Suction Nozzle Imaging for Real-Time Mounting Data
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Solution Overview
Problem
The existing methods for creating mounting data for board production are time-consuming and labor-intensive, requiring preparation of component data and sequence data in advance, which hinders efficient production of testing or trial boards.
Innovation Solution
A mounting data creating device that includes a suction nozzle, imaging devices, and a robot to create top and bottom shape data of components, allowing for automatic positioning and mounting without pre-prepared data, using a robot to move the mounting head relative to the board in the XY plane and designating mounting positions based on imaged data.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If component data and sequence data are prepared in advance using existing methods, then mounting data can be created for board production, but the process becomes time-consuming and labor-intensive
Solution Approach 1:
The system performs self-service by automatically capturing component images during the mounting process itself, eliminating the need for separate pre-preparation of component data. The mounting head with imaging device captures top and bottom views of components as they are being mounted, and the system automatically processes these images to extract mounting parameters and generate mounting data in real-time
Solution Approach 2:
The system performs preliminary actions by pre-capturing component images and pre-processing them to create component data before actual mounting operations begin. The imaging device captures component images in advance during setup, and the control unit processes these images to pre-generate component data including shape, size, and mounting parameters, which are then stored for use during production
2Ease of manufacture
If manual preparation of component data is performed outside the device, then component information can be obtained, but the process requires additional manual operations and increases complexity
Solution Approach 1:
The system merges the component data creation function with the mounting head assembly by integrating an imaging device directly into the mounting head. This allows the same hardware used for mounting components to also capture images and create component data, eliminating the need for separate manual data preparation processes and external devices
Solution Approach 2:
The mounting head is designed with multi-functionality, serving both as a mounting mechanism and as an imaging device for component data creation. The control unit also performs multiple functions by processing captured images to extract component parameters, generate mounting data, and control the mounting process, replacing multiple separate systems with a single integrated unit
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 approach significantly reduces the number of processes required for board production by enabling the creation of mounting data in real-time, allowing for faster and more efficient production of boards without the need for pre-prepared component or sequence data.
Implementation Method 1
a suction nozzle for sucking the component
Implementation Method 2
a first imaging device that is configured to image the component set on the component setting table, from above, a second imaging device that is configured to image the component sucked by the suction nozzle
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
There are provided a top shape data creating unit S106 that creates component top shape data, based on top shape image data of a component P imaged by a first imaging device 29, a suction nozzle positioning unit S108 that positions a suction nozzle 32 at a component suction position by moving a robot R1, based on the component top shape data created by the top shape data creating unit, a bottom shape data creating unit S114 that creates component bottom shape data based on bottom shape image data of the component imaged by a second imagining device 35, a mounting position designation unit S116 that designates a position for mounting the component on a board B, and a mounting data creating unit S126 that creates mounting data for mounting the component on the board, based on component data having top shape data and bottom shape data which are created by the top shape data creating unit and the bottom shape data creating unit, and data of the component mounting position designated by the mounting position designation unit.