Component supply control system

Abstract

The component supply control system includes a state recognition section that, based on image data obtained by capturing the supply region in a state in which the bulk feeder carries a plurality of components to the supply region by vibration, estimates the supply state of the components for each of a plurality of regions that are set in advance in the supply region, and a carrying control section that controls the carrying of the components in the bulk feeder based on the supply state of each of the plurality of regions.

Description

TECHNICAL FIELD

[0001] The present application relates to a component supply control system. BACKGROUND

[0002] A component supply control system controls component supply using a bulk feeder. The bulk feeder is equipped to a component mounting machine that mounts components on a substrate, and supplies components in a bulk state. A structure that transports a plurality of components by applying vibration to a transport path is disclosed in Patent Literature 1. By such a transport operation, the bulk feeder supplies components in a supply region that is open upward to enable a suction nozzle to pick up components.

[0003] PRIOR ART DOCUMENTS

[0004] PATENT LITERATURE

[0005] Patent Literature 1: Japanese Patent Application Publication No. 2011-114084 SUMMARY

[0006] PROBLEMS TO BE SOLVED BY THE INVENTION

[0007] Such a bulk feeder is requested to supply components, for example, by a control device of a component mounting machine, and performs a prescribed transport operation. However, since components are in a bulk state in a supply region, even if the prescribed transport operation is performed, the number of components that can be picked up can deviate. For a system that controls component supply using a bulk feeder, it is required to maintain a good component supply state and improve productivity.

[0008] An object of the present specification is to provide a component supply control system that can make the component supply state in a bulk feeder good and achieve improvement in productivity of a component mounting machine equipped with the bulk feeder.

[0009] TECHNICAL SOLUTION TO THE PROBLEM

[0010] The present specification discloses a component supply control system including: a state recognition section that estimates a component supply state for each of a plurality of regions that are set in advance in a supply region, based on image data acquired by imaging the supply region in a state in which a plurality of components are transported to the supply region by vibration of a bulk feeder; and a transport control section that controls a transport operation of the components in the bulk feeder, based on the component supply state of each of the plurality of regions.

[0011] EFFECT OF THE INVENTION

[0012] According to this structure, the conveying action of the bulk material feeder is controlled based on the supply status of the components in each of the multiple zones within the supply area. This allows for conveying actions corresponding to the current supply status, thereby increasing the number of components that can be picked up in the supply area. Thus, by ensuring a good supply status of components in the bulk material feeder, the productivity of the component assembly machine can be improved. Attached Figure Description

[0013] Figure 1 This is a schematic top view of a component mounting machine equipped with a bulk material feeder.

[0014] Figure 2 This is a three-dimensional view showing the appearance of the bulk material feeder.

[0015] Figure 3 This is a schematic side view showing the main parts of the bulk material feeder.

[0016] Figure 4 From Figure 2 A top view observed from the IV direction.

[0017] Figure 5 This is a block diagram representing a component mounting machine that utilizes a component supply control system.

[0018] Figure 6 It is a graph representing the image data obtained by taking pictures of the supply area.

[0019] Figure 7 It means to Figure 6 The image data is a graph representing the result of the object's supply status recognition processing.

[0020] Figure 8 This is a flowchart representing the component supply control process. Detailed Implementation

[0021] The component supply control system 80, which controls the supply of components using the bulk feeder 30, will be described with reference to the accompanying drawings. The bulk feeder 30 is, for example, equipped on a component mounting machine 10 that mounts components 92 onto a substrate 91, and supplies components 92 in a bulk state (each in an irregularly oriented, scattered state).

[0022] 1. Structure of component mounting machine 10

[0023] The component mounting machine 10, for example, together with various substrate mounting machines including other component mounting machines 10, constitutes a production line for producing substrate products. The substrate mounting machines constituting the production line described above may include printers, inspection devices, reflow ovens, etc.

[0024] 1-1. Substrate handling device

[0025] like Figure 1 As shown, the component mounting machine 10 includes a substrate transport device 11. The substrate transport device 11 transports the substrate 91 sequentially in the transport direction and positions the substrate 91 at a predetermined position within the machine.

[0026] 1-2. Component supply device 12

[0027] The component mounting machine 10 includes a component supply device 12. The component supply device 12 supplies components to be mounted on the substrate 91. The component supply device 12 is equipped with feeders 122 in multiple slots 121. The feeders 122 may be, for example, belt feeders that feed a carrier belt containing a large number of components, supplying the components in a pick-up manner. Alternatively, the feeders 122 may employ bulk feeders 30 that supply components held in a bulk state in a pick-up manner. Details regarding the bulk feeders 30 will be described later.

[0028] 1-3. Component transfer device 13

[0029] The component mounting machine 10 includes a component transfer device 13. The component transfer device 13 transfers components supplied by the component supply device 12 to predetermined mounting positions on the substrate 91. The component transfer device 13 includes a head drive device 131, a moving stage 132, a mounting head 133, and a suction nozzle 134. The head drive device 131 moves the moving stage 132 horizontally (in the X and Y directions) via a linear motion mechanism. The mounting head 133 is detachably fixed to the moving stage 132 by clamping members (not shown) and is configured to move horizontally within the machine.

[0030] The mounting head 133 supports a plurality of suction nozzles 134 in a rotatable and height-adjustable manner. Each suction nozzle 134 is a holding member that picks up and holds the component 92 supplied by the feeder 122. The suction nozzle 134 adsorbs the component supplied by the feeder 122 using supplied negative pressure air. As a holding member mounted on the mounting head 133, a chuck or similar device that holds the component by gripping it can be used.

