Circuit Board Production Method

Abstract

To provide a substrate production method for attaching, to a substrate, components adsorbed and collected from a plurality of automatic feeder devices having an automatic loading function and disposed at a plurality of disposal positions lined up on a pallet provided on a component mounting machine.SOLUTION: A substrate production method includes: a determination step of setting a substrate type of a substrate to be produced, and determining a plurality of component types of a plurality of components to be arranged at a plurality of disposal positions; and a simulation step of, on a condition that a plurality of automatic feeder devices is not moved, performing simulation for arranging the plurality of component types of the components at the plurality of disposal positions.SELECTED DRAWING: Figure 3

Description

[Technical field]

[0001] The present invention relates to a component type placement calculation method for placing a plurality of component types at a plurality of placement positions arranged in a row on a component mounter, in order to increase production efficiency when a feeder device is placed at each of the plurality of placement positions. [Background technology]

[0002] Equipment for producing boards on which many components are mounted includes solder printing machines, component mounting machines, reflow machines, and board inspection machines. It is common to connect these machines to form a board production line. Of these, the component mounting machine includes a board transport device, a component supply device, a component transfer device, and a control device. A representative example of a component supply device is a feeder device that pays out a component storage tape in which components are stored in multiple component storage sections. In combination with this feeder device, a reel holding device is used that rotatably and replaceably holds a component supply reel around which the component storage tape is wound.

[0003] A plurality of feeder devices and a reel holding device are arranged at a plurality of arrangement positions arranged in a row on a component mounting machine. A plurality of component types to be mounted on a board are arranged at the plurality of arrangement positions arranged in a row. At this time, the production efficiency of the board changes depending on the arrangement order of the plurality of component types. For this reason, a technology for simulating the arrangement of component types taking into consideration the moving distance of the mounting head of the component transfer device, etc., has been developed, and an example is disclosed in Patent Document 1. In the device arrangement determination method of Patent Document 1, a management device determines the arrangement of a plurality of feeder devices so that the mounting cycle time (takt time) required to produce one board is the shortest. At this time, the difference in the types of the plurality of feeder devices and the conditions of the component types that can be supplied are taken into consideration (see paragraphs 0026, 0027, etc. of Patent Document 1). [Prior art documents] [Patent documents]

[0004] [Patent Document 1] JP 2009-130337 A Summary of the Invention [Problem to be solved by the invention]

[0005] Incidentally, in order to change the component types supplied from a feeder device, it is necessary to replace the component supply reel. In conventional feeders, it is necessary to rewind the currently used component storage tape that has been unwound onto the component supply reel, and then pull out and load a new component storage tape from the component supply reel, which is a cumbersome task. For this reason, in conventional component type arrangement techniques such as those disclosed in Patent Document 1, in order to realize the simulated arrangement order of component types, it is often the case that the entire feeder device including the component storage tape is replaced, rather than replacing the component storage tape.

[0006] In the conventional method described above, although the direct mounting cycle time for producing the boards can be shortened, a lot of time is required for the changeover work when changing the type of board to be produced. Therefore, the technology of Patent Document 1 is not necessarily a good idea. In particular, there is a recent trend toward high-mix low-volume production, and the opportunities for changeover work increase, so it is important to arrange component types while also taking into consideration the reduction of changeover work. In addition, a large number of feeder devices are required for replacement, which increases the equipment cost.

[0007] Recently, automatic feeder devices (so-called autoloading feeders) with an automatic loading function that automatically loads component storage tapes have been developed with the aim of reducing the amount of changeover work. In an automatic feeder device, when changing the order of component types, the component storage tape is usually replaced, and the entire feeder device is not replaced. This type of automatic feeder device is highly convenient and easy to use when replacing the component storage tape, so it is preferable to make effective use of it. Considering the reduction in changeover work, the increase in equipment costs, and the effective use of automatic feeders, it is becoming necessary to further improve component type arrangement technology.

