Component mounting device, maintenance support device, and maintenance support method

Abstract

To provide a component mounting device capable of predicting when mounting head maintenance is required without additional measurement equipment, a maintenance support device, and a maintenance support method.SOLUTION: The maintenance support method includes the steps: setting a thrust limit value for limiting the thrust of the servo motor (ST1); lowering a component holder by a controlled servo motor based on a preset operation pattern (ST2); and predicting when the mounting head will require maintenance (ST10) based on history data of the thrust limit value at which the component holder descends and the operation time is delayed (ST6).SELECTED DRAWING: Figure 7

Description

[Technical field]

[0001] The present invention relates to a component mounting apparatus, a maintenance support apparatus, and a maintenance support method for supporting maintenance of a mounting head that mounts components on a board. [Background technology]

[0002] The mounting head of the component mounting device lowers a shaft by a servo motor, and mounts a component held by a component holder attached to the lower end of the shaft onto a board. As components have become smaller and thinner in recent years, the appropriate mounting load when mounting a component onto a board has been significantly reduced (see, for example, Patent Document 1). The component mounting device of Patent Document 1 presses the tip of the component holder against a load detection unit installed below, and obtains correlation data that indicates the relationship between the thrust of the servo motor and the load generated at the tip of the component holder. Then, when mounting a component, the servo motor is controlled based on the obtained correlation data, so that the mounting load applied to the component does not exceed a predetermined value. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Patent No. 7223928 Summary of the Invention [Problem to be solved by the invention]

[0004] Incidentally, in conventional technologies including Patent Document 1, correlation data between the thrust of the servo motor and the load generated at the tip of the component holding part can be obtained and compared with previously obtained reference correlation data to determine the need for maintenance of the mounting head, such as an increase in the sliding resistance of the shaft. However, there was a problem in that an additional measuring device such as a load detection part had to be used to obtain the correlation data.

[0005] SUMMARY OF THE PRESENT DISCLOSURE An object of the present invention is to provide a component mounting apparatus, a maintenance support apparatus, and a maintenance support method that are capable of estimating the time when maintenance of a mounting head will be required without adding a measuring device. [Means for solving the problem]

[0006] The component mounting device of the present invention is a component mounting device for mounting components on a board, and comprises a mounting head having a component holding section for holding components, a shaft on which the component holding section is mounted in a state in which it can be displaced in the vertical direction, and a servo motor for raising and lowering the shaft, a control section which sets a thrust limit value that limits the thrust of the servo motor and controls the servo motor based on a predetermined operating pattern, and an estimation section which estimates a maintenance time when maintenance of the mounting head is necessary based on historical data of a limit thrust limit value, which is the thrust limit value that causes a delay in the operating time for the component holding section to descend, or historical data related to the operating time.

[0007] The maintenance support device of the present invention is a maintenance support device that supports the maintenance of a mounting head having a component holding section that holds components, a shaft to which the component holding section is attached in a state in which it can be displaced in the vertical direction, and a servo motor that raises and lowers the shaft, and is provided with an estimation unit that sets a thrust limit value that limits the thrust of the servo motor, and then lowers the component holding section by using the servo motor controlled based on a predetermined operating pattern, and estimates the maintenance time when maintenance of the mounting head will be necessary based on historical data of the limit thrust limit value, which is the thrust limit value that causes a delay in the operating time for the component holding section to be lowered, or historical data related to the operating time.

[0008] The maintenance support method of the present invention is a maintenance support method that supports maintenance of a mounting head having a component holding part that holds components, a shaft to which the component holding part is attached in a state in which it can be displaced in the vertical direction, and a servo motor that raises and lowers the shaft, wherein a thrust limit value that limits the thrust of the servo motor is set, and the component holding part is lowered by the servo motor controlled based on a predetermined operating pattern, and a maintenance time when maintenance of the mounting head will be necessary is estimated based on historical data of the limit thrust limit value, which is the thrust limit value that causes a delay in the operating time for the component holding part to be lowered, or historical data related to the operating time. Effect of the Invention

[0009] According to the present invention, it is possible to estimate the time when maintenance of a mounting head is required without adding a measuring device. [Brief description of the drawings]

[0010] [Figure 1] FIG. 1 is a plan view of a component mounting system including a configuration of a main part of a component mounting device according to an embodiment of the present invention. [Diagram 2] FIG. 2 is a cross-sectional view showing a configuration of a main part of a mounting head provided in a component mounting device according to an embodiment of the present invention; [Diagram 3] FIG. 1 is an explanatory diagram showing the relationship of forces acting on a mounting unit of a mounting head provided in a component mounting device according to an embodiment of the present invention; [Figure 4] FIG. 2 is a block diagram showing the configuration of a control system of the component mounting device according to the embodiment of the present invention. [Diagram 5] FIG. 2 is a diagram for explaining acquisition of a limit thrust limit value by a component mounting device according to an embodiment of the present invention. [Figure 6] FIG. 1 is an explanatory diagram of an example of history data acquired by a component mounting device according to an embodiment of the present invention; [Figure 7] FIG. 1 is a flow diagram of a maintenance support method according to an embodiment of the present invention. [Figure 8] FIG. 2 is a block diagram showing the configuration of a control system of another embodiment of the component mounting apparatus according to the present invention; [Figure 9] FIG. 11 is an explanatory diagram of an example of threshold information used in another embodiment of the component mounting device according to the present invention; [Figure 10] FIG. 11 is an explanatory diagram of an example of history data acquired by another embodiment of the component mounting apparatus according to the present invention; [Figure 11] FIG. 1 is a flow chart of another embodiment of the maintenance support method according to the present invention; DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0011] An embodiment of the present invention will be described in detail below with reference to the drawings. The configurations, shapes, etc. described below are examples for explanation and can be changed as appropriate depending on the specifications of the component mounting device, the mounting head, and the management computer (maintenance support device). In the following, the same reference numerals are used for corresponding elements in all the drawings, and duplicated explanations will be omitted. In FIG. 1 and in some parts described later, the X-axis (left and right direction in FIG. 1) in the board transport direction and the Y-axis (up and down direction in FIG. 1) perpendicular to the board transport direction are shown as two axes perpendicular to each other in the horizontal plane. In FIG. 2 and in some parts described later, the Z-axis (up and down direction in FIG. 2) is shown as the height direction perpendicular to the horizontal plane.

