Component mounting device and component mounting method

Abstract

The present invention provides a tape feeder and inspection jig that allow for easy inspection of whether the carrier tape detection unit is functioning correctly. [Solution] The component mounting device includes a tape transport unit that transports a carrier tape along a tape transport path, a peeling unit that peels a cover tape from a base tape, a tape feeder that supplies components contained on the carrier tape to a component removal position downstream of the peeling unit, a camera that images the carrier tape, including at least the base tape, at the component removal position, and a control unit that determines whether or not the cover tape has been peeled from the base tape based on the image captured by the camera. If the control unit determines that the cover tape has not been peeled from the base tape, it drives the tape transport unit to transport the carrier tape upstream, causing the peeling unit to peel the cover tape from the base tape again.

Description

Technical Field

[0001] The present disclosure relates to a component mounting device that conveys a carrier tape by a tape feeder and mounts components supplied to a component supply position on a substrate, and a component mounting method.

Background Art

[0002] Conventionally, as a component supply device used in a component mounting device, a tape feeder that conveys a carrier tape storing components and supplies the components to a predetermined component supply port is known. The carrier tape includes a base tape that stores components and a cover tape that covers the base tape and the stored components. The tape feeder peels the cover tape from the base tape inside and conveys the base tape to the component supply port with the components exposed.

[0003] In recent years, there is a tape feeder that automatically peels the cover tape and supplies components to the component supply port only by setting the carrier tape in the insertion part of the tape feeder. For example, the tape feeder of Patent Document 1 guides the cover tape to a peeling part inside the tape feeder and peels the cover tape from the base tape by the peeling part.

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0005] Incidentally, in such tape feeders, there are cases where the cover tape fails to be guided to the peeling section, and the cover tape is transported to the component supply position still attached to the base tape without peeling off. In this case, since the component is covered by the cover tape, the mounting head cannot pick up the component, and an error occurs.

[0006] This error requires the worker to completely remove the carrier tape from the tape feeder and then reinsert it, which reduces work efficiency.

[0007] This disclosure aims to provide a component mounting device and a component mounting method that improve work efficiency. [Means for solving the problem]

[0008] The component mounting apparatus of this disclosure mounts components onto a substrate from a carrier tape having a base tape with pockets for accommodating components and a cover tape attached to the upper surface of the base tape. The component mounting apparatus includes a tape transport unit that transports the carrier tape along a tape transport path, a peeling unit that peels the cover tape from the base tape, a tape feeder that supplies components contained on the carrier tape to a component removal position downstream of the peeling unit, a camera that images the carrier tape, including at least the base tape, at the component removal position, and a control unit that determines whether or not the cover tape has been peeled from the base tape based on the image captured by the camera. If the control unit determines that the cover tape has not been peeled from the base tape, it drives the tape transport unit to transport the carrier tape upstream and peels the cover tape from the base tape again at the peeling unit.

[0009] The component mounting method of this disclosure is a component mounting method for mounting components onto a substrate from a carrier tape having a base tape having pockets for accommodating components and a cover tape attached to the upper surface of the base tape. In the component mounting method, a tape transport unit transports the carrier tape along a tape transport path, and a peeling unit peels the cover tape from the base tape, thereby supplying the components accommodating the carrier tape to a component removal position downstream of the peeling unit. A camera images the carrier tape, including at least the base tape, at the component removal position, and a control unit determines whether or not the cover tape has been peeled from the base tape based on the image captured by the camera. If the control unit determines that the cover tape has not been peeled from the base tape, it drives the tape transport unit to transport the carrier tape upstream, causing the peeling unit to peel the cover tape from the base tape again. [Effects of the Invention]

[0010] This disclosure provides a component mounting device and a component mounting method that improve work efficiency. [Brief explanation of the drawing]

[0011] [Figure 1] Side view of the main part of a component mounting system equipped with a component mounting device in Embodiment 1 [Figure 2] Plan view of the parts supply section of the parts mounting device. [Figure 3] Perspective view of the carrier tape [Figure 4] Perspective view of the tape feeder handle [Figure 5] Diagram showing the configuration of a tape feeder [Figure 6A] Side view showing one step of peeling off the cover tape at the peeling section. [Figure 6B] Side view showing one step of peeling off the cover tape at the peeling section. [Figure 7A] Side view showing one step of peeling off the cover tape at the peeling section. [Figure 7B] Side view showing one step of peeling off the cover tape at the peeling section. [Figure 8] Block diagram showing an example of the functional configuration of a tape feeder [Figure 9A] Diagram for explaining the conveyance of the carrier tape within the tape feeder [Figure 9B] Diagram for explaining the conveyance of the carrier tape within the tape feeder [Figure 10A] Diagram for explaining the conveyance of the carrier tape within the tape feeder [Figure 10B] Diagram for explaining the conveyance of the carrier tape within the tape feeder [Figure 11A] Diagram for explaining the conveyance of the carrier tape within the tape feeder [Figure 11B] Diagram for explaining the conveyance of the carrier tape within the tape feeder [Figure 12] Explanatory diagram showing the state where the carrier tape is positioned at the component extraction position [Figure 13] Explanatory diagram showing an imaging image of an embossed carrier tape with the cover tape peeled off [Figure 14] Explanatory diagram showing an imaging image of an embossed carrier tape including the cover tape [Figure 15] Explanatory diagram showing an imaging image of a paper carrier tape with the cover tape peeled off [Figure 16] Explanatory diagram showing an imaging image of a paper carrier tape including the cover tape [Figure 17] Explanatory diagram showing an imaging image obtained by increasing the amount of light irradiated on a paper carrier tape with the cover tape peeled off [Figure 18] Explanatory diagram showing an imaging image obtained by increasing the amount of light irradiated on a paper carrier tape including the cover tape [Figure 19] Flowchart showing the process up to component adsorption of the component mounting device in Embodiment 1 [Figure 20] Flowchart showing the process of checking and re-peeling the cover tape of the component mounting device [Figure 21] Flowchart showing the process up to component mounting of the component mounting device in Embodiment 2 [Modes for carrying out the invention]

[0012] A component mounting device according to a first aspect of the present disclosure mounts components onto a substrate from a carrier tape having a base tape with pockets for accommodating components and a cover tape attached to the upper surface of the base tape. The component mounting device includes a tape transport unit that transports the carrier tape along a tape transport path, a peeling unit that peels the cover tape from the base tape, a tape feeder that supplies components contained on the carrier tape to a component removal position downstream of the peeling unit, a camera that images the carrier tape, including at least the base tape, at the component removal position, and a control unit that determines whether or not the cover tape has been peeled from the base tape based on the image captured by the camera. If the control unit determines that the cover tape has not been peeled from the base tape, it drives the tape transport unit to transport the carrier tape upstream, causing the peeling unit to peel the cover tape from the base tape again.

[0013] The component loading device determines whether the cover tape has been detached from the base tape. If the cover tape has not been detached, it transports the carrier tape upstream and performs the detachment operation again at the detachment section. This reduces the frequency with which the operator has to completely remove the carrier tape from the tape feeder and then re-set it. Therefore, it is possible to provide a component loading device with improved work efficiency.

[0014] According to a second aspect of this disclosure, in the component mounting device of the first aspect, the control unit determines whether or not the cover tape has been peeled off the base tape based on the brightness information of the captured image. This makes it possible to accurately determine whether or not the cover tape has been peeled off the base tape.

[0015] According to a third aspect of this disclosure, in the component mounting device of the second aspect, the control unit determines, as luminance information, that the cover tape has been peeled off the base tape if the median luminance of a predetermined area of ​​the image is less than or equal to a predetermined threshold, and determines that the cover tape has not been peeled off the base tape if the median luminance of a predetermined area of ​​the image is greater than a predetermined threshold. This makes it possible to determine with greater accuracy whether or not the cover tape has been peeled off the base tape.

[0016] According to a fourth aspect of this disclosure, in the component mounting device of the second aspect, the control unit determines, as luminance information, that the cover tape has been peeled off the base tape if the luminance distribution of a predetermined area of ​​the image is within a predetermined range, and determines that the cover tape has not been peeled off the base tape if the luminance distribution of a predetermined area of ​​the image is outside the predetermined range. This makes it possible to accurately determine whether or not the cover tape has been peeled off the base tape.

[0017] According to a fifth aspect of this disclosure, in any one of the component mounting devices of the first to fourth aspects, the camera is equipped with a light illumination unit that illuminates the base tape with light when imaging the base tape. This increases the amount of light reflected from the cover tape when the cover tape is attached to the base tape, thereby making the difference between the brightness information when the cover tape is attached to the base tape and the brightness information when it is not attached more pronounced.

[0018] According to the sixth aspect of this disclosure, in any one of the component mounting devices of the first to fifth aspects, the carrier tape is an embossed carrier tape, the base tape is made of resin, and the cover tape is a transparent tape made of resin.

[0019] According to a seventh aspect of this disclosure, in the component mounting device of the sixth aspect, the base tape has a sheet portion and a recessed pocket from the sheet portion, and the control unit determines whether or not the cover tape has been peeled off the base tape based on the brightness information of the area in the sheet portion. This makes it possible to determine with greater accuracy whether or not the cover tape has been peeled off the base tape.

