Component Mounting Machine Abnormality Detection via Dual Process Comparison
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Solution Overview
Problem
The existing component mounting device requires frequent process interruptions to specify the cause of abnormalities, leading to increased cycle time as the frequency of abnormalities increases.
Innovation Solution
A component mounting machine that includes multiple nozzle holders, nozzles, an abnormality detection section, and a control section to perform two mounting processes with different nozzle combinations, allowing for the comparison of abnormality information to specify the source of issues without stopping operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the cause of abnormality is specified every time abnormality occurs, then the accuracy of abnormality specification is improved, but the cycle time increases
Solution Approach 1:
The control section performs preliminary actions by accumulating abnormality information over multiple mounting processes before specifying the cause. Instead of immediately stopping to specify the cause every time an abnormality occurs, the system continues operating and collects data across multiple cycles, then performs batch analysis to identify the source of abnormalities.
Solution Approach 2:
The system implements feedback by continuously monitoring and accumulating abnormality information from multiple mounting processes, then using this accumulated data to identify the cause of abnormalities. The control section compares abnormality information across different processes to determine whether the abnormality is due to the nozzle holder or the nozzle itself.
2Measurement precision
If the machine stops to specify abnormality cause, then the accuracy of abnormality specification is improved, but the productivity decreases
Solution Approach 1:
The mounting machine continues operating without interruption while the control section accumulates and analyzes abnormality information. The useful action of component mounting continues uninterrupted, and the system performs analysis in parallel by processing abnormality data from multiple completed mounting processes simultaneously.
Solution Approach 2:
The system performs preliminary data collection and analysis during normal operation by accumulating abnormality information from multiple mounting processes before actually specifying the cause. This preliminary action allows the system to maintain continuous productivity while preparing the necessary information for accurate abnormality specification.
3Reliability
If abnormality specification is performed frequently, then the reliability of the system is improved, but the loss of time increases
Solution Approach 1:
The control section uses feedback from accumulated abnormality information to determine when and how to specify the cause of abnormalities. By analyzing patterns across multiple mounting processes, the system can reliably identify whether a specific nozzle holder or nozzle is at fault, reducing unnecessary interruptions while maintaining system reliability.
Solution Approach 2:
The system performs preliminary analysis of abnormality patterns during continuous operation, accumulating data from multiple processes before making a determination about the abnormality source. This preliminary action enables reliable specification of abnormality causes without requiring immediate stops, thereby reducing downtime.
Data Source
AI summary
A component mounting machine includes multiple nozzle holders, multiple nozzles configured to be respectively attached and detached to and from the multiple nozzle holders, an abnormality detection section configured to detect abnormality related to pick-up of the component by each of the nozzles attached to the multiple nozzle holders, and a control section. The control section performs a first mounting process, acquires first abnormality information indicating the number of times of abnormalities detected in the first mounting process, performs a second mounting process, acquires second abnormality information indicating the number of times of abnormalities detected in the second mounting process for each nozzle holder, and specifies a portion where abnormality occurs by comparing the first abnormality information with the second abnormality information.