[0012] First, the configuration of the component mounting system 1 will be described with reference to Fig. 1. The component mounting system 1 is configured with a component mounting device M and a management computer CP, which are connected via a communication network NT. The component mounting device M has a function of executing a component mounting operation in which components supplied from a component supply unit are mounted on a board. The management computer CP has a function of creating programs and control data used by the component mounting device M for the component mounting operation in which the component mounting device M mounts components on a board, as well as a function of acquiring various data from the component mounting device M and estimating the maintenance timing, etc., to support the maintenance of the component mounting device M.

[0013] Next, the configuration of the component mounting device M will be described with reference to Fig. 1. The component mounting device M has a function of performing a component mounting operation in which components supplied from a component supply unit are mounted on a board to manufacture a mounted board. A board transport mechanism 3 is arranged along the X-axis in the center of the base 2. The board transport mechanism 3 transports the board P transported from upstream to the mounting operation position, positions it, and holds it. In addition, the board transport mechanism 3 transports the board P downstream after the component mounting operation has been completed.

[0014] Component supply units 4 are arranged on both sides (front and back directions along the Y axis) of the board transport mechanism 3. Each component supply unit 4 has multiple tape feeders 5 arranged along the X axis. Each tape feeder 5 of the component supply unit 4 pitch-feeds a component tape, on which pockets for storing components are formed, in a direction (tape feed direction) from the outside of the component supply unit 4 toward the board transport mechanism 3, to supply components to a component supply position from which the components are picked up by a mounting head, which will be described below.

[0015] In FIG. 1, a Y-axis table 6 equipped with a linear drive mechanism is arranged along the Y-axis at both ends of the X-axis on the upper surface of the base 2. A beam 7 similarly equipped with a linear drive mechanism is connected to the Y-axis table 6 so as to be freely movable along the Y-axis. The beam 7 is arranged along the X-axis. A mounting head 8 is attached to the beam 7 via a plate 7a so as to be freely movable along the X-axis. The mounting head 8 is detachable from the plate 7a. The mounting head 8 is equipped with a plurality of mounting units 20 (see FIG. 2). A component holder 29 (see FIG. 2) that sucks and holds components is attached to the lower ends of the mounting units 20.

[0016] The Y-axis table 6 and the beam 7 constitute a head moving mechanism 9 that moves the mounting head 8 along the X-axis and Y-axis. The head moving mechanism 9 and the mounting head 8 perform a mounting turn in which a component holder 29 attached to the mounting unit 20 sucks and removes a component from the tape feeder 5 arranged in the component supply section 4, and mounts the component at a mounting position on the board P positioned by the board transport mechanism 3. In this way, a plurality of component holders 29 are attached to the mounting head 8, and each component holder 29 picks up a component supplied from the component supply section 4 and mounts it on the board P.

[0017] In Fig. 1, a component recognition camera 10 is disposed between the component supply unit 4 and the board transport mechanism 3. When the mounting head 8 which has picked up a component from the component supply unit 4 moves above the component recognition camera 10, the component recognition camera 10 captures an image of the component held by the mounting head 8 to recognize the holding posture of the component. A head camera 11 is attached to the plate 7a to which the mounting head 8 is attached. The head camera 11 moves integrally with the mounting head 8.

[0018] As the mounting head 8 moves, the head camera 11 moves above the board P positioned by the board transport mechanism 3, and captures an image of a board mark (not shown) provided on the board P to recognize the position of the board P. When the mounting head 8 mounts components on the board P, the mounting position is corrected taking into account the component recognition results by the component recognition camera 10 and the board position recognition results by the head camera 11.

[0019] 1, a touch panel 12 operated by an operator is provided at a position where an operator works in front of component mounting device M. Touch panel 12 displays various information on its display unit, and the operator inputs data and operates component mounting device M using operation buttons and the like displayed on the display unit.

[0020] Next, the configuration of the mounting head 8 will be described with reference to Fig. 2. The mounting head 8 has multiple mounting units 20 (four in the X direction in this case) arranged inside the mounting head base 8a. The mounting units 20 are configured such that a shaft 21 extending in the vertical direction (Z-axis direction) is raised and lowered by a servo-controlled Z-axis motor 22, thereby raising and lowering a component holder 29.

[0021] The shaft 21 is connected to the lower side of the Z-axis motor 22 via the output unit 23. The lower end of the shaft 21 is inserted into a spline guide unit 24 that is rotatable through θ by bearings 24a arranged above and below, and protrudes outward from the lower surface of the mounting head base 8a. A component holder 29 is attached to the lower end of the shaft 21 that protrudes from the lower surface of the mounting head base 8a. That is, the mounting head 8 has the component holder 29 that holds a component, the shaft 21 on which the component holder 29 is attached so as to be displaceable in the vertical direction, and the Z-axis motor 22 (servo motor) that raises and lowers the shaft 21.

[0022] 2, return spring 25, which is a compression spring, is attached to shaft 21 between output portion 23 and spline guide portion 24. Return spring 25 exerts an upward repulsive force on output portion 23. That is, when component holder 29 is to be lowered, Z-axis motor 22 generates a downward thrust, which lowers shaft 21 against the repulsive force of return spring 25. When component holder 29 is to be raised, Z-axis motor 22 generates an upward thrust, which causes shaft 21 to be raised by the upward repulsive force of return spring 25 that pushes up output portion 23.

[0023] A scale 26 that moves up and down in accordance with the lifting and lowering operation of the output unit 23, i.e., the lifting and lowering movement of the shaft 21, is provided to protrude upward from the upper portion of the Z-axis motor 22. A position detection sensor 27 that detects the movement of the scale 26 is also disposed above the Z-axis motor 22. The position detection sensor 27 outputs encoder pulses that indicate the moving distance and direction of the scale 26 as position signals to the servo control unit 30 (see FIG. 4). The vertical position (height position) of the shaft 21 is detected from the position signal. That is, the scale 26 and the position detection sensor 27 constitute an encoder 28 that detects the height position of the shaft 21 (or the component holder 29).

