Production Mode Selection for Parallel Conveyor Mounters
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Solution Overview
Problem
Current methods for determining the production mode in mounters with parallel conveyors lack a quantitative approach, leading to inefficiencies and operator-dependent decisions, which can reduce production efficiency and increase production time when selecting between synchronous and asynchronous modes, as well as independent and alternating modes.
Innovation Solution
A method to determine the suitable production mode by analyzing mounting information, including component mounting operations, predicted stoppage times, and operational rates, to select the mode with higher production efficiency, allowing for objective judgment and automatic selection of the most efficient production mode before starting production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If synchronous mode is used to carry out component-mounted boards synchronously between respective lanes, then intermediate stock creation is suppressed, but production flexibility and adaptability to stoppages are reduced
Solution Approach 1:
The system dynamically switches between synchronous and asynchronous modes based on real-time production conditions. The control unit monitors operational status of each lane and adjusts the carrying mode accordingly, allowing the system to adapt to stoppages and maintain flexibility while suppressing intermediate stock when conditions permit
Solution Approach 2:
The system changes the operational parameters of the carrier conveyors by switching between synchronous and asynchronous modes. This parameter change allows the same physical system to operate in different production configurations, balancing intermediate stock suppression with adaptability to stoppages based on current conditions
2Adaptability or versatility
If asynchronous mode is used to carry in and carry out boards independently, then production flexibility is improved, but intermediate stock may increase
Solution Approach 1:
The system dynamically adjusts the carrying mode between synchronous and asynchronous based on real-time operational status. When stoppages are detected, the system switches to asynchronous mode to maintain flexibility; when operations are continuous, it switches to synchronous mode to suppress intermediate stock
3Device complexity
If operator-dependent decision making is used for mode selection, then system complexity is reduced, but production efficiency and decision objectivity are worsened
Solution Approach 1:
The control unit automatically monitors operational status of mounting heads and carrier conveyors, and self-determines the appropriate carrying mode without operator intervention. The system serves itself by collecting data, analyzing conditions, and making mode selection decisions autonomously, thereby eliminating operator dependency while maintaining manageable complexity
Solution Approach 2:
The control unit continuously collects feedback on operational status from mounting heads and carrier conveyors, and uses this feedback to automatically adjust the carrying mode. This closed-loop feedback mechanism ensures objective, data-driven decisions that optimize production efficiency without requiring operator judgment
Data Source
AI summary
A mounting condition determining method including: obtaining mounting information including information related to component mounting operations scheduled to be performed by a mounter (S1); judging, using the mounting information obtained in the obtaining: which production mode between a synchronous mode and an asynchronous mode is suitable for the scheduled component mounting operations; or which production mode between an alternating mode and an independent mode is suitable for the scheduled component mounting operations (S2, S3); and selecting the production mode indicated by a result of the judgment in the judging, as the production mode to be executed by the mounter (S5, S6).