PCB Pick-and-Place Sequencing With Changing Table Set Optimization

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Solution Overview

Problem

The existing methods for producing printed circuit boards on SMT assembly lines face inefficiencies due to lengthy changeover processes, leading to significant downtimes and reduced throughput, as changing tables with component stocks require hours to upgrade and are often manually managed, resulting in suboptimal production sequencing.

Innovation Solution

A method and control device that optimize the production sequencing of printed circuit boards by grouping them into clusters, optimizing the use of changing table sets, and employing mixed integer linear optimization to minimize waiting times and maximize throughput, allowing for automated support in production planning and strategic use of fixed and variant armaments.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If changing tables are manually upgraded with components, then component availability is ensured, but production downtime increases significantly

Engineering Contradiction:

Improvecomponent availabilityVSAvoidproduction downtime

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The system performs preliminary actions by pre-equipping changing tables with components before they are needed on the assembly line. The optimization module calculates and schedules which tables to equip in advance, allowing component availability to be ensured without causing production downtime when tables are swapped.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system implements self-service by automatically optimizing the sequence of cluster production and determining which changing tables to equip without manual intervention. The control module autonomously manages the coordination between table preparation and production scheduling, eliminating manual planning delays.

Inventive Principle:

Principle #25Self-service

2Reliability

If changing table sets are upgraded in the pre-equipment area, then component readiness is achieved, but waiting times in production occur

Engineering Contradiction:

Improvecomponent readinessVSAvoidwaiting time in production

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The optimization module ensures continuous useful action by coordinating the pre-equipment process with production scheduling. Tables are equipped and ready to be swapped in without interruption to the production flow, maintaining continuous operation while ensuring component readiness.

Inventive Principle:

Principle #20Continuity of useful action

3Adaptability or versatility

If manual production planning is used, then flexibility in handling production orders is maintained, but throughput optimization is reduced

Engineering Contradiction:

Improveproduction planning flexibilityVSAvoidassembly line throughput

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The system uses feedback by continuously monitoring production progress and adjusting the optimization calculations accordingly. The module receives information about current production status and uses this feedback to dynamically optimize the production sequence and table swapping schedule, maintaining both flexibility and throughput optimization.

Inventive Principle:

Principle #23Feedback

4Adaptability or versatility

If changeover processes are performed between setup families, then product variety is produced, but assembly line downtime increases

Engineering Contradiction:

Improveproduct varietyVSAvoidassembly line downtime

Core Design Contradiction:

Adaptability or versatilityVSLoss of time

Solution Approach 1:

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system applies dynamics by enabling flexible, on-demand changeover between setup families based on real-time production needs. The optimization module dynamically determines the optimal sequence of clusters and schedules table swaps to minimize downtime, allowing the system to adaptively produce product variety while maintaining high throughput.

Inventive Principle:

Principle #15Dynamics

Data Source

PatentEP3556191B1Method and control device for the throughput-optimised production of printed circuit boards on a pick-and-place line

Publication Date: 2021.04.14 SIEMENS AG

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Figure 2~4

AI summary

The invention relates to a method and a control device for the throughput-optimised production of printed circuit boards on a pick-and-place line. The invention relates to a method for the throughput-optimised production of printed circuit boards (120) on a pick-and-place line (110), wherein: the printed circuit boards are divided into groups known as clusters; each cluster (175) is produced using one set-up; the set-up is realised by means of changing tables (140) that can be attached to the pick-and-place line, each changing table having at least one feed device (150) for keeping ready stocks of components (155); a quantity of changing tables needed for each set-up is referred to as a changing table set and an empty changing table set comprises changing tables having feed devices that are empty. In the exemplary embodiment, five clusters having variant set-ups (VI to V5) and one cluster having a fixed set-up F are completed on a pick-and-place line. Two changing table sets are provided for completing the clusters with variant set-ups. There is therefore no waiting time for the clusters having fixed set-ups because the fixed set-ups are only set up once and then retained in this respect for an extended (planning) period. In one embodiment of the invention, clusters having fixed set-ups can be inserted into the production sequence at 'intermediate positions' or fitted in therebetween. This has the advantage that waiting times during production for completion of the necessary variant set-ups can be avoided in this way.