Component Mounting Device Feeder Detection Control
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Solution Overview
Problem
In component mounting devices, pickup misses due to feeder structures like bulk, stick, or bowl feeders lead to tact loss and decreased productivity, as the mounting head waits for components to be supplied, increasing the likelihood of retry failures.
Innovation Solution
Incorporating a component detecting unit in each feeder to verify component presence at the supply position, allowing the control unit to determine if a feeder is not supplying a component and suspend the mounting operation if necessary, enabling the system to read out another mounting turn to prevent pickup misses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the mounting head waits for component supply at component supply position (retry operation), then component pickup accuracy is improved, but productivity deteriorates due to tact loss
Solution Approach 1:
The control unit performs preliminary verification by checking component detection signals from detection units before the mounting head arrives at the component supply position. This advance checking allows the system to predict component availability and adjust the mounting sequence proactively, preventing pickup misses without requiring the mounting head to wait idle during the mounting process.
Solution Approach 2:
The system implements feedback through detection units that continuously monitor component supply status and provide signals to the control unit. The control unit uses this feedback information to dynamically adjust the mounting sequence, suspending mounting operations for feeders that have not yet supplied components and prioritizing feeders with available components, thereby maintaining high productivity while ensuring reliable component pickup.
2Adaptability or versatility
If bulk feeders, stick feeders, or bowl feeders are used instead of tape feeders, then component supply flexibility is improved, but pickup miss frequency increases
Solution Approach 1:
Detection units are integrated into various feeder types (bulk feeders, stick feeders, bowl feeders) to provide real-time feedback on component supply status. This feedback mechanism compensates for the inherent variability in component delivery timing of these flexible feeder structures, allowing the control unit to accurately track when components will be supplied and coordinate mounting operations accordingly, thereby maintaining high pickup reliability despite using diverse feeder types.
Solution Approach 2:
The control unit performs preliminary assessment of component availability by checking detection signals before initiating pickup operations. This preliminary action allows the system to account for the variable supply characteristics of different feeder types and adjust the mounting sequence in advance, ensuring that mounting operations are performed only when components are actually available, thus maintaining high reliability across different feeder configurations.
3Reliability
If the mounting head performs retry operations when pickup miss occurs, then component mounting completeness is improved, but tact loss increases
Solution Approach 1:
The control unit performs preliminary verification of component availability using detection unit signals before the mounting head attempts pickup. This advance checking identifies potential pickup misses before they occur, allowing the system to suspend mounting operations for affected feeders and adjust the sequence in advance, thereby eliminating the need for time-consuming retry operations while ensuring complete component mounting.
Data Source
AI summary
A mounting turn that is going to be performed from now on and the identifiers of the feeders that are the supply sources of the components for the mounting turn are read out from a mounting program, and it is determined whether there is a non-supply feeder which does not supply a component to the component supply position 13p in the feeders corresponding to the identifiers that are read out, based on the output from the component detecting sensors provided in the feeders corresponding to the identifiers that are read out. As a result, when there is not a non-supply feeder, the mounting turn that is read out is performed, and when there is a non-supply feeder, the performing of the mounting turn that is read out is suspended and another mounting turn is read out.