[0008] The present invention has been made in consideration of the problems in the background art described above, and has as its object to provide a component type placement calculation method which makes effective use of an automatic feeder device having an automatic loading function, and which improves production efficiency by comprehensively taking into account the changeover operation time and the mounting cycle time. [Means for solving the problem]

[0009] A board production method that solves the above-mentioned problems has an automatic loading function that automatically loads a component storage tape containing components stored in each of a plurality of component storage sections when the component storage tape is inserted, and mounts components that are picked up by suction from a plurality of automatic feeder devices arranged in a plurality of arrangement positions lined up on a pallet equipped on a component mounter onto a board, the method comprising: a determination step of setting a board type of the board to be produced and determining a plurality of component types of a plurality of components to be arranged in a plurality of the arrangement positions; and a simulation step of performing a simulation of arranging the plurality of component types of the components at the plurality of arrangement positions under the condition that the plurality of automatic feeder devices are not moved. [Brief description of the drawings]

[0010] [Figure 1] 1 is a plan view showing a simplified schematic diagram of an overall configuration of a component mounter; [Diagram 2] FIG. 13 is a side view showing an example of a configuration in which an automatic feeder device and a reel holding device are mounted on a common pallet in use. [Diagram 3] FIG. 4 is a diagram showing a calculation process flow according to the component type arrangement method of the first embodiment together with work items. [Figure 4] FIG. 11 is a diagram of a feeder arrangement table showing an example of a calculation processing result obtained in a fixed setting step in the calculation processing flow. [Diagram 5] FIG. 11 is a diagram of a feeder arrangement table showing an example of a calculation processing result obtained in the simulation step. [Figure 6] FIG. 4 is a diagram of a feeder arrangement table showing an example of a calculation processing result obtained in a fixed setting step when the calculation processing flow of FIG. 3 is executed in the second embodiment. [Figure 7] FIG. 4 is a diagram of a feeder arrangement table showing an example of a calculation processing result obtained in a simulation step when the calculation processing flow of FIG. 3 is executed in the second embodiment. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0011] (1. Overall configuration of component mounter 1) First, the overall configuration of a component mounter 1 that performs the component type placement method of the first and second embodiments of the present invention will be described with reference to FIG. 1. FIG. 1 is a plan view that shows the overall configuration of the component mounter 1 in a simplified manner. The direction from the right side to the left side of the paper in FIG. 1 is the X-axis direction for carrying in and out the board K, and the direction from the rear of the lower side of the paper to the front of the upper side of the paper is the Y-axis direction. The component mounter 1 is configured by assembling a board transport device 12, a detachable manual feeder device 7 and an automatic feeder device 9, a component transfer device 14, a component camera 15, and a control device 16 on a machine base 19. The board transport device 12, the feeder devices 7 and 9, the component transfer device 14, and the component camera 15 are controlled by the control device 16, and each of them performs a predetermined task.

[0012] The substrate conveying device 12 conveys the substrate K to the mounting position, positions it, and conveys it out. The substrate conveying device 12 is composed of a pair of first and second guide rails 121, 122, a pair of conveyor belts, a clamping device, and the like. The first and second guide rails 121, 122 extend in the conveying direction (X-axis direction) across the center of the upper surface of the machine base 19, and are attached to the machine base 19 in parallel with each other. A pair of endless circular conveyor belts (not shown) are arranged side by side on the inner sides facing each other of the first and second guide rails 121, 122. The pair of conveyor belts rotate with both edges of the substrate K placed on the conveyor conveying surface, and convey the substrate K into and out of the mounting position set in the center of the machine base 19. A clamping device (not shown) is provided below the conveyor belts at the mounting position. The clamping device pushes up the substrate K, clamps it in a horizontal position, and positions it at the mounting position. This enables the component transfer device 14 to perform the mounting operation at the mounting execution position.

[0013] The manual feeder device 7 and the automatic feeder device 9 each sequentially feed components. The feeder devices 7, 9 are flat with a small width dimension, and are arranged in a row in the first to ninth slots SL1 to SL9 of the common pallet 5 mounted on the machine base 19 (described in detail later). In FIG. 1, the automatic feeder devices 9 are arranged in the third to seventh slots SL3 to SL7, and the manual feeder devices 7 are arranged in the other slots SL1, SL2, SL8, and SL9. A reel holding device 6 that is detachable from the common pallet 5 is arranged behind the automatic feeder device 9. Meanwhile, the manual feeder device 7 is integrally provided with a reel holding device. In an actual component mounter, many more feeder devices 7, 9 are often arranged in a row.

