Automatic Feeder Configuration Support System and Automatic Feeder Configuration Support Program

Abstract

The configuration support system (10) of the automatic feeder according to the present disclosure is a configuration support system (10) of the automatic feeder in a component mounting line (1) including a component mounter, the component mounter having a component supply device (13) and a mounting head (32) that takes out components from a component supply tape and mounts them on a substrate. The configuration support system (10) of the automatic feeder includes: a component depletion time calculation unit (132) that calculates component depletion time data (137D) based on production plan data (137A) of the substrate (B) and substrate data (137B); and a component depletion detection unit (133) that performs a simulation and detects the presence or absence of component depletion based on the component depletion time data (137D) and available operation time data (137E) associated with the replenishment operation of the manual feeder (18).

Description

Technical Field

[0001] The present invention relates to a configuration support system for an automatic feeder and a configuration support program for an automatic feeder. Background Art

[0002] A component mounting line for producing a mounted substrate by mounting components on a substrate is constituted by connecting a plurality of component mounters. In each component mounter, the component mounting operation of taking out a component from a component feeder assembled in a component supply unit and transferring and mounting it on a substrate is repeatedly performed. During the continuous execution of the component mounting operation, a component replenishment operation of replenishing the component feeder with components in correspondence with the timing when the components are consumed and become component depletion is repeatedly performed.

[0003] For the purpose of performing this component replenishment operation at an appropriate timing, methods such as notifying the occurrence time of component depletion predicted in advance by simulation calculation are used. Here, in the case where there are a large number of component feeders approaching the component depletion time, if the component replenishment operation for the component feeder is started after displaying a "normal warning", there may be a component feeder in which the operation is not completed and the components are depleted.

[0004] Therefore, for example, in the component replenishment support method described in Japanese Patent Application Laid-Open No. 2016-225385 (Patent Document 1 below), the warning exploration start time is set as the time to start exploring whether to display an "early warning" for promoting early component replenishment of the component feeder and a warning of "insufficient man-hours" for prompting an operator to initiate a support request before the "normal warning". The target feeder selection unit selects a feeder whose component depletion time is between the warning start time and the warning exploration start time as a selected feeder that becomes the target of exploration for the "early warning" or the warning of "insufficient man-hours".

[0005] Prior Art Documents

[0006] Patent Documents

[0007] Patent Documents

[0008] Patent Document 1: Japanese Patent Application Laid-Open No. 2016-225385 Summary of the Invention

[0009] Problems to be Solved by the Invention

[0010] The above-described component supply support method merely simulates the splicing operation in a manual feeder to predict the component depletion time. The so-called splicing operation in a manual feeder is an operation of splicing a new component supply tape to the end portion of the component supply tape currently being supplied, using a splicing tape. Since splicing requires skills to be mastered in the supply operation, the installation line may sometimes stop due to human error, which is one of the reasons for reducing production efficiency. As a countermeasure, an automatic feeder has been developed that automates the supply operation by automatically loading a new component supply tape. However, although the introduction of the automatic feeder can improve the operation efficiency (shorten the operation time), it cannot effectively utilize the automatic feeder in terms of operation planning (optimization of the automatic feeder configuration).

[0011] Technical solution for solving the problem

[0012] The automatic feeder configuration support system of the present disclosure is a configuration support system for an automatic feeder in a component mounting line including a component mounter. The component mounter includes: a component supply device capable of placing an automatic feeder and a manual feeder. The automatic feeder holds a plurality of components in advance on a component supply tape formed by a tape, and supplies a new component supply tape while the currently supplied component supply tape is depleted, thereby performing a supply operation. The manual feeder performs a supply operation by splicing a new component supply tape to the end portion of the currently supplied component supply tape. And a mounting head that takes out the component from the component supply tape and mounts it on a substrate. Among them, the automatic feeder configuration support system includes: a component depletion time calculation unit that calculates component depletion time data based on the production plan data of the substrate and the substrate data; and a component depletion detection unit that performs a simulation and detects the presence or absence of component depletion based on the component depletion time data and the operable time data associated with the supply operation of the manual feeder.

[0013] Effect of the invention

[0014] According to the present disclosure, as an advantage of introducing an automatic feeder, operation planning can be achieved. Description of the drawings

[0015] Figure 1 It is a diagram showing the overall structure of a component mounting line.

[0016] Figure 2 It is a top view of a component mounter.

[0017] Figure 3 It is a front view of a component mounter.

[0018] Figure 4 It is a side view of an automatic feeder.

[0019] Figure 5 It is a side view showing an enlarged view of the rear delivery section in the automatic feeder.

[0020] Figure 6 It is a perspective view showing the support method (1) of the component supply belt associated with the loading and unloading of the clamping member.

[0021] Figure 7 It is a perspective view showing the support method (2) of the component supply belt associated with the loading and unloading of the clamping member.

[0022] Figure 8 It is a block diagram showing the electrical structure of the component mounter.

[0023] Figure 9 It is a block diagram showing the electrical structure of the management server.

[0024] Figure 10 (A) is a table showing the production quantity of substrate A and the components used, etc. Figure 10 (B) is a table showing the feeder used for substrate A and the remaining components, etc.

[0025] Figure 11 It is a diagram showing the component depletion timing diagram.

[0026] Figure 12 (A) is a diagram that assigns an operable time to the component depletion timing diagram to simulate the presence or absence of component depletion. Figure 12 (B) is to simulate again when Figure 12 (A) changes the manual feeder that will become component depletion to an automatic feeder, showing the presence or absence of component depletion.

[0027] Figure 13 It is a diagram showing the component selection criteria for AF implementation in Embodiment 1.

[0028] Figure 14 It is a flowchart of the simulation in Embodiment 1.

[0029] Figure 15 It is a flowchart for detecting component depletion during replenishment operations.

[0030] Figure 16 It is a flowchart for selecting components to be AF - enabled to avoid component depletion.

[0031] Figure 17 It is a diagram showing the component selection criteria for AF implementation in Embodiment 2.

[0032] Figure 18 It is a diagram showing the component selection criteria for AF implementation considering the usage speed.

[0033] Figure 19This is an example of a display screen showing the usage status of AF.

[0034] Figure 20 This is a flowchart of the simulation in Embodiment 2.

[0035] Figure 21 This is a flowchart for selecting components to be AF - enabled to avoid component depletion.

[0036] Figure 22 This is a table showing a list of components held in the automated warehouse in Embodiment 3.

[0037] Figure 23 This is a flowchart of the simulation in Embodiment 3. Detailed Embodiments

[0038] [Description of Embodiments of the Present Disclosure]

[0039] First, the embodiments of the present disclosure will be listed and described.

[0040] (1) The configuration support system for an automatic feeder of the present disclosure is a configuration support system for an automatic feeder in a component mounting line including a component mounter. The component mounter includes: a component supply device capable of placing an automatic feeder and a manual feeder. The automatic feeder holds a plurality of components in advance on a component supply tape formed by a belt and replenishes a new component supply tape while the currently supplied component supply tape is depleted, thereby performing a replenishment operation. The manual feeder performs a replenishment operation by splicing a new component supply tape at the end of the currently supplied component supply tape. And a mounting head that takes out the components from the component supply tape and mounts them on a substrate. Among them, the configuration support system for the automatic feeder includes: a component depletion time calculation unit that calculates component depletion time data based on the production plan data of the substrate and the substrate data; and a component depletion detection unit that performs a simulation and detects the presence or absence of component depletion based on the component depletion time data and the available operation time data associated with the replenishment operation of the manual feeder.

[0041] In the above - mentioned system, it may also be that the manual feeder that will not be detected as having component depletion by the component depletion detection unit when changed from the manual feeder to the automatic feeder is cited as a candidate to be changed to the automatic feeder. If the automatic feeder is configured in such a way that component depletion is not detected, component depletion can be avoided in advance. Therefore, as an advantage of introducing the automatic feeder, the scheduling of operations can be achieved.

[0042] (2) In the above system, it is also possible that when the component depletion is detected by the component depletion detection unit, the component depletion detection unit performs simulation again to detect whether there is component depletion when the manual feeder is replaced with the automatic feeder.

[0043] The component depletion time data can be calculated by the component depletion time calculation unit, and simulation is performed to detect whether there is component depletion by the component depletion detection unit. Here, when component depletion is detected, the manual feeder can be replaced with an automatic feeder, and simulation is performed again to detect whether there is component depletion by the component depletion detection unit.

[0044] (3) It is also possible that the manual feeder in which the component depletion is detected by the component depletion detection unit is cited as a candidate to be changed to the automatic feeder.

