PCB Mounting Head Nozzle Assignment for Cycle Time Reduction
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Solution Overview
Problem
In dual production systems for printed circuit board manufacturing, the cycle time is prolonged due to the need to exchange nozzles between different types of boards conveyed in separate conveyance lanes, limiting the degree of freedom in board conveyance and production efficiency.
Innovation Solution
A board production method that uses multiple component mounting machines with dual conveyance lanes and a single mounting head, where nozzles are fixed for continuous production of multiple types of boards, and component groups are strategically disposed to maintain optimal production states without nozzle exchange during production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If nozzles are exchanged between different board types in dual production system, then mounting capability for different boards is achieved, but cycle time becomes longer
Solution Approach 1:
The system pre-calculates and determines the optimal nozzle assignment for each board type before production begins. By analyzing all required board types and their component requirements in advance, the system creates a nozzle allocation plan that maximizes nozzle utilization across different board types, eliminating the need for nozzle exchanges during production.
Solution Approach 2:
The invention makes a single mounting head capable of handling multiple board types by strategically assigning nozzles to components that appear across different board types. The system identifies common components among multiple board types and assigns shared nozzles to these components, enabling one mounting head to service multiple board types without physical nozzle changes.
2Productivity
If independent production system with two mounting heads is used, then parallel production is achieved, but one mounting head stops during disposition changing
Solution Approach 1:
The system ensures continuous operation of the mounting head by maintaining a fixed nozzle configuration that can handle multiple board types. By eliminating nozzle exchange operations, the mounting head operates continuously without stopping, even when switching between different board types, thus maintaining full productivity.
3Productivity
If dual production system with single mounting head is used, then board conveyance time is excluded from cycle time, but nozzle exchange time increases cycle time
Solution Approach 1:
The system performs preliminary calculation of nozzle assignments for all board types before production starts. This advance planning ensures that the single mounting head is equipped with the optimal set of nozzles to handle the entire production batch without requiring intermediate nozzle exchanges, thereby preserving the conveyance efficiency advantage.
4Productivity
If nozzle commonality is optimized for two board types, then production efficiency improves, but degree of freedom in conveyance is limited
Solution Approach 1:
The system dynamically adjusts the production plan to match the predetermined nozzle configuration. Rather than fixing the nozzle configuration to specific board types, the system flexibly schedules and sequences different board types to utilize the available nozzles optimally, thereby maintaining both production efficiency and conveyance flexibility.
Data Source
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AI summary
The present invention provides a board production method which is capable of further shortening a cycle time in a case in which a component mounting machine which is provided with a single mounting head is used. The board production method is a method which uses a plurality of component mounting machines (10 and 20) which are disposed in series to perform continuous production of a plurality of types of printed circuit board (JOBs 1, 2, and 11 to 13). The board production method includes a condition determination step (T1, T2, and T5) of determining a disposition of nozzles and a disposition of a plurality of types of component group such that a state is assumed in which nozzles which are attached to each of the mounting heads (14 and 24) during the continuous production of a plurality of types of printed circuit board (JOB) are fixed, and a production step (T2, T5 to T6, and T8) of performing the continuous production of a plurality of types of printed circuit board (JOB) in the disposition of the nozzles and the disposition of the plurality of types of component group which are determined in the condition determination step (T1, T2, and T5).