Feeder Exchange Control Around Operator Work in Mounting Lines
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The automatic exchanging device in a component mounting line may interfere with operator work when errors occur, and it can move into ranges that hinder production, especially when other machines continue operating and generate feeder exchange requests.
Innovation Solution
A control device monitors the operational state of component mounting machines and sets a movement prohibited area for the automatic exchanging device, ensuring it moves outside this area until operator work is completed, preventing interference and incorporating a monitoring unit to prevent emergency stops by shutting off power supply if 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 the automation and productivity are improved, but it may interfere with operator work when an error occurs in the machine
Solution Approach 1:
The automatic exchanging device is made movable along the conveyance path, allowing it to dynamically position itself at different component mounting machines based on operational needs. The device can move to perform automated feeder exchanges at machines that are operating normally, and move away from machines where operators need to perform error correction work, thus adapting its position to different operational states.
Solution Approach 2:
A control device acts as an intermediary between the automatic exchanging device and the component mounting machines. The control device receives information about operator work status from the machines and coordinates the movement and positioning of the automatic exchanging device, preventing interference by managing the timing and location of automated exchanges relative to operator activities.
2Productivity
If the automatic exchanging device remains positioned at a component mounting machine to perform exchanges, then exchange efficiency is improved, but it becomes an obstacle when operator work is required
Solution Approach 1:
The automatic exchanging device transitions from a static position to a dynamic one, capable of moving along the conveyance path between different component mounting machines. When operator work is detected at a particular machine, the device moves to a different position or waits until the operator completes their task, thereby eliminating the harmful interference while maintaining exchange efficiency at other machines.
Solution Approach 2:
The control device monitors the operational state of component mounting machines and takes preliminary action by preventing the automatic exchanging device from approaching or positioning at machines where operator work is in progress. This anticipatory control avoids the harmful effect of interference before it occurs, allowing operator work to proceed uninterrupted.
3Productivity
If the automatic exchanging device moves to respond to automatic exchange requests from operating machines, then production continuity is maintained, but it may move into ranges that interfere with ongoing operator work
Solution Approach 1:
The control device continuously monitors the operational state of component mounting machines, including whether operators are performing work. This feedback information is used to dynamically adjust the behavior of the automatic exchanging device, allowing it to respond to exchange requests only from machines where no operator work is occurring, thus maintaining production continuity without causing interference.
Solution Approach 2:
The system performs preliminary checking of the operational state before the automatic exchanging device moves to respond to exchange requests. The control device verifies that no operator work is in progress at the target machine before authorizing the exchange device to move and perform the feeder exchange, preventing interference while maintaining production flow.
Data Source
AI summary
An automatic exchanging device for moving in an arrangement direction of multiple component mounting machines alongside the front face of a component mounting line to set feeders to and/or remove feeders from a feeder setting base 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.