Component mounting line

Abstract

To provide an easy-to-use storage for a component supply unit.SOLUTION: A component mounting line 10 includes a plurality of component mounting machines 20 lined up along a board transfer direction, a feeder storage 60 that stores a plurality of detachable feeders 30 in the component mounting machine 20, and an exchange robot 50 capable of exchanging the feeder 30 between the feeder storage 60 and each of the component mounting machines 20, and the feeder storage 60 is provided in the same arrangement as the plurality of component mounting machines 20, and the exchange robot 50 moves along the board transfer direction to exchange the feeder 30. This allows the feeder 30 to be used in any of the component mounting machines 20 to be supplied and recovered through the feeder storage 60 by an operator easily.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to a component mounting line. [Background technology]

[0002] Conventionally, component mounters that pick up components from component supply units that store multiple components and mount them on a board have been proposed that are capable of automatically replacing component supply units. For example, Patent Document 1 discloses a configuration that includes a supply station on which component supply units are placed so that the component mounter can pick up components, a storage cabinet that is located adjacent to the component mounter and stores multiple component supply units, and a loader that swaps component supply units between the storage cabinet and the supply station. In this configuration, when an empty component supply unit runs out of components, the loader swaps the empty component supply unit with a component supply unit in the storage cabinet, automatically replacing the component supply unit. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Publication No. 7-176892 Summary of the Invention [Problem to be solved by the invention]

[0004] When the technology described in Patent Document 1 is applied to a component mounting line configured with multiple component mounters lined up, a storage cabinet corresponding to each component mounter is provided adjacent to each component mounter. This can result in the overall length of the component mounting line becoming longer than expected. Furthermore, when a storage cabinet corresponding to each component mounter is provided, it is necessary to replenish and retrieve component supply units from each storage cabinet. In this way, a configuration in which a storage cabinet is adjacent to each component mounter can actually make the system less user-friendly.

[0005] SUMMARY OF THE INVENTION A primary object of the present invention is to provide a convenient storage for component supply units. [Means for solving the problem]

[0006] In order to achieve the above-mentioned main object, the present invention employs the following means.

[0007] The component mounting line of the present invention is a component mounting line configured by arranging a plurality of component mounting machines, each having a detachable component supply unit set therein, along a transport direction of the mounting object, which mounts the components supplied by the component supply unit onto the mounting object, and is equipped with a unit storage cabinet for storing a plurality of the component supply units, a unit exchange device that can exchange the component supply units attached to the plurality of component mounting machines with the component supply units stored in the unit storage cabinet, and a control device that controls the unit exchange device, wherein the unit storage cabinet is installed in the same row as the plurality of component mounting machines, and the control device controls the unit exchange device to move within a predetermined range along the transport direction to exchange the component supply units.

[0008] In the component mounting line of the present invention, a unit storage unit for storing a plurality of component supply units is installed in the same row as a plurality of component mounters, and a unit exchange device is controlled to move within a predetermined range along the transport direction of the mounting target to exchange the component supply units. This allows the component supply units to be loaded and unloaded, such as for replenishment and collection, in the unit storage unit, regardless of which component supply unit is used by which component mounter. Furthermore, as long as the unit exchange device is located outside the predetermined range in front of the unit storage unit, the component supply units can be loaded and unloaded at any time. As a result, a user-friendly unit storage unit can be provided.

[0009] In the component mounting line of the present invention, the unit storage can be installed upstream of the most upstream component mounter in the line-up direction of the multiple component mounters, or downstream of the most downstream component mounter. In this way, the unit storage is installed at a position that is an end of the line-up of multiple component mounters, making it even easier to carry component supply units in and out of the unit storage.

[0010] In this aspect of the component mounting line of the present invention, the unit stocker may be installed at an intermediate position in the line of the component mounters, in addition to the upstream position or the downstream position. In this way, even if the component mounting line is long and made up of many component mounters, it is possible to prevent the distance that the unit exchange device has to travel between the unit stocker and the component mounters from becoming longer than necessary.

[0011] In the component mounting line of the present invention, the unit storage may also include a transport device that transports the mounting objects in the transport direction, which makes it possible to easily install the unit storage in the same row as multiple component mounters.

[0012] In the component mounting line of the present invention, the unit storage may have a common configuration with the component mounter in which the component supply unit is detachably set, and the unit exchange device may perform the attachment and detachment of the component supply unit in the component mounter and the attachment and detachment of the component supply unit in the unit storage by a common operation using the same mechanism. This prevents the configuration of the unit exchange device from becoming complicated and enables the component supply unit to be attached and detached efficiently.

[0013] In the component mounting line of the present invention, the unit storage can be configured to allow a worker to load and unload the component supply unit, and includes a detector that detects the presence or absence of a worker within a predetermined range of the movement range that includes the front of the unit storage, and the control device can control the unit exchange device so that it does not move within the predetermined range when the detector detects a worker. This ensures the safety of the worker who loads and unloads the component supply unit.

[0014] In the component mounting line of this aspect of the present invention, the control device can also control the unit replacement device to move within the movement range excluding the predetermined range at a slower speed when the detector detects a worker than when the detector does not detect a worker. In this way, the unit replacement device can be moved within a range that does not impede the safety of the worker.

[0015] In the component mounting line of the present invention, the unit storage can be configured so that the component supply units can be loaded and unloaded by an automatic transport device that automatically transports the component supply units from outside the component mounting line. In this way, loading and unloading of the component supply units can be automated and made more efficient.

[0016] Furthermore, in the component mounting line of the present invention, a management device that manages the mounting of the component mounters can be placed in the installation space of the unit storage, thereby enabling efficient use of the space within the component mounting line.

