Nozzle Height Control via Image Capture for Component Mounting

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Solution Overview

Problem

Existing component mounting techniques face challenges in accurately setting the target height of a nozzle for component suction due to variations in air flow rate, especially when dust or debris adheres to the nozzle, leading to inconsistent mounting processes.

Innovation Solution

A component mounting apparatus and method that utilizes an image capturing unit to control the target height of the nozzle based on captured images of the component and nozzle, allowing for precise adjustment regardless of air flow rate changes, and incorporates a control unit to stop the nozzle at the appropriate height for reliable component suction.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If the target height is set based on flow rate detection, then the nozzle can be controlled to contact the component, but the target height cannot be accurately set when dust or debris adheres to the nozzle causing flow rate changes

Engineering Contradiction:

Improvetarget height setting accuracyVSAvoidmounting process consistency

Core Design Contradiction:

Measurement precisionVSReliability

Solution Approach 1:

The patent replaces the pneumatic flow rate detection system with an optical imaging system. Instead of using air flow sensors to detect nozzle-to-component distance, the system uses an image capturing unit to visually measure the gap between the nozzle and component, thereby eliminating the negative impact of dust or debris affecting pneumatic flow rate measurements.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces an image capturing unit as an intermediary measurement tool. This intermediary device optically captures the spatial relationship between the nozzle and component, providing an alternative measurement pathway that is not affected by contamination of the suction system.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Ease of operation

If the nozzle is lowered to contact the component for suction, then component mounting can be performed, but the target height cannot be controlled when component thickness varies due to individual differences

Engineering Contradiction:

Improvecomponent suction capabilityVSAvoidnozzle target height control

Core Design Contradiction:

Ease of operationVSMeasurement precision

Solution Approach 1:

The patent implements a feedback control system where the image capturing unit continuously monitors the distance between the nozzle and component during the lowering process. The control unit adjusts the nozzle position based on real-time image feedback, ensuring accurate target height control even when component thickness varies due to individual differences.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The patent makes the target height control dynamic by using real-time image capture and processing. Instead of relying on fixed pre-set heights, the system dynamically adjusts the nozzle position based on the actual measured distance to the component surface, adapting to variations in component thickness.

Inventive Principle:

Principle #15Dynamics

Data Source

PatentUS11240950B2Component mounting apparatus

Publication Date: 2022.02.01 YAMAHA MOTOR CO LTD

AI summary

The image including both of the component and the nozzle that is being lowered toward the component is captured. The target height at which the nozzle is stopped in the mounting process is controlled based on this image. This enables the target height at the time of lowering the nozzle toward the component to be controlled regardless of a flow rate of air sucked from the nozzle.