Component Mounting Error Analysis for Suction Nozzle Loss
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Solution Overview
Problem
In component mounting systems, identifying the generating factor for suction errors in suction nozzles is difficult, leading to challenges in accurately loading components on boards and resulting in component loss, as existing systems only display suction error count and loss amount data without providing insights into the error's cause.
Innovation Solution
A component mounting system with a management device that recognizes suction errors, accumulates production factor information, and generates error count and loss amount data, allowing operators to display and analyze data sets to identify the contributing factors to suction errors using the amount of loss as an indicator.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of information
If only suction error count data and loss amount data are displayed, then the display device shows basic error information, but operators cannot identify the generating factor for suction errors
Solution Approach 1:
The patent segments error information by production factors (component type, feeder, suction nozzle, loading head) and displays them separately. This allows operators to identify which specific factor is causing suction errors without overwhelming the display with all data at once, resolving the contradiction between providing complete error information and maintaining manageable system complexity.
Solution Approach 2:
The patent adds a new dimension to error display by organizing data along the production factor axis. Instead of only showing error count and loss amount in one dimension, the system creates a multi-dimensional data structure that includes production factors, enabling operators to trace errors to their specific sources while maintaining clear presentation.
2Ease of operation
If detailed production factor information is collected and displayed for each suction error, then operators can identify error generating factors, but the data management system becomes more complex
Solution Approach 1:
The patent applies preliminary action by pre-organizing and accumulating production factor information in the storage unit before errors occur. The system maintains a database that already contains component information, feeder information, suction nozzle information, and loading head information, so when a suction error occurs, the data is immediately available for analysis without requiring complex real-time data collection during the error event.
Solution Approach 2:
The patent introduces the storage unit as an intermediary between the mounting machine operations and the display device. This intermediary component accumulates and organizes production factor information, acting as a buffer that simplifies the data flow and reduces the complexity burden on both the data collection system and the display system.
3Loss of substance
If suction error data is analyzed without associating production factor information, then data processing is simpler, but component loss cannot be effectively reduced
Solution Approach 1:
The patent implements feedback by displaying error count data and error loss amount data in association with specific production factors. This creates a closed-loop system where operators can see the direct relationship between production factors and component loss, analyze which factors contribute most to losses, and take corrective actions. The feedback mechanism enables continuous improvement while maintaining efficient data processing through automated associations.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables operators to confirm and address the generating factors for suction errors, reducing component loss by providing detailed data sets that correlate error counts and loss amounts with specific production factors, thereby improving the accuracy of component loading.
Implementation Method 1
a loading head that includes a suction nozzle that suctions the component supplied by the feeder
Data Source
AI summary
A management device of a component mounting system includes a management storage unit, a data generating unit, and a display control unit. The management storage unit stores management data in which production factor information for identifying production factors in a mounting machine and suction error information output from the mounting machine are associated with one another. The data generating unit generates suction error count data and suction error loss amount data in association with the production factor information based on a data group of the management data. The display control unit controls a display unit such that a suction error data set is displayed with the suction error count data and the suction error loss amount data associated with the production factor information selected via an operating unit as one set.