Component Mounter Defect Tracking via Timestamped Board ID Logging
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
In component mounting lines, frequent measurement of suction nozzle pushing load decreases production efficiency, and detecting stuck or damaged nozzles is infrequent, leading to difficulties in estimating and locating defective circuit boards, resulting in inefficient defect inspection and potential missed or prolonged identification of mounting defects.
Innovation Solution
A production management system that saves board IDs with timestamps from each component mounter, allowing for the identification and display of potentially defective boards since the last measurement, enabling operators to efficiently collect and inspect affected circuit boards by providing a list with current locations, and includes features to stop operations at affected mounters to prevent further defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If frequent measurement of suction nozzle pushing load is performed, then detection of stuck or damaged nozzles is improved, but production efficiency decreases
Solution Approach 1:
The system performs nozzle load measurements at periodic intervals (e.g., every two hours) rather than continuously or at every component pickup, balancing detection needs with production efficiency. The control device automatically schedules measurements and manages the timing of nozzle contact load assessments.
Solution Approach 2:
The system implements feedback by monitoring component pickup error ratios and triggering measurements when thresholds are exceeded. The control device receives error information from component mounters and automatically initiates nozzle load measurements when the error ratio surpasses a predetermined threshold, enabling responsive detection without continuous measurement.
2Productivity
If measurement of pushing load is performed only at specified intervals, then production efficiency is maintained, but ability to detect stuck or damaged nozzles promptly deteriorates
Solution Approach 1:
The system uses feedback from component pickup error ratios to trigger measurements. When the error ratio exceeds a predetermined threshold, the control device automatically initiates a nozzle load measurement, enabling prompt detection of stuck or damaged nozzles while maintaining production efficiency during normal operation.
3Ease of operation
If operator manually estimates quantity and location of defective circuit boards, then inspection work can be performed, but work efficiency and accuracy of defect location deteriorate
Solution Approach 1:
The control device acts as an intermediary that automatically calculates and identifies the specific circuit boards affected by stuck or damaged nozzles. It tracks circuit board conveyance information and determines which boards were processed during the period of nozzle malfunction, eliminating the need for operator estimation and enabling precise, efficient retrieval and inspection of defective boards.
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 system enhances the ability to detect and address mounting defects promptly, reducing the risk of missed defects and unnecessary inspection time by providing a reliable list of potentially defective boards and preventing further defects by stopping affected mounters, thus improving work efficiency and ensuring accurate defect identification.
Implementation Method 1
the suction nozzle is positioned above the load cell and lowered such that the lower end of the suction nozzle contacts the load cell, the contact load (sliding resistance of the suction nozzle) is measured at the load cell
Data Source
Figure 1
Figure 2
Figure 3
AI summary
Multiple component mounters (14) that configure a component mounting line (10) identify a board ID of a circuit board (11) conveyed during production and send the board ID to a production management computer (30), measure actual data for early-stage-discovery of a mounting defect at a specified interval during production, and send the measurement results to the production management computer. The production management computer saves the board IDs sent from each of the component mounters with a time stamp for each component mounter, monitors whether there is a possibility of a mounting defect based on the measurement result for each component mounter, and upon determining that there is a possibility of a mounting defect at one of the component mounters, extracts board IDs of circuit boards on which components were mounted at the component mounters since the previous time measurement was performed based on the board IDs with time stamp saved and the measurement interval, and displays a list of the circuit boards as a list of circuit boards for which it is possible that there is a mounting defect.