A transport vehicle equipped with an exchange device that is rotatable and movable in the vertical direction for a component supply device

Abstract

An apparatus (100) and a method for replacing a component supply device (285) with a mounting machine (BA1, BA2, BA3) are described. The apparatus (100) has (a) a transport vehicle (210) configured to move autonomously on a floor surface (193), (b) a positioning system (230) having a fixed positioning component (232) attached to a fixed position of the transport vehicle (210) and a positioning component (234) movable relative to the fixed positioning component (232), and (c) an exchange device (240) attached to the movable positioning component (234) and configured to removably attach or remove the component supply device (285) to / from the mounting machine (BA1, BA2, BA3) along a linear exchange direction (240a) parallel to the y-axis. The positioning system (230) is configured such that the movable positioning component (234) is rotatable about a vertical z-axis (S) and linearly displaceable along the vertical z-axis (S) relative to the fixed positioning component (232).

Description

Technical Field

[0001] The present invention relates generally to the technical field of manufacturing electronic assemblies. In this case, electronic components are mounted on a component carrier. The present invention particularly relates to the supply of electronic components for a mounting machine that has to process a large number of electronic components in continuous operation. In particular, the present invention relates to an apparatus and a method for replacing a component supply device on a mounting machine.

Background Art

[0002] The mounting of electronic components, in particular surface mount device (SMD) components, on a printed circuit board or a component carrier is generally carried out using a mounting machine that follows the so-called "pick and place" or "collect and place" principle. In this case, the components supplied by a component supply device are (i) picked up by a mounting head of the mounting machine, (ii) transported to a mounting area where the component carrier to be mounted is present, and (iii) then placed at a predetermined component mounting position on the component carrier.

[0003] In order to ensure a high mounting efficiency, i.e., the processing of a large number of components within a predetermined time, the components are preferably attached to a belt having, for example, a so-called plastic blister, or a stable cardboard strip having recesses, and supplied to the mounting process by a suitable component supply device. By using such a belt, which is also clearly called a component belt, the mounting machine can be operated over a certain period without downtime.

[0004] However, when the last component is removed at the end of the belt, the supply of components is interrupted. Nevertheless, in order to continue the mounting process without interruption as much as possible, it is possible to connect the start end of a new belt to the end of the preceding, at least approximately used, belt. Such a connection, also called splicing, is generally still carried out manually and requires careful handling of the component belt wound in a bundle in addition to the actual complex manual splicing.

[0005] In particular, a component supply device is known that includes a housing in which a component belt is located to facilitate handling of the component belt or a bundle thereof. During operation, the belt is unwound from an inner bobbin within the housing, and after the components are removed, it is conveyed into or onto a mounting machine, where the belt is cut by a belt cutting device of the mounting machine, and the resulting more or less short belt pieces are disposed of as waste. Splicing is no longer performed. After using the components, the entire component supply device is replaced with another component supply device pre-assembled with an internal belt. The same applies to so-called setup changes. In such setup changes, after manufacturing a plurality of assemblies of a first type, other types of components must be mounted for manufacturing an assembly of a second type. In this case, generally, a plurality of component supply devices must be replaced simultaneously with other component supply devices pre-assembled with other types of components.

[0006] In the following, when referring to a component supply device or simply a supply device in this specification, unless otherwise stated, it means a component supply device having a housing and a component belt present within the housing.

[0007] In order to ensure that the components supplied to the mounting process by the supply device can be reliably picked up, the supply device must be mounted with high spatial accuracy on the chassis of the mounting machine. The typical accuracy required in this case is at least ±0.25 mm along the conveyance direction of the printed circuit board or component carrier of the mounting machine. This accuracy is generally obtained by an appropriate mechanical centering structure, such as a so-called omega profile, which represents the mechanical interface between the housing of the supply device and the chassis of the mounting machine. Since there is also a mechanical centering structure, the replacement of the component supply device is generally performed manually.

[0008] In order to reduce the burden of operations related to the replacement of supply devices, rails are attached to the mounting machines on the production line, and a robot is moved along the rails by an automated guided vehicle (RGV) with a track, whereby a supply device pre-assembled with parts or a parts belt is transported from the start or end of the production line to the mounting machine, the supply device is automatically exchanged with a pre-assembled supply device, and the replaced supply device is transported to the end of the production line. However, the drawback of this approach is that the RGV and the robot required for the actual replacement of the supply device need a relatively large space on the side of the production line in order to be used without the risk of collisions, such as collisions with operators. As a result, the space required for the production line increases, and the number of mounting machines or production lines that can be installed within the predetermined area of the factory decreases. This is particularly true for (a) production lines equipped with relatively large mounting machines where parts are supplied from two sides, i.e., the left and right sides of the production line, and (b) production lines installed in parallel with other production lines and thus require a larger space between each adjacent production line. Clearly, as the required space or area increases, the mounting efficiency that can be provided within the factory decreases.

[0009] Another drawback of using a robot positioned by an RGV to replace a parts supply device is that the RGV cannot move from one rail of a production line to the rail of an adjacent production line. Therefore, each production line requires not only a dedicated rail but also a dedicated RGV (with a robot). A further drawback is that two RGVs cannot pass each other on one rail for the RGV. Therefore, the performance of supply device replacement based on an RGV cannot be improved simply by adding an RGV (with a robot). Furthermore, the RGV (with a robot) used for the replacement of the supply device requires a linear rail or a straight rail. Therefore, in the case of a production line where the space available on the side is blocked or restricted by other equipment or columns of the factory building, using an RGV for the automatic replacement of the supply device is not a consideration.

[0010] Today, in order to transport and handle relatively large objects such as containers or cartons in a warehouse, automated transport systems are often used, which have at least one automated guided vehicle (AGV) and / or at least one autonomous mobile robot (AMR). In this specification, an AGV is understood to be a robot that is spatially guided by a physical or virtual line (formed on the floor). An AGV cannot move without such spatial guidance. In this specification, an AMR is understood to be a robot that can move freely in space. An AMR can recognize its own position based on the learned environment and does not require additional equipment for normal movement.

