Component assembly machine, component assembly process and calibration device for assembly head

Abstract

A component assembly machine comprises an assembly head carrying a holding element capable of holding a component, which can be raised and lowered and rotated about a central axis of the holding element; a memory section configured to store a correction value for each of several measurement angles, set based on an error in a height direction when the holding element is moved to a specified height in a state where it is indexed to the several measurement angles about the central axis; and a control section configured to correct, during a pickup operation of the component by the holding element, a lowering amount of the holding element to a target height based on a pickup angle of the holding element indexed about the central axis and the correction value for each of the several measurement angles.

Description

Technical area

[0001] The present invention relates to a component mounting machine, a component mounting method and a calibration device for a mounting head. background

[0002] The component mounting machine is used to manufacture a plate product. The component mounting machine picks up a component with, for example, a suction nozzle and mounts the component at a predetermined mounting position on the plate. The component mounting machine includes a mounting head that is movable within the machine and supports the suction nozzle so that the suction nozzle can be raised and lowered and rotated. Patent Literature 1 discloses a configuration in which a correction value based on a result of calibration processing performed before production for a mounting head is incorporated into an assembly process to compensate for an individual difference in a configuration of the mounting head and improve the accuracy of the assembly process. Patent literature

[0003] Patent Literature 1: JP-A-2009-164276 Summary of the inventionTechnical problem

[0004] There is a need for a component assembly machine that further improves production efficiency. Therefore, the component assembly machine needs to adequately reflect the calibration processing result for the assembly head in the assembly process and prevent the occurrence of an error in a picking process or an assembly process.

[0005] An object of the present disclosure is to provide a component mounting machine, a component mounting method, and a calibration device for a mounting head capable of improving the accuracy of an assembly process and production efficiency by absorbing an individual difference in a configuration of the mounting head. Solution to the problem

[0006] The present specification discloses a component mounting machine including a mounting head supporting a holding member capable of holding a component that can be raised and lowered and rotated about a central axis of the holding member, a storage section configured to store a correction value for each of a plurality of measurement angles, which correction value is set based on an error in a height direction when the holding member is moved to a specific height in a state indexed to the plurality of measurement angles about the central axis, and a control section configured to correct, in a picking operation of picking up the component by the holding member, a lowering amount of the holding member to a target height based on a picking angle of the holding member indexed about the central axis and the correction value for each of the plurality of measurement angles. Advantageous effect of the invention

[0007] With this configuration, the amount of lowering the fixture to the target height during the pick-up process is adjusted depending on the pick-up angle of the fixture. Since the fixture is lowered to the target height with greater accuracy, errors in the pick-up process can be prevented. This can improve the accuracy of the assembly process and production efficiency. Short description of the characters Fig. 1 is a plan view schematically showing a component assembly machine. Fig. 2 is a plan view schematically showing a mounting head. Fig. 3 is a side view schematically showing the mounting head. Fig. 4 is a view showing a suction nozzle and a component, seen in direction IV in Fig. 3. Fig. 5 is a plan view showing a feeding section of a component in a mass conveyor. Fig. 6 is a block diagram showing the component mounting machine and a calibration device. Fig. Figure 7 is a diagram highlighting an error in the height direction that may occur due to the rotation of the suction nozzle around a central axis. Fig. Figure 8 is a flowchart showing the calibration processing for the mounting head. Fig. 9 is a table showing measured values ​​(errors in height direction) and correction values ​​in correction data. Fig. 10 is a diagram showing a relationship between an error in the height direction and a correction value for each measurement angle. Fig. 11 is a flowchart illustrating an assembly process by the component assembly machine. Fig. 12 is a flowchart illustrating a pickup cycle in the assembly process. Fig. 13 is a view illustrating the lowering of the suction nozzle in a picking operation. Fig. 14 is a view illustrating the lifting of the suction nozzle in the picking operation. Description of the embodiments

[0008] A component mounting machine for performing a mounting process of a component, a component mounting method, and a calibration device for a mounting head will be described with reference to the drawings. 1. Configuration of the component assembly machine 10

[0009] The component mounting machine 10, together with several types of board processing machines, including, for example, other component mounting machines 10, forms a production line for manufacturing a board product. The board processing machines constituting the above-described production line may include a printer, an inspection device, a reflow oven, and the like. 1-1. Plate conveyor device

[0010] As in Fig. 1, the component assembly machine 10 includes a plate conveyor 11. The plate conveyor 11 then conveys the plate 91 in a transport direction and positions the plate 91 at a predetermined position within the machine. 1-2. Component feeding device 12

[0011] The component mounting machine 10 includes a component feeder 12. The component feeder 12 supplies the component to be mounted on the platen 91. The component feeder 12 includes feeders 122, each arranged in a plurality of slots 121. For example, a tape feeder that feeds and moves a carrier tape holding a large number of components to provide the components so that the components can be picked up is used on a feeder 122. In addition, a bulk feeder 40 that provides the components in a bulk state (loose state in which each layer is irregular) so that the components can be picked up is used on feeder 122. Details of the bulk feeder 40 will be described later. 1-3. Component transfer device 13

[0012] The component mounting machine 10 includes a component transfer device 13. The component transfer device 13 transfers the component supplied by the component feed device 12 to the predetermined mounting position on the platen 91. The component transfer device 13 includes a head drive device 131, a movable table 132, and a mounting head 30. The head drive device 131 moves the movable table 132 in horizontal directions (X direction and Y direction) using a linear motion mechanism. The mounting head 30 is detachably attached to the movable table 132 by a clamp member (not shown) and arranged to be movable in the horizontal direction within the machine.

