Production aid device

Abstract

A production aid is provided for use with a component assembler configured to perform a picking cycle in which a picking operation is repeatedly performed to pick up multiple components from a component feeder equipped with a bulk feeder configured to feed the multiple components into a feed area, and an assembly cycle in which an assembly operation is repeatedly performed to mount the multiple components onto a plate, wherein the production aid includes a setting section configured to set an execution sequence of the picking operations such that the operation of picking up the components from the bulk feeder is performed with priority among the picking operations scheduled for execution in a predetermined picking cycle.

Description

Technical field

[0001] The present invention relates to a production aid device. State of the art

[0002] A production aid supports the production process of product panels by a component assembler using a bulk feeder. A bulk feeder delivers components in a loose state to a feeding area (see patent literature 1). In an assembly operation, the component assembler moves an assembly head to pick up a component fed by a feeder, such as a bulk feeder, and assembles the component at a predetermined position on a panel. Citation list for patent literature

[0003] Patent Literature 1: JP-A-2011-114084 Summary of the invention; Technical task

[0004] When an assembly head operates around a feed area during the production process, simultaneously holding multiple components with multiple suction nozzles, there is a risk that dissimilar components will fall into the feed area. If dissimilar components enter the feed area, the bulk feeder must be serviced, and even if the dissimilar components can be detected by inspecting the plate or similar devices, this leads to a reduction in productivity.

[0005] The aim of this description is to provide a production aid device that can prevent dissimilar components from entering the feed area of ​​a bulk feeder and can maintain productivity in the production process of plate using a bulk feeder. Solution to the problem

[0006] The present description discloses a production aid device applicable to a component assembler configured to perform a picking cycle in which a picking operation is repeatedly carried out to pick up several components from a component feeder equipped with a bulk feeder configured to feed the several components to a feed area, and an assembly cycle in which an assembly operation is repeatedly carried out to mount the several components onto a plate, wherein the production aid device includes a setting section configured to determine an execution sequence of the picking operations such that, among the picking operations planned for execution, the picking operation to pick up the components from the bulk feeder is preferentially executed in a predetermined picking cycle.

[0007] The present description discloses a production aid used in a component assembler, which comprises a component feeder equipped with a bulk feeder configured to feed multiple components to a feed area, and an assembly head carrying multiple holding elements configured to hold the components, wherein the bulk feeder includes a closure configured to be opened and closed with respect to the feed area and configured to close the feed area in a closed state, and the production aid includes a limiting section configured to limit at least one of the movements and rotations of a dissimilar component, which differs from the components fed by the bulk feeder, through the assembly head.when the dissimilar component is held by the retaining element and the closure is in an open state. Advantageous effects of the invention

[0008] With such a configuration, it is possible in the production process of product panels using a bulk feeder to prevent dissimilar components, different from those fed by the bulk feeder, from entering the feed area of ​​the bulk feeder. This allows productivity to be maintained. Brief description of the characters Fig. Figure 1 is a schematic top view depicting a component assembler. Fig. Figure 2 is a top view that schematically represents a mounting head. Fig. Figure 3 is a side view that schematically depicts the mounting head. Fig. Figure 4 is a side view that schematically depicts part of a bulk feeder with a feed area. Fig. 5 is a top view from direction V in Fig. 4. Fig. Figure 6 is a perspective view showing the opening and closing process of a closure. Fig. Figure 7 is a block diagram representing a first embodiment of the production aid device. Fig. is a flowchart that illustrates the assembly process by the component assembler. Fig. 9 is a control program that illustrates a comparison before and after setting an execution sequence. Fig. Figure 10 is a block diagram illustrating a second embodiment of the production aid. Fig. Figure 11 is a flowchart illustrating a production support process in the second embodiment. Fig. Figure 12 is a block diagram illustrating a third embodiment of the production aid. Fig. Figure 13 is a flowchart illustrating a production support process in the third embodiment. Description of the embodiments 1. First embodiment 1-1. Overview of the production aid 70

[0009] The production aid 70 supports the production process of plates by a component assembler 10 using a bulk feeder 30. In a first embodiment, the production aid 70 is integrated into a host computer 60. The production aid 70 aims to prevent errors and maintain productivity by pre-optimizing a control program M1, which is used for the assembly process performed by the component assembler 10 as a production process.

[0010] The component assembler 10 performs the assembly process of mounting components onto the plate 91 as a predetermined plate processing operation. The component assembler 10 is installed along with other plate processing machines in the transport direction of the plate 91 and forms a production line. Each of the several plate processing machines is connected to the host computer 60, which centrally controls the production line. The production line includes, for example, a printer, a component assembler 10, a reflow oven, and an inspection machine as several plate processing machines. 1-2. Configuration of the component assembler 101-2-1. Plate conveyor 11 and component feeding device 12

[0011] As in Fig. As shown in Figure 1, the component assembler 10 comprises a plate conveyor 11. The plate conveyor 11 then conveys the plate 91 in the conveying direction and positions the plate 91 at a predetermined position in the component assembler 10. The component assembler 10 comprises a component feeder 12. The component feeder 12 feeds the components to be mounted onto the plate 91. In the component feeder 12, a feeder 122 is arranged in each of several slots 121. A belt feeder, which feeds the components so that they are ready for removal, for example by feeding and moving a carrier belt that holds a large number of components, is attached to the feeder 122. Additionally, a bulk feeder 30, which feeds the components in a bulk state so that they are ready for removal, is attached to the feeder 122. Details of the bulk feeder 30 are described later. 1-2-2. Component transfer device 13

