Component Mounter Head Control for Nozzle Malfunction Estimation
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Solution Overview
Problem
The existing maintenance notification systems for component mounters fail to accurately determine the need for maintenance of feeder components due to inaccuracies in image recognition, which incorrectly represent the malfunction of nozzles and feeders.
Innovation Solution
A management device and method that calculate the true displacement by summing pickup displacement and correction offset, and perform parameter estimation using a statistical model to accurately assess the degree of malfunction of each constituent element, enabling proper maintenance determination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If image recognition results are used to determine maintenance needs, then the maintenance notification system can operate automatically, but the determination accuracy deteriorates because image recognition fails to properly represent feeder malfunction
Solution Approach 1:
The patent introduces an intermediary calculation process that combines image recognition results with pickup displacement measurements and correction amounts. This intermediary step transforms the raw image recognition data into a more accurate malfunction indicator by accounting for the actual pickup behavior and correction actions, thereby resolving the contradiction between automated operation and determination accuracy
Solution Approach 2:
The patent replaces the purely optical/image recognition-based determination system with a hybrid system that incorporates mechanical displacement measurements and correction data. This substitution of the determination mechanism allows for more accurate malfunction assessment while maintaining automated operation
2Device complexity
If only image recognition results are used for maintenance determination, then the system complexity is reduced, but the reliability of maintenance determination deteriorates
Solution Approach 1:
The patent merges multiple data sources including image recognition results, pickup displacement measurements, and correction amounts into a unified malfunction determination process. This combination of multiple indicators enhances the reliability of maintenance determination while managing system complexity through integrated processing
3Loss of time
If the maintenance notification system uses inaccurate malfunction representation, then processing time is reduced, but manufacturing precision deteriorates due to erroneous pickups and quality issues
Solution Approach 1:
The patent performs preliminary calculations combining image recognition results with pickup displacement and correction data before making maintenance determinations. This preliminary processing ensures that more accurate information is available for maintenance decisions, thereby preventing erroneous pickups and quality issues while managing processing time through efficient calculation sequences
Data Source
AI summary
A management device for managing a component mounter that mounts components onto a substrate using some of constituent elements each selected from one of constituent element groups each including the constituent elements. One group is a nozzle group including nozzles. The device includes: a true displacement amount calculator that calculates, for each target component which is the component, a true amount of displacement which is a sum of (i) an amount of pickup displacement being an amount of displacement between the target component and a target nozzle being one of the nozzles and picks up the target component and (ii) an amount of correction being an amount of offset of a position of the target nozzle when picking up the target component; and a statistical processor that performs parameter estimation for a predetermined statistical model using the true amount to calculate a degree of malfunction of each constituent element.