[0014] The component transfer device 14 picks up components from each of the supply positions 94 of the multiple feeder devices 7 and 9, transports them to the positioned board K, and mounts them. The component transfer device 14 is an XY robot type device that can move horizontally in the X-axis direction and the Y-axis direction. The component transfer device 14 is composed of a pair of Y-axis rails 141 and 142, a Y-axis slider 143, a mounting head 144, a nozzle tool 145, a board camera 146, and the like. The pair of Y-axis rails 141 and 142 are disposed near both sides of the machine base 19 and extend in the front-rear direction (Y-axis direction). The Y-axis slider 143 is mounted on the Y-axis rails 141 and 142 so as to be movable in the Y-axis direction. The Y-axis slider 143 is driven in the Y-axis direction by a Y-axis ball screw mechanism (not shown).

[0015] The mounting head 144 is mounted on a Y-axis slider 143 so as to be movable in the X-axis direction. The mounting head 144 is driven in the X-axis direction by an X-axis ball screw mechanism (not shown). The nozzle tool 145 is replaceably held on the mounting head 144. The nozzle tool 145 has one or more suction nozzles that pick up components and mount them on the board K. The board camera 146 is provided on the mounting head 144 alongside the nozzle tool 145. The board camera 146 captures an image of a fiducial mark provided on the board K to detect the exact position of the board K.

[0016] Component camera 15 is provided facing upward at the center in the width direction of the upper surface of machine base 19 between board transport device 12 and feeder devices 7, 9. Component camera 15 captures an image of the state of the component picked up by the suction nozzle while mounting head 144 moves from feeder devices 7, 9 onto board K. When the image data from component camera 15 reveals an error in the component pickup attitude or a deviation in the rotation angle, control device 16 fine-tunes the component mounting operation as necessary, and performs control to discard the component if mounting is difficult.

[0017] The control device 16 holds mounting sequence data that specifies the types, mounting positions, and mounting order of components to be mounted on the board K, compatible nozzles, etc. The control device 16 controls the component mounting operation in accordance with the mounting sequence data based on the image data of the board camera 146 and the component camera 15, as well as detection data from sensors (not shown). The control device 16 also successively collects and updates operation status data such as the number of completed boards K produced, the mounting time required to mount components, and the number of component suction errors that have occurred.

[0018] (2. Configuration Example of Automatic Feeder Device 9, Reel Holding Device 6, and Manual Feeder Device 7) Next, a description will be given of a configuration example of the automatic feeder device 9 and the reel holding device 6. Fig. 2 is a side view showing a configuration example of the automatic feeder device 9 and the reel holding device 6 mounted on a common pallet 5 in a used state.

[0019] The common pallet 5 is detachably mounted on the upper side of the machine base 19. However, the common pallet 5 may be fixedly mounted on the upper side of the machine base 19. The common pallet 5 has a feeder mounting section 51 and a reel mounting section 55. The feeder mounting section 51 is formed by providing an upright section 53 on the front side of a substantially rectangular flat section 52, and is substantially L-shaped in side view. Nine first to ninth slots SL1 to SL9 extending in the front-rear direction are engraved in the flat section 52 in a line in the width direction. FIG. 1 shows the positions of the first, fifth and ninth slots SL1, SL5 and SL9 in the width direction. The automatic feeder device 9 is inserted from the rear of the slots SL1 to SL9 toward the front upright section 53 and mounted. The first to ninth slots SL1 to SL9 correspond to the installation positions for the feeder devices 7 and 9.

[0020] The automatic feeder device 9 has a tape insertion opening 91 near the mid-height of the rear end, and an insertion lever 92 near the upper part of the rear end. By lifting the insertion lever 92, the first and second component storage tapes 85, 86 can be inserted in order into the tape insertion opening 91. A pay-out rail 93 is disposed from the tape insertion opening 91 of the automatic feeder device 9 toward the upper part of the front end. A supply position 94 is set on the upper surface of the pay-out rail 93 near the front end. A standby position 96 is set on the upper surface of the pay-out rail 93 near the rear end and close to the tape insertion opening 91. The inserted first and second component storage tapes 85, 86 proceed to the standby position 96 and stop temporarily.