[0012] The component assembler 10 comprises a component transfer device 13. The component transfer device 13 transfers the component fed by the component feeder 12 to a predetermined mounting position on the plate 91. The component transfer device 13 comprises a head drive device 131, a motion carrier 132, and a mounting head 20. The head drive device 131 moves the motion carrier 132 in the horizontal direction (X-direction and Y-direction) by means of a linear motion mechanism. The mounting head 20 is detachably attached to the motion carrier 132 by means of a clamping element (not shown) and can be moved in the horizontal direction within the component assembler 10.

[0013] As in the Fig. 2 and Fig. As shown in Figure 3, the mounting head 20 has a rotary head 21 designed to rotate about an R-axis parallel to a vertical axis (a Z-axis). The rotary head 21 carries several supports 22 that can be raised and lowered and rotate about a rotation axis (Q-axis) for each of the several supports 22. A holding element is attached to each of the several supports 22, which holds the component 92. In the present embodiment, the holding element is a suction nozzle 23 that holds the component 92 by suction with supplied vacuum air. A chuck or similar device that holds the component by gripping can also be used as the holding element.

[0014] The mounting head 20 comprises an R-axis rotary device 24 configured to rotate the rotary head 21 about the R-axis. The R-axis rotary device 24 positions the rotary head 21 at a predetermined angle about the R-axis to index one of the brackets 22 into a lifting and lowering position, in which this bracket 22 is raised and lowered by the lifting and lowering device 26 described below. The mounting head 20 comprises a Q-axis rotary device 25 configured to rotate the bracket 22 about its Q-axis. In the present embodiment, the Q-axis rotary device 25 has a mechanism that rotates multiple brackets 22 in an interlocking manner and is used collectively to rotate multiple brackets 22.With the configuration described above, if one of the brackets 22 is positioned at a predetermined angle about its Q-axis, the remaining multiple brackets 22 are also positioned at the predetermined angle in the manner locked with the angular positioning of the one bracket 22.

[0015] The mounting head 20 has a lifting and lowering device 26 that raises and lowers a bracket 22 among the multiple brackets 22, which is indexed into the position of the lifting and lowering device by the rotation of the rotary head 21. The lifting and lowering device 26 raises and lowers the bracket 22 to raise and lower the suction nozzle 23 attached to the bracket 22. It should be noted that the mounting head 20 can have a configuration in which two or more lifting and lowering positions are arranged and multiple lifting and lowering devices are arranged that can be driven independently of one another, so that the brackets 22 arranged at the respective positions can be raised and lowered.

[0016] The number of brackets 22 supported by a mounting head 20 with the configuration described above can vary depending on the type of mounting head 20. Furthermore, the mounting head 20 can have various other embodiments besides the present embodiment, in which several brackets 22 are supported at equal intervals in a ring-shaped arrangement. For example, the mounting head 20 can have an embodiment in which the mounting head 20 supports several brackets 22 arranged in a straight line or a matrix arrangement. 1-2-3. Component camera 14 and plate camera 15

[0017] The component assembler 10 comprises a component camera 14 and a plate camera 15. The component camera 14 and the plate camera 15 are digital imaging devices that include imaging elements such as CMOS. The component camera 14 and the plate camera 15 perform the imaging based on a control signal and transmit the image data acquired during the imaging process. The component camera 14 is configured to image the component held by the suction nozzle 134 from below. The plate camera 15 is movable in the horizontal direction on the motion carrier 132 and is integrally arranged with the assembly head 133. The plate camera 15 is configured to image the plate 91 from above.

[0018] Furthermore, the plate camera 15 can use various devices or the like as imaging targets, provided that the various devices are located within a movable area of ​​the motion carrier 132, in addition to using a surface of the plate 91 as an imaging target. For example, in the present embodiment, the plate camera 15 can, as shown in Fig. Figure 5 shows the feed area As, to which the bulk feeder 30 feeds the components, or a reference mark 49, which is arranged on an upper part of the bulk feeder 30, within a field of view of the camera. As described above, the plate camera 15 can be used together to image different imaging targets in order to acquire image data that can be used for different types of image processing. 1-2-4. Control device 16

[0019] The component assembler 10 includes a control device 16. The control device 16 is primarily configured with a CPU and various types of memory, a control circuit, and a storage device. The storage device of the control device 16 stores various data, such as the control program M1 and the component data M2, which are used to control the assembly process. The control program M1 and the component data M2 are stored, for example, in a storage section 61 of the host computer 60, as shown in Fig. 7 are shown, and are downloaded via communication and stored in the control device 16.

[0020] As in Fig. As shown in Figure 9, the control program M1 specifies the mounting position (P101, P102, ...), the mounting angle (θ101, θ102, ...), and the component type (a, b, ...) of the components to be mounted on the plate 91 in a planned assembly sequence during the assembly process. Here, the assembly process comprises a process in which a pick-and-place cycle (PP cycle), which includes a picking cycle and a mounting cycle, is repeated multiple times. The "picking cycle" described above is a process in which a picking operation, in which the components fed by the component feeder 12 are picked up using the suction nozzle 23, is repeated multiple times.

