Suction Nozzle Cleaning Period Estimation via Flow Rate Measurement
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Solution Overview
Problem
The existing methods for managing the cleaning period of suction nozzles in component mounting machines are inefficient, often resulting in either reduced vacuuming force due to infrequent cleaning or unnecessary cleaning, leading to decreased component mounting efficiency.
Innovation Solution
A nozzle cleaning period management device that measures the flow rate through suction nozzles before and after cleaning, calculates the unit flow rate reduction amount, and estimates the cleaning period based on this data to optimize cleaning schedules, thereby reducing unnecessary cleaning and maintaining nozzle performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If cleaning is performed frequently to maintain vacuuming force, then suction nozzle performance is maintained, but component mounting efficiency decreases due to excessive cleaning time
Solution Approach 1:
The system uses flow rate measurement means to continuously monitor the actual flow rate through each suction nozzle, providing feedback on nozzle condition. The cleaning determination means compares measured flow rates against reference values to automatically determine when cleaning is actually needed, replacing fixed-schedule cleaning with condition-based cleaning decisions
Solution Approach 2:
Each suction nozzle is individually monitored and managed through its own flow rate measurement and cleaning determination process. The system allows nozzles to serve themselves by automatically identifying which nozzles require cleaning based on their actual performance, eliminating the need for uniform cleaning of all nozzles regardless of condition
2Productivity
If cleaning is performed less frequently to maintain component mounting efficiency, then productivity improves, but vacuuming force is reduced leading to vacuuming faults
Solution Approach 1:
The flow rate measurement means provides continuous monitoring of nozzle performance, enabling the system to detect when a nozzle's flow rate drops below acceptable thresholds. This feedback mechanism ensures cleaning is performed only when actually needed to maintain vacuuming force, preventing both over-cleaning and under-cleaning
Solution Approach 2:
The system measures flow rates and determines cleaning needs in advance before vacuuming faults occur. By continuously monitoring flow rates and comparing them against reference values, the system proactively identifies nozzles that require cleaning before their performance degrades to faulty levels
3Ease of operation
If cleaning period is set empirically for all nozzles, then management is simplified, but individual nozzle conditions are not optimized
Solution Approach 1:
The system divides the cleaning management task into individual nozzle-level assessments. Each suction nozzle is independently monitored through dedicated flow rate measurement means, and cleaning determination is made separately for each nozzle based on its specific performance data, allowing customized cleaning schedules for each nozzle
Solution Approach 2:
The system dynamically adjusts cleaning timing based on measured flow rate parameters. Instead of using a fixed empirical cleaning schedule, the cleaning determination means modifies cleaning decisions based on actual flow rate measurements, enabling adaptive cleaning intervals that respond to changing nozzle conditions
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
This approach allows for precise determination of the cleaning period for each nozzle, reducing surplus cleaning workload and improving component mounting efficiency while maintaining suction nozzle performance.
Implementation Method 1
a flow rate measurement means for measuring a flow rate that flows through the suction nozzles
Implementation Method 2
The device disclosed in PTL 1 cleans using an ultrasonic wave washing process by detaching suction nozzles from the mounting head
Data Source
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Figure 5
AI summary
The present invention provides a nozzle cleaning period management device and management method that are configured so as to be capable of indicating a suitable cleaning period of suction nozzles. Therefore, a nozzle cleaning period management device is provided with a cleaning device 20 that cleans suction nozzles 12 that are used in order to perform vacuum retention of an electronic component, a flow rate measurement means 45 for measuring a flow rate that flows through the suction nozzles, a reduction amount calculation means (Step 104) for calculating a unit flow rate reduction amount of the flow rate of the suction nozzle per a number of times of mounting of electronic components on the basis of a flow rate difference before and after cleaning, which is measured by the flow rate measurement means, and an estimation means (Step 204) for estimating a cleaning period, which subsequently cleans the suction nozzles, on the basis of the unit flow rate reduction amount, which is calculated by the reduction amount calculation means, and a flow rate after cleaning.