[0011] AGVs and AMRs are flexible devices that can be used in different environments without significant adaptation. For example, to handle standardized containers or cartons, AGVs and AMRs use active or passive roller conveyors and, more rarely, robotic arms. Apart from the fact that AGVs and especially AMRs can generally move or be positioned with relatively low spatial accuracy, AGVs and AMRs require a relatively large working space to perform their tasks. This has so far been an obstacle to using AGVs and AMRs for the automatic exchange of component supply devices, despite the general trend towards automation in the field of implementation technology. That is, as described above, in a manufacturing hall for manufacturing electronic assemblies, the space available between different mounting lines or machines is usually only small. Summary of the Invention Problems to be Solved by the Invention

[0012] The problem of the present invention is to automate the replacement of component supply devices within a limited space. Means for Solving the Problems

[0013] This problem is solved by the subject matter of the independent claims. Advantageous embodiments of the invention are described in the dependent claims.

[0014] According to a first aspect of the invention, there is described a device for replacing a component supply device in a mounting machine. The described device has (a) a transport vehicle configured to move autonomously on a (two-dimensional) floor surface, (b) a fixed positioning component attached to a fixed position on the transport vehicle, and a positioning system having a positioning component movable relative to the fixed positioning component, and (c) an exchange device attached to the movable positioning component and configured to removably attach or remove the component supply device to or from the mounting machine along a linear exchange direction parallel to the y-axis. According to the invention, the positioning system is configured such that the movable positioning component (and the exchange device attached to the movable positioning component) is rotatable about a vertical z-axis relative to the fixed positioning component and linearly displaceable along the vertical z-axis.

[0015] The described device is based on the recognition that the described rotatability of the exchange device using the positioning system enables the entire device to be realized in a compact structure. This particularly applies to an extension of the device parallel to the y-axis which is preferably (i) horizontal with respect to gravity and (ii) oriented perpendicular to the vertical z-axis. At this time, the vertical z-axis is preferably oriented parallel to gravity.

[0016] A component supply device, in particular a component supply device having a housing with a pre-assembled component belt therein, has an elongated shape (along the y-axis). Therefore, after removing the supply device or before attaching it, the supply device held by the exchange device can be rotated. This means that the overall extent consisting of (i) the described device and (ii) the supply device can be significantly smaller than the longitudinal extent of the supply device, parallel to the x-axis. This applies in an operating state where the exchange device is in an angular position such that the elongated shape of the supply device extends substantially parallel to the x-axis, which is perpendicular to both the vertical z-axis and the other (horizontal) y-axis. In this context, the concept of "elongated shape" is understood to mean, in particular, that the size or dimension of the supply device along its longitudinal direction is significantly larger than the size or dimension of the supply device along an axis or direction perpendicular to the supply device.

[0017] Put simply, due to the described rotatability of the exchange device, at least one (elongated) supply device is held by the exchange device. When the supply device is oriented parallel to the y-axis, the overall consisting of the described device and the held supply device can require a relatively large space only parallel to the y-axis. However, the corresponding rotational state or the corresponding angular position of the positioning system that requires a relatively large space must only be assumed within the relatively short time frame during which the transfer of the supply device between the exchange device and the mounting machine takes place. When exchanging the first supply device for the second supply device, this time frame starts immediately before the first supply device is removed from the mounting machine and ends immediately after the second supply device is detachably attached to the mounting machine. Outside of this time frame, the exchange device can, if necessary, be oriented by the positioning system using at least one held supply device such that the overall width of the described device and the held supply device is significantly smaller than the length of the held supply device.

[0018] Regarding the period of the entire process of replacing a component supply device, which ranges from picking up a new supply device to storing an old or at least partially used supply device, the above-mentioned time frame may be relatively short. That is, the corresponding spatial movement or the movement of the transport vehicle on the floor depends on the movement path and thus may clearly continue much longer depending on (i) the location where the new supply device is picked up and (ii) the location where the old supply device is (temporarily) stored. In this context, it is necessary to note that depending on the logistics concept used for the (temporary) storage of the supply device, the pick-up location and the (temporary) storage location can be the same location or separate locations.

[0019] Put simply, the described device requires a large space along the x direction (parallel to the x-axis) only when the transfer device transports the supply device to or from the mounting machine. The relatively large space requirement can also be determined by the spatial configuration of the linear guiding structure that the supply device must be moved along to be accurately positioned on the mounting machine. For example, the longer the guiding structure, which can be realized by an omega profile or another profile, the greater the displacement of the supply device along the y direction (parallel to the y-axis) before the exchange device (together with at least one held supply device) is rotated by the positioning system and a relatively small space is still required along the y direction by the entire combination of the described device and the supply device.

[0020] The transport vehicle may be the chassis of an automated guided vehicle (AGV) or an autonomous mobile robot (AMR). As already described at the beginning, an AGV is a transport vehicle that is spatially guided by a physical or virtual line (formed on the floor). Also as described at the beginning, an AMR is a robot that can move freely in space. An AMR can recognize its own position based on the learned environment and does not require additional equipment for normal movement.

[0021] The movable positioning component, and thus the exchange device, can similarly be displaced according to the present invention, which has the advantage that the location for picking up or removing the "new" supply device and / or the location for temporarily storing the "old" supply device is not only spatially outside the production line, but may also be, for example, (i) below and / or above the mounting machine, or (ii) below and / or above another mounting machine on the same production line or a different production line. This enables the storage space for the supply device to be provided above or below the mounting machine within the factory building. In this context, it should be noted that the term "below the mounting machine" in this specification means the space region below the mounting plane of the mounting machine. That is, the region below the mounting machine can also be the free region of the chassis or the support structure of the chassis of the mounting machine.

[0022] The exchange device can have a linearly displaceable gripper. The gripper only needs to be configured to ensure reliable handling of the component supply device according to the size and shape of the component supply device to be exchanged. In this context, a person skilled in the art with basic knowledge of robotics should be able to design an appropriate mechanism for the exchange device.

[0023] According to an embodiment of the present invention, the positioning system includes (a) a rotational drive unit for rotating the movable positioning component relative to the fixed positioning component, and (b) a linear drive unit for displacing the movable positioning component relative to the fixed positioning component.

