Tape feeder setup system

Abstract

Provided is a tape feeder setup system comprising: a placement stage on which a tape feeder for supplying components is placed, the tape feeder including a drive mechanism that feeds out, from a reel, a carrier tape carrying a plurality of components to be mounted to a board and transports the carrier tape to a predetermined supply direction; a determination unit that determines, for the tape feeder placed on the placement stage, whether to automatically return the carrier tape in an opposite direction of the supply direction on the basis of a future use plan of the components and an estimable future use frequency of the components; and a control unit that, when the determination unit determines to automatically return the carrier tape in the opposite direction, controls the drive mechanism of the tape feeder to return the carrier tape in the opposite direction.

Description

[Technical field]

[0001] The present specification relates to a tape feeder setup system that assists or supports the setup change of a tape feeder used in a component mounting machine. [Background technology]

[0002] A technology for mass-producing board products by performing substrate-related operations on boards on which circuit patterns are formed has become widespread. Furthermore, it has become common to configure a substrate-related operation line by arranging multiple substrate-related operation machines that perform substrate-related operations. A representative example of a substrate-related operation machine is a component mounting machine that performs component mounting operations. Many component mounting machines use a tape feeder that unwinds and feeds a carrier tape that contains multiple components from a reel. When changing the type of substrate to be produced, it is often necessary to change the setup of multiple tape feeders. Patent Document 1 discloses an example of a technology related to this type of tape feeder setup change.

[0003] The tape feeder setup system disclosed in Patent Document 1 includes a mounting table on which the tape feeder is mounted, a usage schedule determination unit that determines whether or not there is a schedule for using the parts supplied from the tape feeder, and a control unit that controls the drive mechanism of the tape feeder to return the carrier tape in the reverse direction if there is no schedule for use. This is said to enable the engagement state of the carrier tape with the tape feeder to be released without manual work by an operator, and the reel to be removed reliably and without significant effort on the part of the operator. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] International Publication No. 2018 / 109793 Summary of the Invention [Problem to be solved by the invention]

[0005] According to the technology of Patent Document 1, the carrier tape containing the components that are not scheduled to be used is returned in the opposite direction, thereby reducing the effort of removing the reel from the tape feeder. However, when the reel is used again, the reel needs to be reset and the carrier tape needs to be reloaded. For this reason, it is easier to reduce the effort of not removing a reel that will be used in the near future even if it is not scheduled to be used. On the other hand, a tape feeder in which a reel that will not be used for a long period of time is set cannot be used for production. This reduces the efficiency of using the limited number of tape feeders owned and causes problems in the production of board products. Therefore, it is desirable to consider not only whether the reel is scheduled to be used again, but also the likelihood of it being used in the near future when deciding whether to remove the reel.

[0006] Therefore, the problem to be solved by this specification is to provide a tape feeder setup system that can properly determine whether or not a reel should be removed, taking into consideration not only future usage plans for parts but also future frequency of use, and can reliably reduce the effort required for setup changes. [Means for solving the problem]

[0007] This specification discloses a tape feeder setup system that includes a mounting table for mounting a tape feeder having a drive mechanism that unwinds a carrier tape containing a plurality of components to be mounted on a board from a reel and feeds the components in a predetermined supply direction, a determination unit that determines, for the tape feeder mounted on the mounting table, whether or not to automatically return the carrier tape in the direction opposite to the supply direction based on a future use plan for the components and an estimable future frequency of use of the components, and a control unit that controls the drive mechanism of the tape feeder to return the carrier tape in the reverse direction when the determination unit determines that the carrier tape should be automatically returned in the reverse direction. Effect of the Invention

[0008] In the disclosed tape feeder setup system, the tape feeder placed on the placement table is targeted, and it is determined whether or not to automatically return the carrier tape in the reverse direction based on the future use plan and future use frequency of the parts. Therefore, only the carrier tape containing the parts that are not scheduled to be used and are unlikely to be used in the near future because of their low future use frequency can be selected and returned in the reverse direction. This automatically releases the engagement state of the carrier tape with the tape feeder, thereby reducing the effort required for setup change to remove the reel. On the other hand, the carrier tape containing the parts that are not scheduled to be used but are likely to be used in the near future because of their high future use frequency is maintained in a loaded state in the tape feeder. This eliminates the need for the repetitive work of resetting the reel and reloading the carrier tape in the near future, thereby reducing the effort required for setup change. [Brief description of the drawings]

[0009] [Figure 1] 1 is a plan view of a component mounting machine to which a tape feeder setup system according to an embodiment of the present invention is applied. [Diagram 2] FIG. 2 is a side view of the tape feeder and reel. [Diagram 3] FIG. 1 is a diagram illustrating a configuration of a tape feeder setup system according to an embodiment. [Figure 4] FIG. [Diagram 5] FIG. 2 is a block diagram showing a control configuration of the tape feeder setup system. [Figure 6] FIG. 1 is a production flow diagram conceptually showing the process of producing a plurality of types of substrates. [Figure 7] FIG. 11 is an operational flow diagram illustrating the operation of the tape feeder setup system in the setup process. [Figure 8] 13 is a diagram showing an example of a display in which the display unit displays setup work required in a setup process. FIG. [Figure 9] FIG. 4 is a diagram for explaining the operation of a storage unit; [Figure 10]FIG. 11 is an operational flow diagram illustrating the operation of the tape feeder setup system in the post-setup process. [Figure 11] 13 is a diagram showing an example of a display in which the display unit displays a setup task required in a subsequent setup process. FIG. [Figure 12] 11A and 11B are diagrams for explaining the operation of a release unit. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0010] 1. Configuration of component placement machine 1 First, the configuration of a component mounting machine 1 to which the tape feeder setup system of the embodiment is applied will be described with reference to Fig. 1. The component mounting machine 1 is installed on a substrate-to-substrate work line that mass-produces substrate products. As shown in Fig. 1, the component mounting machine 1 is composed of a substrate transport section 2, a component supply section 3, and a component transfer section 4. The left-right direction in Fig. 1 is the X-axis direction in which a substrate K is transported, and the up-down direction in Fig. 1 is the Y-axis direction, which corresponds to the front-rear direction of the component mounting machine 1.

