Parts supply unit storage and retrieval system

Abstract

To provide a parts supply unit storage and retrieval system that streamlines the setup work that involves retrieving parts supply units from the warehouse.SOLUTION: A parts supply unit storage and retrieval system includes a unit storage container formed with a plurality of storage slots arranged to store part supply units, a unit warehouse for storing a larger number of part supply units than the number of the part supply units the unit storage container can accommodate, an unloading station for detachably holding the unit storage container and enabling a transport vehicle to unload the unit storage container, an input / output robot for storing part supply units retrieved from the unit warehouse into the unit storage container on the unloading station, and an efficiency processing unit for performing efficiency processing to improve the efficiency of work on a substrate-related work line composed of a plurality of component mounting machines, and the input / output robot stores part supply units retrieved from the unit warehouse into designated storage slot positions in the unit storage container on the basis of the results of the efficiency processing by the efficiency processing unit.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present specification relates to a warehousing / retrieval system that handles setup work involving the retrieval of a parts supply unit from a warehouse. [Background technology]

[0002] The technology of mass-producing circuit board products by performing substrate-related operations on printed circuit boards has become widespread. Furthermore, it has become common to arrange multiple types of substrate-related operation machines side by side to form a substrate-related operation line. Among the substrate-related operation machines, component placement machines use component supply units loaded with component containers that store multiple components. The loading operation of loading the component containers into the component supply units, in other words, the setup operation of preparing the component supply units for use, is often performed in a setup area away from the component placement machines in operation (external setup). The set-up component supply units are then transported to and installed in the component placement machines (internal setup).

[0003] The above-mentioned loading and mounting operations on component mounting machines have traditionally been performed manually, requiring considerable effort. Furthermore, in order to ensure the achievement of production plans, the loading operations are often performed ahead of schedule, resulting in an increase in in-process component supply units that cannot be used for other purposes. This has made management cumbersome and even more time-consuming. In recent years, in order to reduce labor, container loaders that automate at least part of the loading operations have been put into practical use. Patent Document 1 discloses an example of technology related to the automation of loading and mounting operations.

[0004] The second embodiment of Patent Document 1 describes a configuration including a storage facility for storing reels (an example of a component container), a storage facility for storing feeders (an example of a component supply unit), a reel setting device, a conveying device, and a management unit. The reel setting device performs setup work to set reels in the feeders. The conveying device conveys the set-up feeders to the component mounting machine. The management unit controls the removal of reels and feeders, setup work, conveying operations, etc., to manage the production of the component mounting machine. This is said to make it easy to grasp the combinations and locations of reels and feeders, facilitating their management. [Prior art documents] [Patent documents]

[0005] [Patent Document 1] International Publication No. 2019 / 142336 Summary of the Invention [Problem to be solved by the invention]

[0006] Incidentally, the reel setting device of Patent Document 1 is advantageous in that the loading operation is automated. However, this loading operation is performed one by one in order, which is not necessarily efficient.

[0007] The problem to be solved in this specification is to provide a part supply unit storage / retrieval system that improves the efficiency of setup work involving the retrieval of part supply units from a warehouse. [Means for solving the problem]

[0008] This specification discloses a component supply unit storage and retrieval system comprising a unit storage container that stores multiple component supply units used when supplying multiple components to a component mounting machine, a storage container holder that holds the unit storage container, a unit warehouse that stores a larger number of the component supply units than the unit storage container can accommodate, and an storage and retrieval robot that transfers the component supply units between the unit storage container and the unit warehouse. [Effects of the Invention]

[0009] In the component supply unit storage and retrieval system disclosed in this specification, a storage and retrieval robot automatically retrieves multiple component supply units from a unit warehouse and stores them in a unit storage container. The multiple component supply units stored in the unit storage container are then used together in subsequent setup operations or are installed together in a component placement machine. This improves the efficiency of setup operations compared to conventional techniques in which component supply units are set up one by one. [Brief explanation of the drawings]

[0010] [Figure 1] 1 is a perspective view schematically showing the configuration of a component supply unit storage / retrieval system according to a first embodiment; [Figure 2] 1 is a front view schematically showing the configuration of a component supply unit storage / retrieval system according to a first embodiment; [Figure 3] FIG. 2 is a functional block diagram showing a control configuration in the first embodiment. [Figure 4] FIG. 2 is an operational flow diagram illustrating the control operation of the warehouse entry / exit control unit in the first embodiment. [Figure 5] FIG. 10 is a plan view schematically showing a component supply unit inventory system according to a second embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0011] 1. Configuration of the parts supply unit storage / retrieval system 1 of the first embodiment The configuration of a component supply unit storage / retrieval system 1 according to a first embodiment will be described with reference to the configuration diagrams of Figures 1 and 2 and the functional block diagram of Figure 3. The storage / retrieval system 1 handles the loading operation of loading a component storage container 91 into a component supply unit 92, as well as related operations before and after that. The storage / retrieval system 1 is composed of a unit warehouse 2, a storage container holder 3, unit storage containers (41, 44), a storage / retrieval robot 5, and the like.