[0013] As in the Fig. 2 and Fig. 3, the mounting head 30 includes a rotary head 31 arranged to rotate about an R-axis parallel to a vertical axis (Z-axis). The rotary head 31 supports a plurality of holders 32 that can be raised and lowered and rotated about a central axis (Q-axis) for each of the plurality of holders 32. Attached to each of the plurality of holders 32 is a holding member that holds a component 92. In the present embodiment, the holding member is a suction nozzle 33 that holds the component 92 by picking it up with the aid of supplied negative air. As the holding member, a chuck or the like can be used, which holds the component by gripping it.

[0014] The suction nozzle 33 has a cylindrical shaft portion 331 extending in the direction of the central axis. A flange 332 is attached to the shaft portion 331. The flange 332 is a part that forms a background when the suction nozzle 33 is imaged from below. The shaft portion 331 has an opening 333 formed in a lower tip end portion. The tip end portion (shaft portion 331 and opening 333) of the suction nozzle 33 may be formed in a non-circular shape, as shown in FIG. Fig. 4, in addition to a concentric circular shape, viewed in the direction of the central axis.

[0015] As described above, the suction nozzle 33, in which the tip end portion is formed in a non-circular shape, is used in the mounting process to ensure a larger area (the area of ​​the opening 333) where a suction pick-up force acts on the upper surface of the rectangular fine chip component. As described above, when the opening 333 protrudes beyond the outer edge of the component 92 due to the discharge of negative pressure air and the decrease in the suction pick-up force, the non-circular suction nozzle 33 is used so that the longitudinal direction of the opening 333 during the pick-up process substantially coincides with the longitudinal direction of the component 92.

[0016] The mounting head 30 includes an R-axis rotating device 34 that rotates the rotating head 31 around the R-axis. The R-axis rotating device 34 sets the angle of the rotating head 31 at a predetermined angle around the R-axis to enter a lifting and lowering position in which the first holder 32 is raised and lowered by a lifting and lowering device 36 described later. The mounting head 30 includes a Q-axis rotating device 35 that rotates the holder 32 around the Q-axis. In the present embodiment, the Q-axis rotating device 35 comprises a mechanism that rotates a plurality of holders 32 in an interlocked manner and is used collectively to rotate a plurality of holders 32. With the configuration described above, when the first holder 32 is angled at a predetermined angle around the Q-axis, the second plurality of holders 32 are also angled at a predetermined angle in an interlocked manner.

[0017] The mounting head 30 includes a lifting and lowering device 36 that raises and lowers a holder 32 among a plurality of holders 32, which is indexed to the lifting and lowering position by the rotation of the rotary head 31. The lifting and lowering device 36 raises and lowers the holder 32 to raise and lower the suction nozzle 33 attached to the holder 32. The mounting head 30 may be configured to have two or more lifting and lowering positions, and a plurality of lifting and lowering devices that can be driven independently of each other so that the holders 32 positioned at the respective positions can be raised and lowered.

[0018] The number of holders 32 supported by the mounting head 30 with the configuration described above may vary depending on the type of the mounting head 30. Furthermore, the mounting head 30 may take various forms other than one in which a plurality of holders 32 are supported at regular intervals in an annular shape, as in the present embodiment. For example, the mounting head 30 may take a configuration in which a plurality of holders 32 are supported arranged in a straight line or in a matrix. 1-4. Component camera 14 and plate camera 15

[0019] The component mounting machine 10 includes a component camera 14 and a plate camera 15. The component camera 14 and the plate camera 15 are digital imaging devices using an imaging element such as CMOS. The component camera 14 and the plate camera 15 capture an image based on a control signal and transmit image data captured by the imaging. The component camera 14 is configured to image a component held by the suction nozzle 33 from below. The plate camera 15 is arranged on a movable table 132 so that it is movable in the horizontal direction integrally with the mounting head 30. The plate camera 15 is configured to capture an image of the plate 91 from above.

[0020] Furthermore, the plate camera 15 can use various devices or the like as an imaging target within the moving range of the movable table 132, in addition to using the surface of the plate 91 as an imaging target. For example, in the present embodiment, the plate camera 15 can capture an image of a feeding area As to which the mass feeder 40 delivers the component or the reference mark 444 arranged at an upper part of the mass feeder 40 within the field of view of the camera (see Fig. 5). As described above, the plate camera 15 can be used jointly to capture images for various imaging targets to obtain image data used for various image processing. 1-5. Control device 20

[0021] The component assembly machine 10 comprises a control device 20 as shown in Fig. 1. The control device 20 mainly includes a CPU, various types of memory, and a control circuit. The control device 20 includes a memory section 21, as shown in Fig. 6. The storage section 21 includes an optical drive, such as a hard disk or flash memory. Various data, such as a control program and correction data D1, used to control the assembly process, are stored in the storage section 21 of the control device 20.

