PCB Mounter Restart Imaging for Accurate Component Placement
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Solution Overview
Problem
Mounters face challenges in restarting interrupted mounting work due to emergency stops, particularly when the timing of component mounting and data saving are reversed, leading to discrepancies between saved information and actual states, which can result in inappropriate restarts or components dropping on the circuit board.
Innovation Solution
A mounter equipped with an imaging device and control system that images the mounting position and path to determine the correct placement of components and detect dropped parts, ensuring accurate restarts by verifying the mounting position and reporting any discrepancies to the operator.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If mounting component information is saved immediately after mounting, then productivity is improved by continuous operation, but reliability deteriorates because the timing may be reversed causing discrepancy between saved information and actual mounting state
Solution Approach 1:
The system performs preliminary imaging of the mounting position immediately after component placement, before saving the mounting component information. This preliminary action captures the actual mounting state, ensuring that even if the emergency stop occurs between imaging and data saving, the imaging result accurately reflects the component's position on the board.
Solution Approach 2:
The system uses imaging feedback to verify the actual mounting state and compares it with the saved mounting component information. This feedback mechanism detects discrepancies caused by timing reversals during emergency stops, allowing the system to identify and correct errors in the mounting state data.
2Loss of energy
If the mounter stops at the timing of mounting a component, then energy consumption is reduced by stopping operations, but reliability deteriorates because the component may not be appropriately mounted due to moving device stoppage
Solution Approach 1:
The system performs preliminary imaging of the mounting position immediately after component placement, capturing the actual mounting state before any potential stoppage affects subsequent operations. This ensures that even if the moving device stops, the imaging has already recorded the component's position.
Solution Approach 2:
The imaging feedback verifies whether the component was successfully mounted despite the stoppage. By comparing the imaging results with the planned mounting position, the system can detect mounting failures caused by emergency stops and take corrective actions.
3Productivity
If the component holding tool moves above the circuit board, then productivity is improved by continuous component placement, but reliability deteriorates because the component may separate and drop on the circuit board during emergency stop
Solution Approach 1:
The imaging device acts as an intermediary to monitor the component's position during movement and after placement. By capturing images of the mounting position, the system can detect whether the component has separated from the holding tool or dropped on the circuit board, providing indirect verification of successful placement.
Solution Approach 2:
The system uses imaging feedback to verify component placement success. If the imaging shows that a component is missing or improperly placed, the system can identify that the component may have dropped during movement or emergency stop, and trigger appropriate error handling procedures.
Data Source
AI summary
An electronic component mounter where information indicating completion of component mounting is memorized each time a component is mounted on circuit board by suction nozzle. Then, in a case in which mounting work is interrupted by a stoppage of the electronic component mounter and then restarted, the mounting position of the electronic component is imaged by mark camera according to information memorized immediately before the mounting work was interrupted. Also, with the electronic component mounter, in a case in which mounting work is interrupted by a stoppage of the mounter and then restarted, the mark camera is moved along a path over which the suction nozzle moved until the position of the suction nozzle when mounting work was interrupted. Here, imaging of the circuit board is performed by the mark camera.