[0017] In addition, in the component mounting line of the present invention, the component supply unit supplies the components to the component mounters by sending out a container that stores the components, and includes a waste material transport device that transports waste materials from the container after the components have been supplied from the component supply unit to the component mounters to an installation space of the unit storage, and a collection container can be placed in the installation space of the unit storage to collect the waste materials transported by the waste material transport device. This allows for efficient use of space in the component mounting line. [Brief explanation of the drawings]

[0018] [Figure 1] FIG. 2 is a diagram showing the outline of the configuration of a component mounting line 10. [Figure 2] FIG. 2 is a diagram showing the outline of the configuration of a component mounter 20. [Figure 3] FIG. 2 is a diagram showing the outline of the configuration of a feeder 30. [Figure 4] FIG. 2 is a diagram showing the outline of the configuration of an exchange robot 50. [Figure 5] FIG. 2 is a diagram showing the outline of the configuration of a feeder storage 60. [Figure 6] FIG. 2 is a configuration diagram relating to control of the component mounting line 10. [Figure 7] 10 is a flowchart showing an example of a storage area information update process. [Figure 8] FIG. 10 is an explanatory diagram showing an example of storage area information. [Figure 9] 10 is a flowchart showing an example of a feeder replacement process. [Figure 10] 10 is a flowchart showing an example of a replacement robot movement process. [Figure 11] FIG. 10 is a diagram showing an outline of the configuration of a component mounting line according to a modified example. [Figure 12] FIG. 10 is a diagram showing an outline of the configuration of a component mounting line according to a modified example. DETAILED DESCRIPTION OF THE INVENTION

[0019] Fig. 1 is a configuration diagram showing an outline of the configuration of component mounting line 10, Fig. 2 is a configuration diagram showing an outline of the configuration of component mounter 20, and Fig. 3 is a configuration diagram showing an outline of the configuration of feeder 30. Fig. 4 is a configuration diagram showing an outline of the configuration of exchange robot 50, Fig. 5 is a configuration diagram showing an outline of the configuration of feeder storage 60, and Fig. 6 is a configuration diagram related to the control of component mounting line 10. Note that the left-right direction in Fig. 1 is the X direction, the front-rear direction is the Y direction, and the up-down direction is the Z direction.

[0020] 1, the component mounting line 10 includes a printer 12 that prints solder on a board, a print inspection machine 14 that inspects the condition of the printed solder, multiple component mounters 20 that mount components supplied from feeders 30 onto the board, a mounting inspection machine (not shown) that inspects the mounted condition of the components, a feeder storage 60 that can store multiple feeders 30, and a management device 80 that manages the entire line. In the component mounting line 10, the printer 12, the print inspection machine 14, and the multiple component mounters 20 are arranged in this order in the board transport direction (X direction). The feeder storage 60 is incorporated into the component mounting line 10 and is installed between the most upstream component mounter 20 of the multiple component mounters 20 in the board transport direction and the print inspection machine 14. In other words, the feeder storage 60 is installed upstream of the most upstream component mounter 20. In this embodiment, a worker supplies feeders 30 to the feeder storage 60 and retrieves feeders 30 from the feeder storage 60. The supplying and retrieving of feeders 30 to and from the feeder storage 60 is also referred to as carrying in and out of feeders 30.

[0021] The component mounting line 10 also includes an exchange robot 50 that automatically exchanges feeders 30 between the multiple component mounters 20 and the feeder storage 60. The exchange robot 50 is movable along X-axis rails 18 that are provided in front of the multiple component mounters 20 and the feeder storage 60, parallel to the board transport direction (X direction). The X-axis rails 18 are not shown in FIGS. 2 and 5. In this embodiment, the range in front of the feeder storage 60 and the multiple component mounters 20 will be described as being divided into three ranges. The ranges are, from the upstream side in the transport direction, a storage front range 11a that includes the front of the feeder storage 60 and the front of the component mounters 20 adjacent to the feeder storage 60, an adjacent range 11b adjacent to the storage front range 11a, and a non-adjacent range 11c that is adjacent to the adjacent range 11b but not adjacent to the storage front range 11a.

[0022] 2, the component mounter 20 includes a board transport device 21 that transports the board S in the X direction, a head 22 having a suction nozzle that picks up components supplied by a feeder 30, a head moving mechanism 23 that moves the head 22 in the X and Y directions, and a mounting control device 28 (see FIG. 6) that controls the entire device. The mounting control device 28 is composed of a well-known CPU, ROM, RAM, etc., and outputs drive signals to the board transport device 21, head 22, head moving mechanism 23, etc.

[0023] Feeder 30 is configured as a tape feeder that feeds out a tape that stores components at a predetermined pitch. As shown in FIG. 3, feeder 30 includes tape reel 32 around which tape is wound, tape feeding mechanism 33 that pulls out and feeds out the tape from tape reel 32, connector 35 having two protruding positioning pins 34, rail member 37 provided at the bottom end, and feeder control device 39 (see FIG. 6) that controls the entire feeder. Feeder control device 39 is composed of a known CPU, ROM, RAM, etc., and outputs a drive signal to tape feeding mechanism 33. In addition, feeder control device 39 is capable of communicating with a control unit (such as mounting control device 28 or management device 80) at the location where feeder 30 is attached via connector 35.