[0022] The control program specifies the mounting position, mounting angle, and component type of the component to be mounted on the plate 91 in the assembly process in the planned mounting sequence. Here, the assembly process includes a process in which a pick-and-place (PP) cycle, which includes a pickup cycle and a mounting cycle, is repeated multiple times. The term "pickup cycle" described above refers to a process in which a pickup operation for picking up the component fed from the component feeder 12 by the suction nozzle 33 is repeated multiple times.

[0023] Furthermore, the term "mounting cycle" described above refers to a process in which a mounting process in which the picked-up component is repeatedly mounted at a predetermined mounting position in the plate 91 at a predetermined mounting angle is repeated multiple times. As described above, in the control program, an execution order of the PP cycle, which includes a plurality of picking processes and mounting processes grouped by considering the number of suction nozzles 33 supported by the mounting head 30, the moving distance of the mounting head 30, and the like, is set in advance.

[0024] The control device 20 includes a mounting control section 22. The mounting control section 22 executes the mounting process based on the control program in which the execution order of the PP cycles is specified. The mounting control section 22 performs recognition processing of a holding state of the component held by each of the plurality of holding members (suction nozzles 33). Specifically, the mounting control section 22 performs image processing on image data acquired by imaging the component camera 14 to recognize the position and angle of each component with respect to a reference position of the mounting head 30. The mounting control section 22 may perform image processing on the image data acquired by imaging the component from a side, bottom, or top, for example, using a head camera unit integrally arranged with the mounting head 30 in addition to the component camera 14.

[0025] During the mounting process, the mounting control section 22 controls the operation of the mounting head 30 based on information output from various sensors, the result of image processing, a control program, or the like. This controls the positions and angles of a plurality of suction nozzles 33 supported by the mounting head 30. As a result, the component held by the suction nozzle 33 is mounted at a predetermined mounting position and at a predetermined mounting angle instructed by the control program.

[0026] The control device 20 detects the supply states of a plurality of components in the feed area As of the mass feeder 40 based on the image data acquired by the camera (in the present embodiment, the plate camera 15). The supply state detection processing includes processing for detecting whether there is a pick-up component in the feed area As, and detecting the position and angle of the component if there is a pick-up component. The mounting control section 22 controls an operation of the mounting head 30 in the pick-up process based on a result of the supply state detection processing.

[0027] Furthermore, the control device 20 controls the component supply by the component feeding device 12. In a case where the mass feeder 40 is installed in the component feeding device 12, the control device 20 causes the feeding operation by the mass feeder 40 to be executed at an appropriate execution timing during the execution of the mounting process. 2. Configuration of the mass feeder 40

[0028] The mass feeder 40 is installed in the component mounting machine 10 and functions as part of the component feeding device 12. The mass feeder 40 delivers components 92 housed in a mass state in which the components 92 are not aligned like a carrier tape. Since the mass feeder 40 does not use a carrier tape, unlike a tape feeder, the mass feeder 40 has the advantage of eliminating the loading of the carrier tape, the collection of a used carrier tape, and the like.

[0029] For example, there is a mass feeder 40 of a type that supplies components 92 in an irregular posture to the flat feeding section As. However, when components 92 are so close to each other that they touch each other, components 92 are accumulated (a state where they overlap in the vertical direction), or components 92 are in a horizontally standing posture in which the width direction in the feeding section As is aligned in the vertical direction, the component mounting machine 10 cannot regard these components 92 as a pickup target. In order to increase the proportion of components 92 that can be picked up, there is a mass feeder 40 of a type that supplies components 92 in an aligned state to the feeding section As. In the present embodiment, the mass feeder 40 of this type in which components 92 are aligned will be described as an example.

[0030] When the mass feeder 40 is inserted into the slot 121 of the component feeding device 12, the mass feeder 40 is supplied with power via a connector and is in a state where it can communicate with the control device 20. The mass feeder 40 includes a conveyor main body 41 having a flat box shape. A component housing for receiving a plurality of components 92 in a bulk state is detachably attached to the conveyor main body 41. The mass feeder 40 includes a track member 44 arranged to be vibratable with respect to the conveyor main body 41. The track member 44 is formed with a conveying path Pt along which a plurality of components 92 are conveyed, and the feeding section As, which communicates with the conveying path Pt, is open at the top so that a plurality of components 92 can be received.