[0021] Here, the component, which is a pickup target, can be fed in during the pickup cycle by a bulk feeder 30. If there are recesses 45 in a feed area As of the bulk feeder 30 (see Fig. 5) designed to individually pick up the components, the picking cycle is a process in which the components picked up in several recesses 45 are picked up one after the other by moving the mounting head 133.

[0022] The "assembly cycle" is a process in which the picked-up components are successively mounted on the plate 91, and in particular a process in which an assembly operation is repeated in which the component is mounted multiple times at a predetermined mounting angle and a predetermined mounting position on the plate 91. As described above, an execution sequence of the PP cycle, which comprises several picking operations and assembly operations grouped according to the number of suction nozzles 23 carried by the mounting head 133, the travel distance of the mounting head 20, and the like, is predefined in the control program M1.

[0023] The component data M2 includes shape data for each component type. The "shape data" includes at least one of the following: an outer edge shape of the component, a shape of a feature section of the component, and a dimension of the component. The "outer edge shape" of the component corresponds to the shape of an outer edge when the interior and background of the component are subdivided using the outer edge of the component as the boundary.

[0024] The "shape of the feature section" of the component corresponds to a boundary shape of the feature section in appearance, resulting from a shape, pattern, color, and the like of the component. A corner, a protrusion, a connection, a connection section, and the like of the component can be used as a feature section of the component. Furthermore, the component data M2 can, for example, contain, in addition to the shape data for each component, a maximum permissible movement speed (acceleration), a pickup position (for example, a position in contact with the suction nozzle 23), and the like.

[0025] The control device 16 performs the process of detecting the holding state of the component held by each of the several holding elements (suction nozzles 23). In particular, the control device 16 performs image processing of the image data acquired by capturing an image with the component camera 14 and detects the position and angle of each component relative to a reference position of the assembly head 20. Here, the control device 16 can perform image processing on image data acquired by imaging the component, for example, with a head camera unit integrally provided with the assembly head 20, from the side, from below, or from above, in addition to the component camera 14.

[0026] During the assembly process, the control device 16 directs the assembly process via the assembly head 20 so that the component is mounted in a predetermined position on the plate 91. In this case, the control device 16 controls the assembly process based on the holding state of the detected component. That is, the control device 16 corrects the position of the assembly head 20 and the angle of the suction nozzle 23 about a Q-axis (rotation axis of the suction nozzle 23) to correct deviations in the position and angle of the component held by the suction nozzle 23 relative to the Q-axis. This ensures that the component held by the suction nozzle 23 is mounted at a predetermined assembly position and angle, as specified by the control program M1. 1-3. Configuration of the bulk feeder 30

[0027] The bulk feeder 30 is arranged in the component assembler 10 such that it functions as part of the component feeding device 12. The bulk feeder 30 feeds the components housed in a component container in a bulk state (a scattered state in which each layer is irregular), which is not packaged like a conveyor belt. Accordingly, unlike the belt feeder, the bulk feeder 30 does not use a conveyor belt, which has the advantage that loading the conveyor belt and removing the used belt are unnecessary.

[0028] For example, there is a bulk feeder 30 that feeds the component in an irregular orientation into a feed area As with a flat shape. However, if the components are so close together that they touch or stack (in a state where they are aligned vertically), or if the components are positioned sideways with their widths aligned vertically, the component assembler 10 cannot consider the components as pick-up targets. Therefore, to increase the proportion of components available for pick-up, there is a bulk feeder 30 that delivers components to the feed area As in an aligned state. In the present embodiment, a bulk feeder 30 in which the components are aligned is described as an example. 1-3-1. Feeder main body 31

[0029] In the feeder 30, a track unit 40 is vibratably and removablely attached to the feeder main body 31, which is designed in the form of a flat box.

[0030] On a front section (right end section in Fig. 4) A connector 311 and two positioning pins 312 are arranged on the feeder main body 31. When the feeder main body 31 is inserted into the slot 121 of the component feeder 12, current is supplied via the connector 311, and the feeder main body 31 can communicate with the control device 16 of the component assembler 10. 1-3-2. Track unit 40

[0031] A track unit 40 comprises a track element 41, which is detachably attached to the feeder main body 31. The track element 41 is set into vibration by a vibration device 34. The track element 41 is designed with a conveying path R, through which several components are conveyed, and a feed area As, which is connected to the conveying path R and is open at the top so that the multiple components can be received. Here, the "feed area As" is an area into which the component is fed in a bulk state and an area from which the component can be picked up by the component assembler 10. Furthermore, the "conveying path R" is a component passage through which the component flowing from one side of a component cassette to the track element 41 is conveyed to the feed area As.

[0032] The track element 41 is designed so that it can be oriented in a front-to-back direction (in Fig. 4 the right-left direction) of the feeder main body 31 extends as an overall shape. In the present embodiment, as in Fig. Figure 5 shows an adapter element 42 interchangeably attached to the track element 41. The adapter element 42 is, for example, one or more plate-shaped elements. In this way, the track unit 40 is standardized by attaching one of several types of adapter elements 42, corresponding to the shapes of several types of components, to the common track element 41.

