Component Mounting System Carriage Feeder Management
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Solution Overview
Problem
Existing component mounting systems face a decrease in device operation rate and feeder placement efficiency due to the need for multiple feeder replacements when switching between different board types, leading to device shutdown and reduced productivity.
Innovation Solution
A component mounting system with multiple carriages that hold component supply devices, where components are sorted and allocated based on production information to minimize feeder replacements, allowing continuous operation by supplying components from multiple sources during board type changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If feeder replacement operation is performed when changing board type, then component mounting system can adapt to different board types, but device operation rate decreases due to device shutdown
Solution Approach 1:
The system performs preliminary actions by pre-positioning multiple carriages with different component feeders in advance. When a board type change is required, the system can immediately switch to a pre-prepared carriage configuration without shutdown, as the alternative feeder arrangements are already prepared and staged in the system.
Solution Approach 2:
Multiple carriages serve as intermediary storage units that hold alternative feeder configurations. These carriages act as mediators between the current production state and the desired new board type state, allowing seamless transitions without direct feeder replacement operations that would cause shutdowns.
2Adaptability or versatility
If multiple feeder replacements are performed for different board types, then component mounting system can accommodate various board types, but feeder placement efficiency decreases
Solution Approach 1:
The system prepares multiple carriage configurations in advance with feeders pre-arranged for different board types. This preliminary arrangement eliminates the need for time-consuming feeder placement operations during board type transitions, as everything is pre-positioned and ready for immediate deployment.
Solution Approach 2:
The feeder system is segmented into multiple independent carriages, each capable of holding specific feeder configurations. This segmentation allows individual carriages to be prepared, swapped, or adjusted independently without affecting the entire feeder system, significantly reducing the time required for feeder reconfiguration.
3Adaptability or versatility
If feeder replacement is performed, then component supply can be updated for new board type, but productivity decreases due to device shutdown
Solution Approach 1:
The system maintains continuous component supply and production operation by having multiple carriages ready with alternative feeder configurations. When one carriage is in use, other carriages can be prepared or swapped in the background without interrupting the mounting process, ensuring uninterrupted production flow and maintaining constant productivity.
Solution Approach 2:
Alternative feeder configurations are prepared in advance on standby carriages before they are needed. This preliminary preparation ensures that when a board type change is required, the system can immediately switch to the pre-prepared configuration without stopping production, thereby maintaining continuous output.
Data Source
AI summary
A component mounting system includes at least one component mounter that is provided with a first board transport mechanism, a second board transport mechanism, a first mounting mechanism and a second mounting mechanism that mount components on a board, and a plurality of carriages that is respectively installed on the side of the first board transport mechanism and on the side of the second board transport mechanism and holds a plurality of tape feeders (component supply devices). When changing a production board type of a first board transported by the first board transport mechanism, the components are supplied from the component supply device held by a first carriage, a second carriage, and a third carriage, and the components are mounted on a second board that does not change the production board type by the first mounting mechanism and the second mounting mechanism.