[0045] In this way, component depletion can be reliably eliminated.

[0046] (4) It is also possible that the manual feeder associated with the manual feeder in which the component depletion is detected by the component depletion detection unit is cited as a candidate to be changed to the automatic feeder.

[0047] Here, "associated with the manual feeder in which component depletion is detected" means that whether or not it is the manual feeder in which component depletion is detected, it is cited as a candidate, including other manual feeders included in the specific peak described later.

[0048] For example, an automatic feeder can be applied to components that are effective in eliminating component depletion.

[0049] (5) Preferably, the manual feeder in which the component depletion is detected by the component depletion detection unit and the manual feeder associated with it are cited as candidates to be changed to the automatic feeder.

[0050] As the manual feeder to be changed to an automatic feeder, it can be reduced to the manual feeder in which component depletion is detected and the manual feeder associated with it.

[0051] (6) It is also possible that a peak detection unit is provided. When a period in which the available operation times adjacent to each other in the replenishment operation of the manual feeder overlap, or a period in which the available operation time overlaps with the time of an operation other than the replenishment of the manual feeder is defined as a peak, the peak detection unit performs simulation to detect whether there is such a peak, and the other manual feeders included in the peak including the manual feeder in which the component depletion is detected by the component depletion detection unit are cited as candidates to be changed to the automatic feeder.

[0052] It is possible to determine candidates for manual feeders that are to be changed to automatic feeders based on peaks.

[0053] (7) Preferably, in a case where an uninterrupted time period in which the available operation time of the manual feeder in which the component depletion is detected by the component depletion detection unit among the peaks overlaps with the available operation times of other manual feeders that are consecutive when traced back from this available operation time is defined as a specific peak, the peak detection unit detects the specific peak, and lists the other manual feeders included in the specific peak as candidates to be changed to the automatic feeder.

[0054] It is possible to narrow down the manual feeders to be changed to automatic feeders to other manual feeders in a specific peak.

[0055] (8) Preferably, in a case where multiple peaks are generated in the production plan, the manual feeder that encounters the most number of peaks is listed as a candidate to be changed to the automatic feeder.

[0056] It is possible to determine the manual feeder to be changed to the automatic feeder as the manual feeder that encounters the most number of peaks.

[0057] (9) Preferably, by repeatedly executing the configuration support system for the automatic feeder, a combination of the manual feeders to be replaced with the automatic feeder is determined from among the multiple manual feeders listed as candidates.

[0058] In this way, it is possible to determine a combination of manual feeders to be replaced with the automatic feeder.

[0059] (10) Preferably, the peak detection unit performs a simulation taking into account the non - available operation time to detect the presence or absence of a peak where component depletion occurs.

[0060] In this way, it is possible to detect the presence or absence of a peak where component depletion occurs while taking into account the non - available operation time.

[0061] (11) Preferably, the manual feeder to be changed to the automatic feeder is prompted on the display unit.

[0062] In this way, it is possible to confirm which manual feeder should be replaced through the display unit.

[0063] (12) Preferably, when prompting the manual feeder to be changed to the automatic feeder, the replacement deadline is also prompted on the display unit.

[0064] In this way, it is possible to confirm which manual feeder should be replaced by when through the display unit.

[0065] (13) Preferably, the component depletion detection unit obtains information from the component mounter each time during the production process and periodically performs simulations to detect whether there is component depletion.

[0066] In this way, the configuration of the automatic feeder can be determined according to the actual production situation.

[0067] (14) Preferably, the automatic feeder that uses a value equal to or less than a predetermined set value is cited as a candidate for replacement.

[0068] In this way, the automatic feeder can be effectively utilized.

[0069] (15) Preferably, when replenishing the component supply tape, simulations are performed using the actual remaining amount of the components.

[0070] In this way, it is possible to detect whether there is component depletion corresponding to the actual remaining amount of the components.

[0071] (16) The automatic feeder configuration support program of the present disclosure is configured as an automatic feeder configuration support program in a component mounting line including a component mounter. The component mounter includes: a component supply device capable of placing an automatic feeder and a manual feeder. The automatic feeder replenishes a new component supply tape while the currently supplied component supply tape is depleted by pre-holding a plurality of components on a component supply tape formed by a tape, thereby performing a replenishment operation. The manual feeder performs a replenishment operation by splicing a new component supply tape to the end of the currently supplied component supply tape; and a mounting head that takes out the components from the component supply tape and mounts them on a substrate. Among them, the automatic feeder configuration support program causes a computer to execute the following steps: calculate component depletion time data based on the production plan data of the substrate and the substrate data, perform simulations, and detect whether there is component depletion based on the component depletion time data and the available operation time data associated with the replenishment operation of the manual feeder, and cite the manual feeder that will not be detected as having component depletion by the component depletion detection unit when changing from the manual feeder to the automatic feeder as a candidate to be changed to the automatic feeder.

[0072] [Details of Embodiment 1 of the Present Disclosure]

[0073] Hereinafter, a specific example of the automatic feeder configuration support system 10 in the component mounting line of the present disclosure will be described with reference to the drawings. In addition, the present disclosure is not limited to these examples, but is shown by the scope of claims and is intended to include all changes within the meaning and scope equivalent to the scope of claims. Figure 1Among them, the component mounting line 1 has the function of manufacturing a mounted substrate by mounting components on a substrate, and is structured to connect devices such as a printing machine (not shown), component mounting machines M1 to M4, and a reflow soldering furnace M5 and connect them through a LAN (Local Area Network) 2, and is controlled as a whole by a management server 3.

[0074] The component mounting machines M1 to M4 perform component mounting operations of taking out components E from respective feeders 16 arranged in a component supply device by using a component mounting unit 20 and transferring and mounting them on a substrate B. After that, the substrate B on which the components E are mounted is sent into the reflow soldering furnace M5, and a mounted substrate is manufactured by soldering the components E mounted on the substrate B to the substrate B. In this way, the component mounting line 1 includes the component mounting machines M1 to M4 that take out the components E supplied from the respective feeders 16 and mount them on the substrate B.

[0075] <Overall Structure of Component Mounting Machine>

[0076] Next, with reference to Figure 2 and Figure 3 the structures of the component mounting machines M1 to M4 will be described. Since the component mounting machines M1 to M4 all have the same structure, the component mounting machine M1 will be described as a representative. The component mounting machine M1 is configured to include: a base 11, which is substantially rectangular in plan view; a conveying device 12 for conveying the substrate B; a component mounting unit 20 for mounting (loading) components E on the substrate B; and a component supply device 13 for supplying components E to the component mounting unit 20.

[0077] In the following description, the X direction is based on the left - right direction (the conveying direction of the substrate B) in Figure 2 and is sometimes referred to as the left - right direction. In addition, the Y direction is based on the up - down direction (the direction orthogonal to the conveying direction of the substrate B) in Figure 2 and is sometimes referred to as the front - back direction. When referred to as the front - back direction, the lower side in the drawing is taken as the front side and the upper side in the drawing is taken as the rear side. In addition, the Z direction is based on the up - down direction in Figure 3 and is sometimes referred to as the up - down direction.

[0078] <Base>

[0079] As Figure 2 shown, the base 11 is substantially rectangular in plan view, being horizontally long in the left - right direction, and has an upper surface parallel to the XY plane extending in the X direction and the Y direction. The conveying device 12, the component mounting unit 20, etc. extending in the left - right direction are arranged on the upper surface of the base 11.

[0080] <Conveying Device>

[0081] As Figure 2 and Figure 3As shown, the conveying device 12 has a pair of conveyor belts 14 that are circularly driven in the left - right direction, and is a device for conveying the substrate B along the conveying path CP. The conveyor belts 14 are circularly driven by a conveyor motor 17 (refer to Figure 8 ). The substrate B is carried into the mounting operation position by the pair of conveyor belts 14 from the upstream side. After the mounting operation of the component E is performed at the mounting operation position, it is carried out by the pair of conveyor belts 14 toward the downstream side. Thus, the substrate B is conveyed from the upstream side toward the downstream side along the conveying path CP.

[0082] <Component mounting unit>

[0083] The component mounting unit 20 takes out the component E supplied from the feeder 16 of the component supply device 13 and mounts it on the substrate B. As Figure 2 shown, it is configured to include: a pair of Y - axis frames 23 disposed on both sides in the left - right direction of the base 11; an X - axis frame 26; a head unit 30 movably mounted on the X - axis frame 26; an X - axis moving device 28; and a Y - axis moving device 25.