[0033] As in Fig. As shown in Figure 5, the adapting element 42 forms several recesses 45 arranged in a predetermined pattern (in the present embodiment, a zigzag pattern). Each of the several recesses 45 has a rectangular shape that is slightly larger than the outer shape of a component fed by the feeder 30. In this way, the feeder 30 comprises several recesses 45 in which the component is received in a position where the thickness of the component runs in a top-bottom direction, within a feed area into which the component is fed so that it can be received.

[0034] A pair of upward-projecting side walls 46 is located along both edges of the track unit 40 in a lateral direction (top-bottom direction). Fig. 5) formed. The pair of side walls 46, together with the tip section 47 of the track unit 40, surrounds a circumferential edge of the conveyor path R to prevent the component conveyed via the conveyor path R from escaping. A cover 48 is fitted above the track element 41 to cover an upper part of the conveyor path R. The cover 48 is configured to prevent the component from falling out of the conveyor path R. A pair of left and right circular reference marks 49, indicating a reference position of the feed area As, is fitted to a top side of the tip section 47.

[0035] A closure 50 is arranged on the front of the track element 41. The closure 50 is designed to be opened and closed on the track element 41 and, when closed, seals the opening of the feed area As. The closure 50 is coupled to the closure drive device 35 when the track unit 40 is attached to the feeder main body 31. The opening and closing process of the closure 50 is controlled by the closure drive device 35. The feeder 30 can open and close the closure 50 to prevent components from falling out and foreign objects from entering the feed area As. The aforementioned "foreign objects" also include components that differ from those fed by the feeder 30.

[0036] The locking drive device 35 is a drive device that opens and closes the locking device 50 in a state where the track unit 40 is attached to the feeder main body 31. The locking drive device 35 switches the locking device 50 between a closed and an open state based on a command from the feeder control device 36. The closed state of the locking device 50 is a state in which the locking device 50 is in contact with the track element 41 and the opening of the feeder area As is completely closed, as indicated by the dashed lines in the Fig. 5 and Fig. 6 displayed.

[0037] Furthermore, the open state of the closure 50 is a state in which the opening of the feed area As is not closed and a main area of ​​the feed area As (area in which several recesses 45 are arranged in the present embodiment) is exposed (see the solid line in Fig. 6) At this point, the suction nozzle 23 can perform a picking operation for components in any of the recesses 45. The state of the shutter 50 includes an intermediate state between the closed state and the open state. The intermediate state of the shutter 50 is a state in which the shutter 50 is slightly separated from the track element 41 (to such an extent that the vibration of the track element 41 is not impeded and no components protrude from a gap). Since the intermediate state in the present embodiment is a state in which the mixing of foreign substances can be prevented, the intermediate state is included in a closed state. 1-3-3. Feeder control device 36

[0038] The bulk feeder 30 includes a feeder control device 36. The feeder control device 36 is primarily configured with a CPU, various memory components, and a control circuit. The feeder control device 36 is powered via connector 311 when the bulk feeder 30 is installed in a slot of the component assembler 10 and is communicating with the control device of the component assembler 10.

[0039] The feeder control device 36 controls the operation of the vibrating device 34, the locking drive device 35, and the like. For example, the feeder control device 36 controls the operation of the vibrating device 34 based on a predefined parameter, so that the component feeding process is carried out. Thus, a vibration is exerted on the track element 41, and the components on the conveying path R are moved in the conveying direction by absorbing the external force. The feeder control device 36 controls the operation of the locking drive device 35 and switches the locking device 50 so that the locking device 50 is in a predetermined state. 1-4. Assembly process by the component assembler 10

[0040] The assembly process performed by component assembler 10 is described with reference to the Fig. 8 and Fig. 9 described. Here it is assumed that the feeder 30 is installed in the component feeding device 12. In the assembly process, as described in Fig. Figure 8 shows the plate conveyor device 11 of the component assembler 10 initiating a loading process of the plate 91 (S11). Accordingly, the plate 91 is loaded into the component assembler 10 and positioned at a predetermined position within the component assembler 10.

[0041] Next, the control device 16 executes the PP cycle. In the PP cycle, the control device 16 performs the pickup cycle, in which the pickup process for picking up the component is repeated using multiple suction nozzles 23 (S12). In this case, the control device 16 controls the operation of the assembly head 20 during the pickup process such that the assembly head 20 is positioned sequentially according to the positions of the components available for pickup. When the feeder 30 feeds the component to be picked up, the control device 16 also switches a coordinate value corresponding to the center of the recess 45 and a coordinate value of a reference position of the component as the position of the component available for pickup and positions the suction nozzle 23 accordingly.

[0042] It should be noted that in the control device 16, the execution sequence of the recording operations in the recording cycle corresponds to the execution sequence of the in Fig. The assembly operations shown in the 9 diagrams correspond to this. In particular, in a first PP cycle, assembly operations are arranged in the sequence of the assembly positions (P101, P102, P103, ...) for execution, and in the picking cycle (S12) a series of picking operations is carried out to pick up corresponding component types (a, b, c, ...) from the feeder 122.