[0031] 1-4. Component camera 14, substrate camera 15

[0032] The component mounting machine 10 includes a component camera 14 and a substrate camera 15. The component camera 14 and substrate camera 15 are digital imaging devices with imaging elements such as CMOS. The component camera 14 and substrate camera 15 capture images based on control signals and transmit the image data acquired through this capture. The component camera 14 is configured to capture images of components held in the suction nozzle 134 from below. The substrate camera 15 is mounted on the stage 132 in a manner that allows it to move horizontally integrally with the mounting head 133. The substrate camera 15 is configured to capture images of the substrate 91 from above.

[0033] Furthermore, in addition to photographing the surface of the substrate 91, the substrate camera 15 can photograph various devices as long as they are within the movable range of the stage 132. For example, in this embodiment, such as Figure 4 As shown, the substrate camera 15 can capture images of the supply area As of the supply element 92 of the bulk material feeder 30 and the reference mark 344 provided on the upper part of the bulk material feeder 30 within the camera's field of view. In this way, the substrate camera 15 can be used to capture images of different subjects in order to obtain image data for various image processing.

[0034] 1-5. Control Device 16

[0035] like Figure 1 As shown, the component mounting machine 10 includes a control device 16. The control device 16 mainly consists of a CPU, various memories, control circuits, and storage devices. The control device 16 (storage device) stores various data, such as control programs for the mounting process. The control program indicates the mounting position, mounting angle, and mounting sequence of the components to be mounted on the substrate 91 during the mounting process.

[0036] The control device 16 performs recognition processing on the holding state of the element held by each of the multiple holding members (nozzle 134). Specifically, the control device 16 performs image processing on image data acquired by the element camera 14 to identify the position and angle of each element relative to the reference position of the mounting head 133. In addition to the element camera 14, the control device 16 may also perform image processing on image data acquired by a head camera unit integrally provided on the mounting head 133 from the side, below, or above.

[0037] The control device 16 performs the installation process by controlling the component installation action performed by the mounting head 133 based on a control program. Here, the installation process includes repeatedly performing a PP cycle (pick-and-place cycle) that includes both pick-up and installation actions. The aforementioned "pick-up action" is the action of picking up the component supplied by the component supply device 12 using the nozzle 134.

[0038] In this embodiment, when the control device 16 performs the aforementioned picking operation, it controls the operation of the component supply device 12, including the bulk material feeder 30. The control targeting the operation of the bulk material feeder 30 includes, for example, the control of the supply operation of the component 92 performed by the bulk material feeder 30 and the opening and closing operation of the gate 37, which will be described later.

[0039] The control device 16 includes a status recognition unit 81. The status recognition unit 81 identifies the supply status of multiple components 92 in the supply area As of the bulk material feeder 30 based on image data acquired by a camera (in this embodiment, a substrate camera 15). The supply status recognition process includes identifying whether a pickable component 92 exists in the supply area As, and if so, identifying the position and angle of that component 92. Furthermore, the control device 16 controls the operation of the mounting head 133 during the picking action based on the result of the supply status recognition process. In this embodiment, the status recognition unit 81 constitutes the component supply control system 80. Details of the status recognition unit 81 will be described later.

[0040] Furthermore, the aforementioned "installation operation" refers to the action of mounting the picked-up component to a predetermined installation position on the substrate 91 at a predetermined installation angle. During the installation process, the control device 16 controls the operation of the mounting head 133 based on information output from various sensors, image processing results, control programs, etc. As a result, the position and angle of the plurality of suction nozzles 134 supported on the mounting head 133 are controlled.

[0041] 2. Structure of the bulk material feeder 30

[0042] The bulk feeder 30 is equipped on the component mounting machine 10 and functions as part of the component supply device 12. The bulk feeder 30 supplies components 92 that are contained in a bulk state, which is not as neatly arranged as a carrier belt. Therefore, unlike a belt feeder, the bulk feeder 30 does not use a carrier belt, thus having advantages in terms of eliminating the need for carrier belt loading and recycling of used belts.

[0043] The bulk material feeder 30 has a type that supplies components 92 to a planar supply area As in an irregular posture, for example. However, when components 92 are close to each other or stacked in the supply area As (overlapping in the vertical direction), or are in a horizontal posture where the width direction of components 92 is vertical, the component mounting machine 10 cannot pick up these components 92. Therefore, in order to increase the proportion of components 92 that can be picked up, the bulk material feeder 30 has a type that supplies components 92 in an orderly manner in the supply area As. In this embodiment, a bulk material feeder 30 of the type that arranges components 92 in an orderly manner will be described.

[0044] 2-1. Feeder body 31

[0045] like Figure 2 As shown, the bulk material feeder 30 has a feeder body 31 formed into a flat, box-shaped form. A connector 311 and two pins 312 are provided at the front of the feeder body 31. When the feeder body 31 is placed into the slot 121 of the component supply device 12, it is powered via the connector 311 and is in a state capable of communicating with the control device 16. The two pins 312 are inserted into guide holes provided in the slot 121 for positioning the feeder body 31 when placed in the slot 121.

[0046] 2-2. Receiving component 32

[0047] A component box 70, which holds multiple components 92 in a bulk state, is mounted on the feeder body 31 in a detachable manner via a receiving member 32. The component box 70 is an external device of the bulk feeder 30. One of various types of component boxes 70 suitable for installation and processing is selected and mounted on the feeder body 31. A discharge port 71 for discharging components 92 to the outside is formed at the front of the component box 70.

[0048] The receiving member 32 is configured to vibrate relative to the feeder body 31 and support the mounted component cassette 70. The receiving member 32 forms a receiving area Ar for receiving components 92 discharged from the component cassette 70. In this embodiment, the receiving member 32 has an inclined portion 321 in the receiving area Ar that is inclined forward relative to the horizontal plane. This inclined portion 321 is located below the discharge port 71 of the component cassette 70 and is planar. The receiving member 32 forms a flow path for the components 92 extending above the receiving area Ar, and this flow path forms an upwardly opening discharge portion 322.

