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11 Production Tools / Optimization User Manual Line Computer UNIX 11.1 Fundamental Inf ormation Software Version 501.xx 01/99 Issue 11 - 2 - Auxiliary units su ch as - nozzl e chan ger - compone nt dispos al - CRDL me as…
User Manual Line Computer UNIX 11 Production Tools / Optimization
Software Version 501.xx 01/99 Issue 11.1 Fundamental Information
11 - 1
11 Production Tools / Optimization
11.1 Fundamental Information
Set-up optimization can considerably increase the performance of a placement line consisting of SIEMENS
placement stations. In some cases an increase of the placement performance by 50% could be achieved
following the use of set-up optimization. Set-up optimization aims at attaining an optimal utilization rate of all
stations of a line and for each PCB scheduled. Beyond that, set-up optimization relieves the customer of the
task of having to create a setup with the aid of the Setup Editor. Set-up optimization is a tool that should be
used in the planning phase. This tool is not suited for any uncoordinated setup generation, since even the
smallest changes made to the output data may lead to completely different setup results. The most favorable
results can be achieved by carefully updating the input data so that they are in perfect condition and not modifying
them after a setup has been generated. Even the smallest change such as, for example, deleting or entering
a new nozzle type in a package form description, will result in a completely different setup.
Set-up optimization takes the following factors into account:
- any line configuration comprising the station types
- SIPLACE 80S
- SIPLACE 80F
- HS180
- Waffle-Pack Changer at HS180 or SIPLACE 80F
- all placement heads that could possibly be encountered on the different types of stations, e.g.:
- revolver head for nozzle types of the 3xx, 6xx, 7xx and 8xx generations
- IC-head for the nozzle types of the 2xx and 4xx generations
- all SIEMENS feeders:
- feeders
- modules
- waffle-pack trays with associated waffle-pack tray carriers
- all feeder parts that may be encountered
- feeder parts that are treated as changeover tables
- dominant components
- vibration times per feeder
11 Production Tools / Optimization User Manual Line Computer UNIX
11.1 Fundamental Information Software Version 501.xx 01/99 Issue
11 - 2
- Auxiliary units such as
- nozzle changer
- component disposal
- CRDL measuring device
- all vision systems for component centering (sensor system types nos.: 2, 3, 6, 7, 8, 9, 11,12,13, 14, 17)
(the term „sensor system type“ denotes the vision system with camera and evaluation system)
- PCB centering
- component centering
- coplanarity system
- Component height in relation to the placement head height (so-called clearance height)
- Component height in excess of 12mm
- Correction values: correction values, if any, must be defined only once. They will then be referred to
whenever a new setup is to be created.
- The correction values for feeders are as follows:
- x,y,z,
- pick-up angle
- vibration time
- the following are added for waffle-pack trays:
- pitch n,m
- diagonal vector dx,dy
- Preset bindings and exclusions
- Specific non-productive times such as
- component measuring time as a function of the sensor system type
- changeover time of waffle-pack trays in the waffle-pack changer
- fiducial measuring time:
- for PCB position recognition
- for ink spot recognition
- for placement positions
- The accessibility of pick-up positions, placement positions and fiducials is checked and taken into account
- Collision conditions are taken into account, e.g.:
- nozzle changer and manual tray are not permitted to be set up on the same machine side
- waffle-pack changer on HS180 and movable feeder part are mutually exclusive
- given feeders are not permitted to be set up at the extreme edges
User Manual Line Computer UNIX 11 Production Tools / Optimization
Software Version 501.xx 01/99 Issue 11.1 Fundamental Information
11 - 3
Mathematically, the optimization problem belongs to the class of NP (NP - non-deterministic polynominal)
problems, i.e. the problem cannot be solved by deterministic means in a finite time.
To get an idea of the magnitude of the optimization problem, some maximum figures that must be reckoned
with in extreme cases are listed below:
100 PCBs per optimization job
3000 placement positions per PCB
1000 different components
6 placement stations per line
5 different station types and system components
33 different feeders and waffle-pack trays
5 different placement heads
2 different head types
6 different auxiliary units
The objective of set-up optimization is as follows:
11.1.1 Functionality Extension
Optimization has been extended by the „Setup clustering“ functionality.
Unlike before, when the optimization run used to be aborted together with the release of the error message
„Insufficient line capacity“ more than one setup is now being calculated. To this end, the PCBs are combined
into clusters that can be assembled with the same setup. Not only the aforementioned clustering is performed
but also the changeover operations taking place between the setups are taken into account.
In this way, the entire machine running time (= production time + non-productive time) of an SMT line can now
be optimized for the first time.
"Setup clustering" is available as an additional option.
The minimization of both the total of all production times of all scheduled PCBs and the total of
the changeover times between setups of a line of any configuration.