[0011] The board transport section 2 transports a board K on which a circuit pattern is formed. The board transport section 2 has a pair of guide rails 22, a pair of conveyor belts 26, and a clamp device 28. The pair of guide rails 22 are arranged parallel to each other with a gap therebetween. The pair of conveyor belts 26 are formed of a circular belt member on which the board K can be placed. Each of the pair of conveyor belts 26 is driven to rotate along the guide rails 22 and transports the board K in the X-axis direction. The clamp device 28 is disposed below the mounting position set approximately in the center in the X-axis direction. The clamp device 28 pushes up the board K from below and clamps and positions it between the guide rails 22.

[0012] The component supply unit 3 supplies components P to be mounted on the board K. As shown in FIG. 1, the component supply unit 3 is disposed at the front side of the component mounting machine 1. The component supply unit 3 is composed of a mounting table 32, a feeder holding unit 34, and a plurality of tape feeders 5. The mounting table 32 is detachably attached to the component mounting machine 1. The mounting table 32 is formed, for example, in the shape of a dolly. A label (not shown) indicating a mounting table ID that identifies the individual mounting table 32 is affixed to the mounting table 32.

[0013] The feeder holding section 34 has a generally rectangular shape and is disposed above the mounting table 32. The feeder holding section 34 has a plurality of slots 36 arranged side by side in the X-axis direction and extending in the Y-axis direction and parallel to one another. Different slot numbers are assigned to the respective slots 36. As shown in FIG. 3, sub-connectors 37 are arranged at the rear of the feeder holding section 34, one for each slot 36. Furthermore, the multiple sub-connectors 37 are connected in parallel to one main connector 38.

[0014] Each of the multiple tape feeders 5 is removably inserted and placed in a slot 36 of the feeder holding unit 34. Therefore, the slot number represents the arrangement position of each of the multiple tape feeders 5. When a tape feeder 5 is inserted into a slot 36, the feeder side connector is automatically connected to the sub-connector 37. As a result, a feeder control unit 59, which will be described later, is communicatively connected to the main connector 38. Each tape feeder 5 pulls out a carrier tape T (see FIG. 2) from a reel R held on the front side, feeds the carrier tape T to a component supply position 51 close to the rear end, and supplies a component P at the component supply position 51. A detailed configuration of the tape feeder 5 will be described later.

[0015] The component transfer unit 4 picks up a component P from a component supply position 51 and transfers it to a predetermined mounting position on the board K. The component transfer unit 4 is composed of a pair of guide rails 41, a Y-axis slider 42, an X-axis slider 43, a mounting head 44, a board camera 46, and the like. The pair of guide rails 41 are disposed on both the left and right sides of the component mounting machine 1 at a distance from each other, extend in the Y-axis direction, and are parallel to each other. The Y-axis slider 42 is formed of a member that is long in the X-axis direction, and is mounted by spanning the pair of guide rails 41. The Y-axis slider 42 is driven by a Y-axis servo motor (not shown) to move in the Y-axis direction.

[0016] The X-axis slider 43 is mounted on the Y-axis slider 42. The X-axis slider 43 is driven by an X-axis servo motor (not shown) provided on the Y-axis slider 42 to move in the X-axis direction. The mounting head 44 is attached to the underside of the X-axis slider 43. The mounting head 44 moves in two horizontal directions (X and Y directions) in accordance with the movement of the Y-axis slider 42 and the X-axis slider 43. The mounting head 44 has a detachable suction nozzle 45 that uses negative pressure to pick up the component P. The suction nozzle 45 moves to a component supply position 51 of the component supply unit 3 to pick up the component P, and moves to a predetermined mounting position on the board K to mount the component P. The mounting head 44 may have multiple suction nozzles 45. The mounting head 44 may also have a component mounting tool that clamps the component P instead of the suction nozzle 45.

[0017] The board camera 46 is attached to the rear side of the mounting head 44 below the X-axis slider 43. The board camera 46 captures an image of the reference mark of the positioned board K from above to obtain image data. This image data is processed to obtain accurate position information of the board K. This position information is used for position control when the suction nozzle 45 mounts the component P.

[0018] In addition, a component camera 48 is attached between the board transport unit 2 and the component supply unit 3. The component camera 48 captures an image of the component P picked up by the suction nozzle 45 from below to obtain image data. This image data is processed to obtain information on the shape of the component P and information on the suction position and rotational attitude. The shape information is used, for example, to determine whether the component is correct or not. In addition, the information on the suction position and rotational attitude is used for position control and attitude control when the suction nozzle 45 mounts the component P.

[0019] 2.Detailed configuration of tape feeder 5 Next, a detailed configuration of the tape feeder 5 will be described with reference to FIG. 2. The tape feeder 5 is formed to be thin and have a small width dimension. As shown in FIG. 2, the tape feeder 5 has a reel holding shaft 52 for holding the reel R near the front side. The reel holding shaft 52 is inserted into the center hole of the reel R to hold the reel R detachably and rotatably. The reel R is a rotating body around which the carrier tape T containing a plurality of components P is wound. The carrier tape T is provided with a number of cavities (not shown) that contain the components P one by one. Furthermore, the carrier tape T is provided with a number of sprocket holes on one side in the tape width direction.

[0020] A label 53 indicating a reel ID for identifying an individual reel R is attached to the side of the reel R. The reel ID includes information for identifying the type of part P, or is stored in association with information for identifying the type of part P. The label 53 is created by printing, for example, a barcode, a two-dimensional code, a character string, or the like.

[0021] The tape feeder 5 has a tape insertion opening 54 and a guide rail 55 as a transport path for feeding the carrier tape T. The tape insertion opening 54 is disposed at a position above and behind the reel R held by the reel holding shaft 52. The guide rail 55 extends in a predetermined supply direction, in other words, extends from the tape insertion opening 54 to the component supply position 51. A tape peeling mechanism 56 is provided on the guide rail 55 in front of the component supply position 51. The tape peeling mechanism 56 peels off the cover tape of the carrier tape T to expose the component P accommodated in the cavity portion of the base tape, so that the suction nozzle 45 can suction the component P.

