Parts Mounting System Controller for Unloading Order Adaptation

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Solution Overview

Problem

Existing parts mounting systems face delays in supplying parts to the mounting device when the unloading order is changed, as they do not ensure timely delivery and may cause inconvenience to workers due to abrupt changes in the unloading sequence.

Innovation Solution

A parts mounting system with a controller that detects whether a changed unloading order can be supplied to the parts mounting device in time, queries workers involved in the change regarding the feasibility of the change, and adjusts the unloading order based on their responses, ensuring timely supply and reflecting their intentions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If the unloading order is changed based on urgent request signals, then the responsiveness to worker requests is improved, but the timely supply of parts to the mounting device deteriorates

Engineering Contradiction:

Improveresponsiveness to worker requestsVSAvoidtimely supply of parts

Core Design Contradiction:

Adaptability or versatilityVSLoss of time

Solution Approach 1:

The system performs preliminary actions by predicting future part requirements based on production plans and current inventory levels. The prediction unit calculates expected part consumption and generates advance notifications to the parts storage system, allowing the unloading order to be optimized before actual shortages occur, thus maintaining timely supply while adapting to changing requirements

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system implements feedback mechanisms where the management controller continuously monitors part usage, inventory levels, and mounting device operations. This feedback loop allows the system to detect when unloading order changes might cause delays and automatically adjust the sequence to maintain timely part delivery while still responding to urgent requests

Inventive Principle:

Principle #23Feedback

2Extent of automation

If the unloading order is automatically changed based on urgent request signals, then the system automation is improved, but the smooth supply of parts deteriorates

Engineering Contradiction:

Improveautomatic order changingVSAvoidsmooth supply of parts

Core Design Contradiction:

Extent of automationVSProductivity

Solution Approach 1:

The prediction unit performs preliminary calculations of part requirements based on production plans, allowing the system to anticipate future needs and prepare unloading sequences in advance. This preliminary action enables automatic order changes that maintain smooth part flow by preventing disruptions before they occur

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system provides beforehand cushioning by maintaining buffer inventory levels and predicting potential supply disruptions. When urgent requests are received, the system evaluates whether predicted future requirements will be compromised and only changes the unloading order if the prediction confirms timely supply can be maintained, thus cushioning against potential productivity disruptions

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Data Source

PatentUS20230129516A1Parts mounting system and parts mounting method

Publication Date: 2023.04.27 YAMAHA MOTOR CO LTD

AI summary

A parts mounting system (100) includes a parts mounting device (15) configured to mount parts (E) on a board (S), a parts storage (20) configured to store the parts supplied to the parts mounting device, and a controller (30) configured or programmed to perform a control to detect whether or not an unloading order can be changed based on whether or not the parts can be supplied to the parts mounting device in time when an order in which the parts are unloaded from the parts storage is changed.