[0021] A tape control unit 95 is provided above the standby position 96. The tape control unit 95 allows the first component storage tape 85 to be unwound from the standby position 96, and keeps the second component storage tape 86 on standby. When the first component storage tape 85 runs out, the tape control unit 95 automatically allows the second component storage tape 86 to be unwound from the standby position 96. Therefore, no splicing work is required to connect the first and second component storage tapes 85, 86. A specific configuration of the tape control unit 95 is disclosed in, for example, JP 2014-82454 A.

[0022] Furthermore, the automatic feeder device 9 is equipped with a tape feeding mechanism (not shown) that is composed of a servo motor, a sprocket, etc. When the first component storage tape 85 is inserted up to the standby position 96, the automatic feeder device 9 drives the servo motor in the forward direction. As a result, the automatic feeder device 9 automatically feeds and loads the first component storage tape 85, and preparations for production of the board K are completed. In other words, the automatic feeder device 9 has an automatic loading function. The second component storage tape 86 may be inserted immediately after the first component storage tape 85 is inserted, or may be inserted while production using the first component storage tape 85 is being performed.

[0023] Moreover, when the automatic feeder device 9 receives an ejection command, it drives the servo motor in the reverse direction. As a result, the automatic feeder device 9 ejects the cut end of the loaded first or second component storage tape 85, 86 from the supply position 94 toward the tape insertion port 91. That is, the automatic feeder device 9 has an automatic ejection function. The ejection command is issued from the control device 16, or is issued when an operator presses an unillustrated ejection button attached to the automatic feeder device 9. The automatic feeder device 9 includes a tape control unit 95 and has an automatic loading function and an automatic ejection function, thereby significantly reducing the effort required for reel replacement work. The applicant of the present application has already filed detailed configuration examples of the automatic feeder device 9 in International Application No. JP2014 / 064443 and International Application No. JP2014 / 083619, etc.

[0024] The reel mounting section 55 of the common pallet 5 is composed of two arm members 56, a front transfer plate 57, and a rear transfer plate 58. The reel mounting section 55 is adapted to be able to mount one or more reel holding devices 6. To be described in detail below, the two arm members 56 are fixed to the rear portions on both sides in the width direction of the feeder mounting section 51, respectively. The arm members 56 are formed so as to initially extend horizontally rearward, then extend at an incline downward rearward, and finally extend horizontally rearward. The front transfer plate 57 is provided so as to connect the inclined portions of the two arm members 56. The rear transfer plate 58 is provided so as to connect the horizontal portions at the rear of the two arm members 56. The reel holding devices 6 are detachably mounted on the upper sides of the front transfer plate 57 and the rear transfer plate 58.

[0025] The reel holding device 6 rotatably holds the first and second component supply reels 81, 82 aligned in the front-rear direction. The size of the reel holding device 6 in the width direction (the direction of the reel axis) is not limited, and the reel holding device 6 holds one or more first and second component supply reels 81, 82 aligned in the width direction. Therefore, the reel holding device 6 is attached to the rear of one or more automatic feeder devices 9 in correspondence with them.

[0026] When changing the order of component types arranged in each slot SL1 to SL9 according to the simulation results, the worker replaces the reel holding device 6 arranged behind the automatic feeder device 9, or replaces only the first and second component supply reels 81, 82. Next, the worker pulls out the first and second component storage tapes 85, 86 from the first and second component supply reels 81, 82, and inserts them from the tape insertion port 91 of the automatic feeder device 9 to the standby position 96. This activates the automatic loading function of the automatic feeder device 9, and the first and second component storage tapes 85, 86 are sequentially fed to the supply position 94.

[0027] On the other hand, manual feeder device 7 is provided with a reel holding device integrally therewith, and holds the component supply reel directly. When an operator sets a new component supply reel in the reel holding device of manual feeder device 7, the operator needs to pull out the component storage tape and load it into manual feeder device 7. This makes reel replacement work a cumbersome task for the operator. When changing the order of the component types arranged in each of slots SL1 to SL9 according to the simulation results, the operator usually replaces the entire manual feeder device 7 together with the reel holding device, and does not perform the reel replacement work. Manual feeder device 7 can be configured based on various known techniques, so a detailed description will be omitted.