[0043] The control device 16 then performs a process to detect the holding state of the component held by each of the multiple suction nozzles 23 (S13). In particular, the control device 16 moves the assembly head 20 to a position above the component camera 14 and sends an imaging command to the component camera 14. The control device 16 detects the holding state (position and angle) of the component held by each of the multiple suction nozzles 23 by performing the imaging process for the image data acquired by taking an image with the component camera 14.

[0044] The control device 16 then executes the assembly cycle, in which the assembly process for attaching the components using multiple suction nozzles 23 is repeated (S14). It should be noted that during the assembly process of the assembly cycle (S14), the control device 16 controls the operation of the assembly head 20 such that each component is attached to the assembly position specified by the control program M1. Furthermore, the control device 16 controls the operation of the assembly head 20 such that the suction nozzle 23 is positioned and angularly aligned relative to the assembly position based on the result of the detection process (S13).

[0045] The control device 16 determines, based on the control program M1 (S15), whether all PP cycles have been completed. If not all PP cycles have been completed (S15: No), the PP cycle (S12 to S14) is executed. If all PP cycles have been completed (S15: Yes), the control device 16 performs an unloading operation of the plate 91 (S16). During the unloading of the plate 91, the plate conveyor 11 releases the positioned plate 91 and unloads the plate 91 from the component assembler 10. 1-5. Production aid 70

[0046] A configuration of the production aid device 70 is described with reference to the Fig. Described in sections 7 to 9. The production aid 70 supports the production process of product panels by the component assembler 10 using the bulk feeder 30. Here, the bulk feeder 30 delivers components in a loose state into the feed area As. Then, the component assembler 10 moves the components in the pickup cycle of the assembly process (S12 in Fig. 8) the mounting head 20 to receive the component 92 supplied by the feeder 122, such as the bulk feeder 30, and mounts the component at a predetermined position on the plate 91.

[0047] Here, the closure 50 is located, which can be opened and closed on the feeder 30. Closing the closure 50 prevents foreign objects from being mixed in, except during a period in which a picking-up operation of the components fed by the feeder 30 is being carried out. However, if, for example, the suction nozzle 23 carried by the assembly head 20 is already holding dissimilar components during a period in which a picking-up operation of the fed components is being carried out, there is a risk that the dissimilar components will be dropped when the assembly head 20 is operating (XY movement, R-axis rotation, Q-axis rotation).

[0048] If the mismatched components accidentally enter the feed area As of the bulk feeder 30, a different component 92 than the intended component will be fed, necessitating maintenance of the bulk feeder 30. Even if the mismatched components can be detected by checking the sheet production, this becomes a factor that reduces productivity. Therefore, the production aid 70 of the present embodiment has a configuration that prevents mismatched components from entering the feed area As of the bulk feeder 30 during the sheet production process using the bulk feeder 30.

[0049] In the first embodiment, the production aid device 70 prevents dissimilar components from entering the feed area As by pre-optimizing the control program M1 used for the assembly process. As in Fig. As shown in Figure 7, the production aid 70 is integrated into the host computer 60. The production aid 70 includes an adjustment section 71.

[0050] Setting section 71 determines the execution sequence of the picking operations such that a picking operation for picking up components 92 from the feeder 30 is prioritized among the picking operations planned for execution in a predetermined picking cycle (S12). In the present embodiment, setting section 71 determines the execution sequence of the picking operations by modifying the assembly sequence in the control program M1. Here, the control device 16 of the component assembler 10 executes the picking operations in the picking cycle (S12) in the same sequence as the execution sequence of the assembly operations performed in the assembly cycle.

[0051] The setting section 71 adjusts the control program M1 so that, when intake processes for picking up components 92 from the bulk feeder 30 (corresponding to the one indicated by the dashed line in Fig. 9 enclosed area) belong to the intake operations intended for execution in the first PP cycle; these intake operations are preferably carried out in a predetermined intake cycle. The execution sequence of the intake operations from the bulk feeder 30 can be adjusted within the intake cycle intended for execution.

[0052] As in Fig. As shown in Figure 9, in the first PP cycle, the removal processes for taking the component types (a, b) and the removal process for taking the fed component (c) from the bulk feeder 30 are reversed. Consequently, in the adapted control program M1, the execution sequence of the picking processes in the picking cycle is set such that dissimilar components (a, b, d) from other feeders 122 are picked up after the fed component (c) has been picked up from the bulk feeder 30.

[0053] However, the execution sequence of the recording cycles in the control program M1 may not allow for a change in order due to considerations regarding the efficiency of PP cycle execution and limitations concerning the execution sequence. As in Fig. As shown in Figure 9, the components (e, f, f) in a second PP cycle are subject to the restriction that they must be mounted on the plate 91 before the components (c) fed from the bulk feeder 30, so that an exchange of the corresponding picking operations may be restricted.

[0054] In such cases, setting section 71 adapts the control program M1 by shifting the pickup operations to a different PP cycle or by swapping the pickup operations. If the first cycle L1, which is a pickup cycle scheduled for execution, contains a pickup operation for picking up components 92 from the bulk feeder 30 (corresponding to the one indicated by the dashed line in Fig. 9 enclosed area), setting section 71 determines the execution sequence such that this recording operation is preferably carried out in the second cycle L2, which is a recording cycle different from the first cycle L1 (see right column in Fig. 9).

