Component Mounting System Staged Feeder Storage

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Solution Overview

Problem

Existing component-mounting systems face challenges in efficiently managing and replenishing a large number of component supply units, particularly in small-volume productions that require frequent replacements.

Innovation Solution

A component-mounting system with multiple stages of storage units and two unit moving devices, where the first device exchanges supply units between storage and machine stages, and the second device manages supply unit allocation and collection across different stages, supported by an automatic conveyance system and a management device for efficient inventory control.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If a large number of component supply units are stored in the unit storage container, then the system can handle small-volume productions more efficiently, but the device complexity increases due to multiple stages and moving devices

Engineering Contradiction:

Improvehandling efficiency of component supply unitsVSAvoidstructure complexity of storage and conveyance system

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The unit storage container is divided into multiple stages (first stage, second stage, third stage) with each stage having specific functions. The first stage stores component supply units, the second stage receives units from mounting machines, and the third stage stores collected units. This segmentation allows efficient management of numerous component supply units while organizing the complexity into manageable sections.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The unit storage container acts as an intermediary between component mounting machines and the external environment. It receives component supply units from machines via the second stage and supplies them back through the first stage, while the automatic conveyance device handles external replenishment. This intermediary role simplifies the interaction between machines and reduces direct complexity at each machine station.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Extent of automation

If multiple unit moving devices are used to exchange component supply units, then the automation level increases, but the device complexity and cost increase

Engineering Contradiction:

Improveautomatic exchange of component supply unitsVSAvoidnumber of moving devices

Core Design Contradiction:

Extent of automationVSDevice complexity

Solution Approach 1:

The unit moving device serves multiple functions: it exchanges component supply units between mounting machines and the first stage, transfers units between stages within the unit storage container, and works coordination with the automatic conveyance device. This multi-functionality reduces the need for separate dedicated mechanisms for each task, thereby reducing overall device complexity while maintaining high automation.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent combines the storage function and the moving/exchange function into an integrated unit storage container system. The container not only stores component supply units but also incorporates the moving device that exchanges units between stages and with mounting machines. This merging of functions reduces the total number of separate devices needed in the system.

Inventive Principle:

Principle #5Merging (Combining)

3Adaptability or versatility

If component supply units are frequently replaced for small-volume productions, then production flexibility improves, but the loss of time for replacement operations increases

Engineering Contradiction:

Improveproduction variety capabilityVSAvoidtime for component supply unit replacement

Core Design Contradiction:

Adaptability or versatilityVSLoss of time

Solution Approach 1:

The unit storage container pre-stores multiple component supply units in the first stage before they are needed. When a mounting machine needs a component supply unit, it is immediately available from the first stage without requiring external replenishment or manual search. This preliminary preparation of component supply units eliminates waiting time during production changeovers.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system maintains continuous availability of component supply units through the staged storage structure. While one unit is being used by a mounting machine, other units are already positioned in the first stage ready for immediate exchange. The automatic conveyance device continuously replenishes the first stage from external sources, ensuring uninterrupted supply and eliminating idle time during replacements.

Inventive Principle:

Principle #20Continuity of useful action

Data Source

PatentEP3780929B1Component mounting system

Publication Date: 2023.05.24 FUJI CORP

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AI summary

Component-mounting system 10 includes multiple component mounting machines 20 disposed along a board conveyance direction; feeder storage container 60 for storing multiples of feeders 30, which are capable of being attached/detached to and from component mounting machines 20, in each stage among multiple stages; first feeder moving robot 50 capable of exchanging feeder 30 between the lowest stage (i.e., specific stage) among multiple stages of feeder storage container 60 and component mounting machine 20; and second feeder moving robot 70 capable of exchanging feeder 30 between the lowest stage (i.e., a specific stage) among multiple stages of feeder storage container 60 and the other stages (i.e., non-specified stages).