[0028] (3. Component Type Arrangement Method of the First Embodiment) Next, the component type arrangement method of the first embodiment will be described with reference to Figs. 3 to 5. The component type arrangement method of the first embodiment is realized by the arithmetic processing function of a control device (host computer) (not shown) that manages a board production line configured including the component mounter 1. Without being limited to this, the component type arrangement method may be realized by a control device 16 of the component mounter 1 or a separate computer device that shares various data such as mounting sequence data. Fig. 3 is a diagram showing a arithmetic processing flow related to the component type arrangement method of the first embodiment together with work items. Moreover, Fig. 4 is a diagram of a feeder arrangement table showing an example of the arithmetic processing result obtained in the fixed setting step S1 in the arithmetic processing flow. Furthermore, Fig. 5 is a diagram of a feeder arrangement table showing an example of the arithmetic processing result obtained in the simulation step S4.

[0029] As a prerequisite, a case is assumed in which a board K of a first board type B1 is first produced by the component mounter 1, and then a board K of a second board type B2 is produced. Nine types of components, the first to ninth component types P1 to P9, are mounted on the board K of the first board type B1, and these nine types of components are supplied from the first to ninth component supply reels R1 to R9. Five first to fifth automatic feeder devices ALF1 to ALF5 are prepared as the automatic feeder devices 9 that can be used, and a large number (n) of manual feeder devices M1 to Mn are prepared as the manual feeder devices 7. The first to seventh component types P1 to P7 can be supplied from any of the first to fifth automatic feeder devices ALF1 to ALF5 and the manual feeder devices M1 to Mn, and the eighth and ninth component types P8 and P9 can be supplied only from the manual feeder devices M1 to Mn.

[0030] The feeder arrangement table shown in FIG. 4 and FIG. 5 consists of 10 stages and 4 columns, and the first stage shows the display contents of each column. As shown by the slot numbers in the first column, the second stage to the tenth stage correspond to the first to ninth slots SL1 to SL9, respectively. The second column shows the component types to be arranged in the first to ninth slots SL1 to SL9. The third column shows the unique names of the feeder devices to be installed in the first to ninth slots SL1 to SL9. The fourth column shows the feeder status indicating whether the feeder device shown in the third column is movable or not. That is, "variable" shows a state in which movement of the feeder device is permitted, and "fixed" shows a state in which the feeder device is fixed and movement is prohibited.

[0031] In the fixed setting step S1 in FIG. 3, the control device determines a part of the first to ninth slots SL1 to SL9 as fixed positions. The control device sets the first to fifth automatic feeder devices ALF1 to ALF5 to be disposed at fixed positions. In an example of the calculation processing result in FIG. 4, the consecutive third to seventh slots SL3 to SL7 are determined as fixed positions. Then, the first automatic feeder device ALF1 is disposed in the third slot SL3, the second automatic feeder device ALF2 is disposed in the fourth slot SL4, and so on in order. As a result, the first to fifth automatic feeder devices ALF1 to ALF5 are disposed together in a range of consecutive slots. This setting is performed based on the input setting operation of the worker. In general, the automatic feeder device 9, which is advantageous in reducing the reel replacement work, is often applied to component types that are consumed quickly. For this reason, it is often advantageous to dispose the automatic feeder device 9 near the center in the width direction close to the component camera 15 and the board K, but this is not always determined.

[0032] In the next step S2, the worker actually installs the first to fifth automatic feeder devices ALF1 to ALF5 into the third to seventh slots SL3 to SL7 so as to match the settings.

[0033] In the next step S3, the control device sets a first board type B1 for the boards to be produced. This setting is performed based on the input setting operation of the worker or a board production plan that has been input and set in advance. As a result, it is decided that the first to ninth component types P1 to P9 will be placed in the first to ninth slots SL1 to SL9, but the placement positions are not yet determined.

[0034] In the next simulation step S4, the control device performs a simulation of arranging the first to ninth component types P1 to P9 in the first to ninth slots SL1 to SL9. That is, the first to ninth component types P1 to P9 are arranged in the first to ninth slots SL1 to SL9 so that their positions can be changed within the range of the constraint conditions, and the mounting cycle time required to produce one board is simulated under each arrangement condition. Then, the control device adopts the arrangement of the first to ninth component types P1 to P9 that provides the shortest mounting cycle time. As a constraint condition, the first to fifth automatic feeder devices ALF1 to ALF5 are not moved from their fixed positions in the third to seventh slots SL3 to SL7. Therefore, the eighth and ninth component types P8 and P9 that can be supplied only from the manual feeder devices M1 to Mn are arranged in any of the first, second, eighth, and ninth slots SL1, SL2, SL8, and SL9.