[0022] The tape feeder 5 also has a sprocket 57 and a drive motor 58 as a drive mechanism for feeding the carrier tape T. The sprocket 57 is rotatably supported between the component supply position 51 and the tape peeling mechanism 56. The teeth of the sprocket 57 pass through holes formed in the guide rail 55 and engage with sprocket holes in the carrier tape T. The drive motor 58 is connected to the rotating shaft of the sprocket 57. The drive motor 58 drives the sprocket 57 to rotate in the forward direction by rotating in the forward direction so as to feed the carrier tape T in a predetermined supply direction. The drive motor 58 drives the sprocket 57 to rotate in the reverse direction by rotating in the reverse direction so as to return the carrier tape T in the opposite direction to the supply direction. The operation and stopping of the drive motor 58, as well as the switching between forward and reverse rotation, are controlled by a feeder control unit 59.

[0023] The leading end of the carrier tape T is inserted into the tape insertion port 54 by an operator's loading operation, and is fed along the guide rail 55. After the leading end of the carrier tape T reaches the sprocket 57 and the teeth of the sprocket 57 engage with the sprocket holes of the carrier tape T, the carrier tape T is fed by the drive motor 58. The carrier tape T is appropriately cut after passing the component supply position 51, so that it can be returned in the reverse direction.

[0024] The feeder control unit 59 is connected to a host control unit (not shown) of the component mounting machine 1 for communication and performs bidirectional information transmission. The feeder control unit 59 controls the drive motor 58 according to commands from the host control unit. The feeder control unit 59 also holds information on a feeder ID that identifies an individual tape feeder 5. Furthermore, the feeder control unit 59 holds the reel ID of the set reel R in association with the feeder ID. A label (not shown) indicating the feeder ID is affixed to the case of the tape feeder 5.

[0025] Furthermore, tape feeder 5 has an operation switch 5A and a display unit 5B on the upper front side. Operation switch 5A and display unit 5B are electrically connected to feeder control unit 59. Operation switch 5A has a feed switch that feeds carrier tape T in the supply direction, and a return switch that returns carrier tape T in the opposite direction. When feeder control unit 59 does not receive a command from a higher-level control unit and operation of operation switch 5A is enabled, feeder control unit 59 controls drive motor 58 according to the operation of operation switch 5A.

[0026] When removing reel R from tape feeder 5 during a setup change, if the teeth of sprocket 57 are engaged with the sprocket holes of carrier tape T, the carrier tape T cannot be wound onto reel R and reel R cannot be removed. For this reason, the operator presses the return switch of operation switch 5A to return carrier tape T in the opposite direction, thereby releasing the engaged state. This makes it possible to manually wind carrier tape T and remove reel R.

[0027] Display unit 5B is configured with, for example, a plurality of indicator lights, but is not limited thereto. In the embodiment, display unit 5B is configured with a combination of three indicator lights, namely, a green light, an orange light, and a red light. Display unit 5B displays the lit, blinking, and off states of each indicator light. The contents displayed by display unit 5B are, for example, the current state of tape feeder 5, an abnormality item when an abnormality occurs, and the like.

[0028] 3. Configuration of Tape Feeder Setup System 6 Next, the configuration of the tape feeder setup system 6 of the embodiment will be described with reference to Figs. 3 and 4. The tape feeder setup system 6 assists or supports setup changes such as attachment and detachment of the tape feeder 5 to the mounting table 32 and attachment and detachment of the reel R to the tape feeder 5. In the embodiment, the tape feeder setup system 6 operates on the mounting table 32 removed from the component mounting machine 1 in an external setup area provided separately from the substrate-related work line on which the component mounting machine 1 is installed. Without being limited thereto, the tape feeder setup system 6 may operate on the mounting table 32 attached to the component mounting machine 1. As shown in Fig. 3, the tape feeder setup system 6 is composed of a host computer 7, an external setup station 8, and the mounting table 32 removed from the component mounting machine 1.

[0029] The host computer 7 manages the production plan for the board K using one or more component mounting machines 1, the operation status of the component mounting machines 1, the production status of the board K, the supply status of the components P, and the production results of the board K. The host computer 7 is communicatively connected via a LAN 71 or the like to a personal computer 83 provided in the off-site setup station 8. Therefore, the host computer 7 and the personal computer 83 share a lot of information via communication.

[0030] As shown in FIG. 4, the external setup station 8 is formed in the shape of a carriage that can move in the external setup area. The external setup station 8 is composed of a housing 81, a power tap 82, a personal computer 83, a communication unit 84, a control box 85, a connector 87, a reel set table 89, and the like. The housing 81 is formed in a box shape and has a plurality of casters 811 for movement at the bottom. The power tap 82 is connected to a source power source and supplies, for example, AC 100 volts of power. Specifically, the power tap 82 supplies power to the personal computer 83 and the reel set table 89. Furthermore, the power tap 82 supplies power to the tape feeder 5 on the placement table 32 via the control box 85, the harness 86, and the connector 87. In FIG. 3, the power supply system is depicted by double lines.

[0031] The personal computer 83 is disposed on the left side of the top surface 812 of the housing 81. The personal computer 83 has an operation unit 831 such as a keyboard and a mouse through which the operator performs input operations, a display unit 832 such as a liquid crystal display through which the operator visually confirms, and a central processing unit 833 that performs arithmetic control. The personal computer 83 is communicatively connected to a communication unit 84 via a USB cable 834 or the like. Furthermore, the communication unit 84 is communicatively connected to a control box 85. The control box 85 is connected to a connector 87 via a harness 86 including a power line 861 and a communication line 862. The control box 85 has the functions of a power supply repeater and a communication repeater. The control box 85 may have an operation switch for switching between execution and stop of the relay function.

[0032] The connector 87 is fitted into the main connector 38 provided in the feeder holding portion 34 of the mounting table 32. As described above, the main connector 38 is connected in parallel to the multiple sub-connectors 37 provided for each slot 36 via a branching harness. Thus, each of the feeder control units 59 of the multiple tape feeders 5 is communicatively connected to the personal computer 83. In the embodiment, the mounting table 32 is not detachable from the off-site setup station 8 but is communicatively connected to the personal computer 83. Without being limited thereto, the mounting table 32 may be attached to the off-site setup station 8 to communicatively connect each of the feeder control units 59 to the personal computer 83.

