Component Mounting Line Feeder Automation for Remote Test Runs
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Solution Overview
Problem
In existing component mounting lines, operators must manually set feeders for component mounters during remote operations, such as test operations, which is cumbersome and inefficient.
Innovation Solution
A component mounting line equipped with an automated replacement robot that moves along multiple component mounters and automatically sets feeders, managed by a production management device that can switch to a remote operation mode, ensuring necessary feeders are set before test operations without manual intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the automated replacement robot only follows production schedules, then the production efficiency is maintained, but the operator must manually set feeders during test operations which increases operation time and reduces convenience
Solution Approach 1:
The automated replacement robot is enhanced to autonomously detect when test operations are required and automatically set the necessary feeders without operator intervention. The robot monitors the component mounter's operation state, identifies test operation requirements, and independently completes feeder setup, allowing the system to serve itself during test scenarios.
Solution Approach 2:
The production management device detects test operation requirements in advance and pre-instructs the automated replacement robot to prepare and set the necessary feeders before the test operation begins. This preliminary detection and preparation eliminate the need for manual intervention during the actual test operation.
2Adaptability or versatility
If the automated replacement robot automatically replaces feeders according to production schedule, then production productivity is maintained, but the system lacks adaptability for test operations requiring manual intervention
Solution Approach 1:
The production management device continuously monitors the component mounter's operation state and receives feedback about test operation requirements. Based on this feedback, the system automatically adjusts the automated replacement robot's behavior to either maintain production mode or switch to test operation support mode, enabling adaptive response without increasing operational complexity.
3Productivity
If manual feeder setup is required during test operations, then the test can be performed, but operator workload increases and operational efficiency decreases
Solution Approach 1:
The automated replacement robot autonomously identifies when test operations are needed and independently completes the feeder setup process without requiring operator action. The system serves itself by detecting test requirements and executing the feeder replacement automatically, eliminating operator workload during test operations.
Data Source
AI summary
A production management device, which manages a production schedule of a component mounting line, executes a remote operation mode for remotely operating a component mounter to perform a test operation according to an input operation of an operator, in addition to an automatic production mode in which an automated replacement operation of an automated replacement robot is managed according to the production schedule to produce a component mounting board. The production management device determines, when in the remote operation mode, whether a feeder configured to supply components necessary for the test operation is set in the component mounter, and when the feeder that supplies the necessary components is not set in the component mounter, moves the automated replacement robot to the component mounter and sets the feeder configured to supply the necessary components in the component mounter to cause the component mounter to perform the test operation.