Feeder Slot Arrangement for Faster PCB Setup Changeovers
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Solution Overview
Problem
Existing methods for optimizing component type arrangement in board production, such as those involving feeder devices, are inefficient due to cumbersome reel exchanges and increased facility costs, especially when producing small quantities of various types, and require extensive setup changing work.
Innovation Solution
A method that optimizes component type arrangement by using automatic feeder devices with a reel holding system, where specific feeder devices are fixed and only the reel holding device or component supply reels are exchanged, allowing manual feeder devices to be moved freely without relocating the automatic feeders, thereby reducing setup changing time and facility costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If multiple different part types are arranged in a limited number of storage locations, then storage space utilization is improved, but the time required to identify and retrieve specific parts increases
Solution Approach 1:
The system uses light sources and light receivers to create an automatic feedback mechanism. When a storage location is selected, the system automatically detects which part is present and provides visual feedback by illuminating the correct location, eliminating the need for manual identification and reducing retrieval time.
Solution Approach 2:
The system enables self-service operation where the storage rack automatically identifies and indicates the correct storage locations for different part types. The automated lighting system guides operators without requiring manual searching or complex identification procedures.
2Speed
If storage locations are clearly marked and organized for quick identification, then part retrieval speed is improved, but the complexity of the storage system increases
Solution Approach 1:
The patent replaces complex mechanical marking systems with a simpler optical system. Instead of using complex physical markers, signs, or coded identification systems, the invention uses light sources and receivers to provide clear visual indication of storage locations, reducing mechanical complexity while improving retrieval speed.
Solution Approach 2:
The system uses changes in light states (illumination vs. non-illumination) to provide clear visual distinction between different storage locations and part types. This optical differentiation method is simpler than traditional mechanical or visual marking systems while providing equivalent or superior identification capability.
3Measurement precision
If automated systems are used to track and manage part arrangements, then retrieval accuracy is improved, but the cost and complexity of the system increases
Solution Approach 1:
The system employs a feedback mechanism where light receivers detect the presence of parts and automatically illuminate the correct storage locations. This simple optical feedback loop provides high identification accuracy without requiring complex automated tracking systems, databases, or control software.
Solution Approach 2:
The patent introduces light as an intermediary between the part storage system and the operator. Instead of directly tracking and managing part arrangements through complex systems, the light sources and receivers act as intermediaries that provide accurate identification information in a simple and intuitive manner.
Data Source
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AI summary
There is provided a method for optimizing component type arrangement in which multiple component types (P1 to P9) are optimally disposed on multiple installation positions (first to ninth slots SL1 to SL9) when an automatic feeder device (9) which automatically loads the component storage tape (85 and 86), a manual feeder device (7) which does not automatically load the component storage tape, and a reel holding device (6) are installed into the installation positions on a common pallet (5), the method includes a step (S1) of determining a portion (SL3 to SL7) of the multiple installation positions as a fixed position and fixing the determined automatic feeder device to the fixed position; and an optimizing step (S4) of performing a simulation optimally disposing the multiple component types on the multiple installation positions under a condition that the manual feeder device can be moved to an arbitrary installation position other than the fixed position without moving the automatic feeder device from the fixed position. Accordingly, the automatic feeder device can be effectively used and the production efficiency can be improved by comprehensively considering the setup changing work time and the mounting cycle time.