[0024] 2, the component mounter 20 has two areas, an upper area and an lower area, in which feeders 30 can be attached at the front. The upper area is a component supply area 20A where feeders 30 can supply components, and the lower area is a stock area 20B where feeders 30 can be stocked. Feeder tables 40 on which multiple feeders 30 can be attached are provided in each of the supply area 20A and the stock area 20B. The feeder table 40 is an L-shaped table in a side view, and is equipped with a plurality of slots 42 arranged in the X direction at intervals that allow the rail members 37 of the feeders 30 to be inserted, two positioning holes 44 into which the two positioning pins 34 of the feeders 30 can be inserted, and a connector 45 provided between the two positioning holes 44 to which the connector 35 is connected.

[0025] The mounter 20 also includes a tape duct 24 that sends the tape downward after the feeder 30 has supplied components to it, a tape cutter 25 that cuts the tape that has passed through the tape duct 24 into small pieces, a tape chute 26 into which the waste tape cut by the tape cutter 25 falls, and a waste tape transport device 27 located below the tape chute 26. The waste tape transport device 27 in this embodiment is configured as a belt conveyor device that transports the waste tape using a conveyor belt from the right side to the left side in the X direction. The waste tape transport device 27 is fixed in a state where the conveyor belt is inclined upward from the right side to the left side in the X direction. The waste tape transport device 27 has a length that exceeds the width of the mounter 20 in the X direction so that the left end of the conveyor belt extends beyond the left side of the mounter 20 and is located above the right end of the waste tape transport device 27 (conveyor belt) of the adjacent mounter 20 on the left side (upstream side in the transport direction). As a result, the waste tape conveying devices 27 of adjacent component mounting machines 20 can overlap with each other to transfer waste tape, and the waste tape conveying devices 27 of each component mounting machine 20 form a single waste tape conveying line in the direction opposite to the conveying direction of the board S.

[0026] 4, the exchange robot 50 includes a robot movement mechanism 51 that moves the exchange robot 50 along the X-axis rail 18, a feeder transfer mechanism 53 that transfers the feeder 30 to the component mounter 20 or the feeder storage 60, and a robot control device 59 (see FIG. 6) that controls the entire robot. The robot movement mechanism 51 includes an X-axis motor 52a, such as a servo motor, that drives a drive belt for moving the exchange robot 50, and guide rollers 52b that guide the movement of the exchange robot 50 along the X-axis rail 18. The feeder transfer mechanism 53 includes a Y-axis slider 55 that mounts a clamp unit 54 that clamps the feeder 30 and a Y-axis motor 55a that moves the clamp unit 54 along a Y-axis guide rail 55b, and a Z-axis motor 56a that moves the Y-axis slider 55 along a Z-axis guide rail 56b. The exchange robot 50 also includes an encoder 57 (see FIG. 6) that detects the movement position in the X direction, and left and right monitoring sensors (left side monitoring sensor 58a, right side monitoring sensor 58b, see FIG. 6) such as infrared sensors that monitor the presence or absence of obstacles (workers) on the left and right sides.

[0027] The Y-axis slider 55 of the feeder transfer mechanism 53 is driven by the Z-axis motor 56a to move between an upper transfer area 50A facing the supply area 20A of the component mounter 20 and a lower transfer area 50B facing the stock area 20B of the component mounter 20. The robot control device 59 drives the Y-axis slider 55, which clamps the feeder 30 with the clamp unit 54, from the upper transfer area 50A to the supply area 20A by driving the Y-axis motor 55a, to insert the rail member 37 of the feeder 30 into the slot 42 of the feeder table 40, and releases the clamp of the clamp unit 54, thereby attaching the feeder 30 to the feeder table 40 in the supply area 20A. Furthermore, the robot control device 59 clamps the feeder 30 attached to the feeder table 40 in the supply area 20A with the clamp unit 54, and removes the feeder 30 from the feeder table 40 in the supply area 20A (pulls it into the upper transfer area 50A) by driving the Y-axis motor 55a to move the Y-axis slider 55 from the supply area 20A to the upper transfer area 50A. The robot control device 59 performs the same process for attaching the feeder 30 to the feeder table 40 in the stock area 20B and for removing the feeder 30 from the feeder table 40 in the stock area 20B, except that the Y-axis slider 55 is moved to the lower transfer area 50B by driving the Z-axis motor 56a, and the process is performed in the lower transfer area 50B instead of the upper transfer area 50A, so a description thereof will be omitted.

[0028] As shown in FIG. 5 , the feeder storage 60 has a storage area 60A in which a feeder 30 can be attached, located at the upper right front portion of a housing 61. The storage area 60A is provided with a feeder table 40 having the same configuration as the feeder table 40 provided in the supply area 20A or the stock area 20B of the component mounter 20. The feeder table 40 in the storage area 60A is provided at the same height (position in the Z direction) as the feeder table 40 in the supply area 20A. Therefore, the robot control device 59 of the exchange robot 50 drives the Y-axis motor 55a to move the Y-axis slider 55, which clamps the feeder 30 with the clamp unit 54, from the upper transfer area 50A to the storage area 60A, inserting the rail member 37 of the feeder 30 into the slot 42 of the feeder table 40 and releasing the clamp of the clamp unit 54, thereby attaching the feeder 30 to the feeder table 40 in the storage area 60A. Furthermore, the robot control device 59 can remove the feeder 30 from the feeder table 40 in the storage area 60A (pull it into the upper transfer area 50A) by clamping the feeder 30 attached to the feeder table 40 in the storage area 60A with the clamp unit 54 and driving the Y-axis motor 55a to move the Y-axis slider 55 from the storage area 60A to the upper transfer area 50A. That is, the exchange robot 50 can attach and detach the feeder 30 to and from the feeder table 40 in the storage area 60A of the feeder storage 60 with the same operation as attaching and detaching the feeder 30 to and from the feeder table 40 in the supply area 20A of the component mounter 20. Note that both the storage area 60A of the feeder storage 60 and the stock area 20B of the component mounter 20 can store feeders 30 that are not in use (not supplying components). For example, the stock area 20B can store feeders 30 that have remaining parts or feeders 30 that are scheduled to be used relatively soon, and the storage area 60A can store used feeders 30 that have no remaining parts.

