Component Mounting Head Alignment Using Lead Terminal Imaging
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Solution Overview
Problem
Existing work machines face challenges in accurately mounting electrical components with multiple lead terminals due to difficulties in accounting for the inclination of these components during the mounting process.
Innovation Solution
A work machine equipped with a work head, a moving device, and an imaging device that calculates the inclination of electrical components based on imaging data of their lead terminals, allowing for precise alignment and mounting by adjusting the component's position accordingly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional mounting methods are used without inclination calculation, then the mounting process is simple and fast, but the mounting precision and reliability deteriorate due to misalignment of lead terminals
Solution Approach 1:
The system performs preliminary imaging and inclination calculation before the actual mounting operation. The work head images the lead terminals at multiple positions, the control device calculates the inclination based on these images, and then the mounting is executed with corrected positioning. This preliminary measurement and calculation step ensures high mounting precision without requiring complex real-time adjustment mechanisms during the actual mounting.
Solution Approach 2:
The patent replaces complex mechanical alignment mechanisms with an optical-imaging-based measurement system combined with computational correction. Instead of using sophisticated mechanical devices to physically align and adjust the component inclination during mounting, the system uses imaging devices to detect inclination and the control device to calculate and compensate for it through adjusted positioning commands, substituting mechanical complexity with optical and computational methods.
2Manufacturing precision
If imaging is performed to detect inclination, then mounting accuracy is improved, but the mounting time increases due to additional imaging and calculation steps
Solution Approach 1:
The system performs imaging at a limited number of specific positions (three positions: before, during, and after mounting) rather than continuous imaging throughout the entire process. This partial imaging approach provides sufficient information to calculate inclination and achieve accurate alignment while minimizing the time consumed by imaging operations, avoiding excessive measurement that would extend the mounting cycle.
3Area of stationary object
If the work head moves in the up-down direction during imaging, then the imaging coverage is improved, but the imaging stability deteriorates due to motion blur
Solution Approach 1:
The imaging operation is performed periodically at discrete, predetermined positions (before mounting, during mounting, and after mounting) rather than continuously during the up-down motion. This periodic imaging approach allows the work head to be momentarily stationary or move minimally at each imaging point, ensuring clear images with minimal motion blur while still achieving comprehensive coverage through multiple staged measurements.
Data Source
AI summary
A work machine comprising a work head configured to hold an electrical component having multiple lead terminals; a moving device configured to move the work head in the up-down direction; an imaging device configured to image the electrical component held with work head while being illuminated from the side; and a control device configured to control the operation of the work head and the moving device; wherein the control device calculates the inclination of an electrical component held by the work head based on imaging data of lead terminals of the electrical component imaged by the imaging device while the work head is moved in the up-down direction by the moving device, so that the mounting work of the electrical component is performed by taking the calculated inclination into account.