[0035] The simulation takes into consideration the positional relationship between each slot SL1-SL9 and the component camera 15 and the board K, the number of components of each type P1-P9 to be mounted on one board K, the performance of the nozzle tool 145, and the like. Generally, the type of component with the greatest number of components to be mounted is placed in the fifth slot SL5 directly facing the center of the component camera 15 and the board K, but this is not generally determined. As various techniques are publicly known regarding the specific method of the simulation, detailed explanation will be omitted.

[0036] The arrangement of the first to ninth component types P1 to P9 in the first to ninth slots SL1 to SL9 is determined by the simulation. In the example of the calculation processing result in Fig. 5, the first to fifth component types P1 to P5 are arranged in the fifth, fourth, third, sixth and seventh slots SL5, SL4, SL3, SL6 and SL7, respectively. As a result, the component types P3, P2, P1, P4 and P5 to be supplied from the first to fifth automatic feeder devices ALF1 to ALF5 are determined, respectively.

[0037] On the other hand, the sixth to ninth component types P6 to P9 are placed in the first, second, eighth, and ninth slots SL1, SL2, SL8, and SL9, respectively. However, the name of the manual feeder device 7 is not determined. The control device searches for the first manual feeder device M1 in which the sixth component supply reel R6 that supplies the sixth component type P6 is set, and sets it to be placed in the first slot SL1. If there is no manual feeder device 7 in which the sixth component supply reel R6 is set, the control device sets the first manual feeder device M1 in which the sixth component supply reel R6 can be set. Similarly, the control device sets the second to fourth manual feeder devices M2 to M4 that supply the seventh to ninth component types P7 to P9 to be placed in the second, eighth, and ninth slots SL2, SL8, and SL9, respectively.

[0038] As a result of the above, the feeder allocation table shown in Fig. 5 is completed. The control device displays the completed feeder allocation table to the worker and instructs the details of the changeover work.

[0039] In step S5, the worker performs a setup change operation according to the feeder layout table. In the setup change operation for the first to fifth automatic feeder devices ALF1 to ALF5, the worker sets each of the component supply reels R3, R2, R1, R4, and R5 corresponding to each of the component types P3, P2, P1, P4, and P5 in the reel holding device 6, and attaches the reel holding device 6 to the rear of each of the automatic feeder devices ALF1 to ALF5.

[0040] Here, the reel holding device 6 is suitably configured to rotatably hold five types of component supply reels R3, R2, R1, R4, and R5 in the order described above. This is because an operator only needs to attach one reel holding device 6 during a changeover operation, which is particularly efficient. In addition, a reel holding device 6 that holds multiple types of component supply reels 81, 82, not just five types, reduces the changeover operation for the first to fifth automatic feeder devices ALF1 to ALF5.

[0041] On the other hand, in a changeover operation for the first to fourth manual feeder devices M1 to M4, the worker exchanges the first to fourth manual feeder devices M1 to M4 between the first, second, eighth, and ninth slots SL1, SL2, SL8, and SL9 whose feeder states are "variable". Alternatively, the worker sets the sixth to ninth component supply reels R6 to R9 in the reel holding devices of the first to fourth manual feeder devices M1 to M4 outside the component mounter 1. Then, the worker carries in the first to fourth manual feeder devices M1 to M4 and installs them in the slots SL1, SL2, SL8, and SL9.

[0042] When the changeover work is completed, in step S6, the control device carries out production of the first substrate type B1 substrates K. When production of a predetermined number of substrates K is completed, the control device returns the execution of the computation process flow to step S3.

[0043] Prior to the production of the next board K of the second board type B2, steps S3, S4, and S5 are performed again. Even if the board K to be produced is changed from the first board type B1 to the second board type B2, the first to fifth automatic feeder devices ALF1 to ALF5 are not moved from the fixed positions of the third to seventh slots SL3 to SL7. Then, in response to the change in component type arrangement shown by the simulation result, in the first to fifth automatic feeder devices ALF1 to ALF5, only the reel holding device 6 or the component supply reels R1 to R5 are replaced. Meanwhile, in response to the change in component type arrangement, the first to fourth manual feeder devices M1 to M4 are replaced among the first, second, eighth, and ninth slots SL1, SL2, SL8, and SL9. Alternatively, the fifth and subsequent manual feeder devices M5 to Mn are carried in and installed in the first, second, eighth, and ninth slots SL1, SL2, SL8, and SL9.