[0020] According to the eighth aspect of this disclosure, in any one of the component mounting devices of the first to fifth aspects, the carrier tape is a paper carrier tape, the base tape is made of paper, and the cover tape is a transparent tape made of resin.

[0021] According to the ninth aspect of this disclosure, in the component mounting device of the eighth aspect, the base tape has a sheet portion and a pocket recessed from the sheet portion, and the control unit determines whether or not the cover tape has been peeled off the base tape based on the brightness information of the area in the pocket. This makes it possible to determine with greater accuracy whether or not the cover tape has been peeled off the base tape.

[0022] According to the tenth aspect of this disclosure, in any one of the component mounting devices of the first to ninth aspects, a counter is provided for counting the number of times the carrier tape is transported from the component removal position toward the peeling section, the peeling section has an air nozzle for blowing air onto the leading edge of the cover tape, and the control unit adjusts the amount of air ejected according to the counter count. As a result, the amount of air ejected can be increased as the number of peeling operations in the peeling section increases, making it easier to peel off the cover tape.

[0023] An eleventh aspect of the present disclosure is a component mounting method for mounting components onto a substrate from a carrier tape having a base tape having pockets for accommodating components and a cover tape attached to the upper surface of the base tape. In the component mounting method, a tape transport unit transports the carrier tape along a tape transport path, and a peeling unit peels the cover tape from the base tape, so that the tape feeder supplies the components contained in the carrier tape to a component removal position downstream of the peeling unit, a camera images the carrier tape including at least the base tape at the component removal position, and a control unit determines whether or not the cover tape has been peeled from the base tape based on the image captured by the camera. If the control unit determines that the cover tape has not been peeled from the base tape, it drives the tape transport unit to transport the carrier tape upstream, and the peeling unit peels the cover tape from the base tape again.

[0024] Hereinafter, exemplary embodiments of the component mounting device and component mounting method relating to this disclosure will be described with reference to the attached drawings. This disclosure is not limited to the specific configurations of the embodiments described below, but includes configurations based on similar technical ideas.

[0025] (Embodiment 1) First, the component mounting system 100 and component mounting device 1 of Embodiment 1 of this disclosure will be described with reference to Figure 1. Figure 1 is a simplified side view of the main parts of the component mounting system 100, which includes the component mounting device 1.

[0026] The component mounting system 100 is a system for manufacturing a mounted circuit board by mounting components 5 onto a circuit board 4. The component mounting system 100 comprises a component mounting device 1, a management device 92, and a portable information terminal 95.

[0027] The component mounting device 1 is a device that repeatedly performs a series of component mounting operations, which involves mounting components 5 onto a substrate 4 brought in from other devices in the upstream process and then transporting the substrate to other devices in the downstream process. The component mounting device 1 comprises a main body 2 and a component supply unit 3.

[0028] In Figure 1, the main unit 2 comprises a base 11, a substrate transport unit 12, a mounting head 13, a head movement mechanism 14, a power supply unit 15, an operation unit 16, and a main unit control unit 17. The substrate transport unit 12 is equipped with a conveyor mechanism and transports the substrate 4 received from the upstream process equipment horizontally to position it at a predetermined work position. In this embodiment, the transport direction of the substrate 4 in the component mounting device 1 is the X direction (lateral direction), and the vertical direction is the Z direction. The direction perpendicular to both the X and Z directions is the Y direction (front-back direction). The operation unit 16 is installed on the side of the main unit 2. The operation unit 16 has a touch screen 16a on its surface, which displays information necessary for operating the component mounting device 1, as well as operation buttons, etc.

[0029] In Figure 1, the mounting head 13 picks up the component 5 supplied to the component removal position 23ba (see Figure 5) and mounts it on the substrate 4. The component removal position 23ba is the component supply position in the tape feeder 23. The mounting head 13 is equipped with a plurality of nozzles 13a extending downward, and a vacuum suction force is generated at the lower end of each nozzle 13a to attract the component 5. The head movement mechanism 14 includes, for example, an XY table to move the mounting head 13 in the XY plane. The mounting head 13 also includes a camera 41 that images the carrier tape 24 at the component removal position 23ba and a light irradiation unit 43 that irradiates the carrier tape 24 at the component removal position 23ba with light. The light irradiation unit 43 is, for example, a light-emitting diode.

[0030] The management device 92 is connected to the component mounting device 1 in a communicative manner and manages the production information of the component mounting device 1 collectively. The management device 92 is, for example, a host computer and can be composed of circuits such as a microcontroller, CPU, MPU, GPU, DSP, FPGA, or ASIC. The functions of the management device 92 are realized by combining hardware and software. The management device 92 realizes predetermined functions by reading data and programs stored in the memory unit and performing various arithmetic operations.

[0031] The portable information terminal 95 communicates wirelessly with the control device 92, allowing the worker to check production information held by the control device 92 while carrying the portable information terminal 95. The portable information terminal 95 can be, for example, a tablet or a smartphone.

[0032] In Figure 1, the parts supply unit 3 includes a trolley 21 and a tape feeder 23. The trolley 21 is provided with a feeder base 31 and a reel holding unit 32.

[0033] The feeder base 31 is a component for mounting the tape feeder 23. The feeder base 31 has multiple mounting slots (not shown) for mounting the tape feeder 23, which are spaced at equal intervals in the X direction. The tape feeder 23 supplies components 5 to the mounting head 13 of the component mounting device 1.

[0034] The reel holding unit 32 mounts and holds the reel 22 on which the carrier tape 24 is wound and stored. The reel holding unit 32 is provided with multiple holders (not shown) for holding the reel 22. In this embodiment, the reel holding unit 32 is configured to hold two reels 22 for one tape feeder 23. As a result, the reel holding unit 32 can supply two carrier tapes 24 to one component supply device simultaneously.

[0035] The reel 22 is fitted with a barcode 28 containing information about the parts packaged on the carrier tape 24 (hereinafter referred to as "parts information"). The barcode 28 is a type of identifier that encodes information including parts information, but it is not limited to a one-dimensional code; it may also be a two-dimensional code or other type of identifier.

[0036] Figure 2 is a schematic plan view showing a feeder base 31 with multiple tape feeders 23 mounted on it. As shown in Figure 2, multiple tape feeders 23 can be mounted on the feeder base 31 in a row in the X direction. Each tape feeder 23 is provided with a component supply port 23b, and components 5 supplied to the component supply port 23b are picked up by the mounting head 13 and mounted on the circuit board 4.

[0037] Each tape feeder 23 mounted on the feeder base 31 is a so-called auto-loading feeder, which transports the carrier tape 24 mounted on the tape feeder 23 forward and automatically supplies the parts 5 held on the carrier tape 24 to the parts supply port 23b at a predetermined position. A detailed description of the auto-loading feeder is given in Japanese Patent Application Publication No. 2023-117273, so a description of a configuration similar to that in Japanese Patent Application Publication No. 2023-117273 will be omitted in this specification.

[0038] As shown in Figure 1, the tape feeder 23 is capable of holding a carrier tape 24 to be used after the current tape 24a (next tape 24b), in addition to the carrier tape 24 (current tape 24a) that it is currently transporting. When the components 5 of the current tape 24a run out, the tape feeder 23 discharges the current tape 24a and automatically transports the next tape 24b, supplying the components 5 held in the next tape 24b to the component supply port 23b. In this specification, when the next tape 24b reaches the component supply port 23b, its designation is changed to the current tape 24a.

[0039] When the component mounting device 1 performs component mounting work, first the substrate transport unit 12 operates to bring in the substrate 4 from the outside and position it at a predetermined work position. Once the substrate 4 is positioned at the work position by the substrate transport unit 12, the tape feeder 23 repeatedly performs a mounting turn by coordinating the operation of supplying components 5 to the component supply port 23b with the operation of the head moving mechanism 14 moving the mounting head 13.

[0040] In one mounting turn, the mounting head 13 moves to a position above the tape feeder 23, picks up the component 5 with the nozzle 13a, then moves to a position above the substrate 4, and performs a series of operations to mount the component 5 onto the substrate 4. The mounting turns are repeated until all the components 5 to be mounted on the substrate 4 are mounted, at which point the substrate transport unit 12 operates to transport the substrate 4 to the downstream process equipment. This completes the component mounting work for one substrate 4.

[0041] Returning to Figure 1, the portable information terminal 95 is a component used to provide notifications from the management device 92 to the worker carrying it and to check the status of the component mounting device 1. The portable information terminal 95 is a type of information acquisition device that acquires component information of the reel 22 and carrier tape 24 used in the tape feeder 23. The portable information terminal 95 has, for example, a reader capable of reading barcodes 28 or RFID tags provided on the storage body (reel or cassette) containing the carrier tape 24. The portable information terminal 95 is wirelessly connected to the management device 92 via WiFi or the like and can communicate with the management device 92. The portable information terminal 95 may also be able to communicate with the component mounting device 1. The component information acquired by the portable information terminal 95 is transmitted to the management device 92. The portable information terminal 95 is equipped with a display panel 95a that displays information to be notified to the worker, etc.