[0084] The Y - axis moving device 25 includes a Y - axis ball screw shaft 25A, an unillustrated ball nut screwed with the Y - axis ball screw shaft 25A, and a Y - axis servo motor 25B. A pair of Y - axis guide rails 24 extending in the Y direction are provided on the pair of Y - axis frames 23. The Y - axis ball screw shaft 25A extends in the Y direction. The Y - axis servo motor 25B is provided at the shaft end of the Y - axis ball screw shaft 25A. When power - on control is performed on the Y - axis servo motor 25B, the X - axis frame 26 and the head unit 30 mounted on the X - axis frame 26 move in the front - rear direction along the pair of Y - axis guide rails 24.

[0085] The X - axis moving device 28 includes an X - axis ball screw shaft 28A, an unillustrated ball nut screwed with the X - axis ball screw shaft 28A, and a Y - axis servo motor 28B. As Figure 3 shown, an X - axis ball screw shaft 28A extending in the X direction and an X - axis guide rail 27 extending in the X direction are provided on the X - axis frame 26. The head unit 30 is mounted on the X - axis guide rail 27 so as to be movable in the X direction. The X - axis servo motor 28B is provided at the shaft end of the X - axis ball screw shaft 28A. When power - on control is performed on the X - axis servo motor 28B, the head unit 30 moves in the left - right direction along the X - axis guide rail 27.

[0086] <Head unit>

[0087] As Figure 2 and Figure 3 shown, the head unit 30 has a box - shaped head unit main body 31 and a plurality of mounting heads 32 for performing the mounting operation of the component E.

[0088] A plurality of mounting heads 32 are arranged side by side in the left - right direction in a form protruding downward from the head unit body 31. Each mounting head 32 has a shaft 33 extending in the up - down direction and a nozzle 34 that can be attached to and detached from the front end, i.e., the lower end portion, of the shaft 33.

[0089] A Z - axis servo motor 35 and an R - axis servo motor 36 provided in the head unit body 31 are mounted on the shaft 33. The shaft 33 can move up and down in the up - down direction by the Z - axis servo motor 35 and can rotate around the axis by the R - axis servo motor 36.

[0090] As Figure 3 shown, the nozzle 34 is in a substantially cylindrical shape extending in the up - down direction. The nozzle 34 is held at the lower end portion of the shaft 33 by a holding portion (not shown) provided at the upper end portion of the nozzle 34 and thus is held at the lower end portion of the shaft 33. In addition, negative pressure is supplied from an air supply device 51 to each mounting head 32, and an attractive force is generated at the front end of the nozzle 34.

[0091] As Figure 3 shown, a pair of marking cameras 21 are provided on both side surfaces of the head unit body 31. The marking cameras 21 photograph the reference marks of the substrate B to perform image recognition on the substrate B. On the other hand, a pair of component cameras 15 are provided on the front and rear sides of the substrate B on the base 11. The component cameras 15 photograph the components E adsorbed and held by the mounting heads 32 of the head unit 30.

[0092] <Component supply device>

[0093] As Figure 2 shown, the component supply device 13 includes a plurality of feeders 16, which are arranged in two rows in the left - right direction on the front and rear sides of the conveying device 12, and thus are arranged in a total of four positions. The feeder 16 is composed of a manual feeder 18 and an automatic feeder 40, and they are installed in a neatly arranged state in the left - right direction. Although not shown, the manual feeder 18 includes an electric feeding device for pulling out the component supply tape from the reel, etc., and supplies the components E one by one from the end portion on the conveying device 12 side. The component supply tape is formed by holding a plurality of components E at a constant pitch on the tape.

[0094] As Figure 4 shown, the component supply tape 41 of the automatic feeder 40 is fed forward by a drive shaft motor 42, and a plurality of components E held on the tape are sequentially supplied. In addition, when it is determined that the held components E are exhausted, a pre - placed replacement component supply tape 41 is loaded by a loading shaft motor 43. The drive shaft motor 42 and the loading shaft motor 43 control their operations based on signals from a feeder control unit 116.

[0095] The automatic feeder 40 is a feeder that automatically performs loading (hereinafter sometimes abbreviated as "AF"). As Figure 4As shown, the automatic feeder 40 includes: a main body 44 having a shape that is long in the front-rear direction (the left-right direction in the drawing); a front-side feeding section 45 provided at the front-side portion of the main body 44; a rear-side feeding section 46 provided at the rear-side portion of the main body 44; a belt passage 44A provided inside the main body 44; a belt guide 44B; a belt sensor 44C; a feeder control section 116; and a clamping member 47 detachably disposed at the rear-end side of the main body 44. The main body 44 is made of, for example, an aluminum die-casting.

[0096] The front-side feeding section 45 is composed of a drive shaft motor 42, a front-side gear group 45A composed of a plurality of gears, and a front-side sprocket 45B disposed at the upper front end of the main body 44. The front-side gear group 45A transmits the power of the drive shaft motor 42 to rotate the front-side sprocket 45B. Teeth 45C that engage with the engagement holes of the component supply belt 41 are formed at equal intervals on the outer periphery of the front-side sprocket 45B. The front-side feeding section 45 feeds the component supply belt 41 from the rear-side feeding section 46 to the component supply position 48 at the front end of the automatic feeder 40 by rotating the front-side sprocket 45B in a state where the teeth 45C of the front-side sprocket 45B are engaged with the engagement holes of the component supply belt 41.

[0097] The rear-side feeding section 46 is composed of a loading shaft motor 43, a rear-side gear group 46A composed of a plurality of gears, and a rear-side sprocket 46B disposed at the upper rear end of the main body 44. The rear-side gear group 46A transmits the power of the loading shaft motor 43 to rotate the rear-side sprocket 46B. Teeth 46C that engage with the engagement holes of the component supply belt 41 are formed at equal intervals on the outer periphery of the rear-side sprocket 46B.

[0098] The belt passage 44A is a passage for allowing the component supply belt 41 to pass through. The belt passage 44A penetrates through a substantially rear-side portion of the main body 44 in the front-rear direction and is provided in a form extending obliquely upward from the rear end of the main body 44 toward the front side of the main body 44. As Figure 6 shown, in the belt passage 44A, its front-side portion forms an elongated front-side passage portion 44A1, and the rear-side portion forms a rear-side passage portion 44A2 that expands in the vertical direction from the boundary portion with the front-side passage portion 44A1 toward the rear end of the main body 44. In each automatic feeder 40, the component supply belt 41 pulled out from the reel enters the belt passage 44A from the rear end of the main body 44, is pulled out from the belt passage 44A on the front side of the main body 44, and is exposed on the upper surface of the main body 44.

[0099] Next, the component supply method of the automatic feeder 40 will be described. First, as a preparatory operation, the operator installs the clamping member 47 on the main body 44 of the automatic feeder 40, and as Figure 6As shown, the front end of the preceding component supply tape 41 pulled out from the reel is engaged with the rear sprocket 46B. After that, by rotating the rear sprocket 46B, the front end of the component supply tape 41 is sent out to the front side of the automatic feeder 40 and engaged with the front sprocket 45B.

[0100] The component supply operation is executed by the feeder control unit 116 according to the installation procedure in a state where the above preparation operation is completed. In the component supply operation, the feeder control unit 116 rotates the front sprocket 45B by driving the drive shaft motor 42, and sends out the component supply tape 41 to the component supply position 48. In addition, the rear sprocket 46B is configured to rotate freely. At this time, even if the loading shaft motor 43 is not driven, the preceding component supply tape 41 can be sent out only by rotating the front sprocket 45B.

[0101] Next, while continuously sending out the preceding component supply tape 41 to the component supply position 48, the operator removes the clamping member 47 from the main body 44. As a result, as Figure 7 shown, the portion of the preceding component supply tape 41 supported by the clamping member 47 drops due to its own weight and separates from the rear sprocket 46B. At this time, since the preceding component supply tape 41 is already engaged with the front sprocket 45B, even if the preceding component supply tape 41 separates from the rear sprocket 46B, the preceding component supply tape 41 can be continuously sent out to the component supply position 48 by rotating the front sprocket 45B.

[0102] Next, the clamping member 47 is installed on the main body 44 of the automatic feeder 40 again, and the front end of the subsequent component supply tape 41 is disposed between the clamping member 47 and the rear sprocket 46B and engaged with the rear sprocket 46B. In this way, the subsequent component supply tape 41 can be pre-placed on the main body 44 without exhausting the components of the preceding component supply tape 41.