[0024] Next, the relationship of forces acting on mounting unit 20 will be described with reference to Fig. 3. Thrust Ft is a thrust generated by Z-axis motor 22, and acts in a direction that presses down shaft 21 connected via output unit 23. Weight W is the sum of the weights of the hatched parts indicating the movable parts in the figure, i.e., scale 26, output unit 23, shaft 21, component holder 29, etc., and acts in a direction that presses down shaft 21 like thrust Ft.

[0025] The reaction force Fr is the reaction force of return spring 25, and acts in a direction pushing up shaft 21 via output portion 23. The sliding resistance Ff is an external resistive force of spline guide portion 24 that slidably holds the above-mentioned movable portion, and acts upward on shaft 21 that is driven in the downward direction. The load Fa represents the load when component D held by component holder 29 is pressed against board P.

[0026] 3 shows a state in which component holder 29 presses held component D against board P during component mounting work. In this state, load Fa is expressed as Fa=Ft+W-Fr-Ff. When thrust Ft of Z-axis motor 22 is increased with component D in contact with board P, reaction force Fr of return spring 25 remains constant, and load Fa increases in proportion to thrust Ft. Also, load Fa before component D held by component holder 29 comes into contact with board P is zero, and output unit 23 (shaft 21, component holder 29) descends in proportion to thrust Ft of Z-axis motor 22, increasing reaction force Fr of return spring 25 (Fr=Ft+W-Ff).

[0027] However, if the placing head 8 is used for a long time after the last maintenance, dust accumulates on the spline guide portion 24, the grease deteriorates, and the sliding resistance Ff gradually increases. If the sliding resistance Ff exceeds a predetermined value, the predetermined load Fa is no longer applied to the component D even if the thrust Ft of the Z-axis motor 22 is increased, and the component holder 29 (shaft 21) does not descend to a predetermined height. For this reason, maintenance of the placing head 8 is performed after a predetermined time or number of uses has elapsed. This keeps the sliding resistance Ff from exceeding a predetermined value.

[0028] Next, the configuration of the control system of the component mounting apparatus M will be described with reference to Fig. 4. The main body control device 40 of the component mounting apparatus M is connected to the board transport mechanism 3, tape feeder 5, mounting head 8, head moving mechanism 9, component recognition camera 10, head camera 11, and touch panel 12. Each of the four mounting units 20 of the mounting head 8 is equipped with a servo control unit 30. The servo control unit 30 is connected to a Z-axis motor 22 and an encoder 28.

[0029] The servo control unit 30 drives the Z-axis motor 22 based on the up-down position of the shaft 21 (component holder 29) detected by the encoder 28 in accordance with a command from the main body control device 40. Methods for controlling the Z-axis motor 22 by the servo control unit 30 include position control and torque control. In the case of position control, the servo control unit 30 controls the Z-axis motor 22 so that the height of the lifting / lowering unit 37 becomes the height commanded from the main body control device 40. In the case of torque control, the servo control unit 30 controls the thrust Ft of the Z-axis motor 22 based on a command from the main body control device 40.

[0030] 4, the main body control device 40 includes a main body storage unit 41, a mounting processing unit 42, a measurement processing unit 43, an acquisition unit 44, a determination unit 45, a notification processing unit 46, and an estimation unit 47. The main body storage unit 41 is a storage device, and stores mounting data 41a, history data 41b, threshold information 41c, and the like. The mounting data 41a stores various information such as information for identifying the board P (board type number, size, material, thickness, etc.) for each board type of the mounting board, the type of component D to be mounted on the board P, and the coordinates of the mounting position on the board P. The mounting processing unit 42 controls each unit of the component mounting device M to perform a component mounting operation based on the component name, mounting position, etc. of the component D to be mounted on the board P included in the mounting data 41a.

[0031] 4, the measurement processing unit 43 transmits a command to the servo control unit 30, which will be described later, to cause the Z-axis motor 22 (servo motor) of the mounting unit 20 to lower the shaft 21 and measure a thrust limit value Ftl that causes a delay in the operation time To for the component holder 29 (shaft 21) to lower to a target lowering height H (target height Ht). Specifically, the measurement processing unit 43 sets the operation pattern to position control in which the target lowering height H of the component holder 29 is set to the target height Ht, and commands the servo control unit 30 to lower the shaft 21 by specifying a predetermined thrust limit value Ftl. The thrust limit value Ftl is measured when the board P is not present at the mounting operation position. Alternatively, when the board P is present at the mounting operation position, the target height Ht is set to a position higher than the board surface.

[0032] The servo control unit 30 that has received the command sets the thrust limit value Ftl to a specified value, and causes the Z-axis motor 22 to lower the shaft 21 by position control, and measures the operation time To until the component holder 29 reaches the target height Ht. Then, the measurement processing unit 43 measures the operation time To until the component holder 29 reaches the target height Ht while gradually decreasing the thrust limit value Ftl. When the sliding resistance Ff of the shaft 21 increases due to deterioration of the grease or the like, the operation time To until the component holder 29 reaches the target height Ht becomes longer. Therefore, by comparing the operation time To with a predetermined reference time Td0, it is possible to indirectly determine whether the current sliding resistance Ff is greater or smaller than a predetermined value. In addition, when the thrust limit value Ftl is decreased, the lowering speed of the shaft 21 (component holder 29) becomes slower, and the effect of the current sliding resistance Ff on the operation time To becomes greater.

[0033] The measurement processing unit 43 receives the operation time To measured by the servo control unit 30, and compares it with a reference time Td0 to determine whether a delay has occurred in the operation time To. If a delay has occurred, the acquisition unit 44 associates the thrust limit value Ftl as the limit thrust limit value Ftlt with information identifying the mounting unit 20 to be measured and the measurement date and time, and stores the result as history data 41b in the main body storage unit 41. The measurement of the operation time To of the mounting unit 20 by the measurement processing unit 43 and the acquisition of the limit thrust limit value Ftlt by the acquisition unit 44 are performed every predetermined number of boards produced (e.g., every 1,000 boards), every predetermined number of components mounted (e.g., every 10,000 components), every predetermined time interval (e.g., every 24 hours), or when the component mounting device M starts automatic operation.