[0042] Next, the carrier tape 24 will be described with reference to Figure 3. Figure 3 is a perspective view showing an enlarged portion of the carrier tape 24. The carrier tape 24 has a base tape 51 and a cover tape 52.

[0043] The base tape 51 has a sheet portion 51a and a pocket 53 in which a part of the sheet portion 51a is embossed downwards. Numerous pockets 53 that open upwards are arranged in a row at equal intervals along the longitudinal direction of the base tape 51, and each pocket 53 stores a component 5.

[0044] The cover tape 52 is attached to the upper surface 51aa of the base tape 51, and the component 5 is enclosed in the pocket 53. In this way, the carrier tape 24 packages the component 5. Multiple feed holes 54 are provided in a row and at equal intervals parallel to the row of pockets 53 on the base tape 51.

[0045] The cover tape 52 of the carrier tape 24 has an extension portion 52a that extends from the tip of the base tape 51. The extension portion 52a is provided to allow the cover tape 52 to be captured by the peeling portion 66, which will be described later. The length of the extension portion 52a from the tip of the base tape 51 is such that it is necessary for the tape to reach the peeling portion 66 from the tape transport path 60 and be captured. The tip of the carrier tape 24 is cut so as to divide the feed hole 54.

[0046] Tape feeder The tape feeder 23 shown in Figure 1 has a handle 30. The handle 30 is a component for the operator to hold the tape feeder 23. First, the handle 30 of the tape feeder 23 will be described.

[0047] Figure 4 is a perspective view showing the handle 30 of the tape feeder 23. As shown in Figure 4, the handle 30 is provided with an operation panel 18 for the operator to operate the tape feeder 23. The operation panel 18 shown in Figure 4 comprises an operation section 33 and a feeder display section 34.

[0048] The control unit 33 is equipped with a plurality of switches for performing various operations on the tape feeder 23. The control unit 33 includes, for example, switches 33a, 33b, 33c, 33d, and 33e. Switch 33b instructs forward drive to feed the carrier tape 24 in the tape transport path 60 from upstream to downstream. Switch 33c instructs reverse drive to feed the carrier tape 24 in the tape transport path 60 from downstream to upstream. The amount of carrier tape 24 transported can be adjusted by the number of times and the duration for which switches 33b and 33c are pressed. Other functions can be performed by pressing switches 33d and 33e.

[0049] The feeder display unit 34 displays information related to the tape feeder 23. The feeder display unit 34 shown in Figure 4 includes a 7-segment display 35 and lamps 36 and 37. The 7-segment display 35 is a display for displaying numbers and characters, and consists of seven segments, each of which can be individually lit and extinguished. The 7-segment display 35 displays, for example, the status of the tape feeder 23 and the carrier tape 24, as well as information on any errors that have occurred. The lamps 36 and 37 are lamps that can be lit to notify the operator. For example, the lamps 36 and 37 light up to inform the operator of the tape feeder 23 that is the target of the work among multiple tape feeders 23.

[0050] Next, the detailed configuration of the tape feeder 23 will be described with reference to Figure 5. Figure 5 is a schematic diagram of the tape feeder 23 in this embodiment.

[0051] The tape feeder 23 comprises a tape transport path 60, a tape transport section 61, a tape loading section 62, a shutter unit 63, a unit control unit 64, and a unit-side connector 65. The tape feeder 23 also includes a tape inlet 23a for feeding the carrier tape 24 into the tape transport path 60, a component supply port 23b for supplying components, and an outlet 23c for discharging the carrier tape 24 from the tape transport path 60. The main body 23d of the tape feeder 23 consists of a core unit 23da and a loading unit 23db, the loading unit 23db being detachable from the core unit 23da.

[0052] The tape transport path 60 is formed in the main body 23d of the tape feeder 23, and guides the carrier tape 24, which is pulled out from the reel 22 and inserted into the tape feeder 23 from the tape inlet 23a, through the inside of the tape feeder 23 to the parts removal position 23ba, which is the position of the parts supply port 23b, and further to the discharge port 23c.

[0053] The tape inlet 23a opens on the upstream side in the tape feeding direction of the tape feeder 23. The discharge port 23c opens on the downstream side in the tape feeding direction. The tape transport path 60 is connected from the tape inlet 23a to the discharge port 23c. At the component removal position 23ba located downstream of the tape transport path 60, the mounted head 13 removes the component 5.

[0054] During the process of continuously performing the parts mounting work, multiple carrier tapes 24, each stored in a reel 22, are sequentially inserted from the tape inlet 23a and supplied to the tape feeder 23, with each carrier tape 24 serving as a unit lot.

[0055] The tape transport unit 61 transports the carrier tape 24 to the component removal position 23ba on the downstream side of the tape transport path 60. The tape transport unit 61 includes a first transport sprocket 61a that engages with the feed holes 54 of the carrier tape 24, a second transport sprocket 61b, a third transport sprocket 61c, and a drive unit 61d.

[0056] The first transport sprocket 61a, the second transport sprocket 61b, and the third transport sprocket 61c are arranged in order from the downstream side along the tape transport path 60.

[0057] The drive unit 61d includes, for example, a motor as a power source and a power transmission member that transmits the power from the power source to the first to third transport sprockets 61a to 61c. The power transmission member is, for example, a gear.

[0058] The tape loading unit 62 sends the carrier tape 24 inserted into the tape feeder 23 from the tape inlet 23a to the tape transport unit 61. The tape loading unit 62 is located on the upstream side of the tape transport path 60. The tape loading unit 62 comprises a loading sprocket 62a, a tape support unit 62b, and a drive unit 62c.

[0059] The drive unit 62c has the function of rotating the feed sprocket 62a in the direction of arrow a1 and the function of moving the feed sprocket 62a and the tape support unit 62b in the direction of arrow a2. By driving the feed sprocket 62a to rotate in the direction of arrow a1, the inserted carrier tape 24 can be transported downstream along the tape transport path 60.

[0060] Near the upstream tape inlet 23a of the tape transport path 60, the tape transport path 60 widens considerably, and the tape support section 62b is positioned to divide the tape transport path 60 into two within this widened space. Therefore, the tape feeder 23 can support the leading edge of the carrier tape 24 with the tape support section 62b at the upstream end of the tape transport path 60, and transport another carrier tape 24 downstream along the bottom surface 60a of the tape transport path 60 below the tape support section 62b. Furthermore, the drive unit 62c can move the input sprocket 62a and the tape support section 62b, thereby moving the carrier tape 24 supported by the tape support section 62b to the bottom surface 60a of the tape transport path 60.

[0061] The drive unit 62c includes, for example, a motor as a power source and a power transmission member that transmits power from the power source to the feed sprocket 62a. The power transmission member is, for example, a gear. It also includes a power transmission mechanism that combines a link mechanism, gears, elastic members, etc., to move the feed sprocket 62a and the tape support unit 62b in the direction of arrow a2 using power from another power source.

[0062] The tape transport section 61 and the tape loading section 62 function as transport units that transport the carrier tape 24 along the tape transport path 60 and supply the parts 5 to the parts removal position 23ba. In the case of a tape feeder that does not have a tape loading section 62, the tape transport section 61 functions as the transport unit.

[0063] The tape feeder 23 includes a first sensor PH1, a second sensor PH2, a third sensor PH3, and a fourth sensor PH4, which are arranged in order from upstream along the tape transport path 60. The first sensor PH1, the second sensor PH2, and the fourth sensor PH4 are optical sensors that directly or indirectly detect the presence or absence of the carrier tape 24 at their respective checkpoints, and are, for example, reflective or transmissive photoelectric sensors.

[0064] The first sensor PH1 is positioned at a first checkpoint located at the downstream end of the tape support section 62b. The first sensor PH1 detects whether the carrier tape 24 inserted into the tape support section 62b of the tape feeder 23 has reached the first checkpoint. When the first sensor PH1 detects that the carrier tape 24 has reached the first checkpoint, it transmits a detection signal to the unit control unit 64. This allows the first sensor PH1 to detect that the carrier tape 24 has reached the shutter unit 63 located at the first checkpoint.

[0065] The second sensor PH2 is located downstream of the first checkpoint and is positioned at a second checkpoint near the confluence point where the extension of the tape support section 62b merges with the tape transport path 60. The second sensor PH2 detects whether the carrier tape 24 has reached the second checkpoint, and when it detects that the carrier tape 24 has reached the second checkpoint along the tape transport path 60, it transmits a detection signal to the unit control unit 64.

[0066] The third sensor PH3 is positioned at a third checkpoint located downstream of the second checkpoint and upstream of the peeling section 66 of the tape transport path 60. The third sensor PH3 detects whether the carrier tape 24 has reached the third checkpoint, and when it detects that the carrier tape 24 has reached the third checkpoint, it transmits a detection signal to the unit control unit 64. The third sensor PH3 is equipped with a dog that can mechanically contact the leading edge of the carrier tape 24, and detects the displacement of the dog that occurs when the carrier tape 24 comes into contact with the dog using an optical sensor.