[0012] The component container 91, while accommodating a plurality of components, is loaded into the component supply unit 92. The component supply unit 92 is used to supply the components accommodated in the component container 91 during a mounting operation performed by the component mounting machine 98. Identification codes indicating their respective types and individual components are affixed to the component container 91 and the component supply unit 92. The identification code of the component container 91 includes information indicating the type of component accommodated in the component container 91. The identification code may be a barcode or a two-dimensional code. When the component container 91 is loaded into the component supply unit 92, the identification codes of both are read by a code reader. This generates loading information V (see FIG. 3) that associates the individual component container 91 with the individual component supply unit 92 into which the component container 91 is loaded.

[0013] An example of the component container 91 is a tape reel, and an example of the component supply unit 92 is an integrated feeder device into which the tape reel is directly loaded. A carrier tape containing a large number of components enclosed at a predetermined pitch is wound and held on the tape reel. The feeder device is installed in the component mounting machine 98 with the tape reel loaded. The feeder device supplies components to the component mounting fixtures of the component mounting machine 98 by pulling out the carrier tape from the tape reel and sending it to the component removal position. As the component mounting operation progresses and the components on the tape reel are consumed, the entire feeder device is replaced.

[0014] Feeder devices are not limited to integrated types, and separate types are also available. Separate feeder devices consist of a feeder main body with a carrier tape feeding mechanism and a reel cassette into which tape reels are loaded. The feeder main body is permanently installed in the component placement machine 98, and a separate reel cassette is placed near the feeder main body. As the component placement operation progresses and the components on the tape reel are consumed, the reel cassette is replaced. The reel cassette corresponds to the component supply unit 92 into which the component container 91 is loaded.

[0015] In the following, a case will be described in which the component supply unit 92 is an integrated feeder device and a tape reel is already loaded as the component container 91. Note that a tray can also be used as the component container 91, and a tray loading unit can also be used as the component supply unit 92.

[0016] The unit warehouse 2 stores a larger number of component supply units 92 than the unit storage containers (41, 44) described below can store. As shown in FIGS. 1 and 2, the unit warehouse 2 is formed in the shape of a large, vertical rectangular parallelepiped. The unit warehouse 2 has an inlet / outlet opening 21 at the front. However, this is not limitative, and the inlet opening and the outlet opening may be provided separately. The component supply units 92 loaded with component storage containers 91 are stored through the inlet / outlet opening 21 by an operator.

[0017] An upper section guide 26 extending in the left-right direction is provided below the loading / unloading opening 21 on the front side of the unit warehouse 2. A lower section guide 27 extending in the left-right direction is provided at the bottom of the front side of the unit warehouse 2. The upper section guide 26 and the lower section guide 27 are formed, for example, in a convex shape that protrudes forward or a groove shape that opens upward.

[0018] As shown in Fig. 3, a plurality of storage positions, an actuator 22, and a code reader 23 are provided inside the unit warehouse 2. The actuator 22 transports a part container 91 stored at the loading / unloading opening 21 to a storage position, and also transports a part container 91 from the storage position to the loading / unloading opening 21. The actuator 22 is controlled by the warehouse control unit 29.

[0019] The code reader 23 reads the identification code attached to the stored component supply unit 92 and passes the read result to the warehouse control unit 29. Therefore, the warehouse control unit 29 can recognize all stored component supply units 92 in association with their storage locations. Furthermore, the warehouse control unit 29 can recognize the component containers 91 loaded in each component supply unit 92 by referring to the loading information V. A warning light 24 is provided on the front right side of the upper part of the unit warehouse 2. The warehouse control unit 29 controls the lighting of the warning light 24 in the event of an abnormality or malfunction to alert an operator.

[0020] As shown in Figures 1 and 2, the storage container holder 3 is disposed adjacent to the left side of the unit warehouse 2. However, this is not limiting, and the storage container holder 3 may also be disposed on the right side of the unit warehouse 2. The storage container holder 3 holds the unit storage containers (41, 44) on its upper side. The storage container holder 3 is formed in a rectangular frame shape. An upper section guide 32 extending in the left-right direction is provided at the top of the front surface of the storage container holder 3. A lower section guide 33 extending in the left-right direction is provided at the bottom of the front surface of the storage container holder 3. The upper section guide 32 and the lower section guide 33 are disposed at the same height as the upper section guide 26 and the lower section guide 27 of the unit warehouse 2, and are formed in the same shape.