[0049] 2-3. Bracket 33, Track component 34, Locking unit 35

[0050] The bulk material feeder 30 includes a bracket 33 and a track component 34. The bracket 33 is configured to vibrate relative to the feeder body 31. The bracket 33 is formed as a block extending in the front-rear direction of the feeder body 31, and the track component 34 is mounted on its upper surface. The bracket 33 is supported by a support component 41 of the vibration device 40, which will be described later. The track component 34 has a transport path R for transporting multiple components 92 and a supply area As that communicates with the transport path R and opens upward in a manner that allows multiple components 92 to be picked up.

[0051] The bulk material feeder 30 includes a locking unit 35. The locking unit 35 locks the track component 34 when it is mounted on the bracket 33. When locked by the locking unit 35, the track component 34 vibrates integrally with respect to the feeder body 31 and the bracket 33. The track component 34 can be detached from the bracket 33 when the locking unit 35 is unlocked.

[0052] 2-4. Detailed structure of track component 34, cover 36, gate 37, connecting component 38

[0053] The track component 34 is formed in the front-rear direction of the feeder body 31. Figure 4 Extending in the left-right direction. In the width direction of track component 34 ( Figure 4 The two edges of the component (in the vertical direction) have a pair of upwardly projecting sidewalls 341. The pair of sidewalls 341, together with the front end portion 342 of the track component 34, surround the periphery of the transport path R, preventing the leakage of the component 92 transported on the transport path R. On the upper surface of the front end portion 342, a pair of circular reference marks 344 are attached to the left and right sides to indicate the reference position of the supply area As.

[0054] In this embodiment, a tidying member 50 is replaceably mounted on the track member 34. The tidying member 50 has multiple chambers 51 that house multiple elements 92 one by one. Specifically, the multiple chambers 51 are arranged in a matrix in the supply area As. For example, the tidying member 50 has a total of 80 chambers 51, with 8 arranged regularly in the transport direction and 10 arranged in the width direction of the transport path R. Each of the multiple chambers 51 opens upward and houses the element 92 in an orientation that is vertical in the thickness direction of the element 92.

[0055] The opening of chamber 51 is set to be slightly larger than the external shape of component 92 when viewed from above. The depth of chamber 51 is set according to the type (shape, mass, etc.) of component 92. One of various types of track components 34 is selected based on the type of component 92, the required number of chambers 51, and functionality, and is mounted on the track component 34.

[0056] Here, the "supply area As" of the track component 34 is the area where the component 92 is supplied in a bulk state, and is the area where the component 92 can be picked up using the suction nozzle 134 supported on the mounting head 133. In addition, the "transport path R" of the track component 34 is the channel through which the component 92 flowing from the receiving area Ar to the track component 34 is transported to the supply area As.

[0057] The bulk material feeder 30 includes a cover 36. The cover 36 is fixed to the track component 34 and covers the top of the transport path R. Multiple vents 361 are formed on the upper surface of the cover 36. A mesh with seams smaller than the external dimensions of the component 92 is laid in the vents 361. With this structure, the cover 36 is configured to prevent the component 92 from flying out of the transport path R and to allow air to be discharged to the outside from the vents 361.

[0058] The bulk material feeder 30 includes a gate 37 disposed on the upper part of the track component 34 and capable of closing the opening of the supply area As. The bulk material feeder 30 can prevent the component 92 from flying out and foreign matter from entering the supply area As by opening and closing the gate 37. In this embodiment, the gate 37 switches between an open state, a closed state, and an intermediate state through opening and closing operations. The closed state of the gate 37 is the state in which the gate 37 is in contact with the track component 34 and the opening of the supply area As is completely closed. At this time, as... Figure 4 As shown by the dotted line, the gate 37 is located behind the feeder body 31, relative to the pair of reference marks 344 of the track component 34, allowing for visual confirmation and photographing of the pair of reference marks 344 from a top-down view.

[0059] Furthermore, the so-called open state of the gate 37 is a state in which the opening of the supply area As is not closed and the main area of ​​the supply area As (in this embodiment, the area where multiple chambers 51 are provided) is exposed. At this time, the suction nozzle 134 can perform the picking-up action of the element 92 on any chamber 51. The so-called intermediate state of the gate 37 is a state between the closed state and the open state, and is a state in which the gate 37 is at least further away from the track member 34 than the amplitude of the track member 34 vibrating by the excitation of the excitation device 40, and the limiting element 92 is prevented from flying out of the opening of the supply area As. The gate 37 is opened and closed by a drive device (not shown in the figure), and becomes the closed state, open state, and intermediate state depending on the drive state of the drive device.

[0060] The track component 34 has a flow path for a downwardly extending element 92 at its rear, and this flow path has a downwardly opening inlet 343. The inlet 343 is vertically opposite to the outlet 322 of the receiving component 32. The bulk material feeder 30 has a tubular connecting component 38. The connecting component 38 connects the outlet 322 of the receiving component 32 to the inlet 343 of the track component 34. In this embodiment, the connecting component 38 is a close-fitting helical spring and is flexible overall.

[0061] With the structure described above, the connecting member 38 is connected in a manner that allows multiple elements 92 to flow between the receiving area Ar and the transport path R. Furthermore, the connecting member 38 absorbs vibration by deforming in response to the vibrations of the receiving member 32 relative to the feeder body 31 and the track member 34 relative to the feeder body 31. The connecting member 38 reduces or interrupts the vibrations transmitted between the independently vibrating receiving member 32 and track member 34.

