PCB Pick-and-Place Setup Family Allocation With Integer Programming

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing methods for determining setup families for circuit board assembly lines are often manual, unreliable, or tied to specific assembly systems, leading to inefficient component management and increased economic costs due to redundant setup of components.

Innovation Solution

A method using integer linear programming to optimize the assignment of circuit boards to setup families, minimizing the number of component types required, thereby reducing the number of setup stations and avoiding redundant setups, with a control device and computer program implementing this method.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If manual methods or existing tools are used to define setup families, then the process can be completed, but the results are unreliable, require manual effort, and are tied to specific placement systems

Engineering Contradiction:

Improvereliability of setup family definitionVSAvoidcomplexity of setup family definition process

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent replaces manual mechanical processes with an automated computer-based system that uses mathematical optimization algorithms (integer linear programming) to automatically determine optimal setup families. The control device receives component data, performs automated optimization calculations, and generates setup family assignments without manual intervention, thereby improving reliability while reducing operational complexity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Productivity

If the number of component types kept ready at the assembly line is reduced, then time and cost savings are achieved, but the ability to assemble diverse PCBs is constrained

Engineering Contradiction:

Improveassembly efficiency and cost effectivenessVSAvoidflexibility in PCB assembly capability

Core Design Contradiction:

ProductivityVSAdaptability or versatility

Solution Approach 1:

The patent changes the optimization parameters by using integer linear programming to minimize the sum of component types across setup families while ensuring all PCBs can be assembled. The mathematical model adjusts component allocation parameters to find the optimal balance between reducing setup complexity and maintaining assembly versatility, allowing the system to achieve both productivity improvement and adaptability preservation.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The system dynamically assigns PCBs to different setup families based on their component requirements, allowing flexible reconfiguration of assembly lines. The optimization algorithm continuously adjusts the distribution of PCBs across multiple setup families to minimize total component types while ensuring each PCB type can be assembled within its assigned family's component constraints.

Inventive Principle:

Principle #15Dynamics

3Quantity of substance

If the number of setup stations is reduced by optimizing setup families, then redundant setups are avoided and costs are saved, but the allocation complexity increases

Engineering Contradiction:

Improvenumber of setup stations and component typesVSAvoidcomplexity of allocation optimization

Core Design Contradiction:

Quantity of substanceVSDevice complexity

Solution Approach 1:

The patent extracts the complex optimization problem from manual processes and encapsulates it within an automated control device that performs integer linear programming calculations. By removing the optimization complexity from human operators and concentrating it in a dedicated computational system, the patent reduces the number of setup stations while managing allocation complexity through automated mathematical optimization.

Inventive Principle:

Principle #2Taking out (Extraction)

Data Source

PatentEP3871480B1Method for determining set-up families for a pick-and-place line for populating circuit boards with electronic components

Publication Date: 2023.10.11 SIEMENS AG

Figure 1
Figure 2

AI summary

The invention claims a method for determining set-up families (250, 255) for a pick-and-place line (110) for populating circuit boards (120) with electronic components (155) of one or more component types, the method comprising the following steps: detecting a predetemined or predeterminable number of set-up families (250, 255); wherein a set-up family is defined as a quantity of circuit boards that can be populated on a pick-and-place line without changing the quantity of component types kept ready for population on the pick-and-place line; characterised in that an assignment of circuit boards to be distributed to the detected number of set-up families is optimised by means of integer linear programming in such a way that the sum of the numbers of component types per set-up family is minimised; and populating the circuit boards in the set-up family assigned to them.