[0029] The feeder storage 60 also includes a board transport device 62 at the upper rear of the housing 61, which transports the board S in the X direction. This board transport device 62 is positioned in the same front-to-back and up-to-down directions as the board transport device (not shown) of the print inspection machine 14 and the board transport device 21 of the adjacent component mounter 20. Therefore, the board transport device 62 can transport the board S received from the board transport device of the print inspection machine 14 and hand it over to the board transport device 21 of the adjacent component mounter 20.

[0030] A collection container 64 for collecting waste tape transported by the waste tape transport line is disposed in a lower space 63A at the rear lower part of the housing 61 of the feeder storage 60. As described above, the left end of the waste tape transport device 27 of each mounter 20 protrudes from the left side of the mounter 20, and therefore the left side of the waste tape transport device 27 of the mounter 20 adjacent to the feeder storage 60 also protrudes and enters the housing 61. The collection container 64 is disposed below the left end of the waste tape transport device 27 that has entered the housing 61, thereby enabling the collection of waste tape. In addition, an opening 63B that communicates with the lower space 63A and is larger in height and width than the collection container 64 is formed at the lower part of the front right side of the housing 61. This allows an operator to insert or remove the collection container 64 through the opening 63B to collect the collection container 64 (waste tape). In addition, the feeder storage cabinet 60 may have an area below the storage area 60A where the feeder 30 can be attached, and the opening 63B may not be formed.In that case, the collection container 64 may be configured to be able to be inserted and removed from the rear of the housing 61.

[0031] Furthermore, on the front left side of the housing 61 of the feeder storage 60, a storage section 65A with a rectangular parallelepiped opening at the bottom is formed, and a stand 65B with a horizontal surface is formed at the top. The storage section 65A is formed to be slightly larger than the main body of the management device 80, and as shown in FIG. 1, the main body of the management device 80 is stored in the storage section 65A. Furthermore, as shown in FIG. 1, a display 82 and an input device 84 are placed on the upper stand 65B. In this way, the installation space of the feeder storage 60 is also used as a space for arranging the collection containers 64 and the management device 80.

[0032] As shown in FIG. 6 , the management device 80 is configured with a CPU 80a, ROM 80b, HDD 80c, RAM 80d, and the like, and is equipped with a display 82 such as an LCD and input devices 84 such as a keyboard and a mouse. The management device 80 stores a production program for the boards S. The production program for the boards S defines which components are to be mounted on which boards S and how many boards S with such components are to be produced. The management device 80 is connected to the mounting control device 28 via a wired connection and to the robot control device 59 via a wireless connection. The management device 80 is also connected to the control devices of the printer 12, the print inspection device 14, and the mounting inspection device. The management device 80 receives information regarding the mounting status of the component mounter 20 from the mounting control device 28 and information regarding the operating status of the replacement robot 50 from the robot control device 59. The management device 80 of this embodiment also manages the feeder storage 60. The management device 80 is communicatively connected to the feeder control device 39 of the feeder 30 attached to the feeder table 40 in the storage area 60A via connectors 35, 45. The management device 80 also outputs a drive signal to the substrate transport device 62 of the feeder storage 60 to cause the substrate transport device 62 to transport the substrate S. The management device 80 also receives an input of a detection signal from a storage front monitoring sensor 86, such as an infrared sensor, that monitors the presence of a worker within the storage front range 11a.

[0033] The following is a description of the processing performed by the management device 80 of the component mounting line 10. FIG. 7 is a flowchart showing an example of the storage area information update processing. The storage area information includes the installation position, ID information, and information about contained components of the feeders 30 set on the feeder table 40 in the storage area 60A, and is stored in the HDD 80c. In the storage area information update processing, the CPU 80a of the management device 80 first determines whether a new feeder 30 has been installed on the feeder table 40 in the storage area 60A (S100). If the CPU 80a determines that a new feeder 30 has been installed, it acquires location information of the installation position based on the position of the installed connector 45 (S105), and acquires feeder information, such as the ID information of the feeder 30 and the type and quantity of components stored therein, from the feeder control device 39 of the installed feeder 30 (S110). The CPU 80a then updates the storage area information by registering the feeder information in association with the location information (S115), and proceeds to the next processing of S120. Furthermore, if the CPU 80a determines in S100 that a new feeder 30 has not been attached, it skips the processes of S105 to S115 and proceeds to the next process of S120.

[0034] Next, the CPU 80a of the management device 80 determines whether the feeder 30 has been removed from the feeder table 40 in the storage area 60A (S120), and if it determines that the feeder 30 has not been removed, ends the storage area information update process. On the other hand, if the CPU 80a determines that the feeder 30 has been removed, it acquires position information of the removal position based on the position of the removed connector 45 (S125), and updates the storage area information by deleting the feeder information associated with the position information (S130), and ends the storage area information update process.