[0103] After that, the end of the preceding component supply tape 41 passes through the front passage portion 44A1 of the tape passage 44A. When the tape sensor 44C detects that there is no preceding component supply tape 41 in the front passage portion 44A1, the feeder control unit 116 that has received the detection signal drives the loading shaft motor 43 to rotate the rear sprocket 46B. As a result, the front end of the subsequent component supply tape 41 is sent out to the front side of the automatic feeder 40 and engaged with the front sprocket 45B. As described above, without disassembling the automatic feeder 40 or the like, the transfer is made from the preceding component supply tape 41 to the subsequent component supply tape 41. That is, the loading of the subsequent component supply tape 41 can be automatically performed.

[0104] <Configuration Support System for Automatic Feeder>

[0105] Next, referring toFigure 8 and Figure 9 Briefly describe the electrical structure of the configuration support system 10 for the automatic feeder. The configuration support system 10 for the automatic feeder in this embodiment consists of a component mounter M1 and a management server 3.

[0106] Figure 8 As shown, the overall component mounter M1 is comprehensively controlled by a control unit 110. The control unit 110 includes a mounting control unit 111 composed of a CPU (Central Processing Unit), etc. A motor control unit 112, a storage unit 113, an image processing unit 114, an external input / output unit 115, a feeder control unit 116, a server communication unit 117, a display unit 118, an input unit 119, etc. are connected to the mounting control unit 111.

[0107] The motor control unit 112 drives the Y-axis servo motor 25B, Z-axis servo motor 35, R-axis servo motor 36, conveyor motor 17, etc. according to the instructions of the mounting control unit 111 based on the mounting program stored in the storage unit 113 to mount the component E.

[0108] The mounting program for mounting the component E on the substrate B and various data, etc. are stored in the storage unit 113. The various data include substrate information related to the size and conveying speed of the substrate B to be produced, identification information of the shafts 33 and nozzles 34 assembled to the head unit 30, the positions of the components E measured by the cameras 15 and 21, and the reference positions for judging the position deviation of the components E, etc.

[0109] The image processing unit 114 takes in the image signals output from the mark camera 21 and the component camera 15 and generates images based on the taken-in image signals. The image processing unit 114 performs recognition processing on the image of the reference mark of the substrate B photographed by the mark camera 21. Thus, the position of the substrate B is detected. In addition, the image processing unit 114 performs recognition processing on the image of the component E photographed by the component camera 15. Thus, the adsorption posture and adsorption offset amount of the component E are detected. When the component E is mounted by the mounting head 32, the position correction of the mounting position is performed taking these recognition results into consideration.

[0110] The external input / output unit 115 is a so-called interface. The mounting control unit 111 takes in the detection signal from the pressure sensor 50 through the external input / output unit 115 and exchanges control signals with the air supply device 51. The pressure sensor 50 and the external input / output unit 115 can be connected in a wired manner or in a wireless manner.

[0111] The feeder control unit 116 is connected to a plurality of feeders 16 and comprehensively controls each feeder 16. The server communication unit 117 is connected to the management server 3 and exchanges control signals with the management server 3.

[0112] The display unit 118 is a display device such as a touch panel or a liquid crystal monitor, and displays specified items that need to be notified to the operator. The input unit 119 is an input device such as a touch panel, a keyboard, or a mouse, and performs input operations for data input and operation instruction input.

[0113] As the notification using the display unit 118, it includes warnings of information on the feeder 16 predicted to be out of components and the component depletion time Ts, warnings of a workload that cannot be completed even if the component replenishment operation is successfully implemented and insufficient man-hours, and the like. And each of the above parts is connected to the management server 3 via the server communication unit 117 and the LAN 2 as an interface, thereby exchanging control signals between the component mounter M1 and the management server 3.

[0114] Figure 9 The management server 3 shown includes an overall control unit 130, a storage unit 131, a component depletion time calculation unit 132, a component depletion detection unit 133, a peak detection unit 134, a simulator 135, and a machine communication unit 136. The overall control unit 130 comprehensively manages each device constituting the component mounting line 1 based on various data stored in the storage unit 131 and the like.

[0115] The storage unit 131 stores production plan data 137A, substrate data 137B, machine information 137C, component depletion time data 137D, available working time data 137E, non-working time data 137F, standard working time data 137G, and the like. The production plan data 137A is data related to the production type and quantity in each component mounting line 1. The substrate data 137B is a component list, which is data indicating the used components and quantities per substrate.

[0116] If the production plan data 137A and the substrate data 137B are combined, Figure 10 the data shown in (A) is obtained. That is, data indicating the substrate name, production quantity, production order, and the placement position, component ID, required component quantity, and cycle time of the used components is obtained.

[0117] The machine information 137C is data related to the operating status of the component mounter M1, the components being placed on the feeder 16, the feeder 16 to be used, the remaining amount of the component E, etc. Specifically, Figure 10The data shown in (B). The so-called machine information is, in detail, the substrate name, trolley ID, placement position, feeder ID, reel ID, component ID, total component margin, and component margin warning value. For example, for substrate A, trolley (IDA) is placed in component supply device 13, feeders 16 (IFA1, IFA2,...) are placed at the placement positions (FA1, FA2,...) of trolley (IDA), two reels (IRA11, IRA12) are assembled on feeder 16 (IFA1), and the components E of each reel (IRA11, IRA12) are all the same type of component E (IA1). The margin of component E (IA1) is A11, and its component margin warning value is AAAA1. In addition, since feeders 16 (IFA1, IFA2) both have two reels (IRA11, IRA12), they are automatic feeders 40.

[0118] The component depletion time data 137D is data indicating the time when the component E on the component supply tape placed on the reel is depleted (reaches the component life). The available operation time data 137E is data indicating the time from the component margin warning to when the component is depleted (reaches the component life). The standard operation time data 137G is data indicating the standard time required for the replenishment operation.

[0119] The component depletion time calculation unit 132 calculates the component depletion time, which represents the timing of component depletion in the production plan, that is, the time when component depletion occurs. The calculation method is to successively calculate (Calculation Formula 1) by subtracting "the number of components used in the production of one substrate" from "the margin of the components currently assembled on the machine". At the time point when there is no more margin, it is regarded as component depletion, and this time is taken as the component depletion time. If component depletion occurs, on the basis of taking the number of components assembled on the next reel as "the margin of the components currently assembled on the machine", continue with the above Calculation Formula 1. The component depletion time is stored in the storage unit 131 as the component depletion time data 137D associated with the component type.

[0120] When the component depletion time data 137D is calculated for all substrates (product number 1, product number 2,...), it is possible to generate Figure 11 The component depletion timing diagram shown. The component depletion timing diagram is a timing diagram obtained by calculating the timing of component depletion on the premise of not performing any replenishment operations at all. Therefore, in order to calculate the timing of component depletion on the premise of performing replenishment operations before component depletion occurs, it is necessary to assign the available operation time required for the replenishment operation to the component depletion timing diagram. The available operation time is stored in the storage unit 131 as the available operation time data 137E associated with the component type.

[0121] Figure 12(A) is a diagram that simulates the presence or absence of component depletion by assigning an operable time to the component depletion timing diagram using simulator 135. In the figure, A, B, C, D,... represent component types, 08:00, 08:15, 08:30, 08:45, 09:00,... on the horizontal axis represent times, the horizontal band WB represents the operable time (the time from component margin warning to component depletion), the left part (hatched) WB1 of the horizontal band WB represents the time from component margin warning to replenishment completion, the right part (hatched) WB2 of the horizontal band WB represents the time from replenishment completion to component depletion in the case of no replenishment, the right part (cross-hatched) WB3 of the horizontal band WB for component C represents the time from component depletion to replenishment completion, and the black circle BR represents the replenishment completion time. In component C, component depletion occurred at 08:36 and component replenishment ended at 08:42, so it indicates that a 6-minute machine stop occurred.

[0122] Here, the cause of component depletion is investigated. In Figure 12 (A), it is considered that the replenishment operation is continuous and the replenishment operation of component C has been delayed. In addition, it is also considered that the operable time of component C (the time from margin warning to component life) is short. In addition, it is also considered that the operator cannot perform the replenishment operation of component C during other operations (operations other than replenishment operations). Examples of other operations include solder preparation and being absent for a meeting. The inoperable time is stored in the storage unit 131 as the inoperable time data 137F associated with the component type. If the inoperable time is input to the simulator 135, it is possible to simulate with that time being inoperable.

