Simultaneous Nozzle Exchange in Component Mounting Machines
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Solution Overview
Problem
Existing component mounting machines face inefficiencies in nozzle exchange processes, leading to production stoppages and reduced productivity due to the increasing complexity of handling various component types, which requires frequent nozzle changes.
Innovation Solution
A component mounting machine with a head having multiple holders for detachable suction nozzles, a moving device for horizontal movement, a lifting and lowering device for independent holder control, a nozzle accommodation container, and a nozzle exchange control device that enables simultaneous nozzle exchange and replacement, allowing for efficient management of suction nozzles without stopping production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple types of suction nozzles are accommodated in the nozzle accommodation container, then the adaptability to different component types is improved, but the device complexity increases due to the need for automated exchange mechanisms
Solution Approach 1:
The nozzle accommodation container is divided into multiple accommodation sections, each capable of independently holding different types of suction nozzles. This segmentation allows the system to accommodate various component types while maintaining organized, modular storage that simplifies the exchange process.
Solution Approach 2:
The nozzle accommodation container serves multiple functions: it stores multiple types of suction nozzles, provides automated exchange capabilities, and maintains readiness for different component types. This multi-functionality reduces the need for separate storage systems for each nozzle type.
2Productivity
If automated nozzle exchange is implemented, then the productivity is improved by reducing manual intervention, but the device complexity increases due to additional control mechanisms
Solution Approach 1:
Suction nozzles are pre-accommodated in the nozzle accommodation container before the exchange is needed. The container is prepared in advance with the required nozzle types, allowing the exchange mechanism to simply retrieve and install the correct nozzle without complex real-time decision-making or preparation steps.
Solution Approach 2:
The holder is equipped with mechanisms that enable it to automatically retrieve suction nozzles from the accommodation container and mount them without external assistance. The holder itself performs the exchange operation, reducing the need for additional complex control systems.
3Loss of time
If rapid nozzle exchange is achieved, then the loss of time during production is reduced, but the device complexity increases due to faster actuation mechanisms
Solution Approach 1:
The moving device and lifting and lowering device are integrated into a coordinated system that performs horizontal movement and vertical positioning in a unified exchange operation. This merging of functions allows rapid exchange without requiring separate complex mechanisms for each motion type.
Solution Approach 2:
The nozzle exchange process is designed to be continuous and seamless, with the holder moving horizontally to the accommodation container, retrieving the nozzle, and returning to the mounting position without interruption. This continuous action minimizes exchange time while using simple, reliable motion paths.
Data Source
AI summary
A component mounting machine including a head having two right and left nozzle holders to which suction nozzles are detachably attached, and a nozzle station having multiple sockets for accommodating the suction nozzles. The multiple sockets are arrayed at the same interval as an interval of the right and left nozzle holders. The suction nozzles mounted on the right and left adjacent nozzle holders can be simultaneously returned to right and left empty sockets, and the suction nozzles accommodated in the right and left adjacent sockets can be simultaneously mounted on the right and left nozzle holders.