[0035] FIG. 8 is an explanatory diagram showing an example of storage area information. The storage area information stores information such as ID information of the feeder 30, component type information, and component quantity information, in association with position information of the installation position of the feeder 30. The position information is defined in order, with a reference slot (e.g., the leftmost slot 42) among the multiple slots 42 of the feeder table 40 designated as the leading position "001." In the example of FIG. 8, positions with position information "001" and "002" indicate that a feeder 30 with a component type of "A-001" and a component quantity of "Full" (unused since being replenished by an operator) is installed. Position information "003" indicates that no feeder 30 is installed. Position information "004" and "005" indicate that a feeder 30 with a component type of "B-005" and a component quantity of "Empty" (already used by the component mounter 20) is installed. When the number of "Empty" feeders 30 exceeds a predetermined number, the worker is notified by voice. Note that the storage area information is not limited to storing whether the component quantity is "Full" or "Empty" and may store the value of the remaining number of components, etc. Furthermore, the management device 80 may visually display the storage area information on the display 82 based on a request from the worker. Note that the mounting control device 28 of each component mounter 20 stores supply area information that associates position information within the supply area 20A with feeder information and stock area information that associates position information within the stock area 20B with feeder information, as well as storage area information.

[0036] 9 is a flowchart showing an example of the feeder replacement process. This process is executed when the feeder 30 in the storage area 60A of the feeder stocker 60 is replaced with the feeder 30 in the supply area 20A (or stock area 20B) of the component mounter 20. The management device 80 replaces the feeder 30 based on the production program for the board S by removing the feeder 30 containing the components required for the next mounting process from the storage area 60A and attaching it to the supply area 20A of each component mounter 20, or by removing the feeder 30 containing the components not required for the next mounting process from the supply area 20A and attaching it to the stock area 20B or the storage area 60A. Alternatively, when the remaining number of components in a feeder 30 attached to the supply area 20A reaches 0 and out-of-component information is received from the component mounter 20, the feeder 30 is replaced by removing the used feeder 30 from the supply area 20A and attaching it to the storage area 60A, or by removing a feeder 30 containing the same type of components from the storage area 60A and attaching it to the supply area 20A or the stock area 20B. In this way, the replacement process of the feeder 30 can be performed in two ways: by attaching or detaching the feeder 30 to or from the feeder storage 60 (storage area 60A) or by attaching or detaching the feeder 30 to or from the component mounter 20 (supply area 20A, stock area 20B).

[0037] In the feeder replacement process, the CPU 80a of the management device 80 first determines whether it is the timing to replace or replace the feeder 30 in the feeder storage 60 (storage area 60A) (S200), and if it determines that it is not the timing to replace or replace the feeder 30, proceeds to the next process of S225. On the other hand, if the CPU 80a determines that it is the timing to replace or replace the feeder 30, it sets a processing target position, which is a position where the feeder 30 is to be replaced or replaced, based on the storage area information (S205). Furthermore, the CPU 80a sets a position to which the exchange robot 50 should move in order to replace or replace the feeder 30 at the processing target position, as a target position (S210). For example, when removing a feeder 30 from the feeder storage 60 (storage area 60A), the position (attachment position) of the slot 42 where the feeder 30 is attached becomes the processing target position, and the position of the exchange robot 50 where the feeder 30 can be removed from the processing target position becomes the target position. Furthermore, if a used feeder 30 is to be removed from the feeder storage 60 (storage area 60A), the CPU 80a sets a processing target position, which is a position where the exchange robot 50 should move to replace or replace the feeder 30 at the processing target position (S210). When attaching the feeder 30 to the feeder storage 60 (storage area 60A), the position of an empty slot 42 into which the feeder 30 can be attached becomes the processing position, and the position of the exchange robot 50 at which the feeder 30 can be attached at the processing position becomes the target position. When the CPU 80a sets the target position, it executes an exchange robot movement process to move the exchange robot 50 to the target position (S215), drives and controls the exchange robot 50 at the target position to perform the attachment / detachment process of the feeder 30 to / from the processing position in the feeder storage 60 (storage area 60A) (S220), and then proceeds to the next process of S225.

[0038] Next, the CPU 80a determines whether it is time to attach or detach the feeder 30 to or from the mounter 20 (supply area 20A, stock area 20B) (S225), and if it determines that it is not time to attach or detach the feeder 30, ends the feeder replacement process. On the other hand, if the CPU 80a determines that it is time to attach or detach the feeder 30, it identifies the mounter 20 to be processed (S230), sets a processing target position based on the supply area information and stock area information of the identified mounter 20 (S235), and sets a target position for the exchange robot 50 (S240). For example, when removing the feeder 30 from the mounter 20 (supply area 20A, stock area 20B), the position (mounting position) of the slot 42 to which the feeder 30 is attached becomes the processing target position, and the position of the exchange robot 50 at which the feeder 30 can be removed from the processing target position becomes the target position. Furthermore, when attaching a feeder 30 to the mounter 20 (supply area 20A, stock area 20B), the position of an empty slot 42 into which the feeder 30 can be attached becomes the processing target position, and the position of the exchange robot 50 at which the feeder 30 can be attached becomes the target position. After setting the target position, the CPU 80a executes an exchange robot movement process to move the exchange robot 50 to the target position (S245), and at the target position, drives and controls the exchange robot 50 to attach and detach the feeder 30 to and from the processing target position of the mounter 20 (supply area 20A, stock area 20B) (S250), thereby completing the feeder replacement process. Note that the processes of S235 to S250 may involve swapping the feeder 30 between the supply area 20A and the stock area 20B. The exchange robot movement process of S215 and S245 will be described below. FIG. 10 is a flowchart showing an example of the exchange robot movement process. This process is performed by the CPU of the robot control device 59 based on a drive command from the management device 80.

