Mounting Tool Feeder for Planned Nozzle Exchange and Maintenance
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Solution Overview
Problem
Existing component mounting systems face challenges in efficiently managing the exchange and maintenance of suction nozzles, particularly in high-variety, low-quantity production scenarios, leading to increased operational complexity and reduced mounting reliability.
Innovation Solution
A component mounting system with a conveyance plan creation section that manages the conveyance of mounting tools based on production plans and maintenance schedules, combined with a mounting tool feeder that allows for automatic exchange and detachable mounting tool holding units, ensuring efficient tool supply and operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple suction nozzles are accommodated in multiple locations (in-machine nozzle station and nozzle exchange unit) to address increased exchange frequency, then the ability to handle high-variety production is improved, but device complexity and space requirements increase
Solution Approach 1:
The patent merges the in-machine nozzle station and nozzle exchange unit into a single integrated nozzle exchange unit that can be detachably attached to the component mounter. This consolidation allows multiple suction nozzles to be accommodated in one location rather than distributed across multiple locations, reducing device complexity while maintaining the ability to handle high-variety production through automated nozzle exchange.
Solution Approach 2:
The nozzle exchange unit is designed with multi-functionality, serving both as a storage location for multiple suction nozzles and as an active exchange station. The unit can accommodate various types of suction nozzles and provides automated exchange functionality, making it a universal solution that handles both storage and exchange operations without requiring separate dedicated locations.
2Adaptability or versatility
If multiple suction nozzles are exchanged frequently to match different component types in high-variety production, then production flexibility is improved, but loss of time for exchange operations increases
Solution Approach 1:
The nozzle exchange unit stores multiple suction nozzles in advance, preparing them for immediate exchange. The system maintains an inventory of different nozzle types within the exchange unit, allowing the mounting head to quickly exchange nozzles based on the next required component type without requiring time-consuming preparation or setup operations.
Solution Approach 2:
The system implements automated nozzle exchange where the control device automatically selects and exchanges the appropriate suction nozzle based on the mounting task requirements. This self-service automation eliminates manual intervention and reduces exchange operation time while maintaining production flexibility through automated decision-making.
3Reliability
If suction nozzles are exchanged every time board product type changes to maintain optimal mounting performance, then mounting reliability is improved, but productivity decreases due to frequent exchanges
Solution Approach 1:
The nozzle exchange unit pre-stores multiple suction nozzles that are ready for immediate exchange. By having the required nozzles prepared in advance within the exchange unit, the system can quickly switch between different nozzle types without interrupting the production flow, thus maintaining mounting reliability while minimizing productivity impact.
Solution Approach 2:
The control device monitors the mounting task requirements and automatically determines when nozzle exchange is necessary. The feedback mechanism allows the system to exchange nozzles based on actual production needs rather than fixed schedules, maintaining mounting reliability only when component type changes require it, thereby avoiding unnecessary exchanges that would reduce productivity.
Data Source
AI summary
A component mounting system includes multiple component mounters configured to each hold component mounting tools in an automatically exchangeable manner, a conveyance device configured to convey the component mounting tools between a storage area configured to store the component mounting tools, and a plan creation section configured to create a conveyance plan for the component mounting tools using the conveyance device based on a production plan indicating a type and a production order of the board product, and setup information indicating the types and quantities of the component mounting tools used by each of the multiple component mounters for each type of the board product or maintenance information indicating the maintenance timing of the component mounting tools.