[0062] 2-5. Air supply device 39

[0063] The bulk material feeder 30 includes an air supply device 39. The air supply device 39 supplies positive pressure air from below the receiving area Ar, allowing multiple components 92 to flow from the receiving member 32 to the track member 34 via the connecting member 38. In this embodiment, the air supply device 39 supplies or cuts off the positive pressure air supplied from the outside from below the receiving area Ar based on instructions from the feeder control device 60 described later.

[0064] When the air supply device 39 supplies positive pressure air, the multiple components 92 retained in the receiving area Ar are blown upwards by the positive pressure air. The positive pressure air and the multiple components 92 flow in the order of the delivery part 322, the connecting part 38, and the inlet part 343 of the receiving member 32, reaching the transport path R of the track member 34. Here, the positive pressure air is discharged to the outside from the exhaust port 361 of the cover 36. In addition, the multiple components 92 fall down into the transport path R of the track member 34 due to their own weight.

[0065] 2-6. Vibration excitation device 40

[0066] The bulk material feeder 30 includes a vibration device 40 disposed on the feeder body 31. The vibration device 40 applies vibration to the track component 34 to transport multiple components 92 along the transport path R. Specifically, the vibration device 40 includes multiple support components 41, multiple piezoelectric elements 42, a vibration sensor 43, and a power supply device 44. The multiple support components 41 directly or indirectly connect the feeder body 31 to the bracket 33, supporting the bracket 33.

[0067] In this embodiment, the plurality of support members 41 have a forward support member 41A for front-side transport of the element 92 and a backward support member 41B for rear-side transport. The forward support member 41A and the backward support member 41B each have different inclination directions relative to the vertical direction. The plurality of piezoelectric elements 42 are oscillators that vibrate at a frequency corresponding to the power supplied from the power supply device 44. The plurality of piezoelectric elements 42 are respectively attached to each of the plurality of support members 41.

[0068] When at least a portion of the piezoelectric elements 42 vibrates, the vibration is applied to the track component 34 via the bracket 33. Furthermore, the amplitude of the track component 34 varies depending on the voltage applied to the piezoelectric elements 42. The vibration sensor 43 detects a vibration value representing the vibration state of the track component 34, which vibrates due to excitation by the excitation device 40. The vibration value representing the vibration state can be amplitude, frequency, decay time, vibration trajectory, etc. In this embodiment, the vibration sensor 43 detects the actual frequency or amplitude of the vibration of the track component 34 when the piezoelectric elements 42 are powered and vibrate.

[0069] In this embodiment, vibration sensors 43 are respectively provided on a plurality of support members 41 that support the bracket 33, which vibrates integrally with the track member 34. More specifically, piezoelectric elements 42 and vibration sensors 43 are provided on each forward support member 41A and each backward support member 41B. When the piezoelectric element 42 provided on the forward support member 41A is powered and vibrates the track member 34 via the bracket 33, the vibration sensor 43 provided on the forward support member 41A detects the actual frequency or amplitude as a vibration value.

[0070] Here, when the excitation device 40 applies vibration to the track component 34, the track component 34 undergoes elliptical motion in a side view. As a result, multiple elements 92 located on the transport path R are subjected to an external force in front and above, or an external force in rear and above, depending on the rotational direction of the elliptical motion of the track component 34. As a result, the multiple elements 92 are transported to the front side or the rear side of the track component 34.

[0071] Based on instructions from the feeder control device 60 (described later), the power supply device 44 varies the frequency and applied voltage of the power supplied to the piezoelectric element 42. This adjusts the frequency and amplitude of the vibration applied to the track component 34, determining the rotational direction of the elliptical motion of the track component 34. When the frequency, amplitude, and rotational direction of the elliptical motion caused by the vibration of the track component 34 change, the transport speed, dispersion of the transported element 92, and transport direction also change.

[0072] Therefore, in order to improve handling efficiency, the vibration excitation device 40 is pre-set with a power supply (frequency, applied voltage) corresponding to the individual differences in vibration characteristics (including inherent vibration frequency). For example, the bulk material feeder 30 performs a correction process when the track component 34 for the predetermined feeding action is installed, that is, when the track component 34 is locked relative to the bracket 33 by the locking unit 35. Details of the correction process will be described later.

[0073] 2-7. Feeder control device 60

[0074] The bulk material feeder 30 includes a feeder control device 60. The feeder control device 60 mainly consists of a CPU, various memories, and control circuits. When the bulk material feeder 30 is placed in the slot 121, the feeder control device 60 is powered via connector 311 and is able to communicate with the control device 16 of the component mounting machine 10.

[0075] like Figure 2 As shown, the feeder control device 60 has a storage unit 61. The storage unit 61 is composed of flash memory or the like. The storage unit 61 stores various data such as programs for controlling the component supply process and transport parameters. The aforementioned "transport parameters" are parameters used to control the operation of the excitation device 40 when transporting the component 92 in the component supply process so that the vibration applied to the track component 34 is appropriate, and are preset, for example, in association with each type of component 92.

[0076] The feeder control device 60 includes a vibration control unit 62. The vibration control unit 62 controls the operation of the vibration device 40 to perform the transport operation of the element 92. Specifically, when performing the transport operation, the vibration control unit 62 sends a command to the power supply device 44 of the vibration device 40. Therefore, by supplying a predetermined amount of power to the piezoelectric element 42 from the power supply device 44, vibration is applied to the track component 34 via the bracket 33. Furthermore, the element 92 on the transport path R is transported by an external force in a manner that moves in the transport direction.

[0077] 3. Structure of the component supply control system 80

[0078] The component supply control system 80 controls the supply of components using the aforementioned bulk material feeder 30.