[0034] In this way, the servo control unit 30 is a control unit that sets a thrust limit value Ftl that limits the thrust of the servo motor (Z-axis motor 22), and then controls the servo motor based on a preset operation pattern (position control of the target height Ht). The control unit (servo control unit 30) repeatedly changes the thrust limit value Ftl so that the thrust limit value Ftl gradually decreases, and causes the component holder 29 to perform a descending operation every time the thrust limit value Ftl is changed.

[0035] Specifically, the control unit (servo control unit 30) repeatedly changes the thrust limit value Ftl at a predetermined timing until a delay occurs in the operation time To for the component holder 29 to descend, and causes the component holder 29 to descend each time the thrust limit value Ftl is changed. Then, the acquisition unit 44 acquires the thrust limit value Ftl when a delay occurs in the operation time To for the component holder 29 to descend as the limit thrust limit value Ftlt of the history data 41b. In this way, the history data 41b includes the limit thrust limit values ​​Ftlt acquired at a plurality of different timings.

[0036] Here, with reference to Fig. 5, an example of acquiring the limit thrust limit value Ftlt of the mounting unit 20 executed by a command from the measurement processing unit 43 will be described. State 1 (shown by a solid line), state 2 (shown by a dotted line), and state 3 (shown by a dashed line) indicate the measurement results of the delay time Td of the operation time To at the thrust limit value Ftl executed in this order at a predetermined timing. That is, the mounting unit 20 has passed time (the cumulative number of lifts and lowers has increased) from the previous maintenance in the order of state 3, state 2, and state 1. The sliding resistance Ff1 in state 1, the sliding resistance Ff2 in state 2, and the sliding resistance Ff3 in state 3 increase with the passage of time (Ff1 <Ff2<Ff3)。

[0037] First, the control by the servo control unit 30 (control unit) will be described using state 1 as an example. First, the servo control unit 30 causes the Z-axis motor 22 to lower the shaft 21 at the thrust limit value Ftl1, and measures the operation time To until the component holder 29 reaches the target height Ht. In this example, there is no delay in the operation time To at the thrust limit value Ftl1 (delay time Td=0). Next, the servo control unit 30 causes the Z-axis motor 22 to lower the shaft 21 at the thrust limit value Ftl2, which is smaller than the thrust limit value Ftl1, and measures the operation time To until the component holder 29 reaches the target height Ht. In this example, there is no delay in the operation time To even at the thrust limit value Ftl2.

[0038] 5, the servo control unit 30 decreases the thrust limit value Ftl and measures the operation time To until the component holder 29 reaches the target height Ht in the same manner. In this example, a delay occurs in the operation time To at the thrust limit value Ftl8 (delay time Td>0). Therefore, the acquisition unit 44 records the limit thrust limit value Ftlt as the thrust limit value Ftl8 in the history data 41b. Similar measurements are performed in state 2 and state 3, and the thrust limit value Ftl5 in state 2 and the thrust limit value Ftl4 in state 3 are recorded as the limit thrust limit value Ftlt in the history data 41b. In this way, as the sliding resistance Ff increases with the passage of time since the previous maintenance, the acquired limit thrust limit value Ftlt also increases.

[0039] 6 shows an example of acquired history data 41b. In the history data 41b, the limit thrust limit value Ftlt acquired in the order of measurement timing Tm1, measurement timing Tm2, ​​etc. are recorded. In this example, the limit thrust limit value Ftlt acquired is a constant value up to measurement timing Tm4, and the limit thrust limit value Ftlt acquired gradually increases from measurement timing Tm5. That is, after measurement timing Tm4, the sliding resistance Ff of the mounting unit 20 gradually increases.

[0040] 4, the threshold information 41c stores a warning value Ftlw (first threshold), which is a limit thrust limit value Ftlt for determining whether or not it is time for maintenance when the sliding resistance Ff of the mounting unit 20 has increased and maintenance of the mounting head 8 is required. The threshold information 41c also stores a caution value Ftla (second threshold) at which the limit thrust limit value Ftlt is smaller than the warning value Ftlw.

[0041] The determination unit 45 determines whether the limit thrust limit value Ftlt acquired by the acquisition unit 44 is equal to or greater than the warning value Ftlw (first threshold value), or is smaller than the warning value Ftlw and equal to or greater than the caution value Ftla (second threshold value), based on the threshold value information 41c. In the example of Fig. 5, when the warning value Ftlw is the thrust limit value Ftl4 and the caution value Ftla is the thrust limit value Ftl5, the state 2 is determined as the limit thrust limit value Ftlt being smaller than the warning value Ftlw and equal to or greater than the caution value Ftla (caution state). Also, the state 3 is determined as the limit thrust limit value Ftlt being equal to or greater than the warning value Ftlw (warning state).

[0042] 4, the estimation unit 47 estimates the maintenance timing when maintenance of the mounting head 8 is required based on the history data 41b. Specifically, the estimation unit 47 estimates the time when the limit thrust limit value Ftlt exceeds a warning value Ftlw (first threshold value) as the maintenance timing based on the limit thrust limit value Ftlt acquired at multiple measurement timings Tm1 to Tm7 recorded in the history data 41b.

[0043] For example, the estimation unit 47 estimates the maintenance time using a linear function based on the limit thrust limit value Ftlt acquired at the two most recent time points. In the example of FIG. 6, the estimation unit 47 linearly approximates the limit thrust limit value Ftlt acquired at the measurement timing Tm6 and the measurement timing Tm7 to estimate the estimated maintenance time Te. Alternatively, the estimation unit 47 estimates the maintenance time using an approximation function based on the history data 41b. In the example of FIG. 6, the estimation unit 47 may estimate the estimated maintenance time Te by polynomial approximation of the limit thrust limit value Ftlt acquired at the measurement timing Tm1 to the measurement timing Tm7. Note that the estimation unit 47 may estimate the maintenance time using an approximation function other than a linear function or a polynomial approximation.

[0044] 4, when the determination unit 45 determines that the limit thrust limit value Ftlt is equal to or greater than the warning value Ftlw (first threshold value), the notification processing unit 46 causes the touch panel 12 to display "the mounting unit 20 has a problem with the sliding properties of the shaft 21" and "the mounting head 8 should be maintained immediately." That is, the notification processing unit 46 and the touch panel 12 constitute a notification unit 48 that notifies an error when the acquired limit thrust limit value Ftlt is determined to be equal to or greater than the first threshold value (warning value Ftlw). Furthermore, when the acquired limit thrust limit value Ftlt is determined to be equal to or greater than the first threshold value, the touch panel 12 (display unit) displays a message prompting maintenance. The notification unit 48 that notifies an error may be a rotating light or a buzzer.