[0031] The track element 44 is shaped so that it can move in the forward-backward direction (left-right direction in Fig. 5) of the feeder main body 41. A pair of side walls 441 projecting upwards are formed along both edges in a width direction (vertical direction in Fig. 5) of the track member 44. A pair of side walls 441 surround a peripheral edge of the conveying path Pt together with a tip end portion 442 of the track member 44 to prevent falling out of components 92 conveyed along the conveying path Pt. A pair of left and right circular reference marks 444, each indicating a reference position of the feeding area As, is attached to an upper surface of the tip end portion 442.

[0032] In the present embodiment, an alignment member 50 is replaceably attached to the path member 44. The alignment member 50 has a plurality of cavities 51 that individually accommodate a plurality of components 92. Specifically, a plurality of cavities 51 are arranged in a zigzag shape in which adjacent rows are staggered in the conveying direction in the feeding area As. For example, the alignment member 50 has a total of 64 cavities 51 regularly arranged in eight cavities in the conveying direction and eight cavities in the width direction of the conveying path Pt. Each of the plurality of cavities 51 is open upward to accommodate the component 92 in a posture in which the thickness direction of the component 92 is directed in the vertical direction. A plurality of cavities 51 may be arranged in a matrix.

[0033] The opening of the cavity 51 is set to a dimension slightly larger than the external shape of the component 92 when viewed upward. The depth of the cavity 51 is set according to the type (shape, mass, and the like) of the component 92. One selected from various types of track elements 44 based on the type of component 92, the required number of cavities 51, and the functionality is attached to the track element 44.

[0034] Here, the term "feeding area As" of track member 44 is a region into which components 92 are fed in a bulk state, and a region where the component 92 can be picked up by the suction nozzle 33 carried by the mounting head 30. Furthermore, the term "conveying path Pt" of track member 44 is a path of the component 92 along which the component 92, which is moved from the component housing side to the track member 44, is conveyed to the feeding area As. A cover 46 covering the upper part of the conveying path Pt is attached to the track member 44.

[0035] The mass feeder 40 includes a shutter 47 mounted on an upper portion of the track member 44, which can open and close an opening of the feeding area As. By opening or closing the shutter 47, the mass feeder 40 can prevent the component 92 from protruding and foreign matter from entering the feeding area As. The mass feeder 40 includes a vibrating device (not shown) mounted in the conveyor main body 41. The vibrating device applies vibration to the track member 44, so that a plurality of components 92 are conveyed along the conveying path Pt. When the vibrating device applies vibration to the track member 44, the track member 44 performs an elliptical motion in a side view.As a result, a forward and upward external force or a backward and upward external force is applied to a plurality of components 92 on the conveying path Pt according to a rotational direction of the elliptical movement of the track member 44.

[0036] As a result, each of the plurality of components 92 is conveyed to the front or rear of the track member 44 and accommodated in a plurality of cavities 51, and thus a plurality of components 92 are fed for storage. A feeding process of the components 92 using the above-described vibration device is executed accordingly according to a command from the control device 20. 3. Calibration fixture 60 for mounting head 303-1. Overview and configuration of the calibration fixture 60

[0037] The calibration device 60 performs calibration processing for the mounting head 30 as the target before executing the assembly operation. The calibration processing is performed to determine an individual difference in the configuration of the mounting head 30 and obtain an appropriate correction value according to the operating condition and state before executing the assembly operation. The "individual difference" described above includes, for example, the assembly error of the movable table 132 and the mounting head 30, as well as the operating characteristics of the R-axis rotating device 34, the Q-axis rotating device 35, and the lifting and lowering device 36 of the mounting head 30.

[0038] As a result, for example, in a case where the mounting head 30 lowers a predetermined suction nozzle 33 to a predetermined target height, a difference (height error) may occur between the actual height of the tip end portion and the Z value (actual height) in the controller. Furthermore, as in the present embodiment, in the configuration where the mounting head 30 includes a plurality of holders 32 supporting each of the suction nozzles 33, different height errors may occur for each of the plurality of holders 32.

[0039] Then, as for example in Fig. As shown in Figure 7, the calibration device 60 causes a plurality of holders 32 to support a measuring device nozzle 66 and gradually lowers the device nozzle 66 from above toward the height sensor 65. A height sensor 65 is installed inside the component mounting machine 10 so that a detection section is located at a specific height Hs. The device nozzle 66 is a dummy that imitates the suction nozzle 33. The height sensor 65 transmits a detection signal to the calibration device 60 when a test object (the device nozzle) comes into contact with the detection section. The calibration device 60 measures the difference between the actual height of the device nozzle when the detection signal is input and the specified height Hs of the detection section as the height error of the holder 32.

[0040] By determining the height error for each of the plurality of holders 32 as described above, the command value in the height direction can be corrected to compensate for the height error. This allows the control device 20 to control the raising and lowering of the holder 32 and the suction nozzle 33 with greater precision during the pick-up process and the mounting process. In the calibration processing described above, each of the plurality of holders 32 is adjusted to have a predetermined angle (for example, 0 degrees) around the Q axis.