[0079] In this embodiment, such as Figure 5 As shown, the component supply control system 80 is assembled in the control device 16 and configured to communicate with the bulk material feeder 30 equipped in the tank 121. The component supply control system 80 controls the component supply to maintain a good supply state of the components 92 in the bulk material feeder 30.

[0080] 3-1. Status Recognition Unit 81

[0081] like Figure 5 As shown, the component supply control system 80 includes a status recognition unit 81. As described above, the status recognition unit 81 is based on image data D1 (refer to...) acquired by the substrate camera 15. Figure 6The status recognition unit 81 first identifies the supply status of multiple components 92 in the supply area As of the bulk material feeder 30. More specifically, the status recognition unit 81 first performs supply status recognition processing based on image data D1 obtained by taking pictures of the supply area As when the bulk material feeder 30 transports multiple components 92 to the supply area As by vibration.

[0082] Figure 6 This is an example of image data D1. Thus, a large number of components 92 exist in a bulk state in the supply area As. For example, there may be components housed in the chamber 51 in a normal posture, components located outside the chamber 51, components in contact with or stacked together, components in a horizontal posture, etc. Furthermore, the state recognition unit 81 estimates the supply state of the components 92 for each of the multiple regions N pre-set in the supply area As.

[0083] That is, the state recognition unit 81 does not identify the supply state of each element 92 identified by image processing as being able to be picked up individually, but rather estimates the supply state as whether the element 92 present in each of the multiple regions N can be picked up for each region N. In addition, whether an element 92 belongs to region N is determined based on whether the reference part of the element 92 (e.g., the center of the element) is inside the region N.

[0084] Furthermore, in this embodiment, the aforementioned "supply state" includes a state where element 92 exists in region N and can be picked up, a state where element 92 exists in region N but cannot be picked up, and a state where element 92 does not exist in region N. Additionally, the position, shape, and number of the plurality of regions N can be arbitrarily set. In this embodiment, as... Figure 6 As shown by the dashed lines, each of the multiple regions N corresponds to a chamber 51.

[0085] Specifically, a region N is set to correspond to the position and rectangular shape of the chamber 51, and is separated from other regions N. Thus, with the element 92 housed in the predetermined chamber 51 in a normal posture and without contact or accumulation with other elements, an element 92 is housed inside the region N corresponding to the chamber 51. At this time, the length direction of region N ( Figure 6 The vertical direction is roughly the same as the length direction of component 92.

[0086] In addition, such as Figure 7 As shown, the status identification unit 81 classifies the supply status into multiple categories for estimation. Figure 7 Region N is indicated by an additional slash for regions where element 92 is present and can be picked up (“good”). Additionally, Figure 7For regions N where component 92 exists but cannot be picked up (“defective”), an additional diagonal X-mark is added to indicate the region N. Furthermore, Figure 7 Region N is represented by a dashed outline, indicating a region where the supply of element 92 is absent (“empty”). For example... Figure 7 As shown, the status identification unit 81 calculates the quantity (V1, V2, V3) of each supply status (good, bad, empty).

[0087] Here, sometimes in the supply area As, for example, due to an excess of transported elements 92 relative to the number of chambers 51, etc., therefore, Figure 6 As shown, a component group U is formed by densely packed multiple components 92. In this embodiment, the state recognition unit 81 also estimates the position and size of the component group U as the state of the component group based on the image data D1. Specifically, the state recognition unit 81 can also recognize the contact and stacking states of the components 92 and estimate the state of the component group.

[0088] Furthermore, the status identification unit 81 can also consider the region containing the multiple regions N as equivalent to component group U when the supply status is continuously "defective" for a specified number of consecutive times, and presume the status of the component group. Thus, as... Figure 7 As shown by the single-dot dashed line, the state recognition unit 81 estimates the position Cu and size of the component group U as the state of the component group.

[0089] 3-2. Handling Control Unit 85

[0090] like Figure 5 As shown, the component supply control system 80 includes a transport control unit 85. The transport control unit 85 controls the transport operation of the component 92 in the bulk material feeder 30 based on the supply status of each of the multiple regions N. Here, the transport operation of the component 92 in the bulk material feeder 30 includes a feeding operation and a return operation. The aforementioned "feeding operation" is the operation of transporting the component 92 from the rear to the front of the track member 34, and it is the operation of moving multiple components 92 forward from the transport path R connected to the supply region As towards the supply region As. The "return operation" is the operation of transporting the component 92 from the front to the rear of the track member 34, and it is the operation of moving multiple components 92 backward from the supply region As towards the transport path R.

[0091] The transport control unit 85 controls the number of times and execution time of the aforementioned feed and return actions based on the supply status of each of the multiple regions N. In this embodiment, the transport control unit 85 switches between multiple transport modes in the control of the transport actions based on the ratio (V1:V2:V3) of the supply status (good, bad, empty) estimated by the status recognition unit 81 for each of the multiple regions N. Various methods can be used for switching the transport modes. For example, the transport control unit 85 may only use the transport mode corresponding to the type of supply status that has the maximum number of occurrences.

[0092] Furthermore, the transport control unit 85 can switch between multiple transport modes based on at least one of the positions of each of the multiple regions N set in the supply area As, the weights assigned to each of the multiple regions N, and the ratio of the supply states. Specifically, for the multiple regions N, the weights are increased closer to the front end 342 side of the track component 34, and the ratio of the supply states (V1:V2:V3) is calculated. Thus, for example, the importance of the chamber 51 closer to the substrate 91 is increased, and a higher priority transport operation is performed.

[0093] Here, the aforementioned multiple transport modes include normal transport, replenishment transport, and removal transport. "Normal transport" is a transport mode in which feed and return actions are performed within a predetermined time period. In normal transport, for example, feed and return actions are sometimes performed alternately more than twice. "Replenishment transport" is a transport mode that increases the number of advancing elements 92 or the execution time of the feed action compared to normal transport. Furthermore, "removal transport" is a transport mode that decreases the number of retreating elements 92 or the execution time of the return action compared to normal transport.