[0123] As Figure 12 (B) shows, by applying AF to component C where component depletion occurred, component depletion can be reliably avoided. When the start time of the component installation operation is 08:00, by assembling AF to component C before the start of the operation, replenishment of component C can be performed simultaneously with the start of the operation.

[0124] In Figure 12(A), in the case where time periods with overlapping available operation times are defined as peaks, it can be seen that the cause of component depletion is the peak where operations are concentrated. Moreover, an uninterrupted time period in which the available operation time of the manual feeder 18 in the peak, where component depletion is detected by the component depletion detection unit 133, overlaps with the available operation times of other manual feeders 18 traced back continuously from this available operation time to the past is defined as a specific peak. The peak is detected by the peak detection unit 134. In addition to component C, there are three components, namely component A, component B, and component D, among the components included in the same peak. Among these components A, B, and D, it is sometimes possible to utilize the AF more effectively than component C. The manual feeders that supply components A, B, and D correspond to "the manual feeder associated with the component depletion" in Technical Solution 1. Component depletion can be avoided by applying the AF to any one of components A, B, and D.

[0125] Figure 13 (A) shows a component depletion timing diagram in which multiple peaks occur in a production plan for producing product numbers 1 to 5. Starting from the left side of the chart, the multiple peaks are peak 1, peak 2, and peak 3 in sequence. In Figure 13 (A), peak 1, peak 2, and peak 3 correspond to specific peaks. In peak 1, component depletion of component A occurs. In peak 2, component depletion of component H occurs. In peak 3, component depletion of component B occurs. In each peak, the AF is applied to the component with high effect (high peak encounter frequency). In the case of the same ratio, the usage speed is taken into consideration. The usage speed is the number of pieces used per second (the number of pieces used per sheet / production tact time). Regarding the remaining AF, it can be freely configured. After configuring the AF in this way, the simulation can be performed again.

[0126] Figure 13 (B) shows a table obtained by summarizing the number of times each component type encounters a peak. The number of encounters of component B is three, which is the largest. The number of encounters of components A, C, and G is two each, second only to component B. As Figure 13 (A) shows, the number of AFs in stock is four. It is also possible to assemble AFs for components A, B, C, and G respectively, but it is set that the AF is assembled for component A in peak 1, the AF is assembled for component G in peak 2, and the AF is assembled for component C in peak 3. After configuring the AF in this way, the simulation is performed again using the simulator 135 to confirm whether the component depletion is eliminated. Assuming that in the case where the component depletion is not eliminated, the AF can also be directly assembled for the component where the component depletion occurs. In this way, although the efficiency is reduced, the component depletion can be reliably avoided.

[0127] The machine communication unit 136 is an interface for signal transmission and reception with the component mounter M1 via the LAN 2.

[0128] Next, referring toFigures 14 to 16 The flowchart shows the processing method of the configuration support system 10 of the automatic feeder in the component installation line 1 of this embodiment. The management server 3 accumulates data from the input unit 119 and performs prescribed processing. A computer equipped with a CPU (Central Processing Unit) may also be connected to the management server 3, and the above-mentioned prescribed processing may be executed by a program installed in this computer.

[0129] As Figure 14 shown, the necessary components are set according to the production plan data 137A (step S11), the available AF component list is referred to (step S12), the number of owned AFs is registered (step S13), and the components that are fixed and want to use AF are registered (step S14). The component depletion occurrence timing diagram is created using the simulator 135, and the component depletion time is calculated using the component depletion time calculation unit 132 (step S15). Next, it is calculated whether replenishment can be made before component depletion when the replenishment operation is carried out (step S16). The details of step S16 are described with reference to Figure 15 the flowchart.

[0130] As Figure 15 shown, the standard operation time (the time taken for the operation) of splicing and pre-placement is set (step S21), and the time when the replenishment operation can be carried out (splicing and pre-placement) is calculated based on the component depletion timing diagram (step S22). Next, starting from the beginning, the standard operation time is sequentially allocated from the manual feeders 18 that become available (step S23). When allocating the operation time, it is checked whether there is no component depletion in other manual feeders 18 (step S24). Next, the peak is detected using the peak detection unit 134, and all the manual feeders 18 (component E) in which component depletion has occurred and the components E related to the peak immediately preceding them are listed (all the peaks and related components are detected) (step S25).

[0131] Return Figure 14 , it is calculated whether using AF for the non-replenishable component E and the component group to be replenished near it can avoid component depletion (step S17). The details of step S17 are described with reference to Figure 16 the flowchart.

[0132] As Figure 16 shown, it is calculated how many times the listed component E encounters peaks in the production plan (step S31), and the component E with the most peak encounter times among the peaks is determined (step S32). The simulation is carried out again using the simulator 135 in the state where this component E has been AF-ized, and the component depletion detection unit 133 is used to confirm whether there is component depletion (step S33). If the result is that there is no longer component depletion (yes in step S34), the processing ends.

[0133] On the other hand, in the case where there is an element depletion (No in step S34), it is confirmed whether there is an available AF. In the case where there is no longer an available AF (Yes in step S35), the process also ends. In the case where there is an available AF (No in step S35), the element E with the second most encounter times is determined (step S36), and the process returns to step S33. The simulation is performed again using the simulator 135 in the state where the element has been AF-ized, and the element depletion detection unit 133 is used to confirm whether there is an element depletion.

[0134] As described above, according to the present embodiment, the manual feeder 18 that will not be detected as having an element depletion by the element depletion detection unit 133 when changed from the manual feeder 18 to the automatic feeder 40 is cited as a candidate to be changed to the automatic feeder 40. If the automatic feeder 40 is configured so as not to detect an element depletion, the element depletion can be avoided in advance. Therefore, the scheduling of operations can be achieved as an advantage of introducing the automatic feeder 40.

[0135] The element depletion time calculation unit 132 can calculate the element depletion time data 137D, and the simulation is performed and the element depletion detection unit 133 is used to detect whether there is an element depletion. Here, in the case where an element depletion is detected, the manual feeder 18 can be replaced with the automatic feeder 40, and the simulation is performed again and the element depletion detection unit 133 is used to detect whether there is an element depletion.

[0136] If the manual feeder 18 detected as having an element depletion by the element depletion detection unit 133 is cited as a candidate to be changed to the automatic feeder 40, the element depletion can be reliably eliminated.

[0137] If the manual feeder 18 associated with the manual feeder 18 detected as having an element depletion by the element depletion detection unit 133 is cited as a candidate to be changed to the automatic feeder 40, for example, the automatic feeder 40 can be applied to the element effective in eliminating the element depletion.

[0138] If the manual feeder 18 detected as having an element depletion by the element depletion detection unit 133 and the manual feeder 18 associated therewith are cited as candidates to be changed to the automatic feeder 40, the manual feeder 18 to be changed to the automatic feeder 40 can be reduced to the manual feeder 18 detected as having an element depletion and the manual feeder 18 associated therewith.

[0139] In addition, there is a peak detection unit 134. When a period in which the available operation times adjacent to each other during the replenishment operation of the manual feeder 18 overlap, or a period in which the available operation time overlaps with a time other than the replenishment operation of the manual feeder 18 is defined as a peak, the peak detection unit 134 performs a simulation to detect the presence or absence of a peak. Since the peak detection unit 104 can detect a peak associated with the manual feeder 18 in which component depletion is detected by the component depletion detection unit 133, it is possible to determine the configuration of the automatic feeder 40 using the peak as a clue.

[0140] In addition, since the manual feeder 18 in which component depletion is detected by the component depletion detection unit 133 and the associated manual feeder 18 are cited as candidates to be changed to the automatic feeder 40, the manual feeder 18 to be changed to the automatic feeder 40 can be reduced to the manual feeder 18 in which component depletion is detected and the associated manual feeder 18.

[0141] In addition, by citing the other manual feeders 18 included in the peak that includes the manual feeder 18 in which component depletion is detected by the component depletion detection unit 133 as candidates to be changed to the automatic feeder 40, the manual feeder 18 to be changed to the automatic feeder 40 can be reduced to the other manual feeders 18 in the peak.

[0142] In addition, when multiple peaks occur in the production plan, by citing the manual feeder 18 that encounters the most peaks as a candidate to be changed to the automatic feeder 40, the manual feeder 18 to be changed to the automatic feeder 40 can be determined as the manual feeder 18 that encounters the most peaks.

[0143] In addition, by repeatedly executing the automatic feeder configuration support system 10, it is possible to determine a combination of the manual feeders 18 to be replaced with the automatic feeder 40 from among the multiple manual feeders 18 cited as candidates.