[0033] The personal computer 83 is also provided with a barcode reader 88. The barcode reader 88 is operated by an operator to read the labels 53 indicating the above-mentioned operation console ID, feeder ID, and reel ID. Furthermore, the barcode reader 88 transmits the read ID information to the personal computer 83. The barcode reader 88 is stored hanging in a holder 813 provided on the upper left side of the housing 81 when not in use.

[0034] The reel set table 89 is disposed to the right of the top surface 812 of the housing 81. The reel set table 89 is a place where the tape feeder 5 to be placed on the feeder holding portion 34 is prepared. In other words, the reel set table 89 is a place where the preparation work of setting the reel R on the tape feeder 5 is performed. The reel set table 89 has a slot and a sub-connector of the same shape as the feeder holding portion 34, and is formed so that a plurality of tape feeders 5 can be placed on it. In addition, the feeder control portion 59 of the tape feeder 5 placed on the reel set table 89 is connected for communication with the personal computer 83. Unlike the placement table 32, the reel set table 89 has a wide working space on both sides of the tape feeder 5, which makes it easy to set the reel R and load the carrier tape T.

[0035] 4. Control configuration of tape feeder setup system 6 Next, the control configuration of the tape feeder setup system 6 of the embodiment will be described with reference to Fig. 5. In Fig. 5, one tape feeder 5 is illustrated, and other tape feeders 5 are omitted. As shown in Fig. 5, the host computer 7 stores production plan data 73, production performance data 74, and equipment data 75 in an attached storage device 72.

[0036] The production plan data 73 includes planning information such as the types of boards K to be produced in the future, the production sequence, the number of boards to be produced, ID information of the component mounting machine 1 to be used, the start time of production, and the end time of production. The production plan data 73 includes a usage plan of components P indicating the types and quantities of components P to be used according to the types of boards K. The production plan data 73 is updated sequentially when the production of a certain type of board K ends or when an instruction to produce a new board K is given, or is updated periodically.

[0037] The production performance data 74 includes performance information such as the types of boards K produced up to now, the production sequence, the number of boards produced, ID information of the component mounting machine 1 used, the start time of production, and the end time of production. The production performance data 74 also includes the usage history of components P, which indicates the types and quantities of components P used according to the types of boards K. The production performance data 74 is updated each time the production of a certain type of board K is completed, or is updated periodically.

[0038] The equipment data 75 includes information on the component mounting machine 1 and information on equipment such as the mounting table 32 and the tape feeder 5 that are detachably used in the component mounting machine 1. The equipment data 75 includes information on the performance and specifications of the equipment, as well as information on the operation history and maintenance history of the equipment, and information on the current combination status and past combination history of the equipment when the equipment is used in combination with each other.

[0039] The host computer 7 has six functional units realized by using software, namely, a judgment unit 91, a calculation unit 92, an estimation unit 93, a memory unit 94, a release unit 95, and a discrimination unit 96. Meanwhile, the personal computer 83 has a control unit 97, which is a functional unit realized by using software, in a central processing unit 833. The control unit 97 acquires ID information read by a barcode reader 88. The control unit 97 also controls the feeder control unit 59 of the tape feeder 5, and provides setup information to the operator by displaying it on a display unit 832. Next, the functions of each of the seven functional units will be described.

[0040] The determination unit 91 refers to at least one of the ID information read by the barcode reader 88 and the device data 75 to identify the target placement table 32, tape feeder 5, component P, carrier tape T, and reel R. The determination unit 91 also acquires a future use plan for the component P from the production plan data 73. The determination unit 91 also acquires an estimable future use frequency of the component P from the calculation unit 92 or the estimation unit 93. Then, the determination unit 91 determines whether or not to automatically return the carrier tape T in the opposite direction to the supply direction, for the tape feeder 5 placed on the placement table 32, based on the future use plan for the component P and the estimable future use frequency of the component P. This determination is performed individually for each of the multiple tape feeders 5.

[0041] Here, the calculation unit 92 operates when there is a future production plan for multiple types of boards K in the production plan data 73. The calculation unit 92 calculates the future use frequency based on the usage plan for components P included in the future production plan for multiple types of boards K. The future use frequency is expressed, for example, as a fraction with the total planned production number of boards K as the denominator and the number of boards K on which components P are to be mounted as the numerator. The calculation unit 92 passes the future use frequency of components P to the determination unit 91, prior to the estimation unit 93.

[0042] On the other hand, the estimation unit 93 operates when there is no future production plan for multiple types of boards K in the production plan data 73. In other words, the estimation unit 93 operates only when the type (board type) of the board K to be produced next is undecided, or only one board type is planned to be produced next, and the calculation unit 92 cannot calculate a valid use frequency. The estimation unit 93 refers to the production performance data 74 and estimates the future use frequency based on the actual use frequency obtained from the use performance of the part P. The estimation unit 93 may use the actual use frequency as the future use frequency as it is. In addition, the estimation unit 93 may estimate the future use frequency by taking into account a recent trend in the actual use frequency. For example, even if the average actual use frequency over a long period of time is low, if recent opportunities for use show an increasing trend, it is appropriate for the estimation unit 93 to estimate the future use frequency higher.

[0043] A further description will be given of determination unit 91. During a changeover to change the type of substrate to be produced from the previous substrate type to the next substrate type, determination unit 91 selectively performs the following determinations (1) to (3) on a plurality of tape feeders 5 placed on placement table 32 so as to correspond to the production of substrate K of the previous substrate type.

[0044] (1) It is determined that the carrier tape T containing the components P to be used in the production of the next board type board K will not be returned in the reverse direction. In this case, the tape feeder 5 in question becomes a first type tape feeder 5 that supplies the components P to be used in the production of the next board type board K. Then, the worker performs a first setup operation in which the first type tape feeder 5 is left on the mounting table 32. The first setup operation means that it does not involve any substantial work.

