The difference between dual-gantry and single-gantry surface-mount placement (SMP) machines is that dual-gantry machines exhibit higher complexity and more problems due to their additional gantry robot, such as component allocation and collision. This paper presents algorithms to prescribe the assembly operations of a dual-gantry multi-head surface-mount placement machine. It considers five inter-related problems: (i) component allocation; (ii) automatic nozzle changer assignment; (iii) feeder arrangement; and (iv) pick-and-place sequence; it incorporates a practical restriction related to (v) component height. The paper proposes a solution to each problem: (i) equalizing “workloads” assigned to the gantries, (ii) using quantity ratio method, (iii) using two similarity measurement mechanisms in a modified differential evolution algorithm with a random-key encoding mapping method that addresses component height restriction, (iv) and a combination of nearest-neighbor search and 2-opt method to plan each placing operation. This study reports an experiment that involved the processing of 10 printed circuit boards and compared the performance of a modified differential evolution algorithm with well-known algorithms including differential evolution, particle swarm optimization, and genetic algorithm. The results reveal that the number of picks, moving distance of picking components, and total assembly time with the modified differential evolution algorithm are less than other algorithms.
Component Placement Process Optimization for Multi-head Surface Mounting Machine Using a Hybrid Algorithm