[0067] The fourth sensor PH4 is positioned at a fourth checkpoint located downstream of the peeling section 66 and upstream of the part removal position 23ba. The fourth sensor PH4 detects whether the carrier tape 24 has reached the fourth checkpoint, and when it detects that the carrier tape 24 has reached the fourth checkpoint, it transmits a detection signal to the unit control unit 64. The fourth sensor PH4 may also detect the leading edge of the carrier tape 24 using a dog, as in the configuration of the third sensor PH3 described above. If the displacement of the dog is detected by an optical sensor, it becomes possible to reliably detect the carrier tape 24 even if the carrier tape 24 is made of a light-transmitting material.

[0068] The tape support section 62b supports the carrier tape 24 and maintains the orientation in which the carrier tape 24 is transported. The tape support section 62b can also release the carrier tape 24 downward.

[0069] The carrier tape 24 released from the tape support section 62b moves to the bottom surface 60a of the tape transport path 60 below the tape support section 62b. In this way, once the carrier tape 24 detaches from the tape support section 62b, the next carrier tape 24 (next tape 24b) can be inserted into the tape support section 62b at any time.

[0070] The shutter unit 63 prevents the carrier tape 24, supported by the tape support section 62b, from advancing further downstream along the tape transport path 60.

[0071] When the carrier tape 24 falls from the tape support section 62b, the first sensor PH1 stops detecting the carrier tape 24, and therefore no detection signal is output to the unit control unit 64. As a result, the unit control unit 64 recognizes that the carrier tape 24 is not supported by the tape support section 62b, or that the carrier tape 24 is not present at the first checkpoint.

[0072] Next, the peeling section 66 will be described with reference to Figure 6. Figure 6 is a side view showing the configuration of the peeling section 66. Figure 6A shows the state in which the carrier tape 24 has passed through the peeling section 66, and Figure 6B shows the state in which the carrier tape 24 has turned back from the peeling section 66. In this specification, "forward" of the carrier tape 24 means that the carrier tape 24 is transported in the downstream direction, and "reverse" of the carrier tape 24 means that the carrier tape 24 is transported in the upstream direction.

[0073] A peeling unit 66 is positioned on the inclined portion of the tape transport path 60, diagonally downward and upstream of the component removal position 23ba. The peeling unit 66 peels the cover tape 52 of the carrier tape 24 from the base tape 51, exposing the upper surface of the component 5 stored in the pocket 53. The peeling unit 66 includes a pair of rollers 81 and 82 for feeding the cover tape, and a drive mechanism that drives these rollers 81 and 82. The drive mechanism of the peeling unit 66 has a motor as a drive source and a drive transmission mechanism such as gears that transmit the rotational power of the motor to the rollers 81 and 82. The drive mechanism of the peeling unit 66 is controlled by the unit control unit 64, causing it to rotate, and the rotation of the roller 81 performs the peeling operation of the cover tape 52, which will be described below.

[0074] The extended portion 52a of the cover tape 52 of the carrier tape 24, which has been transported along the tape transport path 60 from the upstream side, is drawn into the rollers 81 and 82 through the opening 83 and peeled away from the base tape 51. The newly set carrier tape 24 is fed in from the tape input port 2a of the tape transport path 60 with the leading edge 52b of the cover tape 52 being longer than the leading edge of the base tape 51 (having an extended portion 52a). When the leading edge of the carrier tape 24 reaches the opening 83, the extended portion 52a of the cover tape 52 is captured by the peeling portion 66.

[0075] In other words, the peeling section 66 traps the extended portion 52a at the tip of the cover tape 52 between the rollers 81 and 82 and pulls it in. As a result, the cover tape 52 is peeled off from the base tape 51 of the carrier tape 24. In the following description, after the cover tape 52 has been peeled off from the base tape 51, the base tape 51 from which the cover tape 52 has been peeled off will also be referred to as the carrier tape 24.

[0076] On the bottom surface 60a side of the tape transport path 60, an air nozzle 84 is positioned opposite the opening 83, with the air injection direction facing the opening 83. The air nozzle 84 is an air injection unit, and the ejected air is directed at the extended portion 52a of the cover tape 52 located near the opening 83, and the force of the ejected air directs the extended portion 52a of the cover tape 52 toward the peeling portion 66. In other words, the air nozzle 84 assists the peeling portion 66 in capturing the cover tape 52 and guides the tip of the cover tape 52 toward the peeling portion 66. The air nozzle 84 is supplied with air from an air supply unit (not shown).

[0077] The unit control unit 64 controls the opening and closing of the control valve 70 (Figure 8) connected to the air supply unit, thereby enabling air to be injected from the air nozzle 84 toward the peeling unit 66 at any desired timing. In this embodiment, the air control unit 64c is controlled to inject air from the air nozzle 84 when the peeling of the cover tape 52 is corrected and the extension portion 52a reaches a position where it can be captured by the peeling unit 66. For example, as shown in Figure 6A, when the fourth sensor PH4 detects the tip of the carrier tape 24, air may be injected after the carrier tape 24 has been moved upstream by the third transport sprocket 61c for a predetermined distance or time, as shown in Figure 6B. As the carrier tape 24 moves in the reverse direction for a predetermined distance or time, the peeling of the cover tape 52 is corrected, and the extension portion 52a moves downward to the opening 83.

[0078] The air nozzle 84 blows air onto the extension portion 52a, pressing it against the roller 81 located on the upstream side. Then, the rollers 81 and 82 are rotated in the direction of the arrows shown in Figure 7A, and the extension portion 52a, which is pressed against the roller 81, is gripped and captured by the roller 81 and the other roller 82. Then, as shown in Figure 7B, the rotation of the rollers 81 and 82 is continued to pull the cover tape 52 away from the base tape 51, thereby peeling the cover tape 52 from the base tape 51.

[0079] In Figure 5, the unit control unit 64 is connected to the drive unit 61d, the peeling unit 66, and the fourth sensor PH4 in a communication manner, and the unit control unit 64 controls the drive unit 61d and the peeling unit 66. In other words, the unit control unit 64 controls the third transport sprocket 61c, thereby executing a tape transport operation in which the carrier tape 24 is transported along the tape transport path 60. At this time, the unit control unit 64 is capable of controlling the transport timing and transport amount of the carrier tape 24.

[0080] Furthermore, the unit control unit 64 controls the rollers 81 and 82 and the air supply unit based on the detection signal from the fourth sensor PH4, thereby performing a peeling operation to separate the cover tape 52 from the base tape 51 of the carrier tape 24. In this peeling operation, air is sprayed from the air nozzle 84 to cause the cover tape 52 to be captured by the peeling unit 66.

[0081] The unit control unit 64 is connected to the operation unit 33 for communication, and the unit control unit 64 is further connected to the main body 2 of the component mounting device 1 for communication. The tape transport operation and tape feeding operation described above are performed by operation commands input from the operation unit 33 and control commands transmitted from the main body 2.

[0082] Next, the functional configuration of the tape feeder 23 will be described with reference to Figure 8. Figure 8 is a block diagram showing an example of the functional configuration of the tape feeder 23.

[0083] Multiple tape feeders 23 can be mounted on the component mounting device 1, and each tape feeder 23 is equipped with a unit control unit 64. The unit control unit 64 comprises a tape transport control unit 64a, an air control unit 64c, and a storage unit 64d. The unit control unit 64 can be implemented as a circuit composed of semiconductor elements or the like. The unit control unit 64 can be composed of circuits such as a microcontroller, CPU, MPU, GPU, DSP, FPGA, or ASIC. The functions of the unit control unit 64 may be implemented using hardware alone, or by combining hardware and software. The unit control unit 64 realizes predetermined functions by reading data and programs stored in the storage unit 64d and performing various arithmetic operations.

[0084] The unit control unit 64 is electrically connected to the switches 33a to 33e of the operation unit 33, and to the 7-segment display 35, lamps 36 and 37 of the feeder display unit 34, and controls the operation of each component. The unit control unit 64 is also electrically connected to the first sensor PH1, the second sensor PH2, the third sensor PH3, the fourth sensor PH4, the drive unit 61d, the drive unit 62c, and the control valve 70, and controls the operation of each component.

[0085] The tape transport control unit 64a controls the feeding operation of the carrier tape 24 mounted on the tape feeder 23 based on commands from the main unit control unit 17.

[0086] The storage unit 64d stores component information of the carrier tape 24 mounted on the tape feeder 23, and the identification number of the tape feeder 23. The storage unit 64d also stores component information of the current tape 24a and the next tape 24b mounted on the tape feeder 23.

[0087] The unit-side connector 65 is connected to the main unit-side connector 10 via the connector on the feeder base 31, enabling communication between the unit control unit 64 and the main unit control unit 17. Alternatively, the unit-side connector 65 may be connected to a connector of an external setup device or maintenance device, etc., after the tape feeder 23 has been removed from the main unit 2, enabling communication between the unit control unit 64 and the external setup device or maintenance device, etc.