[0024] Put simply, the two degrees of freedom of the exchange device (i) "rotation around the vertical z-axis" and (ii) "displacement along the vertical z-axis" are each realized by dedicated drive units. This enables the described positioning system to be realized particularly easily. At this time, the rotational drive unit and the linear drive unit can preferably operate independently of each other, whereby both movements can be executed simultaneously and independently of each other.

[0025] When the linear drive unit operates, both the rotary drive unit and the linear drive unit may be connected to each other or attached to each other such that not only the exchange device but also the rotary drive unit is displaced in the vertical direction. In other embodiments, when the rotary drive unit operates, not only the exchange device but also the linear drive unit rotates.

[0026] According to a further embodiment of the present invention, the rotary drive unit and the linear drive unit are a single drive unit of a positioning system. This means that the additional degrees of freedom of movement required for the overall positioning of the exchange device, including the removal and storage of the supply device described above, are provided by the transport vehicle. These additional degrees of freedom of movement can be used, in particular, for the above-described running or movement of the device on the floor (i) from a storage location where a new supply device is picked up to the location on the mounting machine where the actual exchange takes place, or (ii) from the exchange location to a storage location where the old supply device is (temporarily) stored.

[0027] According to a further embodiment of the present invention, the rotary drive unit is configured to rotate the exchange device in a rotation angle range of at least ±90° with respect to the x-axis, and the x-axis is perpendicular to both the y-axis and the z-axis which is also perpendicular to the y-axis. Thereby, the described device can advantageously also be used to exchange the component supply devices of mounting machines arranged in different production lines adjacent to each other, each having at least one mounting machine. In this case, the device is introduced into the (elongated) intermediate area or passage between the two production lines and only needs to move spatially there.

[0028] When the rotation angle is 0°, the exchange device is aligned along the longitudinally extending portions of the two production lines, i.e., along the y-axis or along the main running direction of the device. When the rotation angle is +90°, the exchange of the mounting machine and the supply device of one production line can be performed, and when the rotation angle is -90°, the exchange of the mounting machine and the supply device of the other production line can be performed. Advantageously, rotating or redirecting the device within the intermediate region may even be impossible when the intermediate region is narrow and / or when the device is relatively large or long, and there is no such need. Thus, in the case of a device having a storage device described below for temporarily accommodating the component supply device, a plurality of supply devices of different mounting machines can be exchanged within a relatively short time even when these mounting machines are arranged on different production lines adjacent to each other.

[0029] According to a further embodiment of the present invention, the device further has a storage device for temporarily accommodating at least one component supply device, and the exchange device is configured to take out at least one component supply device from the storage device and store at least one component supply device in the storage device.

[0030] With the storage device, the described device can execute a plurality of exchange procedures of the supply device without the need to move the device to a temporary storage place for the component supply device. In particular, a (new) supply device pre-assembled with a suitable component belt can be arranged in such a temporary storage place. Furthermore, such a temporary storage place may also have sufficient storage space for accommodating (old) supply devices as needed. Thereby, the movement path can be advantageously shortened.

[0031] Preferably, the storage device is configured such that the storage and removal of the component supply device can be performed when the above-described exchange device has a rotation angle of 0°, and is spatially arranged with respect to the exchange device. That is, even a storage device that can temporarily accommodate a plurality of component supply devices does not necessarily lead to an increase in the overall width of the described device.

[0032] According to a further embodiment of the invention, the apparatus further has a diagnostic device configured to classify defects of a component supply device that has just been stored in the storage device or has just been picked up by the exchange device.

[0033] In some embodiments, the severity of a defect of the supply device can be determined using this diagnostic device, which may have suitable optical, electrical, and / or mechanical measurement techniques. Based on the knowledge of the severity, it can then be determined whether the operator can repair the component supply device near the production line or whether the supply device has to be replaced, at least temporarily, with a new (pre-configured) component supply device. This can increase the overall achievable time during which the component supply device is fully available.

[0034] According to a further embodiment of the invention, the storage device has (a) at least one lower storage location and (b) at least one upper storage location for another component supply device. In the lower position of the positioning system (or linear drive), the exchange device can store the component supply device in the lower storage location or remove it from the lower storage location. In the upper position of the positioning system (or linear drive), the component supply device can be stored in the upper storage location or removed from the upper storage location.

[0035] The possibility of "stacking and storing" the component supply devices can increase the capacity of the storage device without increasing the space required for the component supply devices in the xy plane (formed by the x-axis and the y-axis).

[0036] Preferably, both planes, i.e., the lower plane having at least one lower storage location and the upper plane having at least one upper storage location, have two, three, or more storage locations. The alignment of the (elongated) component supply devices in the stored state is preferably performed parallel to the x-axis described above.

[0037] According to a further embodiment of the invention, the exchange device has at least (a) one first exchange mechanism for a first component supply device and (b) one second exchange mechanism for a second component supply device. This has the advantage that the component supply device can be exchanged particularly quickly. This is especially true when, before the device approaches the supply device exchange position, one exchange mechanism is occupied by the "new" component supply device and the other exchange mechanism is not occupied. That is, in this case, the exchange is carried out such that the unoccupied exchange mechanism removes the component supply device removed from the mounting machine, and immediately afterwards, the exchange device is translated slightly and repositioned so that the new component supply device can be attached to the relevant position of the mounting machine.

[0038] Preferably, each exchange mechanism has a dedicated drive for the linear movement of a gripper or a companion element for the relevant component supply device. The linear movement is carried out along the y-axis in the coordinate system used as an example for the description of the invention in this specification.

[0039] According to a further embodiment of the invention, the transport vehicle has wheels that enable the device to move along the floor surface in any direction. Such wheels are often also called omnidirectional wheels and advantageously enable the proper repositioning of the described device, particularly under spatially restricted conditions. Such repositioning can include linear movement of the device and / or rotation of the device.

[0040] According to a further embodiment of the invention, the device further has a first position sensor, which is attached (directly or indirectly) to the transport vehicle and is configured to detect the positioning of the device while the device is moving along the floor surface.

[0041] The first position sensor may be connected to a control device, which causes the transport vehicle to move spatially in a desired or predefined manner on the floor surface, so that the device can be positioned at a position where the replacement of the component supply device will be carried out reliably and with high precision. In this case, the sensor can detect at least one suitable line, possibly with interruptions, indicating each position on the floor surface. By a suitable evaluation of the position-sensitive sensor signals, a particularly accurate positioning of the transport vehicle can be achieved in a controlled manner. This positioning may preferably be accurate enough for the component supply device to be replaceable by the replacement device, the (old) supply device being removed from the centering structure and the (new) supply device being connectable to the mounting machine via the centering structure. The centering structure may be, for example, the omega profile described above.

