Correction Amount Calculation for Reflowed PCB Components
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
In a board work line where a reflow furnace is followed by an appearance inspection machine, the possibility exists that components may flow during reflow, leading to inaccurate inspection and subsequent correction amounts for component mounting machines, which may not be appropriate for all mounting positions.
Innovation Solution
A correction amount calculation device and method that includes a selection section to identify target components with minimal movement during reflow and a correction amount calculation section to determine the positional deviation correction needed for those components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If correction amount is calculated for all components inspected by the appearance inspection machine, then the inspection coverage is improved, but the accuracy of correction amount deteriorates due to component flow during reflow
Solution Approach 1:
The patent segments the set of all inspected components into two subsets: target components (those with minimal movement during reflow) and non-target components (those with significant movement). The correction amount calculation is applied only to the target component subset, where it remains accurate, while excluding the non-target subset where component flow renders the correction inaccurate. This segmentation resolves the contradiction by maintaining both inspection coverage for all components and correction accuracy for appropriate components.
Solution Approach 2:
The patent applies different processing treatments to different components based on their individual characteristics. For target components with minimal movement, the full correction amount calculation process is applied. For non-target components with significant movement, the correction calculation is excluded. This local differentiation ensures that correction amounts are only generated where they maintain accuracy, resolving the contradiction between comprehensive inspection and accurate correction.
2Reliability
If all components are inspected after reflow, then the inspection completeness is improved, but the reliability of correction amount calculation deteriorates due to component flow
Solution Approach 1:
The patent divides inspected components into target components (reliable for correction calculation) and non-target components (unreliable due to flow). This segmentation allows the system to maintain inspection completeness for all components while ensuring correction amount reliability only for the appropriate subset, resolving the contradiction between comprehensive inspection and reliable correction.
Solution Approach 2:
The patent introduces an intermediary selection mechanism that acts as a filter between the appearance inspection machine and the correction amount calculation process. This intermediary selects only those components suitable for correction calculation based on movement criteria, thereby maintaining both inspection completeness and correction reliability by preventing inappropriate correction calculations.
3Productivity
If correction amount calculation is performed for components with significant movement, then the productivity is improved by processing all components, but the manufacturing precision deteriorates
Solution Approach 1:
The patent segments components into target and non-target groups, applying correction amount calculation only to the target group. This segmentation maintains high productivity by efficiently processing only the subset of components where correction is meaningful, while avoiding waste of computational resources on non-target components where correction would be inaccurate, thus resolving the contradiction between productivity and precision.
Solution Approach 2:
The patent applies partial action by performing correction amount calculation only on the necessary subset of target components rather than all inspected components. This partial processing approach maintains sufficient productivity while ensuring manufacturing precision, as it avoids performing unnecessary correction calculations on components where such calculations would be inaccurate due to flow.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables the selection of target components with minimal movement during reflow and calculates accurate correction amounts for positional deviations, ensuring appropriate mounting processes in the component mounting machine.
Implementation Method 1
The reflow furnace is configured to heat the board on which the component is mounted and melt the solder to perform soldering
Data Source
AI summary
A correction amount calculation device includes a selection section and a correction amount calculation section. The selection section is configured to select a target component in which a movement amount of the component on a board before and after being conveyed to a reflow furnace is equal to or less than a predetermined allowable value. The correction amount calculation section is configured to calculate a correction amount, which is used in a mounting process of a board product to be produced later, regarding a positional deviation amount of the mounting position of the target component selected by the selection section with respect to a target mounting position.