Pick-and-Place Shuttle Table Scheduling for Faster PCB Changeovers

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Solution Overview

Problem

The existing production processes for printed circuit boards on pick-and-place lines face inefficiencies due to lengthy setup times and downtimes, which increase processing time and reduce throughput, particularly when switching between setup families and managing shuttle tables.

Innovation Solution

A method and control device that optimize the use of shuttle tables by sensing clusters, empty shuttle table sets, and cycle times to minimize waiting times and processing times, using mixed integer linear optimization to determine the optimal order of clusters and setups, allowing for the insertion of fixed setups to reduce downtime and inventory costs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If shuttle tables are exchanged for different component types, then component availability is improved, but setup time increases significantly

Engineering Contradiction:

Improvecomponent availabilityVSAvoidsetup time

Core Design Contradiction:

Adaptability or versatilityVSLoss of time

Solution Approach 1:

The system performs preliminary setup actions by preparing replacement shuttle tables in advance with required components before they are needed. The control device plans ahead to have shuttle tables ready with correct component configurations, so when a shuttle table needs to be replaced, the exchange can occur quickly without extensive setup time.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The control device acts as an intermediary that coordinates between production demands and shuttle table availability. It manages the queue of shuttle tables and orchestrates exchanges, allowing the physical shuttle table exchange to be decoupled from the complexity of component configuration management.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Adaptability or versatility

If setup tables are frequently exchanged to match different fabrication orders, then production flexibility is improved, but downtime increases

Engineering Contradiction:

Improveproduction flexibilityVSAvoiddowntime

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

The control device performs preliminary planning to anticipate future setup requirements and prepares appropriate shuttle tables in advance. By looking ahead at the fabrication order queue, the system can pre-configure replacement shuttle tables before they are needed, reducing the actual exchange downtime when production needs to switch between different product types.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system maintains continuity of production by ensuring that shuttle table exchanges are minimized and optimized. The control device sequences the fabrication orders and shuttle table exchanges to maintain continuous productive action, avoiding unnecessary downtime by planning exchanges only when truly necessary and preparing them in advance.

Inventive Principle:

Principle #20Continuity of useful action

3Manufacturing precision

If shuttle table exchanges are performed manually, then setup precision is improved, but labor requirements and time increase

Engineering Contradiction:

Improvesetup precisionVSAvoidexchange time

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

The system implements self-service through automated control. The control device automatically manages the queue of shuttle tables, determines when exchanges are needed, and coordinates the exchange process. This automation maintains precision by following pre-planned sequences while eliminating manual labor and reducing exchange time significantly.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The patent replaces manual mechanical operations with an automated control system. The control device uses computational algorithms to plan and sequence shuttle table exchanges, substituting human manual setup operations with automated decision-making and coordination, thereby maintaining precision while dramatically reducing time and labor requirements.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS11523553B2Method and control device for the processing-time-optimized production of printed circuit boards on a pick-and-place line

Publication Date: 2022.12.06 SIEMENS AG

AI summary

Provided is a transmission device for feedback-free unidirectional transmission of data from a first network zone into a second network zone for evaluation at a remote application server, containing: —a data export device which is arranged in the first network zone and is to detect the data transmitted in a network data format in the first network zone and to transform the data from the network data format into a transport data format, —a unidirectional data transmission unit, to transmit the data in the transport data format into the second network zone unidirectionally—a data import device which transforms the data from the transport data format back into the network data format and to transmit the data to an application server, wherein the data import device and the application server are arranged in a second network zone remote from the first zone, and to a corresponding method.