[0045] When the determination unit 45 determines that the limit thrust limit value Ftlt is smaller than the warning value Ftlw (first threshold value) and is equal to or larger than the caution value Ftla (second threshold value), the notification processing unit 46 causes the touch panel 12 to display "Maintenance of the mounting head 8 should be performed by the maintenance time (for example, September 1st)." In other words, when the acquired limit thrust limit value Ftlt is determined to be smaller than the first threshold value (warning value Ftlw) and equal to or larger than the second threshold value (caution value Ftla), the notification processing unit 46 displays a message encouraging maintenance and an estimated maintenance time (estimated maintenance time Te).

[0046] Next, a maintenance support method for supporting maintenance of the mounting head 8 will be described with reference to Fig. 5 and Fig. 6 along the flow of Fig. 7. The following acquisition of the limit thrust limit value Ftlt is performed at predetermined timings (measurement timings Tm1 to Tm7) such as when the component mounting device M starts automatic operation.

[0047] 7, first, the measurement processing unit 43 transmits the thrust limit value Ftl1 (see FIG. 5) to the servo control unit 30 (control unit), and the thrust limit value Ftl1 is set in the Z-axis motor 22 (ST1: thrust limit value setting step). Next, the servo control unit 30 operates the Z-axis motor 22 to lower the shaft 21 (component holder 29) to the target height Ht (ST2: lowering step). Next, the servo control unit 30 measures the operation time To until the component holder 29 reaches the target height Ht (ST3: operation time measurement step). The measured operation time To is transmitted to the measurement processing unit 43.

[0048] Next, the measurement processing unit 43 judges whether or not a delay has occurred in the operation time To by comparing with the reference time Td0 (ST4: delay judgment step). If no delay has occurred in the operation time To (Yes in ST4), the measurement processing unit 43 transmits a thrust limit value Ftl2 (see FIG. 5) smaller than the thrust limit value Ftl1, and the thrust limit value Ftl2 is set in the Z-axis motor 22 (ST5: thrust limit value decreasing step). Next, a descending step (ST2), an operation time measurement step (ST3), and a delay judgment step (ST4) are executed.

[0049] Thereafter, the thrust limit value reducing step (ST5), the lowering step (ST2), the operation time measuring step (ST3), and the delay determining step (ST4) are repeatedly executed until a delay occurs in the operation time To (until ST4 becomes No), or until the component holder 29 does not reach the target height Ht, the thrust limit value reducing step (ST5), the lowering step (ST2), the operation time measuring step (ST3), and the delay determining step (ST4) are repeatedly executed.

[0050] 7, if a delay occurs in the operation time To (No in ST4), the acquiring unit 44 records the thrust limit value Ftl that causes a delay in the operation time To for the component holder 29 to descend to the target height Ht as the limit thrust limit value Ftlt in the history data 41b (ST6: limit thrust limit value acquiring step). Next, the determining unit 45 determines whether the limit thrust limit value Ftlt is equal to or greater than the warning value Ftlw (first threshold value) (ST7: warning determining step).

[0051] When it is determined that the limit thrust limit value Ftlt is equal to or greater than the warning value Ftlw (Yes in ST7), an error is notified by the notification unit 48 (ST8: warning step). Also, a message urging maintenance is displayed on the touch panel 12 (display unit) (ST8). In the case of state 3 in FIG. 5, it is determined that the limit thrust limit value Ftlt is equal to or greater than the warning value Ftlw (Yes in ST7), and the warning step (ST8) is executed.

[0052] 7, when the limit thrust limit value Ftlt is smaller than the warning value Ftlw (No in ST7), the determination unit 45 determines whether the limit thrust limit value Ftlt is equal to or greater than a caution value Ftla (second threshold value) (ST9: caution determination step). When it is determined that the limit thrust limit value Ftlt is equal to or greater than the caution value Ftla (Yes in ST9), the estimation unit 47 estimates an estimated maintenance time Te based on the history data 41b (ST10: maintenance time estimation step) (see FIG. 6).

[0053] Next, the notification processor 46 displays the estimated maintenance time Te and a message urging maintenance on the touch panel 12 (ST11: warning step). In the case of state 2 in FIG. 5, it is determined that the limit thrust limit value Ftlt is equal to or greater than the warning value Ftla (Yes in ST9), and the warning step (ST11) is executed.

[0054] In FIG. 7, when it is determined that the limit thrust limit value Ftlt is smaller than the caution value Ftla (No in ST9), acquisition of the limit thrust limit value Ftlt at that measurement timing is completed, and at the next measurement timing, the thrust limit value setting process (ST1) to the limit thrust limit value acquisition process (ST6), etc. are executed.

[0055] In this manner, the maintenance support method of this embodiment sets a thrust limit value Ftl that limits the thrust of the servo motor (Z-axis motor 22) (ST1), then lowers the component holder 29 by using the servo motor controlled based on a preset operation pattern (ST2), and estimates the time when maintenance of the mounting head 8 will be required based on history data 41b (ST6) of the critical thrust limit value Ftlt, which is the thrust limit value Ftl that causes a delay in the operation time To for the component holder 29 to descend (ST10). This makes it possible to estimate the time when maintenance of the mounting head 8 will be required without the need for any additional measuring equipment.

[0056] As described above, the component mounting device M of this embodiment includes a mounting head 8 having a component holder 29 that holds a component D, a shaft 21 on which the component holder 29 is mounted so as to be displaceable in the vertical direction, and a servo motor (Z-axis motor 22) that raises and lowers the shaft 21, a control unit (servo control unit 30) that sets a thrust limit value Ftl that limits the thrust of the servo motor and controls the servo motor based on a preset operation pattern, and an estimation unit 47 that estimates the time when maintenance of the mounting head 8 will be required based on history data 41b of the limit thrust limit value Ftlt. This makes it possible to estimate the time when maintenance of the mounting head 8 will be required without adding a measuring device.

