device may interfere with operator work when an error occurs requiring manual intervention
Solution Approach 1:
The automatic exchanging device transitions from a static position to a dynamically controllable position. The control device dynamically adjusts the device's location based on real-time operational status: positioned at the front for automatic feeder exchange when no manual work is needed, and retracted to a prohibited area when operator intervention is required, thereby resolving the contradiction between exchange efficiency and operator accessibility
Solution Approach 2:
The control device receives feedback signals from component mounting machines indicating whether operator work is required. Based on this feedback, the control device automatically commands the exchanging device to either approach for feeder exchange or retreat to avoid interference, enabling adaptive response that balances productivity and operational ease
2Ease of operation
If the automatic exchanging device remains positioned to avoid interfering with operator work, then operator accessibility is improved, but the device cannot respond to automatic exchange requests from other machines continuing production
Solution Approach 1:
The control space is segmented into a movement prohibited area (near affected machines requiring operator work) and a movement permitted area (other locations along the production line). This spatial segmentation allows the exchanging device to simultaneously avoid interfering with operator work on affected machines while remaining accessible to service other machines that continue production and generate feeder exchange requests
Solution Approach 2:
The device dynamically adjusts its positioning based on the spatial distribution of operational needs. When one machine requires operator attention, the device operates in the permitted area to service other machines, and only approaches the prohibited area when explicitly commanded by the control device after operator work completion, thus maintaining both operator accessibility and system-wide productivity
3Loss of time
If the automatic exchanging device moves quickly to respond to exchange requests, then response time is reduced, but the risk of interfering with operator work or causing emergency stops increases
Solution Approach 1:
The control device performs preliminary verification by monitoring operational status and determining whether operator work is required before commanding the exchanging device to move. This preliminary action prevents the device from entering prohibited areas during operator work, eliminating the need for emergency stops and ensuring safe, efficient operation without compromising response time
Data Source
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AI summary
An automatic exchanging device (26) for moving in an arrangement direction of multiple component mounting machines (12) alongside the front face of a component mounting line (10) to set feeders (14) to and/or remove feeders (14) from a feeder setting base (24) of each component mounting machine, and a control device for controlling the movement of the automatic exchanging device. The control device monitors the operational states of the multiple component mounting machines and, when an error requiring the work of the operator occurs in any one of the component mounting machines, sets a predetermined range including the component mounting machine to a movement prohibited area of the automatic exchanging device to move the automatic exchanging device out of the movement prohibited area until it is determined that the work is completed.