[0088] The main control unit 17 controls the component mounting operation in the main unit 2. The main control unit 17 comprises an image processing unit 17a, a suction determination unit 17b, a continuous suction error determination unit 17c, and a storage unit 17d. The main control unit 17 reads data and programs stored in the storage unit 17d and performs various calculations to realize predetermined functions. The storage unit 17d also stores a production program related to the production of the substrate 4 and component information.

[0089] The image processing unit 17a determines whether or not the cover tape 52 has been peeled off the base tape 51 based on the image captured by the camera 41.

[0090] The adsorption determination unit 17b determines whether the nozzle 13a of the mounting head 13 succeeded or failed in adsorbing the part 5.

[0091] The continuous suction error determination unit 17c counts the number of consecutive suction errors, and when the count exceeds a predetermined threshold, it determines that a continuous suction error has occurred and notifies the operator of the continuous suction error via the touchscreen 16a.

[0092] A camera 41 mounted on the head 13 captures an image of the carrier tape 24, including at least the base tape 51, at the component removal position 23ba. The camera 41 transmits the captured image to the image processing unit 17a.

[0093] Next, the carrier tape transport operation by the tape feeder 23 will be explained with reference to Figures 9A to 11.

[0094] Refer to Figure 9A. The operator inserts the carrier tape 24 along the tape support 62b located at the tape inlet 23a of the tape feeder 23, where the lamps 36 and 37 (Figure 4) on the operation panel 18 are flashing. After inserting the carrier tape 24, the operator presses the switch 33d (Figure 4) on the tape feeder 23. If the current tape 24a is downstream of the tape transport path 60, the tape loading unit 62 loads the carrier tape 24 with the shutter unit 63 locked, and stops the loading sprocket 62a when the carrier tape 24 is detected by the first sensor PH1. If the operator has inserted the carrier tape 24 to the position detected by the first sensor PH1, the tape loading unit 62 will not operate. In either case, the carrier tape 24 cannot enter further. In this way, the carrier tape 24 waits at the standby position 23bb located upstream of the parts removal position 23ba, which will be described later.

[0095] When the operator presses switch 33d, if there is no carrier tape 24 downstream of the tape transport path 60, pressing switch 33d unlocks the shutter unit 63, and in that state, the tape loading unit 62 transports the carrier tape 24. This sends the carrier tape 24 into the tape transport path 60. As shown in Figure 9B, when the carrier tape 24 is transported to a position where it hits the pin of the third transport sprocket 61c, the loading by the loading sprocket 62a stops. The carrier tape 24 is transported further downstream by the third transport sprocket 61c, and when detected by the fourth sensor PH4, the tape transport unit 61 performs an operation to cause the peeling unit 66 to capture the cover tape 52.

[0096] When the peeling unit 66 captures the cover tape 52, the peeling unit 66 and the third transport sprocket 61c peel off the cover tape 52 while the carrier tape 24 is transported further downstream. When the pin of the second transport sprocket 61b is inserted into the feed hole 54 of the carrier tape 24, as shown in Figure 10A, the drive unit 61d drives the second transport sprocket 61b to position the leading pocket 53 of the carrier tape 24 at the part removal position 23ba. An opening is formed at the position corresponding to the part removal position 23ba.

[0097] Next, a path change is performed in the tape loading section 62. As shown in Figure 10B, the carrier tape 24 passing through the tape loading section 62 detaches from the tape loading section 62 due to the path change and moves to the bottom surface 60a of the tape transport path 60 below it. The path change is performed when the carrier tape 24 is engaged with the second transport sprocket 61b and the third transport sprocket 61c of the tape transport section 61. When the path change is performed, the shutter unit 63 enters a locked state.

[0098] As shown in Figure 11A, the operator can insert the next carrier tape 24 (next tape 24b) into the tape loading section 62, which has become vacant due to the change in the loading path. The method for inserting the carrier tape 24 into the tape loading section 62 is the same as the method described above.

[0099] As shown in Figure 11B, when a component failure is detected in the carrier tape 24 and the passage of the end of the carrier tape 24 is detected by the second sensor PH2, the tape transport unit 61 ejects the carrier tape 24 (tape ejection). If the passage of the end of the carrier tape 24 has not been detected at the time the component failure is detected, an end search is performed, and then tape ejection is performed. Once the current tape 24a has been ejected, the shutter unit 63 is unlocked, and in this state, the tape input unit 62 transports the next tape 24b that was waiting at the standby position 23bb. As a result, the next tape 24b is fed into the tape transport path 60. When the next tape 24b is transported to a position where it hits the pin of the uppermost sprocket of the tape transport unit 61, the input by the input sprocket 62a stops. The path is changed, and the next tape 24b is transported as the current tape 24a.

[0100] Tape Inspection Next, when the carrier tape 24 is first set in the tape feeder 23, the peeling section 66 may fail to peel the cover tape 52 from the base tape 51, and the cover tape 52 may be transported to the component removal position 23ba while still attached to the base tape 51. In this case, the component 5 housed in the pocket 53 remains covered by the cover tape 52, so even if the nozzle 13a of the mounting head 13 tries to pick up the component 5, it will pick up the cover tape 52 instead, resulting in a picking error.

[0101] Therefore, when the leading pocket 53 of the carrier tape 24 is transported to the parts removal position 23ba, it is checked whether or not the cover tape 52 has been peeled off from the base tape 51.

[0102] The inventors discovered that there is a difference in luminance information between an image taken with a resin cover tape 52 still attached to a resin or paper base tape 51 and an image taken of the base tape 51 with the cover tape 52 removed. First, we will describe the case where the carrier tape 24 is an embossed carrier tape, that is, the case where the base tape 51 is made of resin and the cover tape 52 is a transparent resin tape.

[0103] Refer to Figure 12. Figure 12 is an explanatory diagram showing the state in which the carrier tape 24 is positioned at the component removal position 23ba, and is a plan view of the area around the component supply port 23b in the tape feeder 23.

[0104] As shown in Figure 12, when the carrier tape 24 is positioned at the parts retrieval position 23ba, all of the pockets 53 containing the parts 5 are exposed through the parts supply port 23b, allowing the operator to visually inspect the parts 5. However, the pockets 53 other than the leading pocket 53 are covered by the tape cover 23e, which is part of the housing of the tape feeder 23, and therefore cannot be visually inspected. Although the parts 5 shown in Figure 12 have a rectangular shape in plan view, in the examples described below, they are not limited to this and may have shapes with protrusions.

[0105] The mounted head 13 moves above the component supply port 23b and images the area around the leading pocket 53. An example of the captured image is shown in Figure 13. Figure 13 is an explanatory diagram showing image 101 of the embossed carrier tape from which the cover tape 52 has been peeled off.

[0106] In image 101, the area of ​​pocket 53 of the base tape 51 has the lowest brightness, and the difference in brightness between the upper surface 51aa of the sheet portion 51a and the component 5 is small. The area of ​​electrode 5a on component 5 has the highest brightness.

[0107] Next, refer to Figure 14. Figure 14 is an explanatory diagram showing an image 103 of the embossed carrier tape including the cover tape 52.

[0108] Image 103 of the carrier tape 24 with the cover tape 52 attached to the base tape 51 shows higher overall brightness and lower contrast than image 101 of the carrier tape 24 with the cover tape 52 removed, because light is reflected by the cover tape 52. In image 103, the area of ​​the pocket 53 has the lowest brightness, and the area of ​​the upper surface 51aa of the sheet portion 51a has the highest brightness.

[0109] As shown above, the trends in brightness information differ between image 101 and image 103. Therefore, based on the brightness information of the upper surface 51aa region of the sheet portion 51a in the captured image, it is possible to determine whether or not the cover tape 52 has been peeled off from the base tape 51 by image processing.

[0110] The image processing unit 17a extracts regions from the captured image by, for example, image processing that matches the shape of the component 5 and the pocket 53, and calculates the median or average value of the brightness of the extracted region of the pocket 53 or the upper surface 51aa of the sheet portion 51a. Next, the image processing unit 17a compares the median or average value of the brightness with a predetermined threshold. If the median or average value of the brightness is lower than the predetermined threshold, it determines that the cover tape 52 has been peeled from the base tape 51. If the median or average value of the brightness is equal to or greater than the threshold, it determines that the cover tape 52 has not been peeled from the base tape 51. Note that using the median value of the brightness provides more stable accuracy in the determination.

[0111] If the minimum brightness value is 0 and the maximum value is 1, the predetermined threshold is, for example, 0.6 to 0.7. If brightness is represented in 256 levels, the predetermined threshold is, for example, 153 to 179.

