PCB Pick-and-Place Setup Families for Fewer Changeovers
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Solution Overview
Problem
Existing methods for assigning circuit board types to assembly lines result in suboptimal or rare formation of permanent setups, leading to inefficient assembly line operations and increased costs due to frequent setup changes and downtime.
Innovation Solution
A method that assigns circuit board types to setup families using mixed integer programming to optimize the distribution of component types across fixed and constant setup tables, ensuring at least one constant setup table remains unchanged during setup changes, thereby reducing downtime and improving assembly line efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If circuit board types are assigned to setup families using traditional methods, then the assembly line can operate with predetermined setups, but frequent setup changes are required leading to increased downtime and reduced productivity
Solution Approach 1:
The patent applies preliminary action by pre-assigning circuit board types to setup families and pre-determining optimal setup configurations using mixed integer programming before production begins. This allows the assembly line to operate with predetermined optimal setups, minimizing the need for frequent setup changes and reducing downtime during production cycles.
Solution Approach 2:
The patent implements dynamics by introducing a hierarchical setup structure with fixed setups (for high-volume board types) and variant setups (for low-volume board types). This dynamic structure allows the system to adapt to different production scenarios by selectively activating appropriate setup families, optimizing productivity while minimizing setup changes based on real-time production demands.
2Stability of the object's composition
If fixed setups are formed first and then component types are assigned, then setup stability is improved, but only very few or no constant setup tables can be formed
Solution Approach 1:
The patent applies segmentation by dividing the setup structure into fixed setups and variant setups, and further segmenting component types into those assigned to constant setup tables and those assigned to variant setup tables. This segmentation allows simultaneous formation of stable fixed setups and adaptable constant setup tables, resolving the contradiction between setup stability and adaptability.
Solution Approach 2:
The patent implements local quality by assigning different characteristics to different parts of the setup structure. Fixed setups provide stability for high-volume production, while variant setups provide adaptability for low-volume production. Similarly, constant setup tables maintain stable component compositions, while variant setup tables adapt to different requirements, allowing the system to optimize both stability and versatility simultaneously.
3Adaptability or versatility
If setup changes are performed frequently to accommodate different circuit board types, then adaptability is improved, but assembly line efficiency decreases and costs increase
Solution Approach 1:
The patent applies universality by creating setup families that can accommodate multiple circuit board types within each family. The mixed integer programming optimization ensures that high-volume board types are grouped into setup families with stable, reusable configurations. This multi-functional approach allows the assembly line to handle diverse board types while minimizing setup changes, thereby maintaining high productivity and adaptability simultaneously.
Data Source
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AI summary
Set-up families with associated set-ups are provided for populating printed circuit boards by means of a pick-and-place line. A number of printed circuit board types is associated with each set-up family and a number of component types is associated with each associated set-up, such that a printed circuit board of a printed circuit board type in a set-up family can be populated on the pick-and-place line by means of components of the component types associated with the set-up. Stocks of components of the component types of a set-up can be provided by means of set-up tables on the pick-and-place line. A method for populating the printed circuit boards comprises the steps of detecting printed circuit board types of which printed circuit boards are intended to be populated with components of associated component types, of associating detected printed circuit board types with a predetermined number of set-up families, and of optimizing the association operation with respect to a predetermined criterion. In this case, optimization is performed in such a way that the component types of the set-ups of all set-up families can be divided between set-up tables such that at least one constant set-up table can remain on the pick-and-place line over all set-ups. One of the set-ups can then be provided on the pick-and-place line and printed circuit boards of a printed circuit board type which is associated with the set-up family of the set-up can be populated on the pick-and-place line.