[0041] If the holder 32 is assigned an angle different from the specified angle during the recording or mounting process, the height error described above may vary. As shown by the dashed line in Fig. 7, this is because the height error may vary due to the fact that the holder 32 is slightly curved or the central axis (Q axis) of the holder 32 is slightly inclined with respect to the vertical axis. Such a difference in the height error for each associated angle of the holder 32 can be caused to actuate a sliding portion of the suction nozzle 33, for example, by pressing the suction nozzle 33 toward the plate 91 during the mounting process, and the mounting process is not affected thereby.

[0042] However, if the height of the suction nozzle 33 is controlled with high precision during the pick-up process or the mounting process, the difference in height error for each associated angle of the holder 32, as described above, may affect it. To improve the accuracy of the mounting process and prevent the occurrence of pick-up errors, the component mounting machine 10 in the present embodiment employs a configuration in which the calibration processing is performed by a calibration device 60 having the following configuration, and the mounting process is executed using the result of the calibration processing. The calibration device 60 includes a measuring section 61 and an adjusting section 62.

[0043] During calibration processing (see Fig. 8) of the mounting head 30, the measuring section 61 measures an error (height error Vd) in the height direction when the holding member (including the fixture nozzle 66) is moved to a certain height Hs in a state where it is assigned to multiple measurement angles around the central axis (Q-axis). In addition, the setting section 62 sets the correction value Mc for each of the multiple measurement angles based on the height error Vd (see Fig. 9 and Fig. 10). The correction value Mc set by the setting section 62 is stored in the storage section 21 of the control device 20 as correction data D1. 3-2. Calibration procedure using calibration device 60

[0044] The calibration process of the mounting head 30 is carried out using the Fig. 8 to 10. To prepare for the calibration procedure, it is assumed that the measuring device nozzles 66 are mounted as holding elements on a plurality of holders 32. Furthermore, it is assumed that the mounting head 30 is positioned such that the device nozzle 66 is positioned above the height sensor 65 at the raising and lowering position of the mounting head 30.

[0045] As in Fig. As shown in Figure 8, the calibration device 60 first assigns the predetermined holder 32 of the plurality of holders 32 of the mounting head 30 to the lifting and lowering position by rotating the rotary head 31 around the R axis (S11). Subsequently, the calibration device 60 rotates the holder 32 around the Q axis to assign it to the reference angle Ns (S12). The reference angle Ns is the initial measurement angle Nm in the calibration process and is set to 0 degrees in the present embodiment.

[0046] Subsequently, the measuring section 61 measures the height error Vd (S13). Specifically, the measuring section 61 gradually lowers the holder 32 and the fixture nozzle 66 from above toward the height sensor 65. When the test object (the fixture nozzle 66) comes into contact with the detection section of the height sensor 65 and the detection signal from the height sensor 65 is input, the measuring section 61 causes the holder 32 and the fixture nozzle 66 to be raised to the original initial height. The measuring section 61 measures the difference between the actual height (Z value) of the fixture nozzle 66 when the detection signal is input and the specified height Hs of the detection section as the height error Vd of the holder 32.

[0047] If the measurement of the height error Vd is not completed for all the measurement angles Nm set in advance in the holder 32 as the measurement target (S14: No), the calibration device 60 rotates the holder 32 around the Q axis to index to the next measurement angle Nm (S15). Next, the measurement angle Nm is set to an angle rotated by, for example, 90 degrees from the reference angle Ns. The measuring section 61 measures the height error Vd again (S13). As a result, the measuring section 61 measures the height error Vd of the holder 32 at the changed measurement angle Nm. In other words, the measuring section 61 measures the height error Vd when the holding member (device nozzle 66) is moved to a specific height Hs in a state where it is associated with a plurality of measurement angles Nm around the central axis (Q axis).

[0048] When the measurement of the height error Vd is completed for all measurement angles Nm (e.g., 0 degrees and 90 degrees) set in advance in the holder 32 as the measurement target (S15: Yes), the calibration device 60 determines whether the measurement of the height error Vd is completed for all the holders 32 as the measurement target (S16). If there is an unmeasured holder 32 (S16: No), the calibration device 60 repeatedly performs measurement operations (S11 to S15). When all the measurement operations scheduled to be executed are completed (S16: Yes), the setting section 62 sets the correction value Mc for each measurement angle Nm of all the holders 32 (S17).

[0049] In particular, as in Fig. 9, the height error Vd (V1a, V1b, V2a, V2b, and the like) for each of the plurality of measurement angles Nm (0 degrees, 90 degrees) of the holder 32 (No. 1, No. 2, and the like) as a measurement target is detected by the measurement processing (S11 to S15) described above. As shown in Fig. For example, as shown in FIG. 10, the setting section 62 sets the correction value Mc (M1a, M1b) for compensating the height error Vd (V1a, V1b) for each of the plurality of measurement angles Nm (0 degrees, 90 degrees) of the first holder 32 (No. 1). In other words, the setting section 62 sets the lowering amount Ud that compensates for the height error Vd when the holding member (suction nozzle 33) is lowered to the target height (pick-up height, mounting height) in the mounting process as the correction value Mc (M1a, M1b). The storage section 21 stores the correction value Mc for each of the plurality of holding members (suction nozzles 33) and each of the plurality of measurement angles Nm.

