Substrate Working Machine Position Calibration
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Solution Overview
Problem
Calibration processes in substrate working machines for bending leads of leaded components often decrease productivity due to the need for manual matching and calibration of specified members, which can be overlooked or performed unnecessarily.
Innovation Solution
A substrate working machine with a bending device that uses image data to calculate the position of a contacting section's attachment on a main body section, determining if a threshold difference exists between calculated and set positions, and performing calibration only when necessary to prevent unnecessary calibration and maintain productivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If calibration is performed frequently to ensure positioning accuracy of the contacting section, then manufacturing precision is improved, but productivity decreases due to time loss from repeated calibration operations
Solution Approach 1:
The system captures image data of the contacting section, calculates its actual attachment position, compares it with the set position, and performs calibration only when the difference exceeds a threshold value. This feedback mechanism enables intelligent decision-making about when calibration is necessary, avoiding unnecessary calibration operations while maintaining positioning accuracy.
Solution Approach 2:
The system automatically determines whether calibration is needed by comparing calculated position information with set position information, eliminating the need for manual judgment or frequent scheduled calibration. The machine serves itself by autonomously deciding when calibration operations should be performed based on actual position deviations.
2Manufacturing precision
If manual calibration operations are performed to match the specified member with the lead, then positioning accuracy is improved, but the complexity of operation increases and human error may occur
Solution Approach 1:
The system replaces manual mechanical calibration operations with an automated image processing and calculation system. The controller automatically captures images, calculates attachment positions, compares positions, and performs calibration when needed, eliminating manual intervention and reducing operational complexity and human error.
Solution Approach 2:
The system autonomously performs the entire calibration determination process without human intervention. The controller automatically captures image data, calculates positions, compares deviations, and executes calibration operations when necessary, making the machine self-sufficient in maintaining positioning accuracy.
Data Source
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AI summary
Movable section 122 of a cut and clinch unit includes exchange section 144 in which is formed second insertion hole 136 for cutting and bending a lead, and main body section 143 to which exchange section 144 is removably attached. An opening position of the second insertion hole is calculated as an attachment position of the exchange section on the main body section based on image data. It is determined whether a difference between the calculated opening position and a standard position of the second insertion hole that is set in advance exceeds a threshold value. Here, if the difference between the calculated opening position and the standard position exceeds the threshold value, calibration is performed based on the assumption that the exchange section has been exchanged. That is, calibration is only performed in a case in which there is a concern about a deviation in the opening position of the second insertion hole due to the exchange section having been exchanged. Thus, calibration is only performed when required, and unnecessary drops in productivity are prevented.