[0045] (2) It is determined that the carrier tape T, which will not be used in the production of the next board type board K and which contains components P whose frequency of use is equal to or greater than a predetermined threshold frequency, will not be returned in the reverse direction. The value of the threshold frequency is set appropriately depending on the number of spare tape feeders 5 and the planned number of types of components P. Qualitatively, when there are many spare tape feeders 5 and a small number of types of components P, the threshold frequency is set low. In this case, the tape feeder 5 becomes a second type tape feeder 5 which will not be used in the production of the next board type board K and which supplies components P whose frequency of use is equal to or greater than a predetermined threshold frequency. Then, the worker performs a second setup operation of removing the second type tape feeder 5 from the mounting table 32.

[0046] (3) It is determined that the carrier tape T containing the components P that are not used in the production of the next board type board K and that have a usage frequency lower than the threshold frequency should be automatically returned in the reverse direction. In this case, the tape feeder 5 in question becomes a third type tape feeder 5 that supplies the components P that are not used in the production of the next board type board K and that have a usage frequency lower than the threshold frequency. The worker then removes the third type tape feeder 5 from the mounting table 32, and further performs a third setup operation of removing the reel R from the removed tape feeder 5.

[0047] Furthermore, the determination unit 91 performs a determination in place of (3) for the components P of a preset portion of component types. That is, the determination unit 91 determines to manually return the carrier tape T housing the components P that will not be used in the production of the board K of the next board type and that have a usage frequency lower than the threshold frequency in the reverse direction. That is, by manually returning the carrier tape T in the reverse direction instead of automatically, it is possible to prevent the components P from falling off from the area where the cover tape near the tip of the carrier tape T has been peeled off by the tape peeling mechanism 56. Usually, expensive component types are preset as the portion of component types, and economic losses due to the components P falling off are reduced.

[0048] The control unit 97 receives one of the determination results (1) to (3) from the determination unit 91 for each tape feeder 5. When the determination result of the determination unit 91 is (3), the control unit 97 controls the drive motor 58 (drive mechanism) of the tape feeder 5 to return the carrier tape T in the reverse direction.

[0049] The storage unit 94 associates the arrangement positions (slot numbers) of the multiple tape feeders 5 arranged and placed on the placement table 32, the feeder IDs identifying the individual tape feeders 5, and the reel IDs identifying the individual reels R, and stores them in the device data 75. This allows the current combination status of devices being used in combination with each other to be accurately stored.

[0050] When the control unit 97 automatically returns the carrier tape T in the reverse direction, the release unit 95 releases the association between the arrangement position (slot number), the feeder ID, and the reel ID stored in the storage unit 94. This allows the mutual combination status of the devices after the third setup work is performed to be accurately stored.

[0051] Furthermore, when the tape feeder 5 is removed from the mounting table 32 without the carrier tape T being returned in the reverse direction, the release unit 95 releases the association between the feeder ID and the reel ID and the arrangement position (slot number) while maintaining the association between the feeder ID and the reel ID. This allows the mutual combination status of the devices after the second setup work has been performed to be accurately stored.

[0052] Based on the maintained association between the feeder ID and the reel ID, the discrimination unit 96 discriminates whether or not there is a tape feeder 5 that has sent in the supply direction the carrier tape T containing the components P to be mounted on the boards K to be produced in the future. This makes it clear whether or not there is a single tape feeder 5 in which the reel R is set and the carrier tape T is loaded. Furthermore, it makes clear whether or not setup work for the tape feeder 5 on the reel set table 89 is required.

[0053] 5. Operation of tape feeder setup system 6 Next, the operation of the tape feeder setup system 6 will be described with reference to Figs. 6 to 12. First, an overview of the production flow for producing a plurality of types of substrates K will be described. As shown in Fig. 6, the production flow is made up of a planning process MP1, a warehousing procurement process MP2, a setup process MP3, a production execution process MP4, a post-setup process MP5, and a storage process MP6. The tape feeder setup system 6 is used in the setup process MP3 and the post-setup process MP5. Hereinafter, the description will be given assuming a case in which a setup change of the second placement stage 32 is performed in the setup process MP3 while a substrate K of the current substrate type is being produced using the first placement stage 32 in the production execution process MP4.

[0054] In the plan creation process MP1, the production plan data 73 described above is created and updated. In the next shipping procurement process MP2, the component P to be mounted on the board K of the next board type is procured. If the component P is in stock, the reel R on which the carrier tape T containing the component P is wound is shipped from the storage warehouse 79 (see arrow A1). Alternatively, the tape feeder 5 on which the reel R is already set is shipped from the storage warehouse 79. If the component P is not in stock or the stock amount is insufficient, the component P (reel R) is procured by a method such as purchasing.

[0055] In the next setup process MP3, the setup of second mounting table 32 which has been used in the production of the previous substrate type substrate K is changed over. The worker uses reel set table 89 of external setup station 8 to set reel R on tape feeder 5, and pulls out carrier tape T from reel R to perform loading work. Furthermore, the worker places tape feeder 5 with reel R set thereon on second mounting table 32. The progress of the setup change of second mounting table 32 is displayed on display unit 832 of personal computer 83.

[0056] In the next production execution process MP4, when the production of the board K of the current board type is completed, the first mounting table 32 is removed from the component mounting machine 1. Then, the second mounting table 32 is attached to the component mounting machine 1, and the production of the board K of the next board type is started. Note that, unlike the above explanation, the first mounting table 32 may be changed over after the production of the board K of the current board type is completed. Even so, the downtime of the component mounting machine 1 is reduced by alternately using the two mounting tables 32.

[0057] In the next post-setup process MP5, post-setup of the first mounting table 32 is performed. The worker performs the first, second, and third setup work described above. As a result, the first type tape feeder 5 is left on the first mounting table 32. The second type tape feeder 5 is removed from the mounting table 32, and the loaded state of the carrier tape and the set state of the reel R are maintained. The third type tape feeder 5 is removed from the mounting table 32, and further the reel R is removed. The first mounting table 32 on which the first type tape feeder 5 is left is used for the next setup process MP3 (see arrow A2).