[0042] According to a further embodiment of the invention, the device further has a second position sensor, which is (directly or indirectly) attached to the replacement device and is configured to detect the positioning of the replacement device during the replacement of the component supply device. The second position sensor can, for example, detect suitable markings on the mounting machine and thus, for example, enable the (new) component supply device to be attached to the mounting machine at an exact position. Here too, the position sensor may be connected to a control unit, which can ensure a proper, possibly controlled operation of the positioning system in response to the corresponding position signals. The position signal of the second position sensor can also ensure an optimal positioning of the transport vehicle and thus of the entire device.

[0043] According to a further embodiment of the invention, the device further has an energy storage device, which is firstly arranged on the transport vehicle, but secondly is also provided for operating the positioning system and / or the changing device. This has the advantage that for realizing the described device, only a normal (driverless) transport vehicle which necessarily already has an energy storage device is required for moving within the space, more precisely on the floor surface. A separate energy storage device is not required for the further operable parts of the described device.

[0044] In particular, the energy storage device may be a rechargeable accumulator or battery.

[0045] According to a further embodiment of the invention, the device further has a further energy storage device, which is likewise firstly arranged on the transport vehicle, but secondly is also provided for operating the positioning system and / or the changing device. Thereby, the reliability of the energy supply of the described device can be improved in an advantageous way.

[0046] In particular, one of the two or at least two energy storage devices can be used for operating other parts of the device while the other of the two or at least two energy storage devices is being charged. Thereby, an energy supply without any interruption can be ensured.

[0047] According to a further embodiment of the invention, the energy storage device and / or a further energy storage device has at least approximately the shape of a component supply device and an electrical interface such as a component supply device. This has the advantage that one or more energy storage devices can be easily accommodated in the storage device instead of the component supply device. Furthermore, an energy storage device configured as a rechargeable battery, which is (at least partially) discharged like a component supply device, can be temporarily attached to the mounting machine using an exchange device instead of the component supply device. As a result of the appropriate electrical interface, the energy storage device is charged (by the mounting machine) and then stored again in the storage device (by the exchange device), where it can take over the energy supply of the described device.

[0048] The above-described energy storage concept or rechargeable battery charging concept can advantageously guarantee an uninterrupted energy supply for operations of any length in principle. For this purpose, no additional handling devices such as robots are required.

[0049] According to a further embodiment of the invention, the device further has a belt cutting device, which is configured to cut one end of a component belt hanging out from the housing of the removed component supply device after the component supply device has been removed.

[0050] By means of the described belt cutting device, it can be prevented that the belt end hanging down in the previous operation of the removed component supply device causes problems during further handling of the removed supply device or another (new) component supply device. In particular, it can be prevented that the hanging belt end covers a centering element, which can make it difficult or impossible to properly reposition the exchange device for attaching the (new) component supply device.

[0051] In this context, the cuttable end of the component belt is the part of the component belt that is still not separated from the fixed belt cutting device of the implementation machine, and this part has reached the fixed belt cutting device and thus is still located in the so-called waste belt channel.

[0052] In some embodiments, the belt cutting device is located in the spatial area of the storage device. This makes it possible to realize the described device within a compact structure despite the presence of the belt cutting device.

[0053] According to a further embodiment of the present invention, the device further has a waste container for accommodating the cut end of the component belt. This has the advantage that the cut belt end is reliably discarded and the replacement of the component supply device is not hindered when the described device operates as determined. Thereby, a high reliability of the process is obtained.

[0054] In some embodiments, the waste container is also located in the spatial area of the storage device. This makes it possible to realize the described device within a compact structure despite the presence of the waste container.

[0055] According to a further embodiment of the present invention, the waste container is arranged below the belt cutting device such that the cut end of the component belt is moved into the waste container under the influence of gravity. This has the advantage that the disposal of the belt end can be reliably and easily realized.

[0056] As described above, both the belt cutting device and the waste container may be arranged in the spatial area or inside the storage device. In the embodiment where the storage device has at least one lower storage location and at least one upper storage location, also described above, the belt cutting device is preferably arranged "above the upper floor" of at least one upper storage location, and the waste container is preferably arranged "below the lower floor" of at least one lower storage location.

[0057] According to a further aspect of the present invention, a method for replacing a first component supply device of a mounting machine with a second component supply device using an apparatus of the type described above is described. The method described has the steps of: (a) picking up the second component supply device from a temporary storage for component supply devices; (b) transporting the second component supply device to an area where the first component supply device is located and is removably attached to the mounting machine; (c) removing the first component supply device; and (d) attaching the second component supply device to the mounting machine.

[0058] The method according to the present invention is based on the recognition that the apparatus according to the present invention can similarly automatically perform the replacement of the component supply device even when the space available on or adjacent to the mounting machine is relatively small.

[0059] According to one embodiment of the present invention, the method further has, after attaching the second component supply device to the mounting machine, the step of: (e) transporting the first component supply device to a temporary storage for component supply devices or a further temporary storage.

[0060] After the above-described transport of the first component supply device, which may also be referred to as the removal of the first component supply device, the apparatus according to the present invention for replacing the component supply device advantageously becomes reusable, whereby a fourth component supply device is picked up (from the temporary storage) and then replaced with a third component supply device (or the second component supply device) still attached to the mounting machine. That is, the apparatus according to the present invention can be used quasi-continuously to replace the component supply devices of one or more mounting machines. In this case, the replacement can be carried out within the scope of a so-called setup change when, after a first electronic assembly has been manufactured, a second electronic assembly requiring different electronic components is manufactured. Within the scope of such a setup change, generally, a plurality of component supply devices are replaced (simultaneously). It goes without saying that a replacement can also be carried out when components are brought into the first component supply device and further components (of the same type) have to be provided for a further mounting process by the second component supply device.

