Component Mounting Line Feedback Control for Board Congestion
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Solution Overview
Problem
The component mounting line faces congestion and productivity issues due to unpredictable variations in manufacturing speed caused by factors like abnormal component supply and equipment troubles, leading to decreased operating rates and inhibited productivity despite optimal operation parameters.
Innovation Solution
A component mounting line control system that includes a board retrieving unit and a controller, which acquires information on board accommodation limits and adjusts manufacturing process times to prevent congestion by lengthening or stopping the manufacturing process based on warning information, ensuring efficient board retrieval and transportation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the component mounting line operates at optimal speed to maintain high productivity, then productivity is improved, but board congestion occurs at the exit due to unpredictable variations in manufacturing speed
Solution Approach 1:
The control device receives accommodation state information from the board retrieving unit and dynamically adjusts the manufacturing speed of component mounting devices based on real-time feedback about board accumulation levels, creating a closed-loop control system that prevents congestion while maintaining high productivity
Solution Approach 2:
The system dynamically adjusts the operating speed of component mounting devices rather than maintaining a fixed speed, allowing the manufacturing line to adapt its pace based on real-time board retrieval capacity and accommodation status, thereby preventing congestion without sacrificing overall productivity
2Quantity of substance
If the manufacturing speed is reduced to prevent board congestion, then board congestion is suppressed, but operating rate decreases and productivity is inhibited
Solution Approach 1:
The system uses real-time feedback from the board retrieving unit about accommodation status to make precise, dynamic adjustments to manufacturing speed, ensuring that speed reduction occurs only when necessary to prevent congestion, thereby maintaining high operating rates during normal operation
Solution Approach 2:
The control device changes the speed parameter of component mounting devices based on accommodation state information, adjusting the manufacturing speed dynamically rather than using a fixed speed, allowing the system to maintain high productivity while preventing board accumulation
3Productivity
If the board retrieving unit operates continuously at high speed, then productivity is improved, but the board accommodation limit is reached causing congestion
Solution Approach 1:
The control device receives real-time accommodation state information from the board retrieving unit and uses this feedback to adjust the manufacturing speed of upstream devices, creating a coordinated system where retrieval capacity and manufacturing speed are balanced to prevent accumulation
Solution Approach 2:
The control device proactively adjusts manufacturing speed based on predicted board accumulation trends rather than waiting for congestion to occur, using accommodation state information to preemptively slow down component mounting devices before the board accommodation limit is reached
Data Source
AI summary
A component mounting line control system controls a component mounting line. The component mounting line includes a component mounting device and a board retrieving unit. The component mounting line control system includes an acquirer and a controller. The acquirer acquires information from the board retrieving unit. The controller controls the component mounting device based on the information acquired by the acquirer. The controller lengthens a time taken for a manufacturing process in the component mounting device in a case where the acquirer acquires first warning information, which indicates that a board accommodation limit is about to be reached, from the board retrieving unit.