[0094] As an example, in the supply state ratio (V1:V2:V3), if the supply state ("good") in region N contains the most components 92 and can be picked up, the transport control unit 85 considers the supply state to be good and sets "normal transport" as the transport mode. Conversely, if in the supply state ratio (V1:V2:V3), if the supply state ("bad") in region N contains the most components 92 and cannot be picked up, the transport control unit 85 considers the supply region As to contain an excess of components 92 and sets "removal transport" as the transport mode.

[0095] Furthermore, in the supply state ratio (V1∶V2∶V3), when the supply state of no element 92 in region N is the most frequent ("empty"), the transport control unit 85 considers that there is a shortage of element 92 in the supply region As and sets "replenishment transport" as the transport mode. Here, in order to increase or decrease the number of elements 92 to be transported in replenishment transport or removal transport compared to normal transport, for example, a method can be adopted to monitor the number of elements 92 to be transported in real time and perform control based on this.

[0096] Alternatively, instead of the above method, when switching from normal transport to replenishment transport or removal transport, the transport control unit 85 can change the number of times or the execution time of the feed or return action. Specifically, in normal transport, the transport control unit 85 performs one feed action and one return action each for the same amount of time. Furthermore, when switching from normal transport to replenishment transport, the transport control unit 85 can also make the execution time of the feed action longer than that of the return action, and perform two feed actions and two return actions for each.

[0097] Alternatively, when switching from normal transport to replenishment transport, the transport control unit 85 can maintain the execution time of the return and feed actions without changing them, but only increase the number of times the feed action is executed. This also applies when the transport control unit 85 switches from normal transport to removal transport. That is, the execution time of the return action can be longer than the feed action, or only the number of times the return action is executed can be increased.

[0098] Furthermore, the transport control unit 85 can also change the frequency or amplitude of the vibration applied to the track member 34, which forms the supply area As, when switching from normal transport to replenishment transport or removal transport. Thus, a vibration different from that applied to normal transport is applied to the track member 34, allowing for changes in the magnitude and direction of the external force applied to the element 92 from the track member 34. As a result, it is possible to disperse the element group U or remove the element 92 that is improperly embedded in the chamber 51.

[0099] Here, the transport control unit 85 can control the transport operation not only based on the supply status of each of the multiple regions N, but also based on the component group status, which indicates the position and size of the component group U. The aforementioned "component group status" includes the presence and quantity of component group U. The transport control unit 85 obtains the component group status based on the recognition processing performed by the status recognition unit 81. Furthermore, as... Figure 6 As shown, for example, when the component group U is located on the front end 342 side of the track component 34 in the supply area As, the transport control unit 85 performs a return action to move the component group U to a position further back than the supply area As.

[0100] Furthermore, when the number (V3) of empty chambers 51 (supply state type = empty) present in the component group U is a predetermined number or more, the transport control unit 85 repeatedly performs feed and return operations to move the component group U back and forth in the supply area As. This allows for the attempt to accommodate the component 92 into the empty chamber 51.

[0101] 4. Feeder control performed by the component supply control system 80

[0102] During the component mounting machine 10's mounting process, the component supply control system 80 performs feeder control corresponding to the supply status of the bulk material feeder 30. This feeder control includes control of the conveying motion and control of the opening and closing motion of the gate 37. Here, after the bulk material feeder 30 is placed in the tank 121, the control device 16 of the component mounting machine 10 performs a calibration process to identify the position of the supply area As within the machine.

[0103] In detail, the control device 16 first issues a command to the feeder control device 60 to close the gate 37. This creates a state where multiple reference marks 344 can be photographed from above. The control device 16 moves the substrate camera 15 above the multiple reference marks 344 of the bulk material feeder 30 and acquires image data by photographing with the substrate camera 15. Then, based on the positions of the multiple reference marks 344 included in the image data through image processing and the position of the substrate camera 15 at the time of photographing, the control device 16 identifies the position of the bulk material feeder 30 inside the machine, i.e., the position of the supply area As.

[0104] Next, before picking up component 92 from the bulk feeder 30 during the installation process, the transport control unit 85 instructs the bulk feeder 30 to transport component 92. As a result, the bulk feeder 30 discharges component 92 from component box 70 as needed and allows component 92 to flow to track component 34. Afterwards, the bulk feeder 30 maintains gate 37 in an intermediate state and performs the transport operation of component 92. Thus, component 92 is housed in multiple chambers 51, and excess component 92 is retracted from the supply area As towards the transport path R.

[0105] Reference Figure 8 The details of the component supply control process described above will be explained. When performing supply status identification processing, the status recognition unit 81 issues a command to the bulk material feeder 30 to open the gate 37. The status recognition unit 81 moves the substrate camera 15 above the supply area As and acquires image data by capturing images with the substrate camera 15. Then, as... Figure 8 As shown, the state recognition unit 81 estimates the supply state of the element 92 for each of the multiple regions N by image processing targeting the image data D1 (S11).

[0106] The status recognition unit 81 determines whether the difference (V1-Vn) between the required quantity (Vn) of the components 92 to be picked up from the supply area As through a series of pick-up actions in one PP cycle and the available quantity (V1) calculated based on the supply status of each of the multiple areas N is less than a reference value (Vs) (S12). The reference value (Vs) is set to a number greater than or equal to 0. If the available quantity is greater than the required quantity and the difference is greater than or equal to the reference value (S12: No, V1-Vn≥Vs), the status recognition unit 81 allows the execution of the pick-up action in the PP cycle (S13). The control device 16 executes the pick-up action in the PP cycle, and then executes the installation action.