[0061] According to a further embodiment of the present invention, the temporary storage is located within or on the mounting machine, below and / or above the mounting plane of the mounting machine. This has the advantage that it is possible to temporarily store the "new" and / or "old" component supply devices in the spatial vicinity of the replacement location, thereby keeping the travel distance of the device according to the present invention short. Thus, the replacement of the component supply device can be carried out very quickly. This is a great advantage especially during setup changes where a plurality of component supply devices have to be replaced (as simultaneously as possible). Thus, the downtime of the entire mounting machine or production line due to setup changes can be significantly reduced. A further advantage of the described arrangement of placing the temporary storage below and / or above the mounting plane is that the space required for the entire electronic device production line within the factory building can be advantageously reduced.

[0062] In connection with the described invention, the concept of the mounting plane is understood to be the plane in which the component carrier to be mounted is located during its mounting.

[0063] It should be noted that the embodiments of the present invention have been described with respect to various inventive subjects. In particular, some embodiments of the present invention are described in apparatus claims and other embodiments of the present invention are described in method claims. However, it will immediately become apparent to those skilled in the art that, upon reading this specification, any combination of features belonging to different types of objects of the present invention is possible in addition to combinations of features belonging to one type of object of the present invention, unless explicitly stated otherwise.

[0064] Further advantages and features of the present invention will be apparent from the following exemplary description of the preferred embodiments.

Brief Description of the Drawings

[0065]

Figure 1

Figure 2

Figure 3

[0066] In the following detailed description, features or components of various embodiments that are the same as or at least functionally the same as corresponding features or components of another embodiment are either given the same reference numerals or reference numerals with the same last two digits as the reference numerals of the corresponding same or at least functionally the same features or components. Note that in order to avoid unnecessary repetition, features or components that have already been described with reference to the above-described embodiments will not be described in detail below.

[0067] Furthermore, it should be noted that the embodiments described below are only a limited selection of variations of possible embodiments of the present invention. In particular, since the features of individual embodiments can be combined with each other in an appropriate manner, a number of different embodiments are considered to be clearly disclosed to those skilled in the art together with variations of the embodiments explicitly shown herein.

[0068] FIG. 1 schematically shows an apparatus 100 for replacing a component supply apparatus located in an intermediate region between two production lines FL1 and FL2 for manufacturing an electronic assembly.

[0069] According to the embodiment shown in this figure, the two production lines FL1 and FL2 each include a soldering paste printing device 195, and the soldering paste printing device 195 applies soldering paste to the component connection pads of the component carrier in a known manner. The component carrier BET with the soldering paste printed thereon is also transported to the mounting machine BA using a transport device 194 configured as a conveyor belt in a known manner. According to the embodiment shown in this figure, each production line FL1, FL2 has exactly four mounting machines BA installed continuously along the transport direction of the transport device 194. Depending on the respective mounting content, different types of components are placed on their respective component carriers BET using different mounting machines BA. As is clear from the xy coordinate system inserted in FIG. 1, according to the embodiment shown in this figure, the transport direction extends along the x-axis.

[0070] For the sake of clarity, FIG. 1 shows a so-called single transport device 194, and the transport device 194 has exactly one conveyor belt that can be used to transport the component carrier BET along the transport direction on a single transport track. However, in reality, according to the embodiment shown in this figure, the transport device 194 is a double transport device, and the transport device 194 has two parallel conveyor belts, and each conveyor belt has a transport track for the component carrier BET to be mounted or already at least partially mounted. The components for mounting the component carrier transported on the transport track on the left side of the transport direction are supplied to a mounting head (not shown) by a component supply device 185a shown above each mounting machine BA in FIG. 1. The components for mounting the component carrier transported on the transport track on the right side of the transport direction are supplied by a component supply device 185b shown below each mounting machine BA in FIG. 1.

[0071] Downstream of the mounting machine BA, a so-called reflow oven 197 is positioned along the conveying direction. The reflow oven 197 melts the soldering paste located between the component connection pads and the electrical contacts of the components to be mounted in a known manner. After cooling, the soldering paste hardens, thereby forming a strong electrical and mechanical connection between the components to be mounted and the component carrier on which they are mounted.

[0072] As is apparent from FIG. 1, two guide lines 192 are provided on the floor surface 193 between the two production lines FL1 and FL2. According to the embodiment shown in this figure, the guide lines 192 are simply drawn on the floor surface 193. The guide lines 192 are used by the sensor system of a device 100 (not shown) to move in a spatially accurate manner in the intermediate region between the two production lines FL1 and FL2. According to the embodiment shown in this figure, one of the two guide lines 192 is a broken line or interrupted at a predetermined position. Thereby, the above-described sensor system can accurately recognize at which position it is currently located along these broken lines or interrupted guide lines 192. Absolute position detection can be achieved by recognizing distinct markings within or on the guide lines 192 and / or by counting the number of interruption structures of at least one of the guide lines 192. As is apparent from FIG. 1, the two guide lines 192 also extend parallel to the x-axis.

[0073] As will become apparent from the more detailed description of the following device 100, the device 100 can perform both (i) the replacement of the component supply device located on the left side of the guide line 192 when viewed along the positive x-direction and (ii) the replacement of the component supply device located on the right side of the guide line 192 when viewed along the positive x-direction.

[0074] FIG. 2 is a perspective view schematically showing the device 100 for replacing the component supply device according to an embodiment of the present invention.

[0075] Device 100 has a transport vehicle 210. The transport vehicle 210 may be an automated guided vehicle (AGV) already known per se, or may be the chassis of an autonomous mobile robot (AMR). As described above, an AGV is a transport vehicle spatially guided by a physical or virtual line (formed on the floor surface). Also as described above, an AMR is a robot that can move freely in space. An AMR is capable of recognizing its own position based on the learned environment and does not require additional equipment for normal movement.

[0076] As is apparent from FIG. 2, the transport vehicle 210 has a plurality of wheels 212. For clarity, only two of the four wheels 212 in total are recognized or illustrated. According to the embodiment shown in this figure, the wheels 212 are so-called omnidirectional wheels 212, which have, in addition to the rotation axes of normal wheels, rotation axes (not shown respectively), whereby the wheels 212 can turn around the vertical z direction (refer to the inserted xyz coordinate system). This turning is shown in FIG. 2 by the two curved double arrows marked under the two wheels 212. The omnidirectional wheels 212 enable both linear movement along any direction of the device on the floor surface in a narrow space and rotation of the device. The main movement direction of the transport vehicle 210 or the entire device 100 along the guide line 192 extending parallel to the x-axis (only the solid guide line is shown in FIG. 2 for clarity) is indicated by the double arrow 212a in FIG. 2.