[0039] In this exchange robot movement processing, the robot control device 59 first determines whether or not a sensor on the traveling direction side of the exchange robot 50 (the side toward the target position) has detected a worker (obstacle) (S300). The processing of S300 is performed based on a detection signal from the left monitoring sensor 58a if the traveling direction is leftward, and based on a detection signal from the right monitoring sensor 58b if the traveling direction is rightward. When the robot control device 59 determines that the sensor on the traveling direction side has detected a worker, it stops the exchange robot 50 (S305) and repeats the determination of S300. The processing of S305 is performed by ending the movement of the exchange robot 50 if it is moving, and by maintaining the state if the exchange robot 50 is stopped.

[0040] On the other hand, when the robot control device 59 determines that the sensor on the traveling direction side has not detected a worker, it determines whether the traveling direction of the exchange robot 50 is toward the feeder storage 60 (in this embodiment, the upstream side of the component mounting line 10) (S310). When the robot control device 59 determines that the traveling direction of the exchange robot 50 is not toward the feeder storage 60 (the downstream side of the component mounting line 10), it moves the exchange robot 50 at a predetermined speed (S315) and proceeds to the processing of S360. When the robot control device 59 determines that the traveling direction of the exchange robot 50 is toward the feeder storage 60, it determines whether or not a worker is present in the storage front range 11a based on the detection signal from the storage front monitoring sensor 86 (S320). When the robot control device 59 determines that a worker is present in the storage front range 11a, it determines whether or not the current position of the exchange robot 50 is within the adjacent range 11b based on the position detected by the encoder 57 (S325). When the robot control device 59 determines that there is no worker in the storage front range 11a, or determines that there is a worker in the storage front range 11a but that the exchange robot 50 is not within the adjacent range 11b (in this embodiment, within the non-adjacent range 11c), it moves the exchange robot 50 at a predetermined speed (S330). Furthermore, when the robot control device 59 determines that there is a worker in the storage front range 11a and that the exchange robot 50 is within the adjacent range 11b, it moves the exchange robot 50 at a speed slower than the predetermined speed (S335). In this way, when the exchange robot 50 approaches the worker in the storage front range 11a, the exchange robot 50 is moved at a low speed within the adjacent range 11b, so that the worker can work safely and the movement of the exchange robot 50 can be prevented from being restricted more than necessary.

[0041] Next, the robot control device 59 determines whether the exchange robot 50 has reached the boundary position between the adjacent range 11b and the storage cabinet front range 11a based on the detected position of the encoder 57 (S340), and if it determines that the exchange robot 50 has not reached the boundary position, proceeds to processing of S360. When it determines that the exchange robot 50 has reached the boundary position, the robot control device 59 determines whether or not a worker is present in the storage cabinet front range 11a based on the detection signal from the storage cabinet front monitoring sensor 86 (S345), and if it determines that a worker is present in the storage cabinet front range 11a, stops the exchange robot 50 (S350) and repeats the determination of S345. The processing of S350 is performed by ending the movement of the exchange robot 50 if it is moving, or by maintaining the state if the exchange robot 50 is stopped. In this way, if a worker is present in the storage cabinet front range 11a, the exchange robot 50 is prevented from entering the storage cabinet front range 11a from the adjacent range 11b, and the exchange robot 50 is prevented from moving within the storage cabinet front range 11a, thereby ensuring the safety of the worker who carries the feeder 30 in and out of the feeder storage cabinet 60. Here, for example, the detection range of the monitoring sensor (left side monitoring sensor 58a) of the robot control device 50 is set to be narrower than the detection range of the storage cabinet front monitoring sensor 86 that monitors the storage cabinet front range 11a. Therefore, the safety of the worker in the storage cabinet front range 11a can be appropriately ensured based on the detection signal from the storage cabinet front monitoring sensor 86. Furthermore, the storage cabinet front range 11a includes not only the range in front of the feeder storage cabinet 60 but also the range in front of the adjacent component mounter 20, making it easier to ensure the safety of the worker.

[0042] If the robot control device 59 determines in S345 that there is no worker in the storage front range 11a, it moves the exchange robot 50 at a predetermined speed and causes it to enter the storage front range 11a (S355), and proceeds to the processing of S360. After stopping the exchange robot 50 in S350, if the robot control device 59 determines in S345 that the storage front monitoring sensor 86 does not detect a worker, it may wait until a predetermined time has elapsed before moving the exchange robot 50. Then, the robot control device 59 determines whether the exchange robot 50 has reached the target position (S360). If the robot control device 59 determines that the exchange robot 50 has not reached the target position, it returns to S300 and repeats the processing. If the robot control device 59 determines that the exchange robot 50 has reached the target position, it stops the exchange robot 50 (S365), and ends the exchange robot movement processing. If the exchange robot 50 detects a worker after entering the storage front range 11a and before reaching the target position, it stops its movement in S305.

[0043] Here, the correspondence between the components of this embodiment and the components of the present invention will be clarified. In this embodiment, the feeder 30 corresponds to a component supply unit, the component mounter 20 corresponds to a component mounter, the component mounting line 10 corresponds to a component mounting line, the feeder storage 60 corresponds to a unit storage, the exchange robot 50 corresponds to a unit exchange device, and the management device 80 that executes the feeder exchange process in Fig. 9 and the robot control device 59 that executes the exchange robot movement process in Fig. 10 correspond to control devices. Also, the substrate transport device 62 corresponds to a transport device, the storage front monitoring sensor 86 corresponds to a detector, the management device 80 corresponds to a management device, and the waste material transport device 26 corresponds to a waste material transport device.