[0107] Additionally, the status recognition unit 81 performs an update process (S13) for the supply status identified in S11. In this update process, the region N corresponding to the element 92 picked up by the picking action is set to a supply status where no element 92 exists (“empty”). Furthermore, in the status update process, the number of items picked up (the required number Vn mentioned above) is subtracted from the number of items that can be picked up (V1) to obtain the current number of items that can be picked up (V1' = V1 - Vn). Moreover, in the supply status update process, the number of empty chambers 51 (V3) is added to the number of empty chambers 51 (V3) to obtain the current number of empty chambers 51 (V3' = V3 + Vn).

[0108] After performing the supply status update process (S13), the status identification unit 81 performs the determination process of S12 again to determine whether the difference between the number of components 92 scheduled to be picked up in the next PP cycle (the next required quantity) and the number of remaining components 92 that can be picked up in the supply area As (the current pickable quantity) is greater than or equal to the reference value (Vs). In S12, if the pickable quantity is insufficient, the above difference (V1-Vn) is less than the reference value (Vs) (S12: Yes, V1-Vn < Vs), and there are still PP cycles scheduled to be executed (S14: Yes), the status identification unit 81 does not allow the execution of the picking action in the PP cycle, and performs the handling action by the bulk material feeder 30 before the execution of the picking action.

[0109] Furthermore, in the determination process of S12, the difference between the pickable quantity and the required quantity is compared with a reference value, but the ratio of the pickable quantity to the required quantity can also be compared with the reference value. As described above, after performing the supply status update process (S13), or in the case of insufficient pickable quantity (S12: No), the transport control unit 85 sets the transport mode based on the ratio of the supply status of each of the multiple regions N in the current multiple regions N (S15). In addition, if the difference between the number of components 92 to be picked up in the second PP cycle (required quantity) and the number of remaining components 92 that can be picked up in the supply region As (pickable quantity) is a reference value (Vs) or higher, the status recognition unit 81 omits the transport mode setting (S15), etc., and allows the execution of the pick-up operation.

[0110] The transport control unit 85 sets multiple transport modes in the control of the transport operation based on the ratio (V1:V2:V3) of the current supply status (good, bad, empty) estimated for each of the multiple regions N. Thus, the transport mode (e.g., normal transport, replenishment transport, removal transport) is switched. Then, the transport control unit 85 instructs the bulk material feeder 30 to transport the component 92 in the set transport mode (S16). When instructed to transport the component 92, the bulk material feeder 30 performs the transport operation in the set transport mode.

[0111] In this way, the bulk material feeder 30 performs a transport operation corresponding to the supply status of each of the multiple zones N. Thus, if the components 92 are supplied well according to the initial settings, normal transport is performed; otherwise, if relatively few components 92 can be picked up immediately after the transport operation, supplementary transport is performed. Furthermore, during this supplementary transport, sometimes, according to the instructions of the transport control unit 85, a process is also performed to discharge components 92 from the component box 70 and allow multiple components 92 to flow into the transport path R.

[0112] Furthermore, in cases where the current supply status of each of the multiple regions N indicates an oversupply of component 92, or in the presence of component group U, a removal and handling process is performed. This appropriately adjusts the quantity of component 92 in the supply region As. Such handling facilitates the proper placement of component 92 in the chamber 51, thereby increasing the number of components 92 that can be picked up in the supply region As. Thus, by ensuring a good supply status of component 92 in the bulk feeder 30, the productivity of the component mounting machine 10 can be improved.

[0113] After the material handling operation of component 92 by the bulk material feeder 30 is completed, the status identification unit 81 performs the process of estimating the supply status again (S11). Thus, the current supply status of each of the multiple regions N after the handling operation is identified. If the predetermined PP cycle has been completed and the supply of component 92 is no longer needed (S14: No), the component supply control system terminates the above-described control process.

[0114] 5. Variations of the implementation method

[0115] 5-1. Regarding the component supply control system 80

[0116] In this embodiment, a configuration is described in which the status recognition unit 81 and the transport control unit 85 of the component supply control system 80 are assembled into the control device 16 of the component mounting machine 10. In contrast, one or both of the status recognition unit 81 and the transport control unit 85 may be an external device assembled into the control device 16. For example, the status recognition unit 81 may be assembled into an imaging unit that is integrally movable on the stage 132 and controls the imaging operation of the substrate camera 15.

[0117] Alternatively, the transport control unit 85 can also be assembled into the component supply device 12, which mediates communication between the feeder 122 equipped in the multiple slots 121 and the control device 16. Furthermore, the status recognition unit 81 and the transport control unit 85 can also be assembled into the feeder control device 60 of the bulk material feeder 30 as a self-control function of the bulk material feeder 30. Moreover, the status recognition unit 81 and the transport control unit 85 can also be assembled into a host computer, dedicated equipment, etc., that can communicate with the component mounting machine 10. In any of these configurations, the same effects as in the embodiment are achieved.

[0118] 5-2. Regarding track component 34

[0119] In one embodiment, the track component 34 of the bulk material feeder 30 has a structure comprising neatly arranged components 50 having a plurality of chambers 51. Alternatively, the neatly arranged components 50 may be omitted. That is, in the supply area As of the track component 34, a concave portion for dispersing the elements 92 and a planar portion flush with the upper surface of the transport path R may be formed at a position lower than the upper surface of the transport path R, thereby supplying the elements 92 in a bulk state.

[0120] In this structure, the multiple regions N in the supply area As are, for example, the size of the component 92 to be supplied, and are set to be non-overlapping. The multiple regions N can be arbitrarily set to be adjacent to each other or separated as illustrated in the embodiment. In this manner, the state recognition unit 81, similar to the embodiment, estimates the supply state of the component 92 for each of the multiple regions N. Furthermore, the transport control unit 85 can control the transport operation based on the supply state of each of the multiple regions N.