[0058] In the next storage process MP6, the worker stores the second type tape feeder 5 with the reel R set therein, the third type tape feeder from which the reel R has been removed, and the partially used reel R removed from the third type tape feeder into the storage warehouse 79 (see arrow A3). Note that the worker may not store the second type tape feeder 5 that is planned to be used in the near future, but may instead temporarily store it inside the housing 81 of the off-site setup station 8, for example.

[0059] Next, the operation of the tape feeder setup system 6 in the setup process MP3 will be described together with the work content of the worker. In step S1 of FIG. 7, the worker moves the mounting table 32 close to the external setup station 8 and fits the connector 87 into the main connector 38. In the next step S2, the worker uses the barcode reader 88 to read the operation table ID. The operation table ID is transmitted from the barcode reader 88 to the control unit 97. The control unit 97 acquires the feeder ID and reel ID from each of the feeder control units 59 of the tape feeders 5 at each arrangement position. The combination of the operation table ID, arrangement position, feeder ID, and reel ID represents the current state of the mounting table 32.

[0060] In the next step S3, the control unit 97 acquires a usage plan for components P to be used for the next board type from the production plan data 73 of the host computer 7. In the next step S4, the control unit 97 compares the current state of the mounting tables 32 with the usage plan for components P to determine the shortage of components P. Furthermore, the control unit 97 displays the setup work required to eliminate the shortage of components P on the display unit 832 of the personal computer 83. The display unit 832 performs a display, for example, as shown in FIG.

[0061] In the display example of FIG. 8, the first to third setup operations are indicated by arrows B1 to B3. The first setup operation indicated by arrow B1 is an operation of setting a reel R having an ID of "R101" in a tape feeder 5 having an ID of "F011". The second setup operation indicated by arrow B2 is an operation of placing the tape feeder 5 set up in the first setup operation in the arrangement position S01. The third setup operation indicated by arrow B3 is an operation of placing a tape feeder 5 having an ID of "F012" in which a reel R having an ID of "R102" has already been set, in the arrangement position S02. Note that the presence or absence of a tape feeder 5 in which a reel R has already been set is determined in advance by the determination unit 96. Furthermore, for the arrangement position S03, a first type tape feeder 5 having an ID of "F013" is placed, and no setup operation is required.

[0062] In the next step S5, the worker sets the reel R in accordance with the display on the display unit 832. For example, in the first setup operation described above, the worker first places the tape feeder 5 having an ID of "F011" on the reel set table 89. The worker then sets the reel R having an ID of "R101" on this tape feeder 5, and pulls out the carrier tape T from the set reel R to perform the loading operation. The worker then uses the barcode reader 88 to read the reel ID. The read reel ID is transferred from the control unit 97 to the feeder control unit 59. The feeder control unit 59 holds the reel ID in association with its own feeder ID.

[0063] In the next step S6, the worker places the tape feeder 5. For example, in the second setup work described above, the worker places the tape feeder 5 with an ID of "F011" in the arrangement position S01. In the third setup work, the worker places the tape feeder 5 with an ID of "F012" in the arrangement position S02. As the setup work progresses, the display exemplified in FIG. 8 is updated in real time, and the setup work that has been completed is erased and only the remaining setup work is displayed. This makes it easy for the worker to grasp the progress of the setup work, and also prevents mistakes in the setup work.

[0064] In reality, many more setup operations are often performed for many more tape feeders 5. The second and third setup operations described above are allowed to be performed in a different order. On the other hand, the first and second setup operations cannot be performed in a different order. This is because even if one tries to set the reel R in the tape feeder 5 on the mounting table 32, the work space is too narrow to perform the setting operation.

[0065] In the next step S7, the storage unit 94 associates the ID information and stores it in the device data 75. For example, as shown in Fig. 9, the storage unit 94 stores the association between the arrangement position, the feeder ID, and the reel ID in the form of a list in which each is represented by one line. In the next step S8, the worker removes the connector 87 from the main connector 38. This completes all the setup work for the mounting table 32, and the mounting table 32 is ready to be moved to the component mounting machine 1 and attached.

[0066] Next, the operation of the tape feeder setup system 6 in the post-setup process MP5 will be described together with the work content of the worker. In the following, the description will be given assuming that the placement table 32, the current state of which is illustrated in FIG. 9, has been used. In step S11 in FIG. 10, the worker moves the used placement table 32 close to the external setup station 8 and engages the connector 87 with the main connector 38. In the next step S12, the operator obtains the operation table ID, the arrangement position, the feeder ID, and the reel ID in the same manner as in step S2. As a result, the control unit 97 obtains the current state of the placement table 32 shown in FIG. 9.

[0067] In the next step S13, the determination unit 91 sets a first arrangement position (slot number), and focuses on the tape feeder 5 placed in the first arrangement position and the part P supplied by this tape feeder 5. In the next step S14, the determination unit 91 acquires a future use plan for the part P from the production plan data 73. Furthermore, the determination unit 91 acquires a future use frequency of the part P from the calculation unit 92 or the estimation unit 93.

[0068] In the next step S15, the determination unit 91 performs any one of the above-mentioned determinations (1) to (3) regarding whether or not to automatically return the carrier tape T in the direction opposite to the supply direction. In the next step S16, the determination unit 91 controls the branching destination of the operation flow based on the determination result. That is, the execution of the operation flow is branched to step S22, step S17, or step S19 in response to the determination results (1), (2), or (3).

[0069] In step S17, if the determination result is (2), the fact that it is a second setup operation is displayed on the display unit 832 of the personal computer 83 and the display unit 5B of the tape feeder 5. For example, the display unit 832 displays the display shown in FIG. 11. In the display example of FIG. 11, the second setup operation is indicated by a solid arrow C1. The second setup operation is the operation of removing the tape feeder 5 having the ID "F012" from the arrangement position S02. In addition, the display unit 5B of the tape feeder 5 indicates the second setup operation by turning on an orange light.

[0070] In the next step S18, the release unit 95 releases a part of the association stored in the device data 75. That is, since the tape feeder 5 is removed from the mounting table 32 but the reel R is not removed, the release unit 95 releases the association with the arrangement position (slot number) while maintaining the association between the feeder ID and the reel ID. As a result, as illustrated in FIG. 12, the feeder ID column and the reel ID column corresponding to the arrangement position S02 become blank (indicated by -). Meanwhile, a new row is provided in which the mounting table ID and the arrangement position are blank and the feeder ID of "F012" is associated with the reel ID of "R102". The row in which the two feeder IDs and reel IDs are associated in this way is searched for by the discrimination unit 96. After step S18 is executed, the operation flow merges with step S22.