[0044] The component mounting line 10 described above includes a plurality of component mounters 20 arranged along the board transport direction, a feeder storage 60 storing a plurality of feeders 30 that can be attached to and detached from the component mounters 20, and an exchange robot 50 that can exchange feeders 30 between the feeder storage 60 and each component mounter 20. The feeder storage 60 is installed in the same row as the component mounters 20, and the exchange robot 50 moves along the board transport direction to exchange feeders 30. This allows workers to replenish feeders 30 to each component mounter 20 on the component mounting line 10 simply by storing feeders 30 in the feeder storage 60. In addition, used feeders 30 can be automatically collected from each component mounter 20 in the feeder storage 60, allowing workers to collect feeders 30 from the feeder storage 60 all at once. In other words, workers can replenish or collect feeders 30 used by any component mounter 20 from the feeder storage 60. Furthermore, if the exchange robot 50 is not located in front of the feeder storage 60, it can replenish or retrieve feeders 30 at any time. Furthermore, compared to a system in which an operator supplies feeders 30 to each component mounter 20, it is possible to prevent the exchange robot 50 from being stopped frequently while moving. As a result, it is possible to provide a user-friendly feeder storage 60. Furthermore, by configuring the feeder storage 60 so that the number of feeders 30 stored (housed) in the feeder storage 60 is an appropriate number depending on the number and type of components to be mounted on the component mounting line 10, it is possible to make the feeder storage 60 function appropriately as an in-line component warehouse.

[0045] Furthermore, because the feeder storage 60 is equipped with the board transport device 62, the feeder storage 60 can be easily installed in a position where it is aligned with multiple component mounters 20. In the component mounting line 10, the feeder storage 60 is installed in a position upstream of the most upstream component mounter 20, so interference with the movement of the exchange robot 50 when carrying the feeders 30 into or out of the feeder storage 60 can be reduced. Furthermore, the component mounting line 10 is equipped with a feeder table 40 that is common to the feeder storage 60 and the component mounters 20 at the same height, so the exchange robot 50 can efficiently attach and detach the feeders 30 between the feeder storage 60 and the component mounters 20 through a common operation using the same feeder transfer mechanism 53.

[0046] Furthermore, on the component mounting line 10, when the in-storage monitoring sensor 86 detects a worker, the replacement robot 50 is not allowed to enter the in-storage area 11a, thereby ensuring the safety of the worker. Furthermore, when the in-storage monitoring sensor 86 detects a worker, the replacement robot 50 is moved at a low speed within the adjacent area 11b toward the feeder storage 60, thereby allowing the replacement robot 50 to move within a range that does not impede the safety of the worker. Furthermore, on the component mounting line 10, the management device 80 and the collection container 64 are disposed within the installation space of the feeder storage 60, thereby enabling efficient use of space.

[0047] It goes without saying that the present invention is not limited to the above-described embodiment, and can be embodied in various forms as long as they fall within the technical scope of the present invention.

[0048] For example, in the above-described embodiment, the feeder storage 60 is installed upstream of the most upstream component mounter 20. However, this is not limiting. The feeder storage 60 may be installed downstream of the most downstream component mounter 20 in the line-up direction of the multiple component mounters 20. Alternatively, the feeder storage 60 may be installed midway in the line-up direction of the multiple component mounters 20 (a position sandwiched between the component mounters 20). Also, although only one feeder storage 60 is installed in the component mounting line 10, multiple feeder storages may be installed. FIG. 11 is a schematic diagram illustrating the configuration of a component mounting line 10B of a modified example. As shown in the figure, in the component mounting line 10B of the modified example, a total of two feeder storages 60 are installed, one upstream of the most upstream component mounter 20 and one midway in the line-up direction of the multiple component mounters 20 (approximately the middle position). In this case, the feeders 30 used by the component mounters 20 between the upstream feeder storage 60 and the intermediate feeder storage 60 can be replenished and recovered mainly from the upstream feeder storage 60, and the feeders 30 used by the component mounters 20 downstream of the intermediate feeder storage 60 can be replenished and recovered mainly from the intermediate feeder storage 60. This prevents the movement distance of the exchange robot 50 from becoming longer than necessary, even when multiple component mounters 20 are lined up and the overall length of the component mounting line 10B is long, and suppresses a decrease in the work efficiency of automatic exchange of feeders 30. Note that in addition to the feeder storage 60, multiple exchange robots 50 may be installed.

[0049] In the above-described embodiment, the feeders 30 are loaded and unloaded into the feeder storage 60 by a worker. However, this is not limited thereto. The feeders 30 may be loaded and unloaded into the feeder storage 60 using an automatic transport device capable of automatically transporting the feeders 30 from outside the component mounter 10 line. FIG. 12 is a schematic diagram illustrating the configuration of modified component mounting lines 10C and 10D. As shown in FIG. 12(a), an overhead guided vehicle (OHT) 90 can be used as the automatic transport device. The OHT 90 requires an open top for the loading and unloading destination to load and unload the feeders 30. However, the component mounter 20 has a structure for moving the head 22, making it difficult to configure the top to be open. The feeder storage 60 does not have such a restriction, and the top of the storage area 60A can be opened, enabling the OHT 90 to automatically load and unload the feeders 30. As shown in FIG. 12(b), an AGV (automated guided vehicle) 100 can be used as the automatic transport device. If the AGV transports the feeders 30 to and from each mounter 20, interference between the movement of the AGV and the movement of the exchange robot 50 can frequently occur. To ensure smooth transport of the feeders 30 by the AGV, it is desirable to provide a guide for aligning the AGV's stopping position. However, if the AGV transports the feeders 30 to and from each mounter 20, providing a guide on each mounter 20 can result in space problems. As in the modified example, by having the AGV 100 transport the feeders 30 only to and from the feeder storage 60, interference between the movement of the AGV 100 and the movement of the exchange robot 50 can be prevented only in the storage front area 11a, and guides can be provided only in the feeder storage 60, thereby preventing these problems from occurring.