[0050] Furthermore, the setting section 62 may set the correction value Mc at an angle different from the measurement angle Nm in the setting processing (S17) of the correction value Mc. For example, the setting section 62 calculates the estimated height error Ve (V1c, V1d) at a different angle based on the height error Vd (V1a, V1b) and the error characteristics that are actual measured values. For example, the term "error characteristics" described above indicates that the relationship between the measurement angle Nm and a plurality of height errors Vd can be approximated to a sinusoidal waveform, the maximum value and the minimum value of the height error Vd, and the degree of the difference therebetween. 4. Assembly process by the component assembly machine 104-1. Overview of the assembly process

[0051] With reference to Fig. 11, the assembly process by the component assembly machine 10 is described. Here, it is assumed that the mass conveyor 40 is installed in the component feeding device 12. In the assembly process, the plate transport device 11 of the component assembly machine 10, as shown in Fig. 11, first performs a loading process for the plate 91 (S21). As a result, the plate 91 is loaded into the machine and positioned at a predetermined position within the machine.

[0052] Next, the control device 20 executes the PP cycle. In the PP cycle, the mounting control section 22 executes the pick-up cycle, in which the pick-up process of picking up the component 92 is repeated using a plurality of suction nozzles 33 (S22). In this case, the mounting control section 22 causes the mounting head 30 to operate in the pick-up process to subsequently position the mounting head 30 according to the position of the component 92 that can be picked up. Furthermore, in a case where the mass feeder 40 supplies the component 92 as the pick-up target, the mounting control section 22 switches the coordinate value that is the center of the cavity 51 and the coordinate value of the reference position of the component 92 as the position of the component 92 that can be picked up, and positions the suction nozzle 33.

[0053] Furthermore, in the pickup cycle (S22), the mounting control section 22 executes processing for correcting the lowering amount Ud of the suction nozzle 33 based on the correction data D1 as needed. Details of the pickup cycle including the correction processing of the lowering amount Ud will be described later.

[0054] Subsequently, the control device 20 executes the detection processing of the holding state of the components 92 held by a plurality of suction nozzles 33 (S23). Specifically, the control device 20 moves the mounting head 30 over the component camera 14 and transmits an imaging command to the component camera 14. The control device 20 performs image processing on the image data acquired by the imaging of the component camera 14 to detect the posture (position and angle) of the component 92 held by each of the plurality of suction nozzles 33. The result of the detection processing of the holding state (S23) is recorded in the storage section 21 as an operation result indicating whether a pickup error occurred during the pickup operation.

[0055] Thereafter, the control device 20 executes the mounting cycle, in which the mounting process for mounting the component is repeated using a plurality of suction nozzles 33 (S24). During the mounting process of the mounting cycle (S24), the control device 20 causes the operation of the mounting head 30 to mount each of the components 92 at the mounting positions specified by the control program. Furthermore, the mounting head 30 controls the operation of the mounting head 30 so that the suction nozzle 33 is positioned and angled relative to the mounting position based on the result of the recognition processing (S23).

[0056] The control device 20 determines whether all PP cycles have been completed based on the control program (S25). If all PP cycles have not been completed (S25: No), the PP cycle (S22 to S24) is executed. If all PP cycles have been completed (S25: Yes), the control device 20 executes an unloading operation for the board 91 (S26). During the unloading operation for the board 91, the board transport device 11 releases the positioned board 91 and unloads the board 91 outside the component mounting machine 10. 4-2. Details of the recording cycle

[0057] The details of the recording cycle (S22) in the assembly process are described with reference to the Fig. 12 to 14. In the mounting cycle, the mounting control section 22 first moves the predetermined suction nozzle 33 over the component 92 as a pickup target and sets the suction nozzle 33 to the predetermined pickup angle Np (S31). Specifically, by rotating the rotary head 31 around the R axis, the predetermined suction nozzle 33 is assigned to the lifting and lowering position and rotated around the central axis (Q axis) to adjust the pickup angle Np. For example, the pickup angle Np is an angle at which the longitudinal direction of the tip end portion formed in the non-circular shape of the suction nozzle 33 coincides with the longitudinal direction of the cavity 51 of the mass feeder 40 or the longitudinal direction of the component 92.

[0058] Next, the mounting control section 22 sets the target height Ht (S32). The above-described target height Ht is the height of a lowered end of the suction nozzle 33, which is lowered to pick up the component 92 as a pickup target. In the present embodiment, in a case where the feeder 122 that supplies the component 92 as a pickup target is the mass feeder 40, the mounting control section 22 attempts to perform air pickup so that the component 92 is not pushed down in the series of pickup operations, that is, the sliding portion of the suction nozzle 33 is not actuated. This is control to prevent an impact when the suction nozzle 33 comes into contact with the upper surface of the component 92 from affecting the component 92 housed in another cavity 51.

