Component Placement Machine Feeder Bank Positioning
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Solution Overview
Problem
Current PCB assembly line changeover processes are inefficient, requiring significant time and resources due to the need for parallel feeder preparation and extensive offline setup, leading to unnecessary non-production time and increased floor space and hardware costs.
Innovation Solution
A component placement machine with a feeder/nozzle bank system that allows for concurrent setup of a second product during production of the first product, using a positioning system to facilitate movement of feeder banks and reduce the need for offline setup areas, thereby minimizing changeover time and resource requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If offline feeder setup area is used to prepare feeders for next PCB product, then feeder preparation can be done in parallel with current production, but floor space requirements and hardware costs increase significantly
Solution Approach 1:
The patent merges the feeder preparation function directly into the production line by integrating feeder banks onto the component placement machine itself. This eliminates the need for separate offline feeder setup areas while enabling parallel preparation of feeders for the next product during current production, thus reducing floor space requirements while maintaining the benefit of parallel preparation.
Solution Approach 2:
The component placement machine is designed with multi-functionality to serve both as the production machine for current products and as the preparation station for next product feeders. The feeder banks can be loaded, validated, and positioned on the machine while it continues to produce current products, making the machine universal for both production and setup functions.
2Loss of time
If duplicate feeder carts and offline setup stations are provided for each assembly machine, then parallel feeder preparation is enabled, but hardware costs and device complexity increase
Solution Approach 1:
The patent combines multiple functions (feeder storage, feeder preparation, feeder validation, and PCB assembly) into a single integrated system on the component placement machine. This eliminates the need for duplicate feeder carts and separate offline setup stations, reducing hardware complexity while maintaining parallel preparation capability.
Solution Approach 2:
The component placement machine is designed as a universal platform that can perform both current product assembly and next product feeder preparation simultaneously. The machine's feeder banks serve dual purposes: holding feeders for current production and accommodating pre-loaded feeders for upcoming products, thereby eliminating the need for dedicated duplicate hardware for each function.
3Manufacturing precision
If extensive offline setup and validation is performed before production changeover, then product changeover accuracy is improved, but non-production time increases
Solution Approach 1:
The patent enables preliminary feeder preparation actions (loading components onto feeders, validating feeder positions) to be performed in advance during current production. The feeder banks for the next product can be loaded and validated on the machine while it continues assembling current products, thus maintaining validation accuracy while minimizing non-production time.
Solution Approach 2:
The system maintains continuous useful action by allowing feeder preparation and validation for the next product to occur concurrently with current product assembly. This parallel processing ensures that validation activities do not interrupt production flow, keeping the system continuously productive while maintaining accuracy through proper validation procedures.
Data Source
AI summary
A component placement machine for assembling at least one component on to at least one printed circuit board (PCB) is provided. The component placement machine comprises at least one head configured for picking a component from at least one feeder and placing the picked component on to a PCB of a first PCB product. The component placement machine also includes at least one feeder bank system separate from the head, wherein the feeder system includes a first feeder bank and a second feeder bank and a positioning system for moving both the entire first feeder bank and the entire second feeder bank in both a horizontal X direction and a perpendicular horizontal Y direction, wherein the feeder bank system is configured to enable a setup of a second PCB product on the component placement machine while the component placement machine assembles the PCB of the first PCB product. The entire first feeder bank and the entire second feeder bank of the at least one feeder bank system are each movably located on said component placement machine independently from each other, so that movement of the entire first feeder bank occurs while said component placement machine uses the second feeder bank to assemble said printed circuit board of said first printed circuit board product.