[0077] According to the embodiment shown in this figure, the current position of the transport vehicle 210 is determined by a first position sensor 214 and an evaluation and control unit (not shown) connected downstream of the first position sensor 214. For this purpose, the first position sensor 214 detects the (interrupted) structure or course of the guide line 192. The guide line 192 can be used to limit the degrees of freedom of the transport vehicle 210. Thereby, the transport vehicle 210, and thus the entire apparatus 100, can be positioned more quickly and accurately on the floor surface. Furthermore, due to the appropriate spatial position of the guide line 192, the transport vehicle can move safely even when the distance from the production line or the mounting machine is minimized. Thereby, the space required for a production line enabling automatic replacement of the component supply device 285 is reduced.

[0078] Furthermore, two safety sensors 216 are attached to the transport vehicle 210, and the safety sensors 216 output a signal to an evaluation and control unit (not shown), for example, when the transport vehicle 210 moves toward an obstacle and thus a collision is feared. In response to such a safety-related signal, the evaluation and control unit (not shown) can stop the movement of the transport vehicle 210.

[0079] The apparatus 100 further includes a handling device 220 for the component supply device 285. The handling device 220 includes a positioning system 230 and an exchange device 240. According to the embodiment shown in this figure, the positioning system 230 includes a fixed positioning component 232 and a movable positioning component 234. As is apparent from FIG. 2, the fixed positioning component 232 is attached to the transport vehicle 210. The movable positioning component 234 can be positioned relative to the fixed positioning component 232 via exactly one linear drive unit and exactly one rotational drive unit. In FIG. 2, the linear drive unit is schematically indicated by the double arrow 238. The rotational drive unit is schematically indicated in FIG. 2 by the curved double arrow 236. That is, the positioning system 230 enables, on the one hand, the vertical movement of the exchange device 240 along the axis S and, on the other hand, the rotational movement of the exchange device 240 around the axis S. The axis S is parallel to the z-axis of the inserted xyz coordinate system.

[0080] The exchange device 240 has a mechanism (not shown) that can grip the component supply device 285 and move it along a linear exchange direction 240a. This enables the component supply device 285, which is detachably attached to a mounting machine (not shown in FIG. 2), to be gripped, removed from the mounting machine, and transported to the apparatus 100. Similarly, this mechanism can be used to transport the component supply device 285 from the apparatus to the mounting machine and detachably attach it to the mounting machine. As is apparent from FIG. 2, the exchange device 240 has a total of three such mechanisms. Therefore, the exchange device 240 can handle a total of three component supply devices 285. However, in this context, it is clear that, in order to remove the component supply device 285, at least one of the three mechanisms (contrary to the depiction in FIG. 2) must not be occupied by the component supply device 285.

[0081] For the exact positioning of the exchange device 240, a second position sensor 242 is attached to the exchange device 240 or the movable positioning part 234 in the vertical direction using the linear drive unit 238 and in the horizontal direction using the chassis of the transport vehicle 210. As described above, the second position sensor 242 is capable of detecting appropriate markings on the mounting machine, thereby ensuring that the (new) component supply device 285 is attached to the mounting machine at the exact position. The second position sensor 242 may be connected to an appropriate control unit, for example, the above-described evaluation and control unit, and the control unit ensures the proper and possibly controlled operation of the positioning system 230 and / or the optimal positioning of the transport vehicle 210 on the floor surface according to the corresponding position signals.

[0082] According to the embodiment shown in this figure, the device further comprises a storage device 250. The storage device 250 is used to temporarily accommodate at least one component supply device 285. In this context, the entire exchange device 240 or handling device 220 is configured to take out at least one of the plurality of supply devices 285 from the storage device 250 or store it in the storage device 250. With the storage device 250, the device 100 can perform a plurality of exchange procedures of the supply device 285 without the device 100 moving to a supply device 285 (temporary storage) preconfigured with an appropriate component belt. This advantageously shortens the travel distance and can accelerate the replacement of the component supply device 285.

[0083] As is apparent from FIG. 2, according to the embodiment shown in this figure, when the exchange device 240 is in an angular position rotated approximately 90° with respect to the angular position shown in FIG. 2, the exchange device 240 can perform the storage of the component supply device 285 in the storage device 250 and the retrieval from the storage device 250.

[0084] According to the embodiment shown in this figure, the apparatus 100 further has a diagnostic device 255 attached within or on the storage device 250. The diagnostic device 255 is configured to detect defects of the component supply device 285 and, if necessary, classify which supply device 285 is currently stored in the storage device.

[0085] According to the embodiment shown in this figure, the diagnostic device 255 has appropriate optical, electrical and / or mechanical measurement techniques, by which the severity of the defect of the supply device 285 can be determined. As described above, based on the knowledge of the severity, the operator can determine whether the component supply device 285 can be repaired near the production line or whether the supply device 285 has to be replaced, at least temporarily, with a new (pre-configured) component supply device 285.

[0086] Furthermore, the apparatus 100 also has an energy storage device 260 configured as a storage battery. According to the embodiment shown in this figure, the energy storage device 260 has the outer shape of the component supply device and can be electrically connected to the mounting machine and mechanically attached by the handling device for charging. The energy storage device is first arranged on the transport vehicle 210, but secondarily provided for operating the positioning system 230 and the exchange device 240.

[0087] It is also possible to provide a corresponding additional energy storage device (not shown), and it should be noted that the additional energy storage device preferably also has the shape of the component supply device. These two energy storage devices can be used alternately for the energy supply of the apparatus 100. In this case, alternately, one of the two energy storage devices can be charged by the mounting machine and the other of the two energy storage devices can be used for the energy supply of the apparatus 100.