[0071] In step S19, if the determination result is (3), the fact that it is the third setup work is displayed on the display unit 832 of the personal computer 83 and the display unit 5B of the tape feeder 5. For example, in the display example of FIG. 11, the third setup work is indicated by dashed arrows C2 and C3. The third setup work is the work of removing the tape feeder 5 having the ID "F013" from the arrangement position S03 (see arrow C2), and further removing the reel R having the ID "R103" from the removed tape feeder 5 (see arrow C3). In addition, the display unit 5B of the tape feeder 5 indicates the third setup work by turning on a red light.

[0072] In the next step S20, the control unit 97 commands the feeder control unit 59 to rotate the drive motor 58 in the reverse direction to return the carrier tape T in the reverse direction. This automatically releases the engagement state of the carrier tape T with the tape feeder 5. In the next step S21, the release unit 95 releases the association stored in the device data 75. This causes the feeder ID field and the reel ID field corresponding to the arrangement position S03 to become blank, as exemplified in FIG. 12. After step S21 is executed, the operation flow merges with step S22.

[0073] It should be noted that, when the determination result is (1), the first setup operation causes the tape feeder 5 to remain placed on the placement table 32. Therefore, the display unit 832 does not display an arrow indicating the operation, as shown in the arrangement position S01 in Fig. 11. Furthermore, none of the three indicator lights of the display unit 5B is lit.

[0074] In step S22, the determination unit 91 determines whether or not it is the last arrangement position. If not, in step S23, the determination unit 91 sets the next arrangement position, changes the tape feeder 5 and component P of interest, and returns the operation flow to step S14. If it is the last arrangement position in step S22, the determination unit 91 advances the operation flow to step S24.

[0075] In step S24, the worker performs the work of removing the tape feeder 5 and the reel R corresponding to the second and third setup operations. At this time, the details of the removal work are displayed in two places, display unit 832 and display unit 5B. In addition, as the work of removing the tape feeder 5 progresses, the display exemplified in FIG. 11 is updated in real time, the removal work that has been completed is erased, and only the removal work that remains is displayed. Therefore, the worker can easily grasp the progress of the removal work, and mistakes in the removal work are prevented.

[0076] In step S25 after all of the removal operations are completed, the worker removes the connector 87 from the main connector 38. This allows the mounting table 32 to be stored. Note that the worker may perform the next setup process MP3 on the mounting table 32 without removing the connector 87 from the main connector 38.

[0077] In the tape feeder setup system 6 of the embodiment, for the tape feeder 5 placed on the placement table 32, a determination is made as to whether or not to automatically return the carrier tape T in the reverse direction based on the future use plan and future frequency of use of the components P. Therefore, only the carrier tape T containing the components P that are not scheduled for use and are unlikely to be used in the near future due to their low frequency of use in the future can be selected and returned in the reverse direction. This automatically releases the engagement state of the carrier tape T with the tape feeder 5, thereby reducing the effort required for setup changes to remove the reel R. In addition, the tape feeders 5, the number of which is limited, can be used effectively.

[0078] On the other hand, the carrier tape T containing the components P that are likely to be used in the near future due to their high frequency of future use even if they are not scheduled for use is maintained loaded in the tape feeder 5. This eliminates the need to reset the reel R and reload the carrier tape T in the near future, reducing the effort required for changeover. In addition, the total number of times the reel R is set and removed is reduced, reducing the loss of the components P that fall off the carrier tape T during the work.

[0079] 6. Applications and Modifications of the Embodiments The division of functions between the host computer 7 and the personal computer 83 can be changed in various ways. For example, it is possible to consolidate the seven functional units in the personal computer 83 and omit the host computer 7. Also, one of the calculation unit 92 and the estimation unit 93 may be omitted. Furthermore, the display method of the display unit 832 of the personal computer 83 and the display unit 5B of the tape feeder 5 can be changed in various ways. Also, display may be performed by only one of the display unit 832 and the display unit 5B. The configuration of the tape feeder 5 can also be modified in various ways. For example, this embodiment can be applied to a reel-separate configuration in which the reel R is disposed outside the tape feeder 5. In addition, the embodiment can be applied and modified in various ways. [Explanation of symbols]

[0080] 1: Component mounting machine 2: Board transport section 3: Component supply section 32: Placement table 4: Component transfer section 5: Tape feeder 57: Sprocket 58: Drive motor 59: Feeder control section 5B: Display section 6: Tape feeder setup system 7: Host computer 73: Production plan data 74: Production performance data 75: Equipment data 8: External setup station 83: Personal computer 832: Display section 88: Barcode reader 89: Reel set table 91: Judgment section 92: Calculation section 93: Estimation section 94: Memory section 95: Release section 96: Discrimination section 97: Control section K: Board R: Reel T: Carrier tape P: Component

Claims

1. a mounting table for mounting a tape feeder having a drive mechanism for unwinding a carrier tape containing a plurality of components to be mounted on a board from a reel and feeding the carrier tape in a predetermined supply direction, and for supplying the components; an estimation unit that estimates a future frequency of use in consideration of a recent trend in a frequency of use obtained from a usage record of the part; a determination unit that determines whether or not to automatically return the carrier tape in a direction opposite to the supply direction, based on a future use plan for the component and the future frequency of use of the component estimated by the estimation unit, for the tape feeder placed on the placement table; a control unit that controls the drive mechanism of the tape feeder to return the carrier tape in the reverse direction when the determination unit determines that the carrier tape is to be automatically returned in the reverse direction; A tape feeder setup system comprising:

2. 2. The tape feeder setup system of claim 1, wherein the determination unit and the control unit operate, when a setup change is made to change the type of the substrate to be produced from a previous substrate type to a next substrate type, on the multiple tape feeders placed on the placement table to correspond to the production of the substrate of the previous substrate type.

