Suction Nozzle Imaging for Component Mounting Reliability
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Solution Overview
Problem
In component mounting devices with rotary heads, the existing configuration requires both an optical system unit and a light sensor for nozzle replacement confirmation, which can interfere with mounted components, especially large ones, leading to increased costs due to the need for a mechanism to retract the light sensor.
Innovation Solution
A component mounting method that uses an imaging device with one image sensor and an optical system unit to capture side surface images of three suction nozzles, allowing image processing to confirm component suction and mounting operations without the need for a light sensor, by forming non-overlapping side surface images on the image sensor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a light sensor is used for nozzle replacement confirmation, then nozzle replacement operation can be confirmed, but the light sensor interferes with large components already mounted on the circuit board
Solution Approach 1:
The patent extracts the nozzle replacement confirmation function from the light sensor and transfers it to the imaging device. The imaging device captures images of the suction nozzle at the nozzle replacement position, and image processing determines whether the suction nozzle is present or absent, replacing the light sensor's function without causing interference to mounted components.
Solution Approach 2:
The imaging device is given multiple functions: it captures images for component suction and mounting operation confirmation, and also captures images for nozzle replacement confirmation. This eliminates the need for a separate light sensor and reduces system complexity.
2Object-affected harmful factors
If a mechanism is added to retract the light sensor, then interference with large components is avoided, but device complexity and cost increase
Solution Approach 1:
The patent removes the light sensor entirely from the system and replaces its function with image processing. This eliminates the need for any retract mechanism, significantly reducing device complexity and cost while maintaining the ability to confirm nozzle replacement operations.
3Reliability
If both optical system unit and light sensor are mounted on the side of suction nozzles, then both component suction/mounting confirmation and nozzle replacement confirmation are enabled, but the configuration becomes complex and costly
Solution Approach 1:
The imaging device performs multiple confirmation functions: it captures images to confirm component suction and mounting operations, and also captures images to confirm nozzle replacement operations. This multi-functional approach eliminates the need for separate light sensors and reduces overall system complexity.
Solution Approach 2:
The patent merges the nozzle replacement confirmation function with the component suction and mounting confirmation function by using the same imaging device for both purposes. This consolidation reduces the number of components and simplifies the system architecture.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This configuration enables confirmation of both component suction and mounting operations and nozzle replacement at a relatively low cost, eliminating the necessity for a light sensor and reducing interference with mounted components.
Implementation Method 1
an imaging device which collectively captures a side surface image of at least a portion of the suction nozzle which is raised in order to carry out a component suction and mounting operation or a nozzle replacement operation
Data Source
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AI summary
A component mounting device is provided with an imaging device 41, which out of a plurality of suction nozzles 13 that are held by a rotary head 11 on the component mounting device, collectively captures a side surface image of the suction nozzle 13(B) that is raised and a side surface image of two suction nozzles 13 (A, and C) which are positioned at both sides of the suction nozzle 13(B), in order to carry out a component suction and mounting operation or a nozzle replacement operation. An imaging device 41 has one image sensor 42 and an optical system unit 43 that forms side surface images of an imaging target part of each of three suction nozzles 13 (A, B, and C) on a light-receiving surface of the image sensor 42 such that the side surface images do not overlap. The images of the two suction nozzles 13(A, and C) which are positioned on both ends of the row of the three suction nozzles 13 (A, B, and C) which are captured as imaging targets during the component suction and mounting operation are processed so as to confirm whether or not the suction nozzles 13 (A, and C) suck a component and the suction posture of the components. The image of the suction nozzle 13 which is positioned at the middle of the three suction nozzles that is captured during nozzle replacement, is processed as an imaging target to recognize the presence or absence of the suction nozzle 13.