[0059] In particular, the mounting control section 22 sets the recording process as shown in Fig. 13, the height at which a predetermined distance Lc is located from the upper surface of the delivered component 92 is set as the target height Ht. That is, the mounting control section 22 sets the target height Ht so that the tip end portion of the suction nozzle 33, which has reached the lowered end to receive the component 92, is positioned above the upper surface of the component 92 received in the cavity 51. The mounting control section 22 determines the lowering amount Ud from the current height of the suction nozzle 33 based on the target height Ht.

[0060] Subsequently, the mounting control section 22 acquires the correction value Mc of the lowering amount Ud based on the pickup angle Np of the suction nozzle 33 (S33). Specifically, for example, in a case where the pickup angle Np is 90 degrees, the mounting control section 22 acquires the correction value Mc (M1b) calculated based on the height error Vd (V1d) of 90 degrees in the measurement angle Nm of the first holder 32 supporting the predetermined suction nozzle 33 in the correction data D1. In a case where the correction value Mc of the measurement angle Nm corresponding to the pickup angle Np is not included in the correction data D1, the mounting control section 22 may acquire the correction value Mc of the measurement angle Nm closest to the pickup angle Np, or may estimate and acquire the correction value Mc depending on the pickup angle Np.

[0061] The assembly control section 22 corrects the lowering amount Ud of the suction nozzle 33 based on the detected correction value Mc, lowers the suction nozzle 33, and supplies negative pressure air to the suction nozzle 33 (S34). As a result, the tip end portion of the suction nozzle 33 is lowered by the lowering amount Ud to the target height Ht, in which the correction value Mc for compensating the height error Vd is taken into account. As shown in Fig. As shown in Figure 14, the component 92 as the pick-up target is sucked by the negative pressure air as the suction nozzle 33 approaches. As described above, the mounting control section 22 sucks and picks up the component 92 by causing the suction nozzle 33 to approach the target height Ht. In this case, the sliding portion of the suction nozzle 33 does not operate, and the occurrence of an impact due to the pick-up operation is prevented.

[0062] When the suction nozzle 33 is lowered to the target height Ht, the mounting control section 22 raises the holder 32 and the suction nozzle 33 to the original initial height (S35). If all the pending pickup operations are not completed (S36: No), the mounting control section 22 repeatedly executes the above-described pickup operation (S31 to S35). When all the pickup operations are completed (S36: Yes), the mounting control section 22 ends the current pickup cycle.

[0063] In the above-described pick-up cycle (S22), only in a case where the feeder 122 that supplies the component 92 as a pick-up target is the mass feeder 40, the pick-up operation of the above-described air pick-up can be attempted, and in the case of a belt feeder, the operation can be switched to a normal pick-up operation (an operation of pressing against the component 92 so that the sliding portion of the suction nozzle 33 operates). Even if the mass feeder 40 supplies the component 92 as a pick-up target, for example, when the feeding operation of the component 92 is to be performed immediately after the pick-up operation, a normal pick-up operation can be performed. In addition, in the air pick-up operation, the lowering speed or deceleration of the suction nozzle 33 can be reduced compared to the normal pick-up operation.

[0064] According to the configuration of the component assembly machine 10 and the component assembly method ( Fig. 11 to Fig. 12), the lowering amount Ud to the target height Ht of the suction nozzle 33 during the pick-up process is corrected depending on the pick-up angle Np of the suction nozzle 33. Since the suction nozzle 33 is lowered to the target height Ht with greater accuracy, the occurrence of an error during the pick-up process can be prevented. This can improve the accuracy of the assembly process and production efficiency. 5. Modification aspect of the embodiment

[0065] In the embodiment, in a case where aerial pickup is attempted during the pickup operation, the lowering amount Ud is corrected depending on the pickup angle Np of the suction nozzle 33. On the other hand, by correcting the lowering amount Ud for each pickup angle Np, the suction nozzle 33 can be positioned at the target height Ht with higher accuracy even during the normal pickup operation. This makes it possible to prevent the occurrence of pickup errors and reduce the impact that may be caused by the pickup operation.

[0066] Furthermore, in the embodiment, an aspect in which the control for correcting the lowering amount Ud depending on the angle of the suction nozzle 33 around the central axis (Q axis) is applied to the pick-up process has been described as an example. On the other hand, the control for correcting the lowering amount Ud can be applied to the mounting process. This allows the lowering of the suction nozzle 33 to the target height with respect to the plate 91 to be performed with higher accuracy, and it is possible to prevent the occurrence of a mounting error and reduce the impact that may arise during the mounting process.

[0067] In the present embodiment, the holding member that holds the component 92 is the suction nozzle 33, which picks up and holds the component 92 with the negative air pressure. Alternatively, the holding member may be a chuck or the like for gripping the component 92. Even in this aspect, similar effects to those in the present embodiment are achieved.

[0068] In the embodiment, in the calibration processing, the fixture nozzle 66 is attached to the fixture 32. On the other hand, considering that there are individual differences in the suction nozzle 33, the suction nozzle 33 used for the assembly process to be performed in the calibration processing may be attached to the fixture 32.