[0057] In the above description, the component mounting device M is configured to include the estimation unit 47, but the management computer CP may also be configured to include the estimation unit 47 and estimate the estimated maintenance time Te. In other words, the management computer CP may be a maintenance support device that supports maintenance of the mounting head 8, and may be configured to include the estimation unit 47 that estimates the time when maintenance of the mounting head 8 will be required based on the history data 41b acquired by the component mounting device M. This makes it possible to estimate the time when maintenance of the mounting head 8 will be required without adding a measuring device.

[0058] Next, the configuration of a control system of another embodiment of the component mounting device M (hereinafter simply referred to as "component mounting device MA") will be described with reference to Fig. 8. The component mounting device MA estimates the estimated maintenance time Te based on a delay time Td calculated from the operation time To for the component holder 29 to descend, which differs from the component mounting device M that estimates the estimated maintenance time Te based on the critical thrust limit value Ftlt. Hereinafter, the same parts as those in the component mounting device M are given the same reference numerals, and detailed explanations will be omitted.

[0059] The main body control device 40A provided in the component mounting device MA includes a main body storage unit 41A, a mounting processing unit 42, a measurement processing unit 43A, an acquisition unit 44A, a determination unit 45A, a notification processing unit 46A, an estimation unit 47A, a measurement unit 49, and a calculation unit 50. The main body storage unit 41A is a storage device, and stores mounting data 41a, history data 41Ab, threshold information 41Ac, and the like.

[0060] 9 shows an example of the history data 41Ab. The history data 41Ab includes reference times Td0A, Td0B, caution values ​​TdaA, TdaB, and warning values ​​TdwA, TdwB for each thrust limit value FtlA, FtlB. In this example, the history data 41Ab specifies reference times Td0A, Td0B, caution values ​​TdaA, TdaB, and warning values ​​TdwA, TdwB for each of the two thrust limit values ​​FtlA, FtlB. Note that the number of thrust limit values ​​FtlA, FtlB included in the history data 41Ab is not limited to two, and may be one, or three or more.

[0061] The reference times Td0A, Td0B are reference times for determining whether or not a delay has occurred in the operation time To when the component holder 29 is lowered by setting the thrust limit values ​​FtlA, FtlB. The warning values ​​TdwA, TdwB are third thresholds for determining whether or not it is time for maintenance of the mounting head 8, based on the delay time Td, which is the difference between the operation time To and the reference times Td0A, Td0B. The caution values ​​TdaA, TdaB are fourth thresholds for determining whether or not to display a message prompting maintenance, based on the delay time Td. In other words, the fourth threshold is smaller than the third threshold.

[0062] 8, the measurement processing unit 43A transmits predetermined thrust limit values ​​FtlA, FtlB to the servo control unit 30 based on the threshold information 41Ac. The servo control unit 30 (control unit) sets the thrust limit values ​​FtlA, FtlB in the Z-axis motor 22, and then controls the Z-axis motor 22 by position control to lower the shaft 21 and lower the component holder 29 from the standby position to the target height Ht. The measurement unit 49 receives data from the servo control unit 30 and measures the operation time To during which the component holder 29 descends from the standby position (first height) to the target height Ht (second height).

[0063] The calculation unit 50 calculates the difference between the measured operation time To and the reference times Td0A, Td0B as the delay time Td based on the threshold information 41Ac. The acquisition unit 44A acquires the measured delay time Td, associates it with the set thrust limit values ​​FtlA, FtlB, information identifying the mounting unit 20 to be measured, and the measurement date and time, and stores it in the main body storage unit 41A as history data 41Ab. The acquisition of the delay time Td is executed at the same measurement timings Tm1 to Tm7 as those of the component mounting device M. That is, the history data 41Ab includes a plurality of delay times Td acquired at a plurality of different time points (measurement timings Tm1 to Tm7).

[0064] In this way, at the measurement timings Tm1 to Tm7 (predetermined timings), the servo control unit 30 (control unit) sets the thrust limit values ​​FtlA and FtlB, and then controls the Z-axis motor 22 (servo motor) to lower the component holder 29. Furthermore, the thrust limit values ​​FtlA and FtlB set at the measurement timings Tm1 to Tm7 (predetermined timings) are the same.

[0065] FIG. 10 shows an example of history data 41Ab acquired by setting the thrust limit value Ftl to the thrust limit value FtlA. In the history data 41Ab, delay times Td acquired in the order of measurement timing Tm1, measurement timing Tm2, ​​etc. are recorded. In this example, the acquired delay time Td (operation time To-reference time Td0A) is zero until measurement timing Tm4. Also, from measurement timing Tm5, the operation time To becomes longer than the reference time Td0A, and the acquired delay time Td gradually increases. That is, after measurement timing Tm4, the sliding resistance Ff of the mounting unit 20 gradually increases beyond a predetermined threshold. In FIG. 10, the operation time in a state where the sliding resistance, etc. are normal is set as the reference time Td0. Therefore, in this case, the delay time Td in the normal state is zero. If the operation time in the normal state +α is set as the reference time Td0, the delay time Td in the normal state is negative (-α).

[0066] The judgment unit 45A judges whether the delay time Td acquired by the acquisition unit 44A is equal to or greater than the warning value TdwA (third threshold value) or is smaller than the warning value TdwA and equal to or greater than the caution value TdaA (fourth threshold value) based on the threshold value information 41Ac. In the example of Fig. 10, at the measurement timing Tm7, the delay time Td is judged to be equal to or greater than the caution value TdaA (caution state).

[0067] 8, the estimation unit 47A estimates the maintenance timing when maintenance of the mounting head 8 is required based on the history data 41Ab. Specifically, the estimation unit 47A estimates the time when the delay time Td exceeds warning values ​​TdwA, TdwB (third thresholds) based on the delay time Td acquired at multiple measurement timings Tm1 to Tm7 recorded in the history data 41Ab, as the maintenance timing.

[0068] For example, the estimation unit 47A estimates the estimated maintenance time Te using a linear function based on the delay time Td acquired at the two most recent points in time (measurement timing Tm6 and measurement timing Tm7 in FIG. 10) or an approximation function based on the delay time Td of multiple measurement timings Tm1 to Tm7 included in the history data 41Ab.