3. a mounting table for mounting a tape feeder having a drive mechanism for unwinding a carrier tape containing a plurality of components to be mounted on a board from a reel and feeding the carrier tape in a predetermined supply direction, and for supplying the components; a determination unit that determines whether or not to automatically return the carrier tape in the direction opposite to the supply direction based on a future use plan for the component and a future frequency of use of the component that can be estimated, for the tape feeder placed on the placement table; a control unit that controls the drive mechanism of the tape feeder to return the carrier tape in the reverse direction when the determination unit determines that the carrier tape is to be automatically returned in the reverse direction, the determination unit and the control unit operate, at a time of changeover to change the type of the substrate to be produced from a previous substrate type to a next substrate type, with respect to the plurality of tape feeders placed on the placement table so as to correspond to the production of the substrate of the previous substrate type; The determination unit is determining that the carrier tape housing the components to be used in the production of the substrate of the next substrate type is not to be returned in the reverse direction; determining that the carrier tape containing the components will not be used in the production of the next board type board and that the frequency of use is equal to or greater than a predetermined threshold frequency, and not returned in the reverse direction; determining that the carrier tape housing the components that will not be used in the production of the next board type board and that have a usage frequency lower than the threshold frequency is to be automatically returned in the reverse direction; Tape feeder setup system.

4. 4. The tape feeder setup system according to claim 3, wherein the determination unit determines, for a predetermined portion of component types, that the carrier tape containing the components that will not be used in the production of the boards of the next board type and whose frequency of use is lower than the threshold frequency is to be manually returned in the reverse direction.

5. a mounting table for mounting a tape feeder having a drive mechanism for unwinding a carrier tape containing a plurality of components to be mounted on a board from a reel and feeding the carrier tape in a predetermined supply direction, and for supplying the components; a determination unit that determines whether or not to automatically return the carrier tape in the direction opposite to the supply direction based on a future use plan for the component and a future frequency of use of the component that can be estimated, for the tape feeder placed on the placement table; a control unit that controls the drive mechanism of the tape feeder to return the carrier tape in the reverse direction when the determination unit determines that the carrier tape is to be automatically returned in the reverse direction, the determination unit and the control unit operate, at a time of changeover to change the type of the substrate to be produced from a previous substrate type to a next substrate type, with respect to the plurality of tape feeders placed on the placement table so as to correspond to the production of the substrate of the previous substrate type; the tape feeder of the first type for supplying the components to be used in the production of the substrate of the next substrate type; a second type of tape feeder that supplies the components that are not used in the production of the next type of board and whose frequency of use is equal to or greater than a predetermined threshold frequency; and a display unit that displays a type of the tape feeder of a third type that is not used in the production of the boards of the next board type and that supplies the components having a usage frequency lower than the threshold frequency, Tape feeder setup system.

6. a mounting table for mounting a tape feeder having a drive mechanism for unwinding a carrier tape containing a plurality of components to be mounted on a board from a reel and feeding the carrier tape in a predetermined supply direction, and for supplying the components; a determination unit that determines whether or not to automatically return the carrier tape in the direction opposite to the supply direction based on a future use plan for the component and a future frequency of use of the component that can be estimated, for the tape feeder placed on the placement table; a control unit that controls the drive mechanism of the tape feeder to return the carrier tape in the reverse direction when the determination unit determines that the carrier tape is to be automatically returned in the reverse direction, the determination unit and the control unit operate, at a time of changeover in which a type of the substrate to be produced is changed from a previous substrate type to a next substrate type, with respect to the plurality of tape feeders placed on the placement table so as to correspond to the production of the substrate of the previous substrate type; a first setup operation of leaving the tape feeder, which supplies the components to be used in the production of the board of the next board type, on the placement table; a second setup operation of removing from the placement table the tape feeder that supplies the components that are not used in the production of the next type of board and that have a usage frequency equal to or greater than a predetermined threshold frequency; and a display unit that displays a task distinction of a third setup task of removing, from the placement table, the tape feeder that supplies the components that are not used in the production of the boards of the next board type and that have a usage frequency lower than the threshold frequency, and further removing the reel from the removed tape feeder, Tape feeder setup system.

7. 7. The tape feeder setup system according to claim 5, wherein the display unit is provided on each of the plurality of tape feeders.

8. a mounting table for mounting a tape feeder having a drive mechanism for unwinding a carrier tape containing a plurality of components to be mounted on a board from a reel and feeding the carrier tape in a predetermined supply direction, and for supplying the components; a determination unit that determines whether or not to automatically return the carrier tape in the direction opposite to the supply direction based on a future use plan for the component and a future frequency of use of the component that can be estimated, for the tape feeder placed on the placement table; a control unit that controls the drive mechanism of the tape feeder to return the carrier tape in the reverse direction when the determination unit determines that the carrier tape is to be automatically returned in the reverse direction; a storage unit that stores, in association with one another, an arrangement position of each of the plurality of tape feeders arranged and placed on the placement table, a feeder ID that identifies an individual one of the tape feeders, and a reel ID that identifies an individual one of the reels; a release unit that releases the association between the arrangement position, the feeder ID, and the reel ID stored in the memory unit when the carrier tape is automatically returned in the reverse direction by the control unit, and that releases the association between the arrangement position and the feeder ID while maintaining the association between the feeder ID and the reel ID when the carrier tape is automatically returned in the reverse direction by the control unit; A tape feeder setup system comprising:

9. The tape feeder setup system of claim 8, further comprising a discrimination unit that discriminates whether or not there is a tape feeder that has sent in the supply direction the carrier tape containing the components to be mounted on the board to be produced in the future, based on the maintained association between the feeder ID and the reel ID.

10. 10. The tape feeder setup system according to claim 3, further comprising a calculation unit that calculates the future frequency of use based on the usage plan of the part included in future production plans for the multiple types of boards.

11. 10. The tape feeder setup system according to claim 3, further comprising an estimation unit that estimates the future frequency of use based on a past frequency of use determined from a usage record of the part.

12. The tape feeder setup system according to any one of claims 1 to 11, wherein the mounting table is detachable from a component mounting machine that mounts the components on the board, and further, is detachable from or communicatively connectable to an external setup station equipped with the control unit.

Images