Light Source Device Controller for Component Mounter Imaging Reliability
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Solution Overview
Problem
The existing light source devices in component mounters, which consist of multiple LED illuminants, face efficiency decreases and operational stoppages when even a single light source fails, leading to reduced practicality in component mounting operations.
Innovation Solution
A light source device with a controller that enhances the light intensity of functioning LED sources when one or more fail, ensuring continuous operation by adjusting light emission based on self-diagnosis and brightness distribution across imaging areas.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple light sources are used to ensure reliable imaging, then imaging reliability is improved, but system complexity increases
Solution Approach 1:
The light source device is divided into multiple independent LED illuminants arranged in specific patterns. Each LED can operate independently, allowing the system to segment the lighting function across multiple units. When one LED fails, others can compensate, maintaining imaging reliability while keeping individual component complexity low.
Solution Approach 2:
The controller dynamically adjusts the emission parameters (intensity, timing) of individual LEDs based on their operational status. When an LED fails, the controller changes the operating parameters of remaining LEDs to compensate for the failure, maintaining adequate illumination for imaging without requiring complex hardware changes.
2Measurement precision
If the component mounting operation is stopped when a light source fails, then imaging quality is maintained, but productivity decreases
Solution Approach 1:
The controller continuously monitors the operational status of each LED and provides feedback to adjust the system response. When an LED fails, the controller detects this feedback and automatically compensates by adjusting other LEDs' output, allowing continuous operation without stopping the mounting process, thus maintaining both imaging quality and productivity.
Solution Approach 2:
The system dynamically changes the light emission parameters of functional LEDs based on real-time failure detection. By increasing the intensity or adjusting the emission timing of remaining LEDs, the system maintains adequate illumination for accurate imaging even when multiple LEDs fail, preventing productivity loss while preserving measurement precision.
3Productivity
If light intensity enhancement processing is executed when LEDs fail, then operational continuity is improved, but energy consumption increases
Solution Approach 1:
Instead of maintaining all LEDs at full intensity, the controller applies partial action by activating only the necessary number of functional LEDs to compensate for failures. When one or more LEDs fail, the controller increases the output of remaining LEDs just enough to maintain adequate illumination, avoiding excessive energy consumption while ensuring operational continuity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution minimizes the likelihood of component mounting operations being stopped due to light source failures, maintaining high practicality and efficiency by adapting light intensity to ensure adequate imaging and component placement.
Implementation Method 1
The light source device includes multiple light sources, more specifically, multiple LED illuminants
Data Source
AI summary
In light source device 60, which is disposed in a component mounter for holding a component by using mounting head 24 and mounting a held component that is the component that has been held on a board, and used when the held component is imaged by imaging device 50, and includes multiple light sources 62; and controller 64 configured to control the multiple light sources, when one or more of the multiple light sources do not emit light, the controller executes light intensity enhancement processing of enhancing an intensity of light emitted by any of the other light sources among the multiple light sources. By executing the light intensity enhancement processing, in a case where any of the multiple light sources fails, it is possible to reduce a possibility that a component mounting operation by the component mounter is stopped.