[0069] In the embodiment, the mass feeder 40 supplies a chip component that is rectangular in the thickness direction as the component 92, which is mounted on the board 91 by the component mounting machine 10. On the other hand, the component 92 is used in a board processing machine that performs a predetermined work on the board 91, as in the component mounting machine 10, and various types of components can be used as long as the article can be supplied in a state where it is accommodated in the cavity 51 in the mass feeder 40. For example, the mass feeder 40 can supply a spherical solder ball. Also in such an aspect, similar effects to those in the embodiment are achieved. Reference character list

[0070] 10: Component assembly machine, 12: Component feeding device, 122: Feeder, 13: Component transfer device, 20: Control device, 21: Storage section, 22: Assembly control section, 30: Mounting head, 31: Rotary head, 32: Holder, 33: Suction nozzle (holding member), 40: Mass feeder, 50: Alignment member, 51: Cavity, 60: Calibration device, 61: Measuring section, 62: Adjustment section, 91: Platen, 92: Component, As: Feeding section, Hs: Specified height, Ht: Target height, Nm: Measuring angle, Np: Pick-up angle, Ns: Reference angle, Vd: (Height direction) error, Ve: (Estimated) error, Mc: Correction value, Ud: Lowering amount, D1: Correction data QUOTES CONTAINED IN THE DESCRIPTION

[0000] This list of documents submitted by the applicant was generated automatically and is included solely for the convenience of the reader. This list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions. Cited patent literature

[0000] JP-A-2009-164276

[0003]

Claims

[1] A component assembly machine comprising: a mounting head carrying a holding member capable of holding a component that can be raised and lowered and rotated about a central axis of the holding member; a storage section configured to store a correction value for each of a plurality of measurement angles, which is set based on an error in a height direction when the holding member is moved to a specific height in a state indexed to the plurality of measurement angles about the central axis; and a control section configured to correct, in a picking operation of picking up the component by the holding member, a lowering amount of the holding member to a target height based on a picking angle of the holding member indexed around the central axis and the correction value for each of the plurality of measurement angles. [2] The component mounting machine according to claim 1, wherein the holding member is a suction nozzle that holds the component by negative air pressure, and in the picking up operation, the control section sets a height at which a predetermined distance from an upper surface of a supplied component is present as a target height, and sucks and picks up the component by bringing the suction nozzle close to the target height. [3] The component mounting machine according to claim 2, wherein a tip end portion of the suction nozzle is formed non-circularly as viewed in a central axis direction. [4] The component mounting machine according to any one of claims 1 to 3, wherein the plurality of measurement angles include a reference angle and an angle rotated by 90 degrees from the reference angle. [5] The component mounting machine according to any one of claims 1 to 4, wherein the storage section stores the lowering amount of the holding member which compensates for the error in the height direction as a correction value. [6] The component mounting machine according to any one of claims 1 to 5, wherein the control section corrects the lowering amount of the holding member by the correction value of the measuring angle closest to the receiving angle of the holding member. [7] The component mounting machine according to any one of claims 1 to 5, wherein the control section estimates a correction value depending on the pickup angle of the holding member based on the correction value for each of the plurality of measurement angles and corrects the lowering amount of the holding member. [8] The component mounting machine according to any one of claims 1 to 7, wherein the mounting head carries a plurality of holding elements arranged on the same circumference around a vertical R-axis, and the storage section stores the correction values ​​for each of the plurality of holding elements and for each of the plurality of measuring angles. [9] The component mounting machine according to any one of claims 1 to 8, wherein the control section corrects the lowering amount of the holding member based on the correction value in the case of executing the picking operation for picking up the components from a mass feeder configured to provide a plurality of components in a mass state in a feeding section. [10] The component mounting machine according to claim 9, wherein the mass feeder has a plurality of aligned cavities by accommodating the plurality of components in the mass state one by one in the feeding section. [11] A component mounting method applied to a component mounting machine including a mounting head carrying a holding member capable of holding a component that can be raised and lowered and rotated about a central axis of the holding member, the method comprising: a storing step for storing a correction value for each of a plurality of measuring angles, which is determined based on an error in a height direction when the holding member is moved to a certain height in a state where it is indexed to the plurality of measuring angles about the central axis; and a control step of correcting a lowering amount of the holding member to a target height based on a picking angle of the holding member indexed around the central axis and the correction value for each of the plurality of measuring angles, in a picking operation for picking up the component by the holding member. [12] A calibration device for a mounting head, the calibration device being intended to be applied to a component mounting machine comprising a mounting head carrying a holding member capable of holding a component which can be raised and lowered and rotated about a central axis of the holding member, the calibration device comprising: a measuring section configured to measure an error in a height direction when the holding member is moved to a certain height in a state where it is indexed to a plurality of measuring angles around the central axis; and a setting section configured to set a correction value for each of the plurality of measurement angles based on an error in the height direction.

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