[0112] Furthermore, the image processing unit 17a may determine that the cover tape 52 has been detached from the base tape 51 if the luminance distribution of a predetermined area of ​​the image is within a predetermined range, and determine that the cover tape 52 has not been detached from the base tape 51 if the luminance distribution of a predetermined area of ​​the image is outside the predetermined range. For example, the luminance distribution of the upper surface 51aa of the sheet portion 51a in image 101 is within the range of 0 to 100 in 256 gradations. In contrast, the luminance distribution of the cover tape 52 area in image 103 is within the range of 155 to 256 in 256 gradations. Therefore, the image processing unit 17a can determine that the cover tape 52 has been detached from the base tape 51 if the luminance distribution of the area corresponding to the upper surface 51aa of the sheet portion 51a in the image is within the range of 0 to 100, and determine that the cover tape 52 has not been detached from the base tape 51 if the luminance distribution is outside the range of 0 to 100. This method also allows for accurate determination of whether or not the cover tape 52 has been detached.

[0113] Next, with reference to Figures 15 and 16, we will describe the case where the carrier tape 24 is a paper carrier tape, that is, the case where the base tape 51 is made of paper and the cover tape 52 is a transparent tape made of resin. Figure 15 is an explanatory diagram showing image 105 of a paper carrier tape from which the cover tape 52 has been peeled off. Figure 16 is an explanatory diagram showing image 107 of a paper carrier tape including the cover tape 52.

[0114] In image 105, the area of ​​component 5 has the lowest brightness, and there is a large difference between the brightness of the upper surface 51aa of the sheet portion 51a and the brightness of component 5 and pocket 53. The area of ​​electrode 5a in component 5 has the highest brightness.

[0115] In the captured image 107, light is reflected by the cover tape 52, so the overall brightness is higher and the contrast is lower than in image 105 of the carrier tape 24 from which the cover tape 52 has been removed. In image 107, the area of ​​component 5 and pocket 53 has the lowest brightness, while the area of ​​electrode 5a in component 5 has the highest brightness.

[0116] As shown above, the trends in brightness information differ between image 105 and image 107. Therefore, based on the brightness information of the region in pocket 53 of the captured image, it is possible to determine whether or not the cover tape 52 has been peeled off from the base tape 51 by image processing.

[0117] For paper carrier tapes as well, the image processing unit 17a extracts regions from the captured image by, for example, image processing matching the shapes of component 5 and pocket 53, and calculates the median or average brightness of the extracted pocket 53 region. Next, the image processing unit 17a compares the median or average brightness with a predetermined threshold. If the median or average brightness is lower than the predetermined threshold, it determines that the cover tape 52 has been peeled from the base tape 51. If the median or average brightness is equal to or greater than the threshold, it determines that the cover tape 52 has not been peeled from the base tape 51. Note that using the median brightness provides more stable accuracy in the determination.

[0118] If the minimum brightness value is 0 and the maximum value is 1, the predetermined threshold is, for example, 0.4 or more and 0.5 or less. If brightness is represented in 256 gradations, the predetermined threshold is, for example, 102 or more and 128 or less.

[0119] When the camera 41 images the carrier tape 24, light is irradiated from the light irradiation unit 43 toward the carrier tape 24 at the component removal position 23ba, but the amount of this light may be increased. For example, the amount of light used when imaging to determine whether or not the cover tape 52 has been peeled off may be greater than the amount of light used when imaging to recognize the adsorption position (pocket recognition). This can further improve the detection accuracy of whether or not the cover tape 52 has been peeled off. In this way, the main unit control unit 17 can increase the amount of reflected light from the cover tape 52 by adjusting the amount of light irradiated when imaging with the camera 41, and can further improve the detection accuracy of whether or not the cover tape 52 has been peeled off from the base tape 51. In particular, detection accuracy can be improved for paper carrier tapes.

[0120] Referring to Figures 17 and 18, we will now describe images taken when the carrier tape 24 is a paper carrier tape and the amount of light irradiated is increased. Figure 17 is an explanatory diagram showing image 109 taken when the amount of light irradiated onto the paper carrier tape from which the cover tape 52 has been peeled off is increased. Figure 18 is an explanatory diagram showing image 111 taken when the amount of light irradiated onto the paper carrier tape including the cover tape 52 is increased.

[0121] In image 109, which was captured by increasing the amount of light irradiating the area, the area of ​​component 5 has the lowest brightness, while the brightness of the upper surface 51aa of the sheet portion 51a is higher, with a large difference in brightness between it and the areas of component 5 and pocket 53. The area of ​​electrode 5a in component 5 has the highest brightness.

[0122] In the captured image 111, light is reflected by the cover tape 52, so the overall brightness is higher and the contrast is lower than in image 109 of the carrier tape 24 after the cover tape 52 has been removed. In image 111, although the areas of component 5 and pocket 53 have the lowest brightness, the overall brightness is higher and the contrast is lower.

[0123] Even when the amount of light irradiated is increased to image the paper carrier tape, the image processing unit 17a extracts the respective regions from the captured image by, for example, image processing that matches the shape of the component 5 and the pocket 53, and calculates the median or average value of the brightness of the extracted pocket 53 region. Next, the image processing unit 17a compares the median or average value of the brightness with a predetermined threshold, and determines that the cover tape 52 has been peeled from the base tape 51 if the median or average value of the brightness is lower than the predetermined threshold, and determines that the cover tape 52 has not been peeled from the base tape 51 if the median or average value of the brightness is equal to or greater than the threshold. Note that using the median value of the brightness provides more stable accuracy in the determination.

[0124] When the amount of light irradiating the paper carrier tape is increased and the minimum brightness is set to 0 and the maximum brightness to 1, the predetermined threshold is, for example, 0.6 to 0.7. When brightness is expressed in 256 gradations, the predetermined threshold is, for example, 153 to 179.

[0125] Next, referring to Figure 19, the process from setting the carrier tape in the tape feeder to the component picking up by the component mounting device in Embodiment 1 will be explained.

[0126] In step S1, the main unit control unit 17 of the main unit 2 of the component mounting device 1 determines whether or not there is an auto-loading type tape feeder 23 among the multiple tape feeders set in the component supply unit 3, based on the production program and the identification number of each set tape feeder.

[0127] If the main control unit 17 determines that there is no auto-loading type tape feeder 23 among the multiple tape feeders set in the parts supply unit 3 (No. in step S1), the carrier tapes 24 set in each tape feeder are transported to the parts removal position 23ba with the cover tape 52 peeled off from the base tape 51 by the operator's operation. Therefore, since there is no risk of suction errors occurring due to the cover tape 52, in step S2, the main control unit 17 drives the head moving mechanism 14, and the mounted head 13 moves above the parts removal position 23ba.

[0128] The camera 41 on the mounted head 13 captures an image of the area around the pocket 53 of the carrier tape 24 at the part removal position 23ba, and the image processing unit 17a recognizes the suction position by the nozzle 13a based on the captured image.

[0129] In step S3, the head movement mechanism 14 fine-tunes the position of the mounting head 13 based on the suction position recognized by the image processing unit 17a, and the nozzle 13a picks up the component 5. After this, the mounting head 13 moves above the substrate 4 and mounts the picked-up component 5 onto the substrate 4.

[0130] If, in step S1, the main control unit 17 determines that there is an auto-loading type tape feeder 23 among the multiple tape feeders 23 set in the component supply unit 3 (Yes in step S1), then in step S4, the main control unit 17 determines whether the auto-loading type tape feeder 23 has automatically set the carrier tape 24 and whether the cover tape check has not yet been performed.

[0131] When the main control unit 17 receives a signal from the auto-loading tape feeder 23 indicating that the carrier tape 24 has been automatically set, for example, when it receives a signal indicating that the carrier tape 24 has been transported to a predetermined position downstream of the peeling unit 66, it determines that the auto-loading tape feeder 23 has completed the automatic setting of the carrier tape 24. Furthermore, the main control unit 17 refers to the check history of the cover tape 52 stored in the storage unit 17d, and if the check of the cover tape 52 of the auto-loading tape feeder 23 has not been performed (Yes in step S4), it transports the carrier tape 24 to the parts removal position 23ba and performs a check of the cover tape 52 of the tape feeder 23 and a re-peeling operation according to the check result (step S5). The operation in step S5 will be described later. Furthermore, if the main unit control unit 17 determines that the auto-loading type tape feeder 23 has not completed the automatic setting of the carrier tape 24 (No. in step S4), after a predetermined time has elapsed via step S6, it will again determine in step S4 whether or not the automatic setting of the carrier tape 24 has been completed.

[0132] Upon completion of step S5, the main unit control unit 17 recognizes that in the auto-loading type tape feeder 23, the carrier tape 24 is positioned at the component removal position 23ba with the cover tape 52 peeled off from the base tape 51, and proceeds to step S6.

[0133] In step S4, if the main unit control unit 17 determines that the auto-loading tape feeder 23 has automatically set the carrier tape 24 and has already checked the cover tape (No. in step S4), step S5 is omitted and the process proceeds to step S6.

[0134] In step S6, the main control unit 17 determines whether it has completed checking the cover tapes of all target auto-loading tape feeders 23 by referring to the check history of the cover tapes 52 of each tape feeder 23 stored in the storage unit 17d. If the main control unit 17 determines that the cover tape check has not been completed for all auto-loading tape feeders 23 (No. in step S6), it executes step S4 for the auto-loading tape feeders 23 whose cover tape checks are incomplete. Also, for auto-loading tape feeders 23 in which the automatic setting of the carrier tape 24 was incomplete, the check of the cover tape 52 is also incomplete, so step 4 is executed again.