[0121] However, in the aforementioned manner, the elements 92 are not arranged neatly relative to the multiple regions N, thus the processing load for determining whether they can be picked up and for image processing of the orientation of the elements 92 may be relatively high. Therefore, from the viewpoint of improving the efficiency of element supply processing and reducing the image processing load in the processing of identifying the supply state in the supply region As, the structure illustrated in the embodiment is preferred.

[0122] 5-3. About the camera

[0123] In this embodiment, a substrate camera 15 is used to capture images of the supply area As of the bulk material feeder 30. Alternatively, the camera capturing images of the supply area As can also be a fixed camera positioned above the bulk material feeder 30. This fixed camera can be used exclusively for capturing images of the supply area As, or it can be used for other purposes.

[0124] Alternatively, the camera that captures images of the supply area As can be a built-in camera of the bulk material feeder 30 located below the supply area As. In this configuration, the supply area As of the track member 34 and the aligning member 50 are formed of a transparent material. The built-in camera of the bulk material feeder 30 can capture images of the element 92 housed in the chamber 51 through them. With this structure of a fixed camera and a built-in camera, the supply area As can be captured at any time regardless of the position of the moving stage 132, thus enabling image capture processing, status recognition processing, etc., to be performed during the installation process. However, from the viewpoint of reducing equipment costs, the configuration illustrated in this embodiment is preferred.

[0125] Explanation of reference numerals in the attached figures

[0126] 10: Component mounting machine; 12: Component supply device; 13: Component transfer device; 15: Substrate camera; 16: Control device; 30: Bulk feeder; 31: Feeder body; 34: Track component; 40: Vibration device; 41: Support component; 41A: Forward support component; 41B: Backward support component; 42: Piezoelectric element (oscillator); 43: Vibration sensor; 44: Power supply device; 50: Neat arrangement component; 51: Chamber; 60: Feeder control device; 80: Component supply control system; 81: Status recognition unit; 85: Transport control unit; 91: Substrate; 92: Component; As: Supply area; R: Transport path; N: Area; U: Component group; D1: Image data.

Claims

1. A component supply control system, comprising: The status recognition unit, based on image data obtained by capturing images of the supply area while the bulk material feeder is transporting multiple components to the supply area via vibration, estimates the supply status of the components for each of the multiple areas pre-defined in the supply area; and The material handling control unit controls the handling actions of the components in the bulk material feeder based on the supply status of each of the multiple regions. The status identification unit classifies the supply status into multiple categories for estimation. The transport control unit switches between multiple transport modes in controlling the transport operation based on the proportion of the supply status estimated for each of the multiple regions. The transport control unit switches between multiple transport modes based on at least one of the following: the position of each of the multiple regions set in the supply region and the weight set for each of the multiple regions, and the ratio of the supply state.

2. A component supply control system, comprising: The status recognition unit estimates the supply status of the component for each of the multiple regions preset in the supply area based on image data obtained by taking pictures of the supply area while the bulk material feeder is transporting multiple components to the supply area by vibration. and The material handling control unit controls the handling actions of the components in the bulk material feeder based on the supply status of each of the multiple regions. The transport control unit switches between multiple transport modes during the control of the transport action. The various transport modes include: normal transport, which performs a feeding action that moves the plurality of said elements forward from a transport path connected to the supply area and a returning action that moves the plurality of said elements backward from the supply area; replenishment transport, which increases the number of said elements moving forward or the execution time of the feeding action compared to normal transport; and removal transport, which decreases the number of said elements moving backward or the execution time of the returning action compared to normal transport.

3. The component supply control system according to claim 2, wherein, When switching from normal transport to replenishment transport or removal transport, the transport control unit changes the number of times or the execution time of the feed action or the return action.

4. The component supply control system according to claim 2, wherein, When switching from the normal transport to the replenishment transport or the removal transport, the transport control unit changes the frequency or amplitude of the vibration applied to the component where the supply area is formed.

5. A component supply control system, comprising: The status recognition unit, based on image data obtained by capturing images of the supply area while the bulk material feeder is transporting multiple components to the supply area via vibration, estimates the supply status of the components for each of the multiple areas pre-defined in the supply area; and The material handling control unit controls the handling actions of the components in the bulk material feeder based on the supply status of each of the multiple regions. The state recognition unit also estimates the position and size of the component group based on the image data to determine the state of the component group, wherein the component group is formed by densely packed multiple components in the supply area. The transport control unit controls the transport action based on the supply status and component group status of each of the multiple regions.

6. A component supply control system, comprising: The status recognition unit, based on image data obtained by capturing images of the supply area while the bulk material feeder is transporting multiple components to the supply area via vibration, estimates the supply status of the components for each of the multiple areas pre-defined in the supply area; and The material handling control unit controls the handling actions of the components in the bulk material feeder based on the supply status of each of the multiple regions. If the difference between the required number of components to be picked up from the supply area through a series of picking actions and the pickable number calculated based on the supply status of each of the multiple areas is less than a reference value, or if the ratio of the pickable number to the required number is less than a reference value, the transport control unit performs the transport action before performing the series of picking actions.

7. The component supply control system according to any one of claims 1 to 6, wherein, The supply status includes a status where the element is present in the area and can be picked up, a status where the element is present in the area but cannot be picked up, and a status where the element is not present in the area.

8. The component supply control system according to any one of claims 1 to 6, wherein, The bulk feeder has multiple chambers in the supply area for accommodating the components. Each of the multiple regions is configured to correspond to one of the chambers.

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