[0144] In addition, by performing a simulation while taking into account the non - available operation time, the peak detection unit 134 can detect a peak where component depletion occurs while taking into account the non - available operation time.

[0145] In addition, it is also possible to reliably eliminate component depletion by citing the manual feeder 18 in which component depletion is detected by the component depletion detection unit 133 as a candidate to be replaced with the automatic feeder 40.

[0146] [Details of Embodiment 2 of the Present Disclosure]

[0147] A specific example of a configuration support system for an automatic feeder in a component mounting line of the present disclosure will be described below with reference to the accompanying drawings. In addition, the present disclosure is not limited to these examples, but is defined by the scope of claims and is intended to include all modifications within the meaning and scope equivalent to the scope of claims.

[0148] In Embodiment 1, the configuration of the automatic feeder 40 is determined after identifying the location where the peak occurs according to the overall production plan. However, in Embodiment 2, the current configuration of the automatic feeder 40 can be changed while the simulation is always running to determine the optimal configuration.

[0149] In Embodiment 1, when there are multiple component mounting lines and a deviation occurs due to a short-term shutdown (such as an error) during the production process, it is expected that component depletion will not occur. Or, new component depletion may occur due to the deviation in timing.

[0150] In addition, in Embodiment 1, when the automatic feeder 40 is insufficient, it is impossible to completely avoid machine stoppage caused by component depletion. That is, when the AF inventory is insufficient, it may not be possible to fully handle the peak. In addition, due to confusion in the plan caused by mistakes / errors during the production process, the replenishment time may change, and the peak may increase or decrease. In addition, sometimes it is desired to replace the AF that is no longer scheduled for use during production in order to make effective use of it.

[0151] To address these situations, in Embodiment 2, instead of throughout the entire production plan, the detection of component depletion is performed during production, and component depletion is avoided whenever it is detected. In this case, as production progresses, the locations that require AF also change, so the replacement of the AF is successively instructed.

[0152] The replacement of the AF is performed when there is a free AF at the current time point and there are scheduled replenishments more than a specified number of times after the AF replacement. By "free" it means not being used in the types currently in production. The specified number of times can be, for example, two times. In addition, if component depletion occurs when replacing the AF with a manual feeder 18, the replacement may not be performed. When setting the specified number of times as n times, as a setting method for n, for example, setting the replacement time to about 40 seconds, as long as 40 seconds + pre-placement n times < the number of splicing n times, it can be freely set.

[0153] When there is no free AF at the current time point, or when the replenishment has not been scheduled more than a specified number of times after the AF replacement, the replacement of the AF may not be performed. The reason is that there is a risk of machine stoppage due to mistakes during replacement, and new peaks may occur when the in-use AF is moved. In addition, as described later, when the replacement is not performed, by displaying a warning on the display unit 118, it is also possible to avoid it with the help of other installation lines and other operations.

[0154] When there are no peaks after the current time point, or when there is no manual feeder 18 that should be preferentially replaced, the usage speed (number of pieces used per sheet / production cycle time) can also be used instead of the peak. In this way, it is possible to avoid the situation of assembling the AF to a component that is not used at all, and the AF can be assembled to a component whose components are not exhausted but need to be replenished more than a specified number of times.

[0155] Next, refer to Figure 17 and Figure 18 Specifically describe the configuration support system for the automatic feeder in Embodiment 2. A, B, and C in the figure represent production timings. The A time point is the production start timing, and the B and C time points represent timings during production. Production is carried out in the order of product numbers 1, 2, 3, 4, and 5. The A time point is the production start time point of product number 1, the B time point is the production start time point of product number 3, and the C time point is the production start time point of product number 5.

[0156] As Figure 17 shown, regarding the priority of the A time point, after performing a simulation and detecting Peaks 1 to 3, based on the replenishment times within the peak (peak encounter times), Component A has the most at three times, Component B has the second most at two times, and Components C to H have the third most at one time. Regarding Components C to H, when dealing with them starting from the nearest peak, the priority of Components F, G, and H is high. When further considering the usage speed, the priority of Component G is the highest. Therefore, AFs are assembled to Components A, B, C, and G. However, since the number of AFs in stock is only four, it is not possible to handle Components D and E in Peak 3.

[0157] When the simulation is performed again at the B time point, the nearest peak is changed to Peak 3. For the priority of the B time point, based on the replenishment times within the peak (peak encounter times), Components A, D, and E have the most at one time, and Components B, F, G, and H have 0 times. In this case, for Component B, since the replenishment times in Peak 3 are 0 times and it is not used in product number 3, it is recommended to change the AF of Component B to Component D. For Component G, since the replenishment times in Peak 3 are 0 times and it is not used in product number 3, it is recommended to change the AF of Component G to Component E.

[0158] When the simulation was performed again at time point C, no peak was detected. Therefore, the priority at time point C remains the same as that at time point B. Additionally, for the replenishment times of product number 5, components B and C have the most at two times, components A and D have the second most at one time, and components E, F, G, and H have 0 times.

[0159] Next, as Figure 18 shown, the situation where component E was not used as scheduled at time point C will be described. In this case, for the priority at time point C, based on the usage speed, component C has the most at 3.2, component B has the second most at 1.8, component A has the third most at 1.1, component D has the fourth most at 0.5, and components E, F, G, and H have 0. In this case, it is recommended to change the AF of component E to component B. This is because component E was not used, component B is scheduled to be replaced more than twice, and the usage speed of component B is faster than the existing AF component (component E).

[0160] In Embodiment 2, the display unit 118 presents Figure 19 information like that. First, the "AF setting request" is an instruction as follows: There is currently no AF assembled, and through simulation, accidents such as component depletion are anticipated. To avoid accidents, an AF setting is requested. When the operator issues this instruction, the AF must be set at the specified position. Here, it is shown that the installation line is LINE-B, the machine is M3, the placement position is F23, the request time is ~10:24, and the AF setting needs to be completed before 10:24.

[0161] Next, the "AF setting recommendation" means that there is currently no AF assembled, and there is no concern about component depletion, but through simulation, it is anticipated that there will be more component replenishments in the future. Therefore, the assembly of AF is recommended, and the judgment of whether to assemble AF is made by the operator. Here, it is shown that the installation line is LINE-C, the machine is M2, the placement position is F10, and the replacement times are 6 times.

[0162] Next, the "used-up AF" notification indicates the situation where although an AF is currently assembled, since there are no scheduled component replenishments in the future, the AF can be replaced. Here, it is shown that the installation line is LINE-D, the machine is M1, the placement position is R125, and the replacement times are 0 times. For example, the automatic feeder 40 with 0 replacement times (taking the replacement times as the set value, and the set value is 0.5 or less) can be cited as a candidate for replacement, and the automatic feeder 40 with 1 or less replacement times (taking the replacement times as the set value, and the set value is 1 or less) can also be cited as a candidate for replacement.

[0163] In addition, in the case of the "Inefficient AF" notification, although AF is currently installed, since the scheduled component replenishment is decreasing, it is possible to replace the AF. Here, the installation line is LINE-A, the machine is M4, the placement position is F38, and the number of replacements is 1 time.

[0164] Next, with reference to Figure 20 and Figure 21 's flowchart, the processing method of the automatic feeder configuration support system in the component mounting line 1 of the present embodiment will be described.

[0165] As Figure 20 shown, the production plan data 137A is compared with the types currently in production, the current time point in the production plan is set (step S41), and the component E required after the current time point is set (step S42). Next, the available AF component list is referred to (step S43), and the number of unused AFs is registered (step S44). In step S44, the AFs not used in the current type are also registered. Next, the components E that are fixed and want to use AF are registered (step S45), the component depletion occurrence timing diagram is created using the simulator 135, and the component depletion time is calculated using the component depletion time calculation unit 132 (step S46). Next, it is calculated whether replenishment can be made before component depletion when the replenishment operation is carried out (step S47). The details of step S47 are the same as those of Figure 15 's flowchart, so the description is omitted. It is calculated whether using AF for the non-replenishable component E and the component group to be replenished near it can avoid component depletion (step S48). The details of step S48 are described with reference to Figure 21 's flowchart.

[0166] As Figure 21 shown, the manual feeder 18 (component E) related to the peak is received (step S51). Next, it is calculated how many times the listed component E encounters the peak in the production plan (step S52), the beginning peak is focused on (step S53), and the component E with the most encounters in the focused peak is determined (step S54). The simulation is carried out again using the simulator 135 in the state where the component E is AF-enabled, and the component depletion detection unit 133 is used to confirm whether there is component depletion (step S55). In the case where there is a component E with the second most encounters, this component E is determined (step S56), and the process returns to step S55. The simulation is carried out again using the simulator 135 in the state where the component E is AF-enabled, and the component depletion detection unit 133 is used to confirm whether there is component depletion.