[0135] In step S6, if the main unit control unit 17 determines that the cover tape check has been completed for all auto-loading type tape feeders 23 (Yes in step S6), then in step S7, it determines whether there is a tape feeder capable of picking up the component 5.

[0136] In step S7, if the main control unit 17 determines that there is no tape feeder 23 capable of picking up the component 5 (No. in step S7), it displays an error message on the touchscreen 16a to inform the operator that there is no tape feeder 23 capable of picking up the component.

[0137] In step S7, if the main control unit 17 determines that there is a tape feeder 23 capable of picking up the component 5 (Yes in step S7), it executes the operations of steps S2 and S3.

[0138] Next, with reference to Figure 20, the checking of the cover tape 52 in step S5 and the re-peeling operation according to the check result will be explained in detail. Figure 20 is a flowchart showing the flow of the checking and re-peeling operation of the cover tape 52 of the component mounting device.

[0139] First, in step S11, the camera 41 of the mounted head 13, located above the component removal position 23ba, captures an image of the carrier tape 24.

[0140] Next, in step S12, the image processing unit 17a extracts a predetermined area based on the captured image, and in step S13, it determines whether or not the cover tape 52 has peeled off from the base tape 51 based on the brightness value of that area.

[0141] If the image processing unit 17a determines that the cover tape 52 has peeled away from the base tape 51 (Yes in step S13), it terminates the process of checking the cover tape 52. If the image processing unit 17a determines that the cover tape 52 has not peeled away from the base tape 51 (No in step S13), the retry count determination unit 64b of the unit control unit 64 determines whether the number of retries for the re-peeling operation is equal to the maximum number of retries. This number of retries is the number of times the carrier tape 24 is transported in the reverse direction from the part removal position 23ba to the peeling unit 66, and the peeling operation of the cover tape 52 is performed again at the peeling unit 66, as will be explained later.

[0142] If the retry count determination unit 64b determines that the number of retries for the re-peeling operation is less than the maximum number of retries, that is, not equal to the maximum number of retries (No. in step S14), then in step S15, the tape transport control unit 64a drives and controls the drive unit 61d to reverse-rotate the second and third transport sprockets 61b and 61c, thereby transporting the leading edge 51b of the carrier tape 24 to a predetermined position upstream of the peeling unit 66. The amount of carrier tape 24 transported at this time can be controlled by the amount of reverse rotation of each sprocket.

[0143] In step S16, the tape transport control unit 64a performs the peeling operation of the cover tape 52 shown in Figures 6B to 7B again, and in step S17, the unit control unit 64 counts the number of retries by adding one to the count of the counter 64da in the storage unit 64d.

[0144] In step S18, the tape transport control unit 64a drives the drive unit 61d to transport the carrier tape 24 that has undergone the peeling operation back to the parts removal position 23ba. Next, the process from step S11 is repeated to check again whether the cover tape 52 has peeled off from the base tape 51.

[0145] After repeating the peeling operation several times, the retry count on counter 64da reaches the maximum retry count. In step S14, if the retry count determination unit 64b determines that the retry count is equal to the maximum retry count (Yes in step S14), in step S19, the unit control unit 64 sets a peeling failure error and displays this on the feeder display unit 34 and the touchscreen 16a.

[0146] In step 20, the tape transport control unit 64a drives the drive unit 61d to transport the carrier tape 24 in the reverse direction as much as possible, so that the operator can pull the carrier tape 24 out of the tape feeder 23. The operator pulls out the carrier tape 24 from the tape feeder 23 where the error of the cover tape 52 peeling failure has occurred, checks the condition of the cover tape 52 on the carrier tape 24, and takes appropriate measures to make the cover tape 52 easier to peel off.

[0147] As described above, the component mounting device 1 of Embodiment 1 mounts components 5 onto a substrate 4 from a carrier tape 24 having a base tape 51 with pockets 53 for accommodating components 5 and a cover tape 52 attached to the upper surface of the base tape 51. The component mounting device 1 includes a tape transport unit 61 that transports the carrier tape 24 along a tape transport path 60, a peeling unit 66 that peels the cover tape 52 from the base tape 51, a tape feeder 23 that supplies the components 5 contained in the carrier tape 24 to a component removal position 23ba downstream of the peeling unit 66, a camera 41 that images the carrier tape 24, including at least the base tape 51, at the component removal position 23ba, and an image processing unit 17a that determines whether or not the cover tape 52 has been peeled from the base tape 51 based on the image captured by the camera 41. If the image processing unit 17a determines that the cover tape 52 has not been peeled from the base tape 51, it drives the tape transport unit 61 to transport the carrier tape 24 upstream, and the peeling unit 66 peels the cover tape 52 from the base tape 51 again.

[0148] Furthermore, the component mounting method of Embodiment 1 involves mounting the component 5 onto the substrate 4 from a carrier tape 24 having a base tape 51 with pockets 53 for accommodating the component 5, and a cover tape 52 attached to the upper surface of the base tape 51. In the component mounting method, the tape transport unit 61 transports the carrier tape 24 along the tape transport path 60, and the peeling unit 66 peels the cover tape 52 from the base tape 51, so that the tape feeder 23 supplies the component 5 contained in the carrier tape 24 to the component removal position 23ba downstream of the peeling unit 66. The camera 41 images the carrier tape 24, including at least the base tape 51, at the component removal position 23ba, and the image processing unit 17a determines whether or not the cover tape 52 has been peeled from the base tape 51 based on the image captured by the camera 41. If the image processing unit 17a determines that the cover tape 52 has not been peeled from the base tape 51, the main unit control unit 17 drives the tape transport unit 61 to transport the carrier tape 24 upstream, and the peeling unit 66 peels the cover tape 52 from the base tape 51 again.

[0149] Thus, the component mounting device 1 and component mounting method determine whether or not the cover tape 52 has been peeled from the base tape 51. If the cover tape 52 has not been peeled, the carrier tape 24 is transported in the reverse direction to perform the peeling operation again at the peeling section 66. This reduces the frequency with which the operator has to pull the carrier tape 24 completely out of the tape feeder 23 and then set it back into the tape feeder 23. Therefore, it is possible to provide a component mounting device 1 and component mounting method that improve work efficiency.

[0150] Furthermore, the image processing unit 17a determines whether or not the cover tape 52 has been peeled off the base tape 51 based on the brightness information of the captured image. By making the determination based on brightness information, the accuracy of the determination can be improved.

[0151] (Embodiment 2) Next, with reference to Figure 21, the component mounting device 1 in Embodiment 2 will be described. In Embodiment 1, the component mounting device 1 checked whether the cover tape 52 had been peeled from the base tape 51 after the carrier tape 24 was automatically set in the tape feeder 23, but is not limited to this. In Embodiment 2, the component mounting device 1 checks whether the cover tape 52 has been peeled from the base tape 51 when a suction error occurs by the nozzle 13a of the mounting head 13. Figure 21 is a flowchart showing the flow of component mounting in the component mounting device 1 in Embodiment 2.

[0152] Embodiment 2 is a method for checking whether a peeling error has occurred in the tape feeder 23 when a suction error occurs during repeated mounting turns, which are performed in conjunction with component supply and component mounting operations, after the substrate 4 has been positioned at a predetermined working position. For example, during repeated mounting turns, a peeling error of the cover tape 52 may occur in the tape feeder 23 after the carrier tape 24 has been replaced. Instead of checking the cover tape 52 immediately after a suction error occurs during a particular mounting turn, the check of the cover tape 52 is performed in the next mounting turn for the auto-loading type tape feeder 23 that had a suction error up to the previous mounting turn.

[0153] During the component mounting process, the suction determination unit 17b of the main unit control unit 17 determines whether a suction error has occurred by detecting, for example, a change in the air flow rate each time the nozzle 13a of the mounting head 13 picks up a component 5 located at the component removal position 23ba.

[0154] When the component mounting process for a particular mounting turn begins, in step S21, the main unit control 17 determines whether or not a suction error occurred in the previous mounting turn by referring to the suction error occurrence history in the storage unit 17d. If it is determined that no suction error occurred (No in step S21), steps S2 and S3 are executed in the same manner as in Embodiment 1. In step S22, the suction determination unit 17b determines whether or not suction occurred in the current mounting turn, and if it is determined that suction was successful (Yes in step S22), step S24 is executed.

[0155] In step S22, the suction determination unit 17b determines that suction failed during the current mounting turn (No. in step S22), and in step S23, the storage unit 17d records the history of the number of suction failures for the feeder where the suction failure occurred. For the nozzle 13a where the suction failure occurred, the orientation recognition of the part that was not suctioned during the current mounting turn and the mounting of the part are skipped, and the current mounting turn for that part is ended. Since the mounting head 13 has multiple nozzles 13a, step S24 is executed for the parts of the nozzles 13a that successfully suctioned.