[0021] The number of storage container holders 3 can be increased. When an increase is made, multiple storage container holders 3 are arranged adjacent to each other in the left-right direction. Alternatively, multiple storage container holders 3 may be distributed on both the left and right sides of the unit warehouse 2. In this way, multiple upper section guides 32 are connected in a row in the left-right direction and are further connected to the upper section guide 26 of the unit warehouse 2 to form a long moving guide. Similarly, multiple lower section guides 33 are connected in a row in the left-right direction and are further connected to the lower section guide 27 of the unit warehouse 2 to form a long moving guide.

[0022] Of the three container holders 3 shown in Figures 1 and 2, a full-width unit container 41 is held above the right and center container holders 3. Two half-width unit containers 44 are held above the left container holder 3. The width of the full-width unit container 41 is slightly smaller than the width of the component mounting machine 98. The width of the half-width unit container 44 is approximately half the width of the full-width unit container 41.

[0023] The unit storage containers (41, 44) store a plurality of component supply units 92. A plurality of storage slots aligned in the left-right direction are formed on the inner bottom surface of the unit storage containers (41, 44). The storage slots are formed, for example, by grooves extending in the front-rear direction, and the component supply units 92 are inserted from the front side to be stored. In Figures 1 and 2, one component supply unit 92 is illustrated in the right full-width unit storage container 41, but in reality, a large number of component supply units 92 are stored aligned left and right. The half-width unit storage container 44 has half the number of storage slots as the full-width unit storage container 41.

[0024] The full-width unit storage 41 is mounted on the component mounting machine 98 and serves as a main part of the component supply device. Similarly, the two half-width unit storages 44 are mounted on the component mounting machine 98 and serve as a main part of the component supply device. However, the present invention is not limited to this, and the unit storages (41, 44) may not be mounted on the component mounting machine 98, but may be used to collectively perform setup work and transportation of the stored multiple component supply units 92, thereby improving efficiency.

[0025] The storage / retrieval robot 5 delivers a prepared component supply unit 92 loaded with a component storage container 91 between the unit storage container (41, 44) and the unit warehouse 2. The storage / retrieval robot 5 is formed vertically long. The storage / retrieval robot 5 is equipped with a guide member and a movement drive unit at its rear. The guide member engages with a movement guide consisting of multiple section guides (26, 27, 32, 33). This allows the entire weight of the storage / retrieval robot 5 to be supported by the movement guide and regulates its movement direction. The movement drive unit operates using, for example, a non-contact power supply device or a battery (not shown) as its power source. The movement drive unit is composed of, for example, a combination of traveling wheels and a drive motor, or a movement mechanism that applies a linear motor. This allows the storage / retrieval robot 5 to move along the movement guide in front of the unit storage container (41, 44) and the unit warehouse 2.

[0026] The loading / unloading robot 5 further comprises a unit holding space and a unit operation mechanism. The unit holding space is a space partitioned inside the loading / unloading robot 5 and opens to the rear. The unit holding space temporarily holds the component supply unit 92 to be transported. The unit operation mechanism delivers the component supply unit 92 between the unit holding space and the unit storage container (41, 44), and between the unit holding space and the loading / unloading opening 21 of the unit warehouse 2. At this time, the height of the loading / unloading robot 5 is maintained appropriately by the engagement of the guide member and the moving guide, stabilizing the delivery operation. The loading / unloading robot 5 is controlled by the loading / unloading control unit 8.

[0027] 2. Configuration related to control of storage / retrieval system 1 Next, a configuration related to the control of the inventory system 1 will be described. As shown in FIG. 3, inventory control unit 8 is communicatively connected to efficiency improvement processing unit 95. Efficiency improvement processing unit 95 is communicatively connected to line control unit 96. Furthermore, line control unit 96 is communicatively connected to each of a plurality of types of substrate-related work machines that make up substrate-related work line 97. Substrate-related work line 97 is a production line that mounts components on boards to mass-produce board products. Component mounting machines 98 that make up substrate-related work line 97 are equipped with set-up unit storage containers (41, 44) and are therefore able to supply components.

