Placement Machine Feeder Exchange for Low-Downtime Replenishment
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Solution Overview
Problem
Current automated systems for replenishing feeder modules in placement machines are inefficient, leading to machine downtimes due to the need for multiple automatic handling machines and the inability to manage cartridge-based feeding systems effectively.
Innovation Solution
A method involving an exchange unit with a storage that temporarily retains at least two feeder modules, allowing for the transfer of a partially depleted feeder module to a spare slot before it is fully depleted, thereby minimizing downtime and optimizing feeder module placement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual splicing method is used for replenishing carrier tapes, then replenishment can be performed in advance with flexible timing, but high level of personnel input is required and the process is time-consuming
Solution Approach 1:
The system enables automatic self-service replenishment where the placement machine autonomously performs feeder module exchanges based on component inventory levels. The control unit automatically detects when a feeder module is depleted and triggers the exchange mechanism to replace it, eliminating the need for manual intervention while maintaining continuous operation.
Solution Approach 2:
The system performs preliminary actions by preparing replacement feeder modules in advance and positioning them in ready-to-use locations. The automatic exchange mechanism pre-positions multiple feeder modules so that when one is depleted, the replacement is already in place, enabling seamless substitution without machine downtime.
2Productivity
If automated replenishment systems are implemented, then machine downtime is reduced, but multiple automatic handling machines are required increasing system complexity
Solution Approach 1:
The system merges the functions of multiple automatic handling machines into a single integrated automatic exchange mechanism. This mechanism combines the capabilities of tape splicing, feeder module replacement, and component transfer into one unified device that operates within the placement machine structure, eliminating the need for separate handling machines.
Solution Approach 2:
The automatic exchange mechanism is designed with multi-functionality to perform various replenishment tasks including feeder module extraction, insertion, and positioning. This universal mechanism can handle different types of feeder modules and carrier tapes, replacing the need for specialized handling machines for each function.
3Device complexity
If traditional manual replenishment is used, then system complexity is low, but machine downtime increases due to manual intervention requirements
Solution Approach 1:
The system replaces manual mechanical operations with an automated exchange mechanism that uses programmed mechanical movements. The control unit directs the exchange mechanism to perform precise mechanical actions for feeder module replacement, substituting human-operated mechanical processes with automated ones that occur without interrupting machine operation.
4Speed
If automated feeder exchange is implemented, then replenishment speed increases, but the ability to manage cartridge-based feeding systems is limited
Solution Approach 1:
The automatic exchange mechanism is designed with universal compatibility to handle multiple feeder types including both traditional feeder modules and cartridge-based feeding systems. The mechanism can accommodate different geometries and mounting methods, allowing high-speed automated replenishment across various feeder configurations without sacrificing adaptability.
Data Source
AI summary
Feeders at a placement machine are replaced, automatically, according to a new protocol in which a partially-depleted feeder is temporarily moved from its slot to an external storage, a full replacement feeder is put in its slot, and the partially-depleted feeder is returned to a spare slot of the placement machine, from where its remaining components are picked.