Component Mounting Shift Visualization for Placement Accuracy
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Solution Overview
Problem
Existing component mounting systems fail to accurately confirm and address the tendencies of suction and mounting position shifts, which can affect the quality of the component mounting boards, as they do not account for positional shifts caused by the suction nozzle and mounting head operations.
Innovation Solution
A component mounting system that includes a mounting machine, an inspection device, and a management device, which analyze and visualize suction and mounting position shifts through data communication and display systems to identify and correct positional discrepancies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the mounting machine performs component mounting operations using a suction nozzle, then the component mounting operation can be automated and productivity is improved, but positional shifts occur between actual suction positions and target suction positions, worsening manufacturing precision
Solution Approach 1:
The system captures images of components at actual suction positions using an imaging device, compares these positions with target suction positions, calculates positional shifts, and feeds back this information to the management device. This feedback loop enables real-time monitoring and correction of suction position deviations, resolving the contradiction between automated mounting and positioning accuracy.
Solution Approach 2:
The system replaces purely mechanical positioning with an optical measurement system (imaging device) that captures and analyzes component positions. By substituting mechanical position sensing with optical imaging and digital image processing, the system achieves higher position detection accuracy while maintaining automated mounting operations.
2Productivity
If the mounting machine operates at high speed to improve productivity, then output increases, but positional shifts and mounting quality deteriorate
Solution Approach 1:
The imaging device captures component positions during high-speed mounting operations, and the management device calculates positional shifts in real-time. This feedback mechanism allows the system to monitor and correct position deviations even during high-speed operations, enabling maintaining both high productivity and mounting precision simultaneously.
3Manufacturing precision
If traditional inspection methods are used to check mounting quality, then manufacturing precision can be verified, but the system cannot confirm tendencies of positional shifts across the whole board, worsening the ability to take corrective measures
Solution Approach 1:
The system continuously captures images at actual suction positions and calculates positional shifts for each component. The management device accumulates this data and generates visual representations showing positional shift tendencies across the entire board, providing comprehensive feedback that enables identification of systematic positioning issues and implementation of corrective measures.
Solution Approach 2:
The imaging device serves multiple functions: it captures images for position measurement, tracks positional shifts throughout the mounting process, and provides data for analyzing overall positioning tendencies. This multi-functional approach replaces traditional single-purpose inspection methods, enabling both verification of individual mounting positions and analysis of overall positioning trends.
4Manufacturing precision
If detailed inspection of each component position is performed to improve manufacturing precision, then position accuracy can be verified, but the complexity of the inspection system increases
Solution Approach 1:
The system merges the imaging function with the mounting process itself, using the same imaging device to both guide the mounting operation and inspect component positions. The management device integrates position calculation, tendency analysis, and visual representation functions in a single system, reducing overall complexity compared to separate inspection systems while maintaining detailed position verification capability.
Data Source
AI summary
A component mounting system is a system in which a mounting machine and an inspection device are connected to a management device so as to enable data communication therewith. The mounting machine includes a mounting analysis unit that acquires suction position shift data for each component mounting operation of a mounting head. The inspection device includes an inspection analysis unit that acquires mounting position shift data corresponding to each of a plurality of target mounting positions. The management device includes a mark generating unit and a display unit. Based on each suction position shift data and each mounting position shift data, the mark generating unit generates a suction shift mark and a mounting shift mark each of which visualizes the direction and the size of a positional shift. The display unit displays each suction shift mark or each mounting shift mark at each marking position on board graphics.