[0069] 8, when the determination unit 45A determines that the delay time Td is equal to or greater than the warning values ​​TdwA, TdwB (third threshold), the notification processing unit 46A causes the touch panel 12 to display "the mounting unit 20 has a problem with the sliding properties of the shaft 21" and "the mounting head 8 should be maintained immediately." That is, the notification processing unit 46 and the touch panel 12 constitute a notification unit 48A that notifies an error when the acquired delay time Td is determined to be equal to or greater than the third threshold (warning values ​​TdwA, TdwB). Furthermore, the touch panel 12 (display unit) displays a message encouraging maintenance when the acquired delay time Td is determined to be equal to or greater than the third threshold.

[0070] When the determination unit 45A determines that the delay time Td is smaller than the warning values ​​TdwA, TdwB (third thresholds) and is equal to or larger than the caution values ​​TdaA, TdaB (fourth thresholds), the notification processing unit 46A causes the touch panel 12 to display "Maintenance of the mounting head 8 should be performed by the maintenance time (for example, September 1)." In other words, when the acquired delay time Td is determined to be smaller than the third thresholds (warning values ​​TdwA, TdwB) and equal to or larger than the fourth thresholds (caution values ​​TdaA, TdaB), the notification processing unit 46A displays a message encouraging maintenance and an estimated maintenance time (estimated maintenance time Te).

[0071] Next, another embodiment of the maintenance support method for supporting the maintenance of the mounting head 8 will be described with reference to Fig. 10 along the flow of Fig. 11. The delay time Td is acquired at a predetermined timing (measurement timings Tm1 to Tm7) such as when the automatic operation of the component mounting device M starts. Hereinafter, the same steps as those in the maintenance support method shown in Fig. 7 are denoted by the same reference numerals, and detailed explanations will be omitted.

[0072] 11, first, a thrust limit value setting step (ST1) is executed, and the measurement processing unit 43A transmits the thrust limit values ​​FtlA and FtlB to the servo control unit 30 (control unit) based on the threshold information 41Ac, and the thrust limit values ​​FtlA and FtlB are set in the Z-axis motor 22. Next, a descending step (ST2) is executed, and the component holder 29 descends from the standby position (first height) to the target height Ht (second height). Next, the measurement unit 49 measures the operation time To during which the component holder 29 descends from the standby position (first height) to the target height Ht (second height) (ST21: operation time measurement step).

[0073] Next, the calculation unit 50 calculates the difference between the measured operation time To and the reference times Td0A, Td0B based on the threshold information 41Ac as the delay time Td (ST22: delay time calculation step). Next, the acquisition unit 44A acquires the measured delay time Td and stores it as history data 41Ab (ST23: delay time acquisition step). Next, the judgment unit 45A judges whether the delay time Td is equal to or greater than the warning values ​​TdwA, TdwB (third thresholds) (ST24: warning judgment step).

[0074] If it is determined that the delay time Td is equal to or greater than the warning values ​​TdwA, TdwB (Yes in ST24), a warning step (ST8) is executed. If the delay time Td is smaller than the warning values ​​TdwA, TdwB (No in ST24), the determination unit 45A determines whether the delay time Td is equal to or greater than the warning values ​​TdaA, TdaB (fourth threshold) (ST25: warning determination step). If it is determined that the delay time Td is equal to or greater than the warning values ​​TdaA, TdaB (Yes in ST25), the estimation unit 47A estimates the estimated maintenance time Te based on the history data 41Ab (ST26: maintenance time estimation step) (see FIG. 10).

[0075] Next, the caution step (ST11) is executed. In Fig. 10, the delay time Td is determined to be the caution value TdaA at the measurement timing Tm7 (Yes in ST25), and the caution step (ST11) is executed. If it is determined that the delay time Td is smaller than the caution values ​​TdaA and TdaB (No in ST25), the acquisition of the delay time Td at that measurement timing is completed, and the thrust limit value setting step (ST1) to the delay time acquisition step (ST23), etc. are executed at the next measurement timing.

[0076] Thus, in another example of the maintenance support method of this embodiment, thrust limit values ​​FtlA, FtlB that limit the thrust of the servo motor (Z-axis motor 22) are set (ST1), the servo motor controlled based on a preset operation pattern is used to lower component holder 29 (ST2), and the timing when maintenance of mounting head 8 will be required is estimated (ST26) based on history data 41Ab (ST23) related to operation time To for lowering component holder 29. This makes it possible to estimate the timing when maintenance of mounting head 8 will be required without adding any measuring device or repeating the operation of lowering component holder 29 while decreasing thrust limit value Ftl.

[0077] As described above, the component mounting apparatus MA of this embodiment includes a mounting head 8 having a component holder 29 for holding a component D, a shaft 21 on which the component holder 29 is mounted so as to be displaceable in the vertical direction, and a servo motor (Z-axis motor 22) for raising and lowering the shaft 21, a control unit (servo control unit 30) that sets thrust limit values ​​FtlA and FtlB for limiting the thrust of the servo motor and controls the servo motor based on a preset operation pattern, and an estimation unit 47A that estimates the time when maintenance of the mounting head 8 will be required based on history data 41Ab related to the operation time To for the component holder 29 to descend. This makes it possible to estimate the time when maintenance of the mounting head 8 will be required without adding a measuring device or repeating the operation of lowering the component holder 29 while decreasing the thrust limit value Ftl.