[0088] According to the embodiment shown in this figure, the apparatus 100 further has a belt cutting device 270 schematically shown in FIG. 2. The belt cutting device 270 is configured to cut the end of the component belt hanging from the housing of the removed component supply device 285 after the removal of the component supply device 285. Thereby, as described above, it can be prevented that the end of the belt hanging down in the previous operation of the removed component supply device 285 causes problems during further handling of the removed component supply device 285 or another (new) component supply device 285. In addition, according to the embodiment described herein, the apparatus 100 further has a waste container 275 for accommodating the cut end of the component belt. As is apparent from FIG. 2, the waste container 275 is disposed directly below the belt cutting device 270. Thereby, the end of the cut component belt directly falls into the waste container 275 under the influence of gravity.

[0089] In the following, a method for replacing a plurality of component supply devices will be described based on individual steps 1 to 13 without referring to the drawings.

[0090] 1. In a first step, the apparatus 100 moves to a temporary storage for the entire production line. In this temporary storage, there are a plurality of component supply devices 285 preconfigured with component belts or new ones. The temporary storage for the entire production line is preferably located next to the first mounting machine of the production line. 2. Next, the replacement device 240 picks up a new preconfigured component supply device 285 from the temporary storage and transports it to the storage device 250. 3. Next, the apparatus 100 moves to a mounting machine where at least one component supply device 285 is to be replaced. 4. The apparatus 100 stops at the mounting machine. At this time, the above-described position sensor system including the first position sensor 214 interlocked with the guide line 192 ensures a spatially precisely defined stop position. This stop position exactly corresponds to the position where the old component supply device 285 to be replaced is located. 5. The exchange device 240 removes a new component supply device 285 from the storage device 250. 6. Next, the exchange device 240 docks to the mounting machine at the position of the component supply device 285 to be replaced. 7. The exchange device 240 is rotated 90° using the rotational drive unit 236. 8. The old supply device 285 with at least partially empty components is removed from the exchange device 240. 9. The new supply device 285 is attached to the said position of the mounting machine. 10. The exchange device 240 is disconnected from the mounting machine. 11. The exchange device 240 is rotated 90° (so as to return) using the rotational drive unit 236. 12. The old supply device 285 is conveyed from the exchange device 240 to the storage device 250. 13. The device 100 moves to the next mounting machine where the component supply device 285 is to be exchanged. If the storage device 250 no longer contains a new component supply device 285, the device moves to the above-mentioned temporary storage location of the entire production line and exchanges the old component supply device 285 with a new component supply device 285.

[0091] To save time, the transfer of the component supply device 285 between the storage device 250 and the exchange device 240 can also be performed during the movement of the device 100.

[0092] FIG. 3 shows a method for setup change in a mounting machine of a production line using the device described herein for exchanging a component supply device. According to the embodiment shown in this figure, a temporary storage location for the component supply device is used, and the said temporary storage location is located in the lower area of each mounting machine.

[0093] As is apparent from FIG. 3, the production line has a total of three mounting machines arranged in series along a conveying device (not shown), and the mounting machines are labeled with reference numerals BA1, BA2, and BA3. At the front end (or rear end) of the three mounting machines BA1, BA2, and BA3, there is a production line temporary storage FLZL where a plurality of component supply devices can be (temporarily) stored. Each of the mounting machines BA1, BA2, and BA3 has a local temporary storage below its mounting plane, which is called a mounting machine temporary storage and is labeled with reference numerals BAZL1, BAZL2, and BAZL3.

[0094] The various stages of setup changes for all three mounting machines BA1, BA2, and BA3 are described below.

[0095] Step 1: The three mounting machines operate with the "old set" of component supply devices, which are attached to the mounting machines in a known manner so that the component supply devices can grip or pick up components by a mounting head (not shown). The "new set" of pre-configured new supply devices is located in the production line temporary storage FLZL or is stored in the production line temporary storage FLZL by the device 100 described in this specification.

[0096] Step 2: The device 100 is located in the production line temporary storage FLZL or moves to the production line temporary storage FLZL. In the production line temporary storage FLZL, the device takes out the entire new set of component supply devices and transports them to the three mounting machine temporary storages BAZL1, BAZL2, and BAZL3. It should be noted that, contrary to the depiction in FIG. 3, the number of component supply devices shown in the production line temporary storage FLZL is not equal to the total of the component supply devices of the three mounting machine temporary storages BAZL1, BAZL2, and BAZL3.

[0097] Step 3: The apparatus 100 moves to the mounting machine temporary storage BAZL1 of the first mounting machine BA1. At the mounting machine temporary storage BAZL1, the apparatus 100 takes out the set of old component supply devices, moves to the production line temporary storage FLZL, and stores it in the production line temporary storage FLZL. Thereafter, the apparatus returns to the first mounting machine BA1 and attaches the corresponding new component supply device to the mounting plane of the mounting machine BA1 so that the mounting head for picking up the supplied components can be used in a known manner. Next, the apparatus moves to the mounting machine BA2 and picks up the set of old component supply devices at the mounting machine BA2 in one or more steps (in its storage device), returns to the first mounting machine BA1 in each case, and stores the old component supply device of the second mounting machine BA2 in the mounting machine temporary storage BAZL1. Thereafter, the apparatus returns to the second mounting machine BA2 and moves the corresponding new component supply device upward from the mounting machine temporary storage BAZL2 to the mounting plane of the second mounting machine BA2. Thereafter, the set of old component supply devices of the third mounting machine is stored in the mounting machine temporary storage BAZL2 in a corresponding manner, and the component supply device provided for the third mounting machine BA3 is lifted upward and attached to the third mounting machine BA3 in a suitable manner.

[0098] Step 4: The apparatus 100 sequentially moves the component supply devices located in the two mounting machine temporary storages BAZL1 and BAZL2 to the production line temporary storage FLZL.

[0099] Step 5: The component supply devices present in the production line temporary storage FLZL are taken out from the production line temporary storage FLZL and conveyed to a (central) storage not shown. This can similarly be done automatically using the apparatus 100 or manually. Thereby, the production line temporary storage FLZL is brought into a state where it can accommodate another new set of component supply devices.

[0100] It should be noted that the concept of "having" does not exclude other elements, and "one" does not exclude a plurality. Also, elements described in connection with different embodiments may be combined. It should also be noted that the reference signs in the claims should not be construed as limiting the scope of protection of the claims.