[0055] At this point, setting section 71 can swap the pick-up operations between the first cycle L1 and the second cycle L2. For example, if it is permissible to execute assembly operations for components (g, g, ..., h) contained in a third PP cycle, which includes the second cycle L2, in the second PP cycle, setting section 71 adjusts these assembly operations so that they are executed in the second PP cycle. This sets the execution sequence so that the pick-up operations for the components (g, g, ..., h) are executed at the end of the first cycle L1, and the pick-up operation for the fed component (c) is executed at the beginning of the second cycle L2.

[0056] According to such a configuration, without increasing the number of PP cycle executions in the predefined control program M1, intake operations from the bulk feeder 30 are preferably carried out in the intake cycles of predetermined PP cycles (the first and third PP cycle in Fig. 9) executed. When the assembly process is carried out using such an adapted control program M1, the suction nozzle 23 carried by the assembly head 20 does not hold any dissimilar components during the execution of the intake operations from the feeder 30. This prevents dissimilar components from being mixed, even when the assembly head 20 is operating while the closure 50 is in an open state. 2. Second embodiment 2-1. Configuration of the production aid device 170

[0057] The production aid device 170 of a second embodiment is described with reference to the Fig. 10 and Fig. 11 described. Here, in the production aid device 70 of the first embodiment, an aspect was adopted in which, by performing an optimization process (editing the assembly sequence) for the control program M1 before the execution of the assembly process, it is prevented that the assembly head 20 works in the feed region As while holding dissimilar components.

[0058] Here, a control program M1, which has not undergone such an optimization process, can be used for the assembly process of the component assembler 10. Furthermore, during the execution of the assembly process, an assembly operation not provided for in control program M1 can be added and executed as a recovery operation due to the occurrence of component picking errors or assembly errors. In such cases, the picking operations performed in the recovery operation can include picking operations from the bulk feeder 30.

[0059] To handle such cases, the production aid 170 of the second embodiment has an aspect that appropriately adjusts the execution sequence of recording operations during a period in which the assembly process is carried out. In the second embodiment of the production aid 170, as shown in Fig. Figure 10 shows the production aid device 170 integrated into the control device 16 of the component assembler. The other configurations are essentially the same as in the first embodiment, so a detailed description of them is omitted. 2-2. Production assistance process by the production assistance device 170

[0060] As in Fig. As shown in Figure 11, the production auxiliary device 170 performs a production auxiliary operation. This production auxiliary operation is performed, for example, at the time when the control device 16 downloads the control program M1 from the host computer 60, at the time when the assembly operation is carried out using the control program M1, at the time when the recovery operation takes place during the assembly operation, or at a similar time.

[0061] The production auxiliary device 170 executes the operating mode setting operation (S22) when a picking operation for components 92 from the bulk feeder 30 is included in a picking cycle whose execution is scheduled (S21: Yes). Here, the operating modes of the component assemblers 10 include a safety mode, which executes a safety operation to prevent dissimilar components from entering the feed area As of the bulk feeder 30. Additionally, the operating mode of the component assemblers 10 includes a production mode, which executes the normal production process, in which the probability of dissimilar components entering the feed area As of the bulk feeder 30 is low.

[0062] Several aspects can be applied to the operating mode setting process. For example, the operator of the component assembler 10 can set the operating mode for each assembly operation or for each production line to either safety mode or production mode. Furthermore, the operating mode can be switched and set according to the type of components picked up during the picking cycle. For example, if the planned picking cycle includes one picking operation to pick up components 92 from the bulk feeder 30 and one picking operation to pick up components other than components 92 from the feeder 122, which is not a bulk feeder 30, the operating mode can be set based on at least one of the following characteristics: the type of dissimilar components and the type of suction nozzle 23 that holds the dissimilar components.

[0063] Here, the production aid device 170 aims to prevent dissimilar components from entering the feed area As during the assembly process. For example, if components 92 are removed from the feed area As of the bulk feeder 30, the type of dissimilar components already held by the assembly head 20 may differ significantly from the type of components fed by the bulk feeder 30. In such a case, if, for example, the dissimilar components are large and cannot be introduced into the feed area As, or even if they are introduced, can be easily removed, there is no reason not to set the operating mode to a production mode.

[0064] Furthermore, the ability to drop dissimilar components can vary depending on the performance of the suction nozzle 23, which is used as a holding element to hold the dissimilar components, and the pickup capacity between the dissimilar components and the suction nozzle 23. For example, if the pickup surface of the dissimilar components is flat and a sufficient area is secured, and the suction nozzle 23 has sufficient pickup capacity (determined by the performance due to the shape of the suction nozzle 23, the presence / absence of maintenance, or the like), there is no reason not to set the operating mode to a production mode. In this way, the operating mode can be set based on device data specifying the type and characteristics of the suction nozzle 23 and component data M2 specifying the shape and size of the feature section of the components 92.