[0156] If the continuous suction error determination unit 17c successfully suctions a component before the number of suction errors reaches a predetermined threshold, it clears the number of suction errors for that feeder and executes step S24.

[0157] In step S24, the component 5 is imaged by a camera positioned on the base 11 to recognize the orientation of the component 5. In step S25, the main unit control 17 moves the mounting head 13 and rotates the nozzle 13a according to the orientation of the component 5 to mount the component 5 onto the substrate 4.

[0158] Furthermore, if the main control unit 17 determines that a suction error occurred in the previous suction turn after the component mounting process has started (Yes in step S21), in step S30, the continuous suction error determination unit 17c determines whether there is a feeder whose number of suction errors has exceeded a predetermined threshold. If there is no feeder that has exceeded the threshold (No in step S30), step S2 is executed. If there is a feeder that has exceeded the threshold (Yes in step S30), in step S31, the main control unit 17 determines whether that feeder is an auto-loading type tape feeder. If the main control unit 17 determines that the feeder is an auto-loading type tape feeder 23 (Yes in step S31), steps S5 to S7 are executed in the same manner as in Embodiment 1. If the main control unit 17 determines that the feeder is not an auto-loading type tape feeder 23 (No in step S31), steps S6 and S7 are executed in the same manner as in Embodiment 1.

[0159] As described above, in Embodiment 2, the check to determine whether or not the cover tape 52 has been peeled from the base tape 51 is performed based on information from when a suction error occurred by the nozzle 13a of the mounting head 13 during the previous mounting turn. This reduces the likelihood of another suction error occurring during the current mounting turn, thereby improving work efficiency.

[0160] While this disclosure is adequately described in relation to preferred embodiments with reference to the accompanying drawings, various variations and modifications will be obvious to those skilled in the art. Such variations and modifications should be understood to be included within the scope of this disclosure as defined by the attached claims. Furthermore, variations in combinations and sequences of elements in each embodiment can be realized without departing from the scope and spirit of this disclosure.

[0161] (1) In the component mounting device 1 of the above-described embodiment, the image processing unit 17a determined whether or not the cover tape 52 was peeled off from the base tape 51 based on the brightness information of the captured image, but is not limited to this. For example, by forming a mark on the base tape 51, when the cover tape 52 is attached to the base tape 51, the mark is hidden by the cover tape 52 and cannot be recognized from the captured image, and when the cover tape 52 is peeled off from the base tape 51, the mark is exposed and can be recognized from the captured image. In this case, for example, the cover tape 52 is colored and transparent, and the mark is the same color as the cover tape 52, so that the mark cannot be recognized when the cover tape 52 is attached to the base tape 51.

[0162] (2) In the component mounting device 1 of the above-described embodiment, the light irradiation unit 43 was provided on the mounting head 13 of the main body 2, but is not limited to this. The tape feeder 23 may also be equipped with the light irradiation unit 43.

[0163] (3) In the component mounting device 1 of the above embodiment, the counter 64da counted the number of times the carrier tape 24 was transported from the component removal position 23ba toward the peeling section 66. When performing a re-peeling operation from the peeling section 66, the air control unit 64c may adjust the amount of air blown from the air nozzle 84 according to the count of the counter 64da. For example, by increasing the amount of air blown as the count increases, it is possible to make it easier for the leading edge 52b of the cover tape 52 to be caught by the rollers 81 and 82 of the peeling section 66.

[0164] Furthermore, by appropriately combining any embodiment or modification from among the various embodiments and modifications, the effects of each can be achieved. [Industrial applicability]

[0165] The component mounting device described herein is applicable to a component mounting device that includes a tape feeder that supplies components using a carrier tape containing components. [Explanation of symbols]

[0166] 1. Component mounting device 2 Main body 3. Parts Supply Department 4 circuit boards 5 parts 5a electrode 10 Main unit side connector 11 Base 12. Substrate transport section 13 Mounted Heads 13a Nozzle 13b tube 13c negative pressure sensor 14. Head movement mechanism 15 Power supply section 16 Control section 16a Touchscreen 17 Main Unit Control 17a Image Processing Unit 17b Adsorption judgment section 17c Continuous adsorption error determination unit 18. Control Panel 21 bogies 22 reels 23 Tape feeder 23a Tape entrance 23b Parts supply port 23ba Parts removal location 23c outlet 23d Main unit 23da Core Unit 23dB Loading Unit 24 Carrier Tapes 24a Current Tape 24b Next Tape 28 barcodes 30 Handle 31 Feeder Base 32 Reel holding section 33 Operation section 33a, 33b, 33c, 33d, 33e switches 34 Feeder display unit 35 7-segment display 35a First 7-segment display 35b Second 7-segment display 36 Lamps 37 Lamps 41 Cameras 43 Light-irradiating section 51 Base Tape 51a Seat section 51aa top surface 51b Tip 52 Cover Tape 52a Extension 52b Tip 53 pockets 54 feed holes 60 Tape transport path 60a Bottom 60b top surface 61 Tape transport section 61a First conveyor sprocket 61b Second transport sprocket 61c Third conveyor sprocket 61d Drive unit 62 Tape Loading Section 62a Delivery sprocket 62aa pin 62b Tape support section 62c drive unit 63 Shutter Unit 64 Unit Control Unit 64a Tape transport control unit 64b Retry count determination unit 64c Air Control Unit 64d storage section 64da counter 65 Unit-side connector 66 Peeled section 70 Control valve 81, 82 Laura 83 Opening 84 Air Nozzles 92 Management device 95 Portable Information Terminals 95a Display Panel 96 Network Images 101, 103, 105, 107, 109, 111 PH1 First Sensor PH2 Second Sensor PH3 Third Sensor PH4 Fourth Sensor

Claims

1. A component mounting device for mounting components onto a substrate using a carrier tape having a base tape with pockets for accommodating components and a cover tape attached to the upper surface of the base tape, A tape feeder comprising a tape transport unit that transports the carrier tape along a tape transport path, and a peeling unit that peels the cover tape from the base tape, and which supplies the components contained in the carrier tape to a component removal position downstream of the peeling unit, A camera that images the carrier tape, including at least the base tape, at the aforementioned part removal position, The system includes a control unit that determines whether or not the cover tape has been peeled off the base tape based on an image captured by the camera, When the control unit determines that the cover tape has not been peeled from the base tape, it drives the tape transport unit to transport the carrier tape upstream, and the peeling unit peels the cover tape from the base tape again. Component mounting device.

2. The control unit determines, based on the brightness information of the captured image, whether or not the cover tape has been peeled off the base tape. The component mounting device according to claim 1.

3. The control unit determines, as the brightness information, that the cover tape has been peeled off the base tape if the median brightness of a predetermined area of ​​the image is less than or equal to a predetermined threshold, and determines that the cover tape has not been peeled off the base tape if the median brightness of a predetermined area of ​​the image is greater than a predetermined threshold. The component mounting device according to claim 2.

4. The control unit determines, based on the brightness information, that if the brightness distribution of a predetermined area of ​​the image is within a predetermined range, the cover tape has been peeled off the base tape, and determines, if the brightness distribution of a predetermined area of ​​the image is outside the predetermined range, the cover tape has not been peeled off the base tape. The component mounting device according to claim 2.

5. The camera includes a light irradiation unit that irradiates the base tape with light when capturing images of the base tape. The component mounting device according to claim 1.

6. The carrier tape is an embossed carrier tape, The aforementioned base tape is made of resin, The aforementioned cover tape is a transparent tape made of resin. The component mounting device according to claim 2.

7. The base tape has a sheet portion and a pocket recessed from the sheet portion. The control unit determines whether or not the cover tape has been peeled off the base tape based on the brightness information of the upper surface region of the sheet portion. The component mounting device according to claim 6.

8. The carrier tape is a paper carrier tape, The aforementioned base tape is made of paper, The aforementioned cover tape is a transparent tape made of resin. The component mounting device according to claim 2.

9. The base tape has a sheet portion and a pocket recessed from the sheet portion. The control unit determines whether or not the cover tape has been peeled off the base tape based on the brightness information of the region in the pocket. The component mounting device according to claim 8.

10. The system includes a counter that counts the number of times the carrier tape has been transported from the parts removal position toward the peeling section, The peeling section has an air nozzle that blows air onto the tip of the cover tape. The control unit adjusts the amount of air ejected according to the number of times the counter is run. The component mounting device according to claim 1.

11. A component mounting method for mounting components onto a substrate using a carrier tape having a base tape with pockets for accommodating components and a cover tape attached to the upper surface of the base tape, The tape transport unit transports the carrier tape along the tape transport path, and the peeling unit peels the cover tape from the base tape, thereby supplying the components contained in the carrier tape to a component removal position downstream of the peeling unit. The camera images the carrier tape, including at least the base tape, at the part removal position. The control unit determines whether or not the cover tape has been peeled off the base tape based on the image captured by the camera. When the control unit determines that the cover tape has not been peeled from the base tape, it drives the tape transport unit to transport the carrier tape upstream, and the peeling unit peels the cover tape from the base tape again. Component mounting method.

Images