[0078] Although the above description is of a configuration in which the component mounting device MA includes the estimating unit 47A, the management computer CP may also be configured to include the estimating unit 47A and estimate the estimated maintenance time Te. That is, the management computer CP may be a maintenance support device that supports maintenance of the mounting head 8, and may be configured to include the estimating unit 47A that estimates the maintenance time when the mounting head 8 will require maintenance, based on the history data 41Ab regarding the operation time To for the component holder 29 to descend, acquired by the component mounting device MA. This makes it possible to estimate the time when the mounting head 8 will require maintenance, without adding a measuring device, or repeating the operation of descending the component holder 29 while decreasing the thrust limit value Ftl. [Industrial Applicability]

[0079] The component mounting device, maintenance support device, and maintenance support method of the present invention have the advantage of being able to estimate when maintenance of the mounting head will be required without the need for an additional measuring device, and are useful in fields where components are mounted on circuit boards. [Explanation of symbols]

[0080] 8 Placement head 21 Shaft 22 Z-axis motor (servo motor) 29 Parts holder CP Management computer (maintenance support device) D parts Ftl, Ftl1~Ftl8 Thrust limit value M, MA component mounting device P board

Claims

1. A component mounting device that mounts components on a board, a mounting head including a component holder for holding a component, a shaft on which the component holder is mounted so as to be displaceable in the vertical direction, and a servo motor for raising and lowering the shaft; a control unit that sets a thrust limit value that limits the thrust of the servo motor and controls the servo motor based on a preset operation pattern; and an estimation unit that estimates a maintenance time when maintenance of the mounting head is required based on history data of a limit thrust limit value, which is the thrust limit value at which a delay occurs in the operating time for the component holding unit to descend, or history data related to the operating time.

2. An acquisition unit is further provided, the control unit repeatedly changes the thrust limit value at a predetermined timing until the delay occurs, and causes the component holder to perform a lowering operation each time the thrust limit value is changed; The component mounting device according to claim 1 , wherein the acquisition unit acquires the thrust limit value at the time when the delay occurs as the ultimate thrust limit value of the history data.

3. 3. The component mounting device according to claim 2, wherein the control unit repeatedly changes the thrust limit value so that the thrust limit value gradually decreases, and causes the component holder to perform a lowering operation every time the thrust limit value is changed.

4. 3. The component mounting device according to claim 2, wherein the critical thrust limit value is obtained every time a predetermined number of boards are produced, every time a predetermined number of components are mounted, every predetermined time interval, or when automatic operation of the component mounting device starts.

5. the history data includes a plurality of the critical thrust limit values ​​acquired at a plurality of different timings, The component mounting device according to claim 2 , wherein the estimation unit estimates, as the maintenance time, a time when the limit thrust limit value exceeds a first threshold value, based on the history data.

6. The component mounting device according to claim 5 , wherein the estimation unit estimates the maintenance time by using a linear function based on the limit thrust limit value acquired at the two most recent points in time and an approximation function based on the history data.

7. The component mounting device according to claim 5 , further comprising a determination unit that determines whether the acquired limit thrust limit value is equal to or greater than a first threshold value.

8. The component mounting device according to claim 7 , wherein the determination unit determines whether the acquired limit thrust limit value is smaller than the first threshold value and equal to or larger than a second threshold value.

9. 8. The component mounting device according to claim 7, further comprising a notification unit that notifies an error when it is determined that the acquired limit thrust limit value is equal to or greater than the first threshold value.

10. 9. The component mounting device according to claim 8, further comprising a display unit that displays the estimated maintenance time when the acquired limit thrust limit value is determined to be smaller than the first threshold value and equal to or greater than the second threshold value.

11. 11. The component mounting device according to claim 10, wherein the display unit displays a message prompting the user to perform maintenance when the acquired limit thrust limit value is determined to be equal to or greater than the first threshold value, or when the acquired limit thrust limit value is determined to be smaller than the first threshold value and equal to or greater than the second threshold value.

12. a measuring unit that measures an operation time of the servo motor while the component holder is lowered from a first height to a second height; A calculation unit that calculates a difference between the measured operation time and a reference time as a delay time; An acquisition unit, The control unit causes the component holder to perform a lowering operation at a predetermined timing, The component mounting device according to claim 1 , wherein the acquisition unit acquires the delay time as the history data.

13. 13. The component mounting device according to claim 12, wherein the thrust force limit value set at each of the predetermined timings is the same.

14. 13. The component mounting device according to claim 12, wherein the delay time is acquired every time a predetermined number of boards are produced, every time a predetermined number of components are mounted, every predetermined time interval, or when automatic operation of the component mounting device starts.

15. the historical data includes a plurality of the delay times acquired at different times; The component mounting device according to claim 12 , wherein the estimation unit estimates, based on the history data, a time when the delay time exceeds a third threshold as the maintenance time.

16. The component mounting device according to claim 15 , wherein the estimation unit estimates the maintenance time by using a linear function based on the delay times acquired at two most recent points in time and an approximation function based on the history data.

17. The component mounting device according to claim 15 , further comprising a determination unit that determines whether the acquired delay time is equal to or greater than a third threshold value.

18. 18. The component mounting device according to claim 17, wherein the determination unit determines whether the acquired delay time is smaller than the third threshold value and equal to or greater than a fourth threshold value.

19. 18. The component mounting device according to claim 17, further comprising: a notification unit that notifies an error when it is determined that the acquired delay time is equal to or greater than the third threshold value.

20. 20. The component mounting device according to claim 18, further comprising a display unit that displays the estimated maintenance time when it is determined that the acquired delay time is smaller than the third threshold value and equal to or greater than the fourth threshold value.

21. 21. The component mounting device according to claim 20, wherein the display unit displays a message prompting the user to perform maintenance when the acquired delay time is determined to be equal to or greater than the third threshold value, or when the acquired delay time is determined to be smaller than the third threshold value and equal to or greater than the fourth threshold value.

22. 1. A maintenance support device for supporting maintenance of a mounting head having a component holder for holding components, a shaft on which the component holder is mounted in a state in which the component holder can be displaced in an up-down direction, and a servo motor for raising and lowering the shaft, a thrust limit value that limits the thrust of the servo motor is set, and the servo motor is controlled based on a preset operation pattern to lower the component holding part, and an estimation unit is provided that estimates a maintenance time when maintenance of the mounting head is required based on history data of a limit thrust limit value, which is the thrust limit value that causes a delay in the operation time for the component holding part to be lowered, or history data related to the operation time.

23. 1. A maintenance support method for supporting maintenance of a mounting head having a component holder that holds components, a shaft on which the component holder is mounted in a state in which it can be displaced in an up-down direction, and a servo motor that raises and lowers the shaft, comprising: a thrust limit value for limiting the thrust of the servo motor is set, and the component holder is lowered by the servo motor controlled based on a preset operation pattern; A maintenance support method that estimates a time when maintenance of the mounting head is required based on historical data on a limit thrust limit value, which is the thrust limit value that causes a delay in the operating time for the component holding unit to descend, or historical data related to the operating time.

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