[0065] Setting section 171 executes the setting operation for the execution sequence of the pickup operations (S24) when the operating mode of the component assembler 10 is a safety mode (S23: Yes) during the execution of the pickup cycle. This setting operation for the execution sequence (S24) does not modify the control program M1, but rather takes as its processing target the sequence data loaded on the control device 16, which was created by reading the control program M1 with an optionally added recovery operation. This setting operation for the execution sequence of the pickup operations (S24) is essentially the same as the setting operation of the first embodiment (see Fig. 9), the detailed description of which is omitted here. On the other hand, setting section 171 skips the setting process for the execution sequence of recording operations (S24) if the operating mode is a production mode (S23: No).

[0066] According to this configuration, picking operations from the feeder 30 are preferably performed within the picking cycles of predetermined PP cycles (including the recovery operation). When the assembly process is performed with such a customized sequence of picking operations, the suction nozzle 23 carried by the assembly head 20 does not hold dissimilar components during the period in which picking operations are being performed from the feeder 30. This prevents dissimilar components from being mixed, even when the assembly head 20 is operating while the closure 50 is in an open state.

[0067] The feeder 30 brings the closure 50 into a closed state after the picking process, which is preferably carried out in the picking cycle, has been completed. This prevents dissimilar components from entering the feeding area of ​​the feeder 30, even if components 92 accidentally fall due to the operation of the assembly head 20, including subsequent picking processes. 3. Third embodiment 3-1. Configuration of the production aid device 270

[0068] The production aid device 270 of a third embodiment is described with reference to the Fig. 12-13 described. Here, in the production aid device 170 of the second embodiment, an aspect was adopted which, without modification of the control program M1, prevents the assembly head 20 from operating in the feed region As while holding dissimilar components, by changing the execution sequence of the picking operations and assembly operations in the PP cycles planned for execution accordingly.

[0069] Here, a control program M1, which has not undergone such an optimization process, can be used for the assembly process of component assembler 10. It is also assumed that the adjustment of the execution sequence of recording operations during a period in which the assembly process is carried out may be limited by various circumstances, or that the PP cycle may be extended as a result of the adjustment of the execution sequence, thereby increasing the time required for the assembly process.

[0070] To handle such cases, the production aid 270 of the third embodiment has an aspect that performs a control such that the operation of the assembly head 20 is carried out with the closure 50 closed during the period in which the assembly process is performed. In the third embodiment, as in Fig. Figure 12 shows the production aid device 270 integrated into the control device 16 of the component assembler 10.

[0071] The production aid 270 comprises a limiting section 272. The limiting section 272 limits at least one of the movements and rotations (R-axis rotation, Q-axis rotation) of dissimilar components 92 through the assembly head 20 when dissimilar components 92, which differ from the components 92 fed by the feeder 30, are held by the holding element (suction nozzle 23) and the closure 50 is in an open state. The other configurations are essentially the same as in the first embodiment; therefore, a detailed description is omitted. 3-2. Production assistance process by production assistance device 270

[0072] As in Fig. As shown in Figure 12, the production auxiliary device 270 performs a production auxiliary operation. This production auxiliary operation is performed, for example, at the time an operating command is sent to the assembly head 20, or at a similar time. The production auxiliary device 270 performs an operating mode setting operation (S32) when the assembly head 20 is holding dissimilar components and the closure 50 is in an open state (S31: Yes).

[0073] Various aspects can be applied to the operating mode setting process. For example, the operating mode can be set according to the degree of possibility of mixing dissimilar components that accompanies the operation of the assembly head 20. For example, the operating mode can be set to a safety mode if the assembly head 20 is within a predetermined range Na (see Fig.1) from the feed area As, and to a production mode when the assembly head 20 is outside a predetermined area Na from the feed area As.

[0074] Similar to the second embodiment, the operating mode can also be set based on the type of the dissimilar components 92 and the type of suction nozzle 23 that holds the dissimilar components 92. Since the execution time of this production support operation falls within a period during which the assembly operation is carried out, the operating mode can also be set based on the holding status of the dissimilar components 92 by the holding element (suction nozzle 23). In particular, a component camera 14 or a head camera unit (not shown) is used to check whether the dissimilar components are held in a normal posture and position by the suction nozzle 23, and if it can be determined that the probability of falling is low, the operating mode is set to a production mode.

[0075] The limiting section 272 performs a limiting operation (S34) in which at least one of the movements and rotations of the dissimilar component 92 is limited if the operating mode of the component assembler 10 for executing the pickup cycle is a safety mode (S33: Yes). As a result, the assembly head 20 waits for the closure 50 of the feeder 30 to move into a closed state and then executes the operation to be performed after the limiting section 272 lifts the limiting operation. During the limiting operation, the limiting section 272 can limit all movements in the XY direction, rotation about the R-axis, and rotation about the Q-axis during the operations of the assembly head 20, or it can allow rotation about the Q-axis along with the raising and lowering of the suction nozzle 23.On the other hand, the limiting section 272 skips the restriction process (S34) if the operating mode is a production mode (S33: No).

[0076] According to such a configuration, in a state where the feed area As of the bulk feeder 30 is open, the assembly head 20, which holds components 92 other than those fed by the bulk feeder 30, is prevented from working in the area of ​​the feed area As, thus preventing dissimilar components 92 from entering the feed area As. 4. Modified embodiment

[0077] Here, as in the third embodiment, a configuration that restricts the operation of the mounting head 20 according to the position of the mounting head 20 and the open / closed state of the shutter 50 can be useful insofar as the configuration does not require any operation to change the execution sequence of the shooting operations. However, since a waiting time may occur for the aperture 50 to transition to a closed state, adjusting the execution sequence of shooting operations (first and second embodiments) can lead to a reduction in the time required for the mounting operation.