[0028] The efficiency improvement processing unit 95 performs efficiency improvement processing to improve the efficiency of work on the substrate-related work line 97. As part of the efficiency improvement processing, the efficiency improvement processing unit 95 optimizes the storage positions of the multiple component supply units 92 in the unit storage containers (41, 44) to improve the efficiency of component mounting work on the component mounting machine 98. This efficiency improvement processing is also called optimization processing, and various known techniques can be applied. The line control unit 96 controls the operation of the substrate-related work line 97 based on the results of the efficiency improvement processing received from the efficiency improvement processing unit 95.

[0029] On the other hand, the incoming / outgoing control unit 8 is connected to communicate with the warehouse control unit 29 of the unit warehouse 2. The incoming / outgoing control unit 8 also controls the incoming / outgoing robot 5. Furthermore, a loading information storage unit 81 attached to the incoming / outgoing control unit 8 stores loading information V. The incoming / outgoing control unit 8 is equipped with a man-machine interface (input unit, display unit, wireless communication unit, etc.) for exchanging information with workers.

[0030] The loading information V and various other information are transmitted and received as appropriate between the above-mentioned control elements. Therefore, the loading / unloading control unit 8 can share the loading information V between the unit warehouse 2 and the component placement machine 98. Furthermore, the above-mentioned control elements do not all need to be independent hardware. For example, the loading / unloading control unit 8 and the warehouse control unit 29 may be realized by different software on a single computer device. Furthermore, the loading / unloading control unit 8 may be realized as a partial function of the efficiency improvement processing unit 95. Furthermore, the above-mentioned communication connection and information transmission may be performed using a wireless communication device. The control functions of the loading / unloading control unit 8 and the like will be described in detail in the following explanation of the operations.

[0031] 3. Operation of Storage / Retrieval System 1 Next, the operation of the inventory system 1 will be described with reference to Fig. 4. In step S1 of Fig. 4, the inventory control unit 8 acquires the results of the efficiency improvement processing from the efficiency improvement processing unit 95. The results of the efficiency improvement processing include the identification code of the component supply unit 92 to be used and information on the storage position within the unit storage container (41, 44). The storage position information is represented, for example, by a slot number indicating the position of the storage slot.

[0032] In the next step S2, the inventory control unit 8 commands the warehouse control unit 29 to input the identification code of the component supply unit 92 to be used. The warehouse control unit 29 controls the actuator 22 in accordance with the command to transport the component supply unit 92 to the inventory opening 21. In the next step S3, the inventory control unit 8 commands the inventory robot 5 to transport the component supply unit 92. In accordance with the command, the inventory robot 5 transports the component supply unit 92 at the inventory opening 21 to the unit storage container (41, 44).

[0033] In the next step S4, the inventory control unit 8 commands the inventory robot 5 to a storage position in the unit storage container (41, 44). The inventory robot 5 stores the component supply unit 92 in the commanded storage position. In the next step S5, the inventory control unit 8 determines whether or not all component supply units 92 included in the result of the efficiency improvement processing have been stored in the unit storage container (41, 44). If the determination is negative, the inventory control unit 8 repeatedly executes steps S2 to S5.

[0034] When all component supply units 92 are assembled through repetition, the operation flow ends. At this point, the unit storage containers (41, 44) are ready for use. The worker transports one full-width unit storage container 41 or two half-width unit storage containers 44 to the component mounting machine 98 and installs them. In one example of this installation work, the worker first connects a transport cart (not shown) to the storage container holder 3 on the side opposite the loading / unloading robot 5. Second, the worker pulls out the unit storage containers (41, 44) from the storage container holder 3, transfers them to the cart, and transports them to the component mounting machine 98. Third, the worker connects the cart to the installation position of the component mounting machine 98. Finally, the worker transfers the unit storage containers (41, 44) from the cart to the component mounting machine 98. This completes the component mounting machine 98's preparation for supplying components. At this time, the loading information V is shared with the component mounting machine 98 via communication or the like.

[0035] In the component supply unit storage / retrieval system 1 of the first embodiment, the storage / retrieval robot 5 automatically retrieves a plurality of component supply units 92 from the unit warehouse 2 and stores them in the unit storage containers (41, 44). The plurality of component supply units 92 stored in the unit storage containers (41, 44) are then used collectively in the subsequent setup work, or are collectively mounted on the component mounting machine 98. Therefore, the setup work can be made more efficient than in the prior art in which component supply units 92 are set up one by one.

[0036] Furthermore, the inventory control unit 8 selects and controls the multiple component supply units 92 to be delivered from the unit warehouse 2 based on the results of the efficiency improvement process, and further controls the storage positions of the multiple component supply units 92 within the unit storage containers (41, 44). This allows the unit storage containers (41, 44) to be equipped in the component mounting machine 98 to be set up in a timely manner following the efficiency improvement process. Furthermore, since the storage positions of the multiple component supply units 92 within the unit storage containers (41, 44) are automatically controlled, there is no risk of incorrect storage positions. Furthermore, since the unit warehouse 2 that stores the component supply units 92 and the storage container holder 3 that stores them in the unit storage containers (41, 44) are arranged adjacent to each other, a space-saving system configuration is realized.