[0050] In the above-described embodiment, the management device 80 and the collection container 64 are arranged within the installation space of the feeder storage 60, but this is not limitative, and one or both of the management device 80 and the collection container 64 may not be arranged. Note that the collection container 64 is not limited to being one that collects waste tape, but may also be one that collects waste materials from storage members (for example, tray-shaped members) that store parts.

[0051] In the above-described embodiment, when a worker is present in the storage area 11a, the exchange robot 50 moves within the adjacent area 11b toward the feeder storage area 60 at a speed slower than a predetermined speed, but this is not limited to this, and the exchange robot 50 may also be moved at a predetermined speed.

[0052] In the above-described embodiment, the storage cabinet front monitoring sensor 86 detects (monitors) the presence or absence of an operator in the storage cabinet front area 11a, but the present invention is not limited to this. For example, a safety fence that can be pulled out by an operator may be provided between the feeder storage cabinet 60 and the adjacent component mounter 20, and the sensor may detect whether the safety fence is pulled out.

[0053] In the embodiment described above, if a worker is present in the storage area 11a, the exchange robot 50 is stopped without entering the storage area 11a, but the present invention is not limited to this process. For example, in the feeder exchange process, if it is detected that a worker is present in the storage area 11a, the exchange robot 50 may be controlled so that processes that can be executed in areas other than the storage area 11a are performed first.

[0054] In the above-described embodiment, the storage front monitoring sensor 86 and the left and right monitoring sensors 58a, 58b of the exchange robot 50 are used in the movement control of the exchange robot 50, but this is not limited thereto, and only the left and right monitoring sensors 58a, 58b of the exchange robot 50 may be used. In this case, the left and right monitoring sensors 58a, 58b may each be composed of a plurality of sensors having a first detection range and a second detection range wider than the first detection range, and may move at a low speed when detecting a worker in the second detection range and stop when detecting a worker in the first detection range. Alternatively, even if the movement of the exchange robot 50 is controlled using only the storage front monitoring sensor 86, it is possible for the worker to work safely in the storage front range 11a.

[0055] In the above-described embodiment, the worker may carry feeders 30 into or out of the feeder storage 60 one by one, or may carry multiple feeders 30 into or out all at once. For example, the storage area 60A of the feeder storage 60 is configured to allow a magazine to be set that can collectively attach and detach multiple feeders 30. The worker then attaches multiple new feeders 30 to the magazine and replenishes the storage area 60A, or, when multiple used feeders 30 are attached to a magazine in the storage area 60A, the worker collects the magazine. In this case, the worker may use a cart that can carry the magazine to carry the magazine. Alternatively, the storage area 60A of the feeder storage 60 may be configured to allow carts carrying such magazines to be set, and a work vehicle may replace each cart (including the feeders 30 in the magazine on the cart).

[0056] In the above-described embodiment, the component mounter 20 is provided with the feeder stock area 20B, but this may not be provided. In this case, the exchange robot 50 may not be provided with the lower transfer area 50B, or the lower transfer area 50B may be used as a stock area for the feeders 30 in the exchange robot 50. Furthermore, the exchange robot 50 may be configured to accommodate multiple feeders 30 and be able to replace multiple feeders 30 collectively. [Industrial Applicability]

[0057] The present invention can be used in the manufacturing industry for component mounting lines, etc. [Explanation of symbols]

[0058] 10, 10B, 10C, 10D component mounting line, 11a storage area, 11b adjacent area, 11c non-adjacent area, 12 printing machine, 14 print inspection machine, 18 X-axis rail, 20 component mounting machine, 20A supply area, 20B stock area, 21 board transport device, 22 head, 23 head movement mechanism, 24 tape duct, 25 tape cutter, 26 tape chute, 27 waste tape transport device, 28 mounting control device, 30 feeder, 32 tape reel, 33 tape feed mechanism, 34 positioning pin, 35 connector, 37 rail member, 39 feeder control device, 40 feeder table, 42 slot, 44 positioning hole, 45 connector, 50 exchange robot, 50A upper transfer area, 50B lower transfer area, 51 robot movement mechanism, 52a X-axis motor, 52b Guide roller, 53 Feeder transfer mechanism, 54 Clamp unit, 55 Y-axis slider, 55a Y-axis motor, 55b Y-axis guide rail, 56a Z-axis motor, 56b Z-axis guide rail, 57 Encoder, 58a Left side monitoring sensor, 58b Right side monitoring sensor, 59 Robot control device, 60 Feeder storage, 60A Storage area, 61 Housing, 62 Board transport device, 63A Lower space, 63B Opening, 64 Collection container, 65A Storage unit, 65B Stand, 80 Management device, 80a CPU, 80b ROM, 80c HDD, 80d RAM, 82 Display, 84 Input device, 86 Storage front monitoring sensor, 90 OHT, 100 AGV, S Board.

Claims

[Claim 1] A component mounting line configured by arranging a plurality of component mounters, each of which has a component supply unit detachably set and which mounts components supplied by the component supply unit onto a mounting object, along a transport direction of the mounting object, a unit storage that stores a plurality of the component supply units; a unit exchange device that can exchange the component supply units attached to the plurality of component mounters with the component supply units stored in the unit storage; a control device that controls the unit replacement device; Equipped with the unit storage facility allows an operator to carry the component supply unit in and out; a detector for detecting the presence or absence of a worker within a predetermined range including a front of the unit storage cabinet within a predetermined movement range along the conveying direction, The control device controls the unit replacement device to move within the movement range to replace the component supply unit, and controls the unit replacement device not to move within the predetermined range when the detector detects a worker. Component mounting line.

Images