[0078] However, adjusting the execution sequence of pick-up operations can increase the number of PP cycle executions, and in such cases, executing pick-up operations in the originally planned sequence, even if a waiting time occurs due to the constraint operation (S34), can lead to a reduction in the time required for the assembly operation. Therefore, the production auxiliary devices 170 and 270 can include a setting section 171 and a limiting section 272.

[0079] This makes it possible, for example, to appropriately select the procedure that results in a shorter assembly time by comparing the case in which the setting operation for the execution sequence of the picking operations (S24) is carried out with the case in which the restriction operation (S34), which restricts a predetermined operation of the assembly head 20, is carried out without adjusting the execution sequence of the picking operations. This prevents dissimilar components from entering the feed area of ​​the bulk feeder 30 and maintains productivity. List of reference symbols

[0080] 10: Component assembler, 12: Component feeder, 122: Feeder, 13: Component transfer device, 20: Assembly head, 23: Suction nozzle, 14: Component camera, 15: Plate camera, 16: Control device, 30: Bulk feeder, 35: Closure drive device, 36: Feeder control device, 40: Track unit, 41: Track element, 42: Adjustment element, 45: Recesses, 50: Closure, 60: Host computer, 70, 170, 270: Production aid device, 71, 171: Setting section, 272: Limiting section, 91: Plate, 92: Component, As: Feeding area, R: Conveyor path, M1: Control program, Na: Predetermined area, L1: First cycle, L2: Second cycle QUOTES INCLUDED IN THE DESCRIPTION

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

[0000] JP-A-2011-114084

[0003]

Claims

[1] A production aid for use with a component assembler configured to perform a picking cycle in which a picking operation is repeatedly performed to pick up multiple components from a component feeder equipped with a bulk feeder configured to feed the multiple components to a feed area, and to perform an assembly cycle in which an assembly operation is repeatedly performed to assemble the multiple components onto a plate, wherein the production aid comprises: a setting section that is configured to define an execution sequence of the picking operations such that, among the picking operations planned for execution, the picking operation for picking up the components from the bulk feeder is preferably carried out in a predetermined picking cycle. [2] The production aid device according to claim 1, wherein The component assembler executes the picking cycle and the assembly cycle based on a control program that specifies the assembly positions and an assembly sequence of the components to be mounted on the plate, and The setting section determines the execution sequence of the recording processes by editing the assembly instructions in the control program. [3] The production aid device according to claim 1, wherein the setting section, if the intake cycle intended for execution includes the intake process for taking up the components from the bulk feeder, determines the execution sequence of several intake processes included in the intake cycle. [4] The production aid device according to claim 1, wherein the setting section, if a first cycle which is a receiving cycle intended for execution comprises the receiving process for receiving the components from the bulk feeder, determines the execution sequence such that the receiving process is preferably carried out in a second cycle which is a receiving cycle different from the first cycle. [5] The production aid device according to claim 4, wherein the adjustment section reverses the recording process between the first cycle and the second cycle. [6] The production aid device according to any one of claims 1 to 5, wherein the setting section performs the setting process for the execution sequence of the taking operations if an operating mode of the component assembler is a safety mode during the execution of the taking cycle, and skips the setting process for the execution sequence of the taking operations if the operating mode is a production mode. [7] The production aid device according to claim 6, wherein, if the intake cycle planned for execution comprises the intake process of picking up the components from the bulk feeder and the intake process of picking up a dissimilar component that differs from the components from a feeder other than the bulk feeder, the operating mode is set on the basis of at least one type of dissimilar component and one type of holding element that holds the dissimilar component. [8] The production aid device according to any one of claims 1 to 5, wherein the feeder comprises a closure configured to be opened and closed with respect to the feed area and to close the feed area in a closed state, and wherein the closure is brought into the closed state after the intake process, which is preferably carried out in the intake cycle, has been completed. [9] A production aid device for use with a component assembler, comprising a component feeder equipped with a bulk feeder configured to feed multiple components to a feed area, and an assembly head carrying multiple holding elements configured to hold the components, wherein The feeder includes a closure configured to be opened and closed with respect to the feed area and to close the feed area in a closed state, and The production aid device includes a limiting section configured to limit at least one of the movements and rotations of a dissimilar component, which differs from the components fed by the bulk feeder, through the assembly head when the dissimilar component is held by the holding element and the closure is in an open state. [10] The production aid device according to claim 9, wherein the limiting section performs a limiting operation to limit at least one movement and / or rotation of the dissimilar component when an operating mode of the component assembler during operation of the assembly head is a safety mode, and skips the limiting operation when the operating mode is a production mode. [11] The production aid device according to claim 10, wherein the operating mode is set to a safety mode when the assembly head is within a predetermined area from the feed area, and is set to a production mode when the assembly head is outside the predetermined area from the feed area. [12] The production aid device according to claim 10 or 11, wherein the operating mode is set on the basis of at least one of the following features: type of dissimilar component, type of holding means that holds the dissimilar component, and holding state of the dissimilar component by the holding means.

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