Nozzle ID Recognition in Component Mounting Machines
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Solution Overview
Problem
Existing component mounting machines face inefficiencies in exchanging multiple suction nozzles due to manual operation errors and increased complexity with miniaturization, leading to longer exchange times and decreased operating rates.
Innovation Solution
A component mounting machine with a nozzle station and camera system that enables on-the-fly imaging of nozzle ID codes, allowing for continuous and efficient exchange of suction nozzles by moving the camera along the nozzle arrangement direction, reversing direction between columns, and storing ID codes with position association, reducing imaging time and errors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the suction nozzle exchange is performed by manually changing each nozzle on the nozzle station, then the type checking can be performed by imaging identification marks, but the exchange time becomes excessively long when multiple nozzles need to be exchanged continuously
Solution Approach 1:
The system pre-reads and stores the ID codes of all suction nozzles on the nozzle station before the actual nozzle exchange begins. This preliminary action allows the mounting head to exchange nozzles without waiting for individual identification and verification, significantly reducing exchange time while maintaining accuracy through pre-validated nozzle type information.
Solution Approach 2:
The patent replaces the manual mechanical process of visually identifying and verifying nozzle types with an automated optical reading system. The camera captures images of ID codes, and image processing automatically recognizes and validates nozzle types, eliminating the need for manual verification during each nozzle exchange operation.
2Adaptability or versatility
If the number of suction nozzles on the mounting head is increased to handle miniaturized components, then the mounting capability is improved, but the time required to exchange all nozzles during production changes increases
Solution Approach 1:
The system performs preliminary reading of all nozzle ID codes on the nozzle station before the mounting head arrives for exchange. This allows the increased number of nozzles to be pre-validated, so when the mounting head exchanges nozzles, the process is rapid without individual verification delays, maintaining the benefit of having multiple nozzles for miniaturized components.
Solution Approach 2:
The patent enables continuous nozzle exchange operations by pre-reading all nozzle IDs and storing them in advance. The mounting head can continuously exchange multiple nozzles without interruption for verification, maintaining high-speed operation even when handling the increased number of nozzles required for miniaturized component mounting.
3Measurement precision
If the camera stops to image each nozzle ID code individually, then the image processing can be performed accurately, but the total imaging time for multiple nozzles becomes excessively long
Solution Approach 1:
The camera performs preliminary imaging of all nozzle ID codes on the nozzle station before the nozzle exchange process begins. All images are captured and processed in advance, storing the recognized ID codes for later use during the actual exchange operation, eliminating the need for repeated imaging during the exchange process.
Solution Approach 2:
The system maintains continuous camera operation by imaging all nozzle ID codes in sequence without stopping between nozzles. The camera moves continuously along the nozzle station, capturing images of multiple nozzles in one continuous operation, which is then processed to extract all ID codes efficiently.
Data Source
AI summary
In a component mounting machine, before the suction nozzle held by the rotary head is automatically exchanged, the nozzle ID codes of all suction nozzles arranged on the nozzle station are continuously read at a high speed and stored in association with the position of each suction nozzle. Sequentially imaging the nozzle ID code display section of each suction nozzle of each column is performed without stopping the mark imaging camera while moving the camera in an arrangement direction of the suction nozzle of each column of the nozzle station. The movement direction of the camera is reversed each time the last imaging operation of one column is completed and the camera is moved to imaging an adjacent column and the nozzle ID code of each suction nozzle of each column read at the image processing is stored in the storage in association with the position of each suction nozzle.