Screen Printer Dynamic Inspection Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing screen printers face productivity issues due to the need for frequent print state inspections, which are not adaptable to changing manufacturing situations, and operator instructions may not be clear, leading to inadequate response to positional deviations in print patterns.
Innovation Solution
A screen printer with a control device that acquires inspection data based on operator instructions through an input device, allowing for selective inspection and correction of positional deviations, incorporating a board positioning device, mask holding device, squeegee device, and correction device to adjust the relative position between the board and mask.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If print state inspection is performed for each board printed, then manufacturing precision is improved, but productivity deteriorates due to increased cycle time
Solution Approach 1:
The inspection frequency is made dynamic rather than fixed. The system automatically adjusts inspection timing based on detected changes in manufacturing conditions (such as board material changes, mask changes, or squeegee pressure changes). When changes are detected, inspection frequency increases; when conditions are stable, inspection frequency decreases. This dynamic adjustment resolves the contradiction by optimizing the balance between quality assurance and productivity.
Solution Approach 2:
The system changes the parameter of inspection frequency based on manufacturing conditions. Instead of a fixed inspection rate (either every board or never), the inspection frequency parameter is adjusted according to detected changes in board properties, mask status, or printing parameters. This allows the system to maintain high precision when needed while preserving productivity during stable production phases.
2Productivity
If inspection frequency is reduced to maintain productivity, then cycle time is improved, but manufacturing precision deteriorates due to insufficient quality control
Solution Approach 1:
The system implements feedback mechanisms that continuously monitor manufacturing conditions (board material, mask status, squeegee pressure, printing parameters) and use this information to dynamically adjust inspection frequency. When feedback indicates a change in conditions that may affect print quality, the system automatically increases inspection frequency to maintain precision while minimizing impact on productivity.
Solution Approach 2:
The system performs self-monitoring of manufacturing conditions and self-adjustment of inspection frequency without requiring external intervention. The screen printer automatically detects changes in board properties, mask status, or printing parameters and autonomously decides when inspection is necessary, enabling the system to maintain quality control while optimizing productivity.
3Device complexity
If preset inspection conditions are used, then device complexity is reduced, but adaptability deteriorates due to inability to respond to changing manufacturing situations
Solution Approach 1:
The system replaces complex preset inspection condition configurations with an automated detection system that uses sensors and image processing to monitor manufacturing conditions. Instead of requiring operators to set up complex inspection parameters for different scenarios, the system automatically detects changes in board material, mask status, and printing parameters, substituting mechanical configuration complexity with automated sensing and decision-making.
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A screen printer comprising: a board positioning device configured to convey and hold a board to a work position in the screen printer; a mask holding device configured to hold a mask above the work position; a squeegee device configured to spread a cream solder on a mask on the board; a correction device configured to correct a relative position between the board of the board positioning device and the mask of the mask holding device; a control device configured to acquire inspection data of a print state from a print inspection device provided inside or outside the screen printer and perform correction control on the correction device by a correction value corrected according to a deviation amount of printing based on the inspection data; and an input device configured to include an instruction input section that senses an inspection instruction operation of an operator and transmit, to the control device, an inspection data acquisition signal for acquiring the inspection data of the print state from the print inspection device based on an instruction operation of the operator to the instruction input section.