Component Mounting Line Image Comparison for Error Verification
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
In component mounting lines, detecting mounting errors requires operators to manually check images from both inspection and component mounters, which is time-consuming and labor-intensive, and can be difficult to determine which device erroneously recognized the component state.
Innovation Solution
A manufacturing management system that includes a component mounter and an inspection machine, with an image searching section that automatically retrieves and displays images of the suction and mounted states of components in a comparative manner, using production and inspection information to identify errors and facilitate understanding of erroneous recognition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If operators manually check images from both inspection machine and component mounter to confirm mounting errors, then they can verify whether erroneous recognition occurred, but the process becomes time-consuming and labor-intensive
Solution Approach 1:
The patent merges the display functions of the inspection machine and component mounter into a single integrated display interface. When a mounting error is detected, the system automatically retrieves and displays both the mounted state image (from inspection machine) and suction state image (from component mounter) together on one screen, eliminating the need for operators to separately access multiple devices and reducing verification time while maintaining comprehensive error analysis capability
Solution Approach 2:
The patent introduces a centralized image management system that acts as an intermediary between the inspection machine, component mounter, and display device. This intermediary system automatically retrieves relevant images from multiple sources, correlates them based on production information, and presents them in a coordinated manner, reducing the operational complexity and time required for error verification
2Measurement precision
If operators separately check images from inspection machine and component mounter, then they can identify mounting errors, but it becomes difficult to determine which device erroneously recognized the component state
Solution Approach 1:
The patent combines the display of mounted state images and suction state images on a single integrated interface, showing both images simultaneously with clear labels indicating their sources. This merging allows operators to directly compare the component state at different stages (suction vs. mounted) and immediately determine whether the error originated from the component mounter's recognition or the inspection machine's recognition, significantly improving ease of operation
Solution Approach 2:
The patent segments the error analysis process into distinct visual components: the suction state image showing how the component was picked up, the mounted state image showing the final placement, and automated comparison indicators. This segmentation presents complex information in an organized, easily comparable format that helps operators quickly identify which device made the recognition error
3Reliability
If operators check both mounted state and suction state images to confirm errors, then they can verify recognition results, but the process requires significant manual effort and coordination
Solution Approach 1:
The patent implements a self-service error verification system where the display device automatically retrieves, correlates, and displays the appropriate mounted state and suction state images based on the detected mounting error. The system autonomously matches images using production information (mounting position, board identification, component type) without requiring manual intervention to coordinate between devices, thereby maintaining reliable verification while significantly reducing operational complexity
Solution Approach 2:
The patent establishes an automated feedback loop where the detection of a mounting error triggers automatic retrieval and display of relevant images for verification. The system provides real-time feedback to operators by presenting the necessary comparison images immediately when an error is detected, eliminating the manual coordination steps previously required while ensuring comprehensive verification
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
A component mounter (12) images by a component imaging camera (18) suction states of components picked up by a suction nozzle, processes images of the suction states of the components to recognize the suction state of the component, and stores the images in a storage device (20 or 33) with linking production information related to the components. An inspection machine (14) images by an inspection camera (28) a mounted state of each component on a board (11) conveyed out from the component mounter, processes an image of mounted state of each component to recognize the mounted state of each component, and inspects whether a mounting error occurred for each component based on the recognition result. Then, when the inspection machine determines that a mounting error occurred for any of the components, the image, being obtained by imaging the suction state of the component for which a mounting error was determined to have occurred, is searched from the images stored in the storage device based on the production information and the inspection information related to the component, and the image of the mounted state of the component for which a mounting error was determined to have occurred and the searched image of the suction state of the component are displayed on the display monitor (any of 25 to 27) in a comparative manner.