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User Manual Line Computer UNIX 11 Production Tools / Optimization Software Version 501.xx 01/99 Issue 11.3 Setup Optimization 11 - 13 ● Nozz le Changer and M anual Tray A nozz le change r for th e revolver h ead and a ma…
11 Production Tools / Optimization User Manual Line Computer UNIX
11.3 Setup Optimization Software Version 501.xx 01/99 Issue
11 - 12
11.3.3.5 Machine Restrictions Taken Into Account
In the Setup Optimization the following restrictions relating to the IC head or turret head have been taken into
account for the following procedures:
IC Head
● External mechanical centering
If a component is to be centered by means of the external mechanical centering station it may only be placed
by the IC head if an external mechanical centering station is available that can be accessed by the head.
● External optical centering
If a component is to be centered by means of the external optical centering station, it may only be placed
by the IC head if an external optical centering station is available that can be accessed by the head. Moreover,
at least one sensor type contained in the package form description of the component (see chapt. 6) must
be identical to the sensor type of the optical centering station.
● Coplanarity Measurement
If a coplanarity measurement is to be performed on the component, and if a coplanarity module is available
on the line, the component may only be placed by the IC head if the coplanarity module can be accessed
by the head. Moreover, at least one sensor type contained in the package form description of the component
(see chapt. 6) must be identical to the sensor type of the coplanarity module. If no coplanarity module is
available on the line, the component may be placed by the IC head without these restrictions applying.
● IC Disposal by Means of Disposal Belt
If in the case of faults the component is to be disposed of on a disposal belt and if such a device is available
on the line, the component may only be placed by the IC head if the IC disposal belt can be accessed by
the head. If no IC disposal belt is available on the line, it may be placed by the IC head without this restriction
applying.
Turret Head
● Centering on the head by means of jaws
If the component is to be centered on the head, it may only be placed by the turret head if the head is
equipped with jaws.
● Centering by means of head camera
If the component is to be centered by means of a head camera, it may only be placed by the turret head if
a camera is available on the head. Moreover, at least one sensor type contained in the package form
description of the component (see chapt. 6) must be identical to the sensor type of the head camera.
● CRDL Test
If the components requires electrical testing, it may only be placed by the revolver head if a CRDL measuring
system (measuring jaws, measuring board) is available at the head. If no CRDL measuring system is
available on the line the component can be placed without any restrictions to be observed. A corresponding
warning will be displayed.
User Manual Line Computer UNIX 11 Production Tools / Optimization
Software Version 501.xx 01/99 Issue 11.3 Setup Optimization
11 - 13
● Nozzle Changer and Manual Tray
A nozzle changer for the revolver head and a manual tray must never be set up simultaneously on one side.
● Feeders at the Border Regions of Feeder Parts
Certain feeders must not be set up in the border region of feeder parts as otherwise the component
pick-up divisions are located outside the travel range. This is taken into account.
11.3.3.6 Capacities Taken Into Account For Setup Optimization
● For setup optimization the following capacities are taken into account:
● All feeder types known to the system are supported irrespective of the head type.
● The space available (track allocation) to the feeder parts must not be exceeded.
● Allowance is made for the individual space requirements of each feeder and each module. Each
compartment of a feeder can be assigned components. Feeders requiring modules for their setting
up in the feeder part are placed into modules.
Waffle-pack magazines are placed onto waffle-pack tray carriers.
IC Head
● The IC head can access all feeder parts that lie within the reach of its portal.
Turret Head
● The turret head can access all feeder parts that lie within the reach of its portal with the exception of the
Waffle-Pack Changer feeder part.
11.3.3.7 Inclusion of Feeders in Clustering
As soon as more than one setup is calculated, setup changeover operations between setups play a role.
Optimization takes these setup changeover operations into account. Each feeder of the initial setup which is
not set up in the follow-up setup with the same component type on the same track, is considered a feeder setup
changeover operation. In this case, the time expended for the setup changeover is merely the time required for
exchanging the previous feeder for the new feeder. The feeders themselves are considered as having been
preset with the respective component type.
The setup changeover time per feeder can be entered together with the optimization parameters (see section
11.4.3.1).
Effects:
- Short setup changeover time: More feeders are set up in the fixed feeder part.
- Long setup changeover time: Fewer feeders are set up in the fixed feeder part.
11 Production Tools / Optimization User Manual Line Computer UNIX
11.3 Setup Optimization Software Version 501.xx 01/99 Issue
11 - 14
11.3.3.8 Inclusion of Changeover Tables in Clustering
As soon as more than one setup is calculated, setup changeover operations on changeover tables play a role.
A changeover table denotes a feeder part that can be completely exchanged by means of a lift-truck. The
feeders are considered as being preset thus not causing any increase in the setup changeover effort.
Optimization proceeds from the assumption that the setup changeover time to be expended for feeder parts
that are identified as changeover table only consists of the changeover time of the changeover table irrespective
of the number of feeders whose setup is to be changed.
The identification of the feeder parts as changeover tables can be performed in the Configuration Editor for the
stations (see chapt. 12, section 12.1).
The setup changeover time can be entered together with the optimization parameters (see section 11.4.3.1).
Effects:
- Short setup changeover time: More feeders are set up in the fixed feeder part.
- Long setup changeover time: More feeders are set up on the changeover table.
11.3.3.9 Inclusion of a Basic Time in Clustering
As soon as more than one setup is calculated, the basic time plays a role in the setup changeover procedure.
The basic time comprises the time elapsing between the last placement from the predecessor setup and the
first placement of the follow-up setup. The changeover times are not taken into account.
Effects:
- Short basic time: More setups are created. The focus of the changeover procedures is placed on the
changeover tables.
- Long basic time: As few setups as possible are created. Setup changeover operations on fixed
feeder parts are permitted.
11.3.3.10 Handling of Dominant Components
If the placement time of a component on a given PCB type is so high owing to its high usage frequency that
the production of the PCB would result in an imbalance even if the fastest placement head were used, such a
component must be supplied in feeders on several stations of the line. The placement positions associated with
the component can be distributed among the stations thus preventing an imbalance of the line from occurring.
The number of feeders required for the dominant component depends on
- the proportion of the imbalance
- the number of placement positions
- and the number of heads by means of which the component can be placed.
However, if a dominant component is not to be set up any number of times, e.g. because a sufficient number
of feeders is not available, the number of feeders per component type can be restricted. This has the advantage
that a component type occupies only a limited number of feeder locations. However, this may result in an
increase of the production time since the components are not always located at the most advantageous
locations. Moreover, several setup clusters („families“) may under certain circumstances be calculated even
though one single setup would have sufficed.
This setting is to be set in the standard/job parameters by means of the „Maximum number if dominant“
parameter (see section 11.4.3.1).