Component Mounter Timing Control for Bulk Feeder Supply
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Solution Overview
Problem
In the mounting process using a bulk feeder, when the collectable quantity of components is less than the required quantity, it leads to inefficiencies such as incomplete mounting operations or waiting for the supply operation to finish, resulting in decreased production efficiency.
Innovation Solution
A component mounter with a mounting control section, a supply control section, and a timing setting section is implemented. The timing setting section sets the execution timing of the supply operation based on the current collectable quantity and the required time for the supply operation, ensuring that the difference between the required and collectable quantities is not less than a reference value, and minimizing waiting time before the collection operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If the bulk feeder supplies components in a bulk state, then the mounting process can be automated, but the collectable quantity of components is indefinite and may be less than the required quantity
Solution Approach 1:
The timing setting section performs preliminary calculation of the execution timing for the supply operation based on the current collectable quantity and the required time for the supply operation. This preliminary action ensures that the supply operation is scheduled in advance to maintain sufficient component inventory for the PP cycle, preventing insufficient collectable quantity while maintaining automation.
2Reliability
If the supply operation is executed early to ensure sufficient components, then the collectable quantity is sufficient, but the waiting time before the collection operation increases
Solution Approach 1:
The timing setting section dynamically calculates and adjusts the execution timing parameter of the supply operation based on real-time parameters including the current collectable quantity and the required time for the supply operation. This dynamic parameter adjustment ensures that the supply operation is scheduled at the optimal moment to maintain sufficient components while minimizing waiting time before the collection operation.
3Loss of time
If the supply operation is executed late to minimize waiting time, then the waiting time is reduced, but the collectable quantity may be insufficient for the PP cycle
Solution Approach 1:
The timing setting section continuously monitors the current collectable quantity and uses this feedback information to calculate the appropriate execution timing for the supply operation. This feedback mechanism ensures that the supply operation is scheduled at the precise moment when sufficient components are needed, preventing both insufficient collectable quantity and excessive waiting time.
4Ease of operation
If the execution timing of the supply operation is not optimized, then the system is simple to control, but production efficiency decreases due to waiting or incomplete mounting operations
Solution Approach 1:
The timing setting section autonomously calculates and determines the execution timing of the supply operation based on the current collectable quantity and required time parameters, without requiring manual intervention or complex external control. This self-service approach maintains ease of operation while optimizing production efficiency by preventing waiting time and ensuring sufficient component availability.
Data Source
AI summary
The component mounter is a component mounter including a mounting control section configured to execute a mounting process based on a control program in which an execution order of a PP cycle including a collection operation of components and a mounting operation of mounting the components on a board is set, a supply control section configured to cause a bulk feeder supplying multiple components in a bulk state to execute a supply operation of the components at a predetermined execution timing, and a timing setting section configured to set the execution timing of the supply operation based on a current collectable quantity and a required time for the supply operation so that, in the PP cycle to be executed, a difference between a required quantity of the components to be collected from the bulk feeder and the collectable quantity of the components in the bulk feeder is not less than a reference value, and waiting time for waiting for completion of the supply operation before execution of the collection operation is minimized.