Rotary Head Nozzle Exchange With Vision-Based Station Alignment
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Solution Overview
Problem
In rotary head type component mounters, position deviations and angle misalignments of the nozzle station can lead to failed suction nozzle exchanges, as existing systems rely on precise alignment with reference coordinates, which may not account for attachment tolerances or manual deviations.
Innovation Solution
A rotary head type component mounter with a head rotating mechanism, Z-axis driving mechanism, and station position and angle detecting means, allowing for the detection and correction of nozzle station position and angle, enabling simultaneous exchange of suction nozzles even with position and angle deviations, using image recognition and control systems to align and correct the rotary head's position and angle.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the nozzle station is attached using attachment tolerances, then the ease of manufacture is improved, but the position precision of the suction nozzle in the nozzle station deteriorates
Solution Approach 1:
The system performs preliminary detection of the nozzle station's actual position and angle using a vision system before the suction nozzle exchange operation. This allows the control unit to pre-calculate correction values and adjust the rotary head's positioning in advance, ensuring accurate alignment despite attachment tolerances.
Solution Approach 2:
The vision system continuously monitors the position and angle of the nozzle station and provides feedback to the control unit. The control unit uses this feedback to dynamically adjust the rotary head's position and rotation angle, creating a closed-loop control system that compensates for position deviations caused by attachment tolerances.
2Productivity
If the rotary head is positioned at reference coordinates for simultaneous exchange of multiple suction nozzles, then the productivity is improved, but the reliability of suction nozzle exchange deteriorates due to position deviation
Solution Approach 1:
The vision system detects the actual position and angle of the nozzle station before the simultaneous exchange operation, and the control unit pre-calculates the necessary corrections to the rotary head's position and rotation angle, ensuring accurate alignment for reliable multi-nozzle exchange.
Solution Approach 2:
The system uses vision-based feedback to continuously monitor the nozzle station's position and adjusts the rotary head's positioning dynamically, ensuring that even when positioning at reference coordinates for high-speed simultaneous exchange, the actual alignment remains accurate and reliable.
Data Source
AI summary
In a rotary head type component mounter, among a specified quantity of suction nozzles held by a rotary head, multiple suction nozzles are lowered simultaneously. When the rotary head is moved by a head moving mechanism to a nozzle exchange area and exchange of suction nozzles is performed, two station reference marks of the nozzle station are imaged by a mark imaging camera, image recognition is performed of the positions of the two station reference marks, and the position and angle of the nozzle station is calculated. Then, the position and angle of the rotary head is corrected to be aligned with the position and angle of the nozzle station, multiple of the suction nozzles held on the rotary head are lowered simultaneously by Z-axis driving mechanisms and simultaneously exchanged with multiple of the suction nozzles in the nozzle station.