[0167] In the case where there is no component depletion in the peak of interest (Yes in step S57), if the available AF is insufficient, the process ends, or if production is completed, the process ends (step S59). In the case where there is still component depletion in the peak of interest in step S57 (No in step S57), the next peak is focused on (step S58), and the processes after step S54 are performed.

[0168] As described above, according to the present embodiment, by prompting the manual feeder 18 to be replaced with the automatic feeder 40 on the display unit 118, it is possible to confirm which manual feeder 18 should be replaced through the display unit 118.

[0169] In addition, when prompting the manual feeder 18 to be replaced with the automatic feeder 40, by also prompting the replacement deadline on the display unit 118, it is possible to confirm through the display unit 118 which manual feeder 18 should be replaced by when.

[0170] In addition, the component depletion detection unit 133 detects the presence or absence of component depletion by obtaining information from the component mounter each time during production and periodically performing simulations, and can determine the configuration of the automatic feeder 40 based on the actual production status.

[0171] In addition, by listing the automatic feeder 40 with a usage predetermined to be below the set value as a replacement candidate, the automatic feeder 40 can be effectively utilized.

[0172] [Details of Embodiment 3 of the Present Disclosure]

[0173] Hereinafter, a specific example of the automatic feeder configuration support system in the component mounting line of the present disclosure will be described with reference to the drawings. In addition, the present disclosure is not limited to these examples, but is shown by the scope of claims, and is intended to include all changes within the meaning and scope equivalent to the scope of claims.

[0174] In Embodiment 1, when predicting the component depletion timing, the calculation is performed assuming a new reel as the replacement target, but in the present embodiment, data from a component management system such as an automatic warehouse is used, and the component depletion prediction is performed using the number of incoming predetermined reels actually shipped out relative to the production plan. For example, in Embodiment 1, if the number of incoming new products (full number) is 6000 reels, when replacement is performed, it is assumed that 6000 are replenished and the simulation is performed.

[0175] However, in actual production, it is rare to exhaust components at the end of production, and most are in a state of being in use (opened). Among them, depending on the type, there are also components for which there is no production schedule for the time being. In this case, sometimes the unused components are removed from the feeder 16, and the remaining amount is recorded and stored. In addition, there are also cases where these reels are stored in the automated warehouse.

[0176] In this case, when producing the type of component to be used, it is mostly preferred to use the opened reels first. At this time, for component exhaustion, it is also expected that there will be more component exhaustion than in the case of only using new reels. Therefore, if the status of the reels allocated for the production plan is determined in advance, it is preferable to use the remaining amount of the reels to advance the simulation.

[0177] Along with this, as an index when selecting the reel to be replaced with an AF, the priority can be given according to the number of out-of-stock reels allocated to the production plan. The logic from the extraction peak to the stop to avoid component exhaustion is the same as that of Embodiments 1 and 2, but the allocation logic of the remaining AFs and the AFs without production schedule in Embodiment 2 is different. Instead of the usage speed of the components as the selection condition in Embodiments 1 and 2, the "number of scheduled out-of-stock" is used to calculate the priority of the AF installation destination.

[0178] Therefore, in Embodiment 1, the component exhaustion timing is calculated based on the production plan data 137A (the production type and quantity are set for each mounting line), the substrate data 137B (or the component list, the used components and quantities for each substrate), and the machine information 137C (the operating status of the machine, the components placed, the feeder used, and the remaining amount). However, in this embodiment, in addition to the production plan data 137A, the substrate data 137B, and the machine information 137C, the list of components stored in the automated warehouse (or the list of components stored in the component management system) is also taken into consideration to calculate the component exhaustion timing.

[0179] Figure 22 shows an example of the list of components stored in the automated warehouse. It shows the case where the component E with the component ID of IA1 is assembled on the reel with the reel ID of IRA11, and the component margin is RA11. Similarly, it shows the case where the component margin of the component E of IA1 in the reel with the reel ID of IRA12 is RA12, the component margin of the component E of IA2 in the reel with the reel ID of IRA21 is RA21, and the component margin of the component E of IA2 in the reel with the reel ID of IRA22 is RA22.

[0180] The calculation method for calculating the component depletion time by the component depletion time calculation unit 132 is to successively calculate (Calculation Formula 1) of subtracting "the quantity of components used in producing one substrate" from "the remaining quantity of components currently assembled on the machine". When there is no remaining quantity, it is regarded as component depletion, and this time is taken as the component depletion time. If component depletion occurs, based on taking the quantity of components assembled on the next reel (allocating the remaining quantity of the used reel) as "the remaining quantity of components currently assembled on the machine", the above Calculation Formula 1 is continued. The component depletion time is stored in the storage unit 131 as component depletion time data 137D associated with the component type.

[0181] Next, referring to Figure 23 the flowchart of, the processing method of the configuration support system of the automatic feeder in the component mounting line 1 of the present embodiment will be described.

[0182] Perform the setting of necessary components according to the production plan data 137A (Step S61), refer to the list of available AF components (Step S62), register the number of owned AFs (Step S63), and register the component E that is fixed and desired to use AF (Step S64). Next, when calculating the component depletion time, instead of setting the quantity of replenishment components to the full number, allocate the remaining quantity of the used reel. Create a component depletion occurrence timing diagram using the simulator 135, and calculate the component depletion time using the component depletion time calculation unit 132 (Step S65). Next, calculate whether replenishment can be performed before component depletion when the replenishment operation is carried out (Step S66). Calculate whether using AF for the non-replenishable component E and the component group to be replenished near it can avoid component depletion (Step S67).

[0183] As described above, according to the present embodiment, when replenishing the component supply tape, by performing simulation using the actual remaining quantity of component E, it is possible to detect the presence or absence of component depletion corresponding to the actual remaining quantity of component E.

[0184] <Other Embodiments>

[0185] (1) In the above Embodiments 1 to 3, the time period during which the available operation times overlap with each other is defined as the peak, but it is also possible to define the time period during which the available operation time overlaps with the time of other operations (operations other than unscheduled replenishment) as the peak.

[0186] (2) In the above Embodiments 1 to 3, the other manual feeders 18 included in the peak including the manual feeder 18 where component depletion is detected are changed to automatic feeders 40, but it is also possible to change the other manual feeders 18 not included in this peak to automatic feeders 40. For example, it is possible to change the manual feeder 18 of the same component type as the manual feeder 18 where component depletion is detected but not included in the peak to an automatic feeder 40.

[0187] (3) In the above-described Embodiments 1 to 3, the manual feeder 18 with the highest number of peaks is changed to the automatic feeder 40. However, it is also possible to exclude the component with the highest number of peaks but with a slow usage speed or a large component margin from the replacement targets, and use the component with the second highest number of peaks as the replacement target.

[0188] (4) In the above-described Embodiments 1 to 3, the combination of the manual feeders 18 to be replaced with the automatic feeder 40 is determined by repeatedly performing simulations. However, it is also possible to determine the manual feeder 18 to be changed to the automatic feeder at each simulation and perform the replacement each time. That is, it is also possible to determine the manual feeder 18 to be replaced with the automatic feeder 40 only through the initial simulation and not perform the simulation again. Here, the manual feeder 18 to be changed to the automatic feeder 40 does not necessarily have to be the manual feeder 18 where component depletion occurs, and it can also be the manual feeder 18 associated with component depletion (such as including the case of peaks) on the condition that component depletion can ultimately be avoided.

[0189] (5) In the above-described Embodiments 1 to 3, the simulation is performed taking into account the non-operable time. However, it is also possible to give an instruction to have other operators perform it during the non-operable time.

[0190] (6) In the above-described Embodiment 2, the manual feeder 18 to be replaced is displayed on the display unit 118. However, in the case where there is a manual feeder 18 to be replaced, it is also possible to give a notification by sound or light.

[0191] (7) In the above-described Embodiment 2, information is obtained from the component mounter each time during the production process and the simulation is performed regularly. However, if the simulation is performed too frequently, the replacement operations increase and it is possible to increase the peaks. Therefore, it is also possible not to perform the simulation when there is no change point and perform the simulation when a change point is confirmed.