Explanation of Signs

[0101] 100 Device for replacing the component supply device 185a Component supply device for the component carrier on the left transfer track 185b Component supply device for the component carrier on the right transfer track 192 Guide line 193 Floor surface 194 Conveying device 195 Solder paste printing device 197 Reflow oven BA Mounting machine BET Component carrier FL1 First production line FL2 Second production line 210 Conveying vehicle 212 Wheels 212a Main traveling direction 214 First position sensor 216 Safety sensor 220 Handling device 230 Positioning system 232 Fixed positioning component 234 Movable positioning component 236 Rotation drive unit 238 Linear drive unit 240 Exchange device 240a Linear exchange direction 242 Second position sensor 250 Storage device 255 Diagnostic device 260 Energy storage device / battery 270 Belt cutting device 275 Waste container 285 Component supply device FLZL Production Line Temporary Storage BA# Mounting Machine (# = 1, 2, 3) BAZL# Mounting Machine Temporary Storage (# = 1, 2, 3)

Claims

1. An apparatus (100) for replacing a component supply device (285) in a mounting machine (BA1, BA2, BA3), the apparatus (100) comprising: A transport vehicle (210) configured to move autonomously on a floor surface (193); A positioning system (230) having a fixed positioning component (232) attached to a fixed position of the transport vehicle (210) and a positioning component (234) movable relative to the fixed positioning component (232); An exchange device (240) attached to the movable positioning component (234) and configured to removably attach or remove the component supply device (285) to / from the mounting machine (BA1, BA2, BA3) along a linear exchange direction (240a) parallel to the y-axis; and The positioning system (230) is configured such that the movable positioning component (234) is rotatable about a vertical z-axis (S) relative to the fixed positioning component (232) and linearly displaceable along the vertical z-axis (S). Apparatus (100).

2. The positioning system (230) comprising: A rotation drive unit (236) for rotating the movable positioning component (234) relative to the fixed positioning component (232); A linear drive unit (238) for displacing the movable positioning component (234) relative to the fixed positioning component (232); The apparatus (100) according to claim 1.

3. The rotation drive unit (236) and the linear drive unit (238) are a single drive unit of the positioning system (230). The apparatus (100) according to claim 2.

4. The rotation drive unit (236) is configured to rotate the exchange device (240) within a rotation angle range of at least ±90° with respect to the x-axis, and the x-axis is perpendicular to both the y-axis and the vertical z-axis (S). The apparatus (100) according to claim 2.

5. Further comprising a storage device (250) for temporarily storing at least one component supply device (285), The exchange device (240) is configured to take out at least one of the component supply devices (285) from the storage device (250) and store at least one of the component supply devices (285) in the storage device (250). The apparatus (100) according to claim 1.

6. The apparatus (100) according to claim 5, further comprising a diagnostic device (255), the diagnostic device being configured to classify defects of a component supply device (285) stored in a storage device (250) or picked up by an exchange device (240).

7. The storage device has (a) at least one lower storage location, and (b) at least one upper storage location for another component supply device, and the exchange device can store the component supply device in the lower storage location or take it out from the lower storage location at a lower position of the positioning system, and store the component supply device in the upper storage location or take it out from the upper storage location at an upper position of the positioning system (or linear drive unit). The apparatus (100) according to claim 5.

8. The exchange device (240) has (a) at least one first exchange mechanism for a first component supply device (285), and (b) at least one second exchange mechanism for a second component supply device (285). The apparatus (100) according to claim 1.

9. The transport vehicle (210) has wheels (212), and the wheels enable the apparatus (100) to move along any direction on the floor surface (193). The apparatus (100) according to claim 1.

10. The apparatus (100) according to claim 1, further comprising a first position sensor (214), the first position sensor being attached to the transport vehicle (210) and configured to detect the positioning of the apparatus (100) while the apparatus (100) is moving on the floor surface (193).

11. The apparatus (100) according to claim 1, further comprising a second position sensor (242), the second position sensor being attached to the exchange device (240) and configured to detect the positioning of the exchange device (240) while the component supply device (285) is being exchanged.

12. The apparatus (100) according to claim 1, further comprising an energy storage device (260), the energy storage device being first disposed on the transport vehicle (210) and second provided for operating the positioning system (230) and / or the exchange device (240).

13. It further has an additional energy storage device, and the additional energy storage device is similarly first disposed on the transport vehicle (210), and second, it is also provided for operating the positioning system and / or the replacement device. The device (100) according to claim 12.

14. The energy storage device (260) and / or the additional energy storage device has at least substantially the shape of the component supply device (285) and an electrical interface like the component supply device (285). The device (100) according to claim 12.

15. It further has a belt cutting device (270), and the belt cutting device is configured to cut one end of the component belt that hangs outside the housing of the removed component supply device (285) after the component supply device (285) is removed. The device (100) according to claim 1.

16. It further has a waste container (275) for accommodating the cut end of the component belt. The device (100) according to claim 15.

17. The waste container (275) is disposed below the belt cutting device (270) such that the cut end of the component belt is moved into the waste container (275) under the influence of gravity. The device (100) according to claim 16.

18. A method for replacing the first component supply device (285) of the mounting machine (BA1, BA2, BA3) with the second component supply device (285) using the device (100) according to any one of claims 1 to 17, The step of picking up the second component supply device (285) from a temporary storage location (FLZL; BAZL1, BAZL2, BAZL3) for the component supply device (285); The step of transporting the second component supply device (285) to the area where the first component supply device (285) is located and is detachably attached to the mounting machine (BA1, BA2, BA3); The step of removing the first component supply device (285); and The step of attaching the second component supply device (285) to the mounting machine (BA1, BA2, BA3). The method having these steps.

19. Furthermore, after attaching the second component supply device (285) to the mounting machine (BA1, BA2, BA3), The method according to claim 18, having a step of transporting the first component supply device (285) to the temporary storage (FLZL; BAZL1, BAZL2, BAZL3) for the component supply device (285) or a further temporary storage (FLZL; BAZL1, BAZL2, BAZL3).

20. The method according to claim 18, wherein the temporary storage (BAZL1, BAZL2, BAZL3) within or on the mounting machine (BA1, BA2, BA3) is located below and / or above the mounting plane of the mounting machine (BA1, BA2, BA3).

Images