[0037] 4. Parts supply unit storage and retrieval system 1A of the second embodiment Next, the differences between the storage and retrieval system 1A of the second embodiment and the first embodiment will be mainly described with reference to Fig. 5. As shown in Fig. 5, in the second embodiment, a travel path 65 and a transport vehicle 66 are added to the configuration of the first embodiment.

[0038] The travel path 65 is laid from the rear of the left storage container holder 3 to the substrate-related work line 97. The left storage container holder 3 serves as both an unloading station for unloading the component supply unit 92 loaded with the component container 91 toward the component mounting machine 98 and an unloading station for loading the component supply unit 92 that has been used by the component mounting machine 98. The transport vehicle 66 travels along the travel path 65 in accordance with wireless commands from the inventory control unit 8, and loads and unloads the half-width unit storage container 44. The transport vehicle 66 reports the progress of the transport operation to the inventory control unit 8 as appropriate. The waiting position of the transport vehicle 66 is set behind the left storage container holder 3 (shown in FIG. 5). The travel path 65 may be laid across multiple substrate-related work lines 97, allowing multiple transport vehicles 66 to travel while avoiding collisions. Furthermore, the transport vehicle 66 may be an AGV that does not require a physical travel path 65 and travels by referring to travel path information on map data.

[0039] In the above configuration, the transport vehicle 66 removes the half-width unit storage container 44 that is ready for use from the storage container holder 3 and loads it on the transport vehicle 66. The transport vehicle 66 then travels to the component mounting machine 98 to transport the half-width unit storage container 44 and mounts it on the component mounting machine 98. Alternatively, the transport vehicle 66 hands over the half-width unit storage container 44 to an operator beside the component mounting machine 98. The transport vehicle 66 then transports a second half-width unit storage container 44 in the same manner. According to the second embodiment, in addition to storing the component supply unit 92 in the half-width unit storage container 44, automation of the transport work of the half-width unit storage container 44 is achieved.

[0040] 5. Applications and Modifications of the Embodiments In the second embodiment, the transport vehicle 66 may return the half-width unit storage container 44 that has been used by the component mounting machine 98 to the storage container holder 3. After this, the component supply unit 92 is returned to the unit warehouse 2 for storage. At this time, the loading information V is shared with the unit warehouse 2 via communication or the like. Also, due to performance constraints, the transport vehicle 66 transports the half-width unit storage container 44 twice. However, by increasing the size of the transport vehicle 66 and improving its performance, it becomes possible to transport the full-width unit storage container 41. In addition, various applications and modifications are possible for the first and second embodiments. [Explanation of symbols]

[0041] 1, 1A: Component supply unit storage / retrieval system 2: Unit warehouse 21: Storage / retrieval gate 22: Actuator 23: Code reader 26: Upper section guide 27: Lower section guide 29: Warehouse control unit 3: Storage container holder 32: Upper section guide 33: Lower section guide 41: Full-width unit storage container 44: Half-width unit storage container 5: Storage / retrieval robot 66: Transport vehicle 8: Storage / retrieval control unit 81: Loading information memory unit 91: Component storage container 92: Component supply unit 95: Efficiency processing unit 98: Component placement machine V: Loading information

Claims

1. a unit storage container having a plurality of storage slots arranged to store component supply units used when supplying a plurality of components to a component mounting machine; a unit warehouse for storing a greater number of the component supply units than the unit storage container can store; a carry-out station that detachably holds the unit storage container and allows a transport vehicle to carry out the unit storage container; a loading / unloading robot that moves between the unit warehouse and the carrying-out station and stores the component supply unit taken out from the unit warehouse in the unit storage container on the carrying-out station; an efficiency processing unit that performs an efficiency processing for improving the efficiency of work in a substrate-related work line that is made up of a plurality of the component mounting machines, The in-stock / out-stock robot stores the part supply unit, which has been shipped out from the unit warehouse, in a predetermined storage slot position of the unit storage container based on the results of the efficiency processing by the efficiency processing unit.

2. the efficiency improvement processing unit performs the efficiency improvement processing to optimize the storage slot positions of the plurality of component supply units in the unit storage container; the loading / unloading robot stores the unloaded component supply unit in the optimized storage slot position of the unit storage container; 2. The parts supply unit storage and retrieval system according to claim 1.

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