Two-Step Component Mounting via Suction Nozzle

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Solution Overview

Problem

Component mounting systems that use suction nozzles to fit pin insertion type components on substrates often result in abnormal postures due to uneven insertion pin force, caused by nozzle displacement, leading to incomplete insertion of pins into holes.

Innovation Solution

A method and system that involves a two-step process: initial fitting of components using a suction nozzle to position pins into holes, followed by a secondary push to ensure complete insertion, with optional inspection and use of different nozzles for correction, to prevent abnormal postures.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If a suction nozzle is used to fit pin insertion type components on substrates, then versatility of the component mounting apparatus is improved, but insertion pins may not be uniformly pushed, causing abnormal component postures

Engineering Contradiction:

Improveversatility of component mounting apparatusVSAvoidinsertion pin alignment precision

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The component mounting process is divided into two distinct phases: a first pushing process for initial component placement, and a second pushing process for correction. This segmentation allows each phase to address specific requirements - the first phase achieves basic positioning while the second phase corrects alignment errors, thereby resolving the contradiction between versatility and precision.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The first pushing process performs preliminary component placement before the second pushing process refines the positioning. By performing the initial placement action first, the system establishes a baseline position that can then be corrected, allowing the suction nozzle to handle diverse components while subsequent correction ensures precision.

Inventive Principle:

Principle #10Preliminary action

2Productivity

If component pushing force does not uniformly act on all insertion pins, then component fitting speed is improved, but insertion pins may be insufficiently inserted, causing abnormal postures

Engineering Contradiction:

Improvecomponent fitting speedVSAvoidinsertion pin insertion reliability

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The component pushing is performed in periodic cycles: first pushing process followed by inspection, then second pushing process for correction if needed. This periodic action allows rapid initial placement while ensuring reliability through repeated verification and correction cycles, resolving the contradiction between speed and reliability.

Inventive Principle:

Principle #19Periodic action

Solution Approach 2:

An inspection step is introduced between the first and second pushing processes to detect abnormal component postures. This feedback mechanism identifies components that require correction, allowing the system to maintain high productivity by only applying additional pushing force when necessary, thus ensuring reliability without sacrificing overall efficiency.

Inventive Principle:

Principle #23Feedback

3Productivity

If a single pushing action is used to fit components, then manufacturing efficiency is improved, but abnormal postures occur due to insufficient pin insertion

Engineering Contradiction:

Improvemanufacturing efficiencyVSAvoidcomponent posture accuracy

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The single pushing action is segmented into multiple pushing processes with an inspection step in between. This segmentation maintains manufacturing efficiency by using a quick first push for most components while applying a second push only when inspection detects abnormalities, thereby achieving both efficiency and precision.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The second pushing process is applied selectively to specific components that are detected to be in abnormal postures, rather than applying additional pushing to all components. This local quality approach ensures precision where needed while maintaining overall manufacturing efficiency by avoiding unnecessary operations on correctly positioned components.

Inventive Principle:

Principle #3Local quality

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

Ensures complete insertion of pins into holes, preventing abnormal postures and ensuring secure component mounting on the substrate.

Implementation Method 1

sucks the component by a suction nozzle

Methodology Applied

Scientific EffectSuction: Suction

Data Source

PatentUS9699945B2Component mounting method which fits and pushes component on substrate

Publication Date: 2017.07.04 PANASONIC INTELLECTUAL PROPERTY MANAGEMENT CO LTD

AI summary

There is provided a component mounting method for fitting a component including downwardly-extending insertion pins on a substrate by sucking the component by a suction nozzle and moving the suction nozzle such that the insertion pins of the sucked component are inserted into pin insertion holes formed in a substrate. The component mounting method includes: positioning the insertion pins and the pin insertion holes, and then pushing the component against the substrate by the suction nozzle, thereby fitting the component on the substrate such that the insertion pins are inserted into the pin insertion holes; and pushing again the component against the substrate after the component is fitted on the substrate, so as to push the insertion pins into the pin insertion holes.