Electronic Component Mounting Machine Splice Detection
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Solution Overview
Problem
Existing electronic component mounting machines face errors due to unreliable detection of splice portions, leading to incorrect resetting of component counts, which can result in inaccuracies and malfunctions.
Innovation Solution
Incorporating a determining device that sets a normal range for count values based on the initial number of components in the tape material, allowing for detection of correct splice portion identification and preventing inappropriate count value corrections, along with a notifying and correction mechanism to address potential malfunctions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the detection device detects the splice portion and the counting device resets the count value, then the error in count value is eliminated, but when the detection device malfunctions and detects non-splice portions as splice portions, incorrect resetting occurs reducing reliability
Solution Approach 1:
The determining device provides feedback verification by checking whether the count value after splice detection falls within the expected range (0 to threshold value). This feedback mechanism prevents incorrect resetting by validating the detection results before accepting them, thus resolving the contradiction between maintaining count accuracy and dealing with detection device unreliability.
Solution Approach 2:
The system performs preliminary verification of the count value range before finalizing the splice detection result. By checking if the count value is within the expected range before resetting, the system prevents premature or incorrect resetting operations, thereby maintaining both accuracy and reliability.
2Extent of automation
If the detection device is used to detect splice portions, then automatic detection is achieved, but the limited reliability causes malfunction where non-splice portions are detected as splice portions
Solution Approach 1:
The determining device implements a feedback verification mechanism that checks whether the detected splice portion result is reasonable by validating the count value range. This automated feedback loop maintains the automation benefit while correcting detection errors, thus resolving the contradiction between automation extent and detection reliability.
Solution Approach 2:
The system performs self-verification of detection results through the determining device, which automatically checks whether the count value falls within the expected range. This self-service mechanism allows the system to automatically identify and correct false detections without external intervention, maintaining automation while improving reliability.
3Productivity
If the count value is reset upon splice detection, then continuous counting across tape splices is maintained, but incorrect detection leads to allowable errors in the count value
Solution Approach 1:
The system performs preliminary verification of the count value range before executing the reset operation. This preliminary check ensures that resetting only occurs when the detection is valid, thus maintaining continuous counting capability while preventing erroneous resets that would compromise count reliability.
Solution Approach 2:
The determining device provides a safety buffer by establishing an expected count value range (0 to threshold) before the reset operation. This beforehand cushioning prevents incorrect resetting by validating that the detection result is reasonable, thus protecting the continuity and reliability of the counting process.
Data Source
AI summary
An electronic component mounting machine includes: a mounting head that mounts electronic components onto a circuit board; a tape feeder which feeds a first tape material that accommodates a plurality of electronic components to the mounting head; a counting device which counts the number of electronic components remaining in the first tape material by subtracting the number of consumed electronic components which corresponds to an operating amount of the electronic component mounting machine from an initial value of the number of the electronic components accommodated in the first tape material; a detection device which detects a splice portion that joins a starting end of a second tape material to a tail end of the first tape material; and a determining device which determines whether or not a count value obtained by the counting device is within a predetermined normal range when the detection device detects the splice portion.