[0192] Reference Numeral Explanation

[0193] 1: Component mounting line, 2: LAN, 3: Management server,

[0194] 10: Configuration support system for automatic feeders,

[0195] 11: Base, 12: Conveyor device, 13: Component supply device, 14: Conveyor belt, 15: Component camera, 16: Feeder, 17: Conveyor motor, 18: Manual feeder,

[0196] 20: Component mounting unit, 21: Marking camera, 23: Y-axis frame, 24: Y-axis guide rail, 25: Y-axis moving device, 25A: Y-axis ball screw shaft, 25B: Y-axis servo motor, 26: X-axis frame, 27: X-axis guide rail, 28: X-axis moving device, 28A: X-axis ball screw shaft, 28B: X-axis servo motor,

[0197] 30: Head unit, 31: Head unit body, 32: Mounting head, 33: Shaft, 34: Nozzle, 35: Z-axis servo motor, 36: R-axis servo motor,

[0198] 40: Automatic feeder, 41: Component supply tape, 42: Drive shaft motor, 43: Loading shaft motor, 44: Main body, 44A: Tape passage, 44A1: Front side passage part, 44A2: Rear side passage part, 44B: Tape guide, 44C: Tape sensor, 45: Front side delivery part, 45A: Front side gear set, 45B: Front side sprocket, 45C: Teeth, 46: Rear side delivery part, 46A: Rear side gear set, 46B: Rear side sprocket, 46C: Teeth, 47: Clamping member, 48: Component supply position,

[0199] 50: Pressure sensor, 51: Air supply device,

[0200] 110: Control unit, 111: Mounting control unit, 112: Motor control unit, 113: Storage unit, 114: Image processing unit, 115: External input / output unit, 116: Feeder control unit, 117: Server communication unit, 118: Display unit, 119: Input unit,

[0201] 130: Overall control unit, 131: Storage unit, 132: Component depletion time calculation unit, 133: Component depletion detection unit, 134: Peak detection unit, 135: Simulator, 136: Machine communication unit, 137A: Production plan data, 137B: Substrate data, 137C: Machine information, 137D: Component depletion time data, 137E: Available operation time data, 137F: Unavailable operation time data, 137G: Standard operation time data,

[0202] B: Substrate, BR: Black circle, CP: Conveyor path, E: Component, Ts: Component depletion time,

[0203] M1: Component mounter, M5: Reflow oven,

[0204] WB: Horizontal band, WB1: Left shaded part, WB2: Right shaded part, WB3: Cross-hatched part.

Claims

1. A configuration support system for an automatic feeder, which is a configuration support system for an automatic feeder in a component mounting line including a component mounter. The component mounter includes: a component supply device capable of placing an automatic feeder and a manual feeder. The automatic feeder is held on a component supply tape formed by pre-placing a plurality of components on a tape, and when the currently supplied component supply tape is exhausted, a new component supply tape is replenished, thereby performing a replenishment operation. The manual feeder performs a replenishment operation by splicing a new component supply tape at the end of the currently supplied component supply tape; and a mounting head that takes out the components from the component supply tape and mounts them on a substrate. wherein, the configuration support system for the automatic feeder includes: a component exhaustion time calculation unit that calculates component exhaustion time data based on the production plan data of the substrate and the substrate data; and a component exhaustion detection unit that performs a simulation and detects whether there is component exhaustion based on the component exhaustion time data and the operable time data associated with the replenishment operation of the manual feeder. A manual feeder is cited as a candidate to be changed to the automatic feeder such that when changing from the manual feeder to the automatic feeder, the component exhaustion detection unit does not detect component exhaustion.

2. The configuration support system for the automatic feeder according to claim 1, wherein, when the component exhaustion detection unit detects component exhaustion, the component exhaustion detection unit performs a simulation again to detect whether there is component exhaustion when the manual feeder is replaced with the automatic feeder.

3. The configuration support system for the automatic feeder according to claim 1 or 2, wherein, the manual feeder detected by the component exhaustion detection unit to have component exhaustion is cited as a candidate to be changed to the automatic feeder.

4. The configuration support system for the automatic feeder according to claim 1 or 2, wherein, the manual feeder associated with the manual feeder detected by the component exhaustion detection unit to have component exhaustion is cited as a candidate to be changed to the automatic feeder.

5. The configuration support system for the automatic feeder according to claim 1 or 2, wherein, the manual feeder detected by the component exhaustion detection unit to have component exhaustion and the manual feeder associated with it are cited as candidates to be changed to the automatic feeder.

6. The configuration support system for the automatic feeder according to claim 4, wherein, the configuration support system for the automatic feeder includes a peak detection unit. When a period in which adjacent operable times overlap during the replenishment operation of the manual feeder, or a period in which the operable time overlaps with the time of an operation other than the replenishment of the manual feeder is defined as a peak, the peak detection unit performs a simulation to detect whether there is such a peak. Among the peaks including the manual feeder in which component depletion is detected by the component depletion detection unit, other manual feeders included in the peak are cited as candidates to be changed to the automatic feeder.

7. The automatic feeder configuration support system according to claim 5, wherein the automatic feeder configuration support system includes a peak detection unit. When a period in which adjacent available operation times overlap during the replenishment operation of the manual feeder, or a period in which the available operation time overlaps with the time of an operation other than the replenishment of the manual feeder is defined as a peak, the peak detection unit performs a simulation to detect the presence or absence of the peak. Among the peaks including the manual feeder in which component depletion is detected by the component depletion detection unit, other manual feeders included in the peak are cited as candidates to be changed to the automatic feeder.

8. The automatic feeder configuration support system according to claim 6 or 7, wherein when an uninterrupted period in which the available operation time of the manual feeder in which component depletion is detected by the component depletion detection unit in the peak overlaps with the available operation times of other manual feeders that are traced back continuously from this available operation time to the past is defined as a specific peak, the peak detection unit detects the specific peak, and other manual feeders included in the specific peak are cited as candidates to be changed to the automatic feeder.

9. The automatic feeder configuration support system according to claim 6 or 7, wherein when multiple peaks are generated in the production plan, the manual feeder that encounters the most peaks is cited as a candidate to be changed to the automatic feeder.

10. The automatic feeder configuration support system according to any one of claims 1, 2, 6, and 7, wherein by repeatedly executing the automatic feeder configuration support system, a combination of the manual feeders to be replaced with the automatic feeder is determined from among the multiple manual feeders cited as candidates.

11. The automatic feeder configuration support system according to claim 6 or 7, wherein the automatic feeder configuration support system includes a peak detection unit. When a period in which adjacent available operation times overlap during the replenishment operation of the manual feeder, or a period in which the available operation time overlaps with the time of an operation other than the replenishment of the manual feeder is defined as a peak, the peak detection unit performs a simulation to detect the presence or absence of the peak. The peak detection unit performs a simulation considering the non - available operation time to detect the presence or absence of the peak in which component depletion occurs.

12. The automatic feeder configuration support system according to any one of claims 1, 2, 6, and 7, wherein the manual feeder to be replaced with the automatic feeder is prompted on the display unit.

13. The automatic feeder configuration support system according to claim 12, wherein when prompting the manual feeder to be replaced with the automatic feeder, the replacement deadline is also prompted on the display unit.

14. The automatic feeder placement support system according to any one of claims 1, 2, 6, and 7, in, The component depletion detection unit acquires information from the component mounting machine every time during the production process and periodically performs simulation to detect whether or not components are depleted.

15. The automatic feeder placement support system according to any one of claims 1, 2, 6, and 7, in, The automatic feeder whose usage is expected to be less than the set value is listed as a candidate for replacement.

16. The automatic feeder placement support system according to any one of claims 1, 2, 6, and 7, in, During the replenishment operation, the simulation is performed using the actual remaining quantity of the component.

17. A configuration support program for an automatic feeder, which is a configuration support program for an automatic feeder in a component mounting line including a component mounting machine, the component mounting machine comprising: a component supply device capable of placing an automatic feeder and a manual feeder, the automatic feeder replenishing a component supply tape by pre-placing a plurality of components held on a tape and replenishing a new component supply tape when the component supply tape currently being supplied is exhausted, the manual feeder replenishing a new component supply tape by splicing the new component supply tape at the end of the component supply tape currently being supplied; and a mounting head for taking the components out of the component supply tape and mounting them on a substrate, in, The automatic feeder configuration support program causes the computer to execute the following steps: Component depletion time data is calculated based on the production plan data and substrate data of the substrate, and a simulation is performed to detect whether component depletion exists based on the component depletion time data and the operable time data associated with the replenishment operation of the manual feeder, and the following manual feeder is cited as a candidate to be changed to the automatic feeder: by changing from the manual feeder to the automatic feeder, the component depletion will not be detected by the component depletion detection unit.

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