[0044] (4. Aspects and Effects of the First Embodiment) The component type arrangement method of the first embodiment is a component type arrangement method for arranging a plurality of component types P1 to P9 of components at a plurality of arrangement positions (first to ninth slots SL1 to SL9) arranged in a row on a common pallet 5 equipped in a component mounter 1, when an automatic feeder device 9 having an automatic loading function for automatically loading component storage tapes 85, 86 when component storage tapes 85, 86 each having components stored therein are inserted into a plurality of component storage sections, a manual feeder device 7 not having an automatic loading function, and a reel holding device 6 for rotatably holding component supply reels 81, 82 around which the component storage tapes 85, 86 are wound. The method includes a fixed setting step S1 for determining some of the plurality of installation positions (third to seventh slots SL3 to SL7) as fixed positions and setting the first to fifth automatic feeder devices ALF1 to ALF5 to be installed at the fixed positions, and a simulation step S4 for performing a simulation of arranging a plurality of component types P1 to P9 at the plurality of installation positions under the condition that the first to fifth automatic feeder devices ALF1 to ALF5 are not moved from the fixed positions and the first to fourth manual feeder devices M1 to M4 are movable to any installation positions (first, second, eighth and ninth slots SL1, SL2, SL8, SL9) other than the fixed positions.

[0045] According to this, when the automatic feeder device 9 and the manual feeder device 7 are used in combination to produce the board K, the first to fifth automatic feeder devices ALF1 to ALF5 are arranged in the fixed positions (the third to seventh slots SL3 to SL7) and are used regularly. Therefore, the first to fifth automatic feeder devices ALF1 to ALF5, which have good workability during the changeover work, can be effectively used. Furthermore, the simulation of the component type arrangement is performed under the condition that the first to fifth automatic feeder devices ALF1 to ALF5 are not moved from the fixed positions, and the manual feeder device 7 can be moved to any arrangement position other than the fixed position. According to this, when changing the component type at the fixed position, the first to fifth automatic feeder devices ALF1 to ALF5 are not moved, and only the reel holding device 6 or the component supply reels R1 to R5 are replaced, thereby shortening the changeover work time. On the other hand, when changing the component type at the arrangement position other than the fixed position, the manual feeder device 7 is replaced, and the changeover work is performed in the same manner as in the conventional case. This allows the mounting cycle time to be minimized. Therefore, production efficiency can be improved by comprehensively taking into account the changeover work time and the mounting cycle time.

[0046] In addition, since the first to fifth automatic feeder devices ALF1 to ALF5 are used regularly, the number of replacement feeder devices 7, 9 is reduced, thereby suppressing equipment costs.

[0047] Furthermore, the reel holding device 6 rotatably holds the first to fifth component supply reels R1 to R5 on which the component storage tapes used for the first to fifth automatic feeder devices ALF1 to ALF5 are wound, or multiple types of component supply reels 81, 82. Then, in a fixing setting step S1, the first to fifth automatic feeder devices ALF1 to ALF5 are set to be arranged together in a continuous range of multiple slots (the third to seventh slots SL3 to SL7).

[0048] According to this, during the changeover work, the worker needs to attach fewer reel holding devices 6 than the number of the first to fifth automatic feeder devices ALF1 to ALF5. Therefore, the changeover work for the first to fifth automatic feeder devices ALF1 to ALF5 is further reduced.

[0049] The component type placement method of the first embodiment can also be implemented as a component type placement calculation device. This component type placement calculation device may be realized by the calculation processing function of a control device (host computer) (not shown) that manages a board production line configured to include the component mounter 1, but is not limited to this, and may be realized by a separately installed computer device that shares various data such as the control device 16 of the component mounter 1 and mounting sequence data. That is, the component type placement calculation device multiple component types P1 to P9 of components are multiplexed when an automatic feeder device 9 having an automatic loading function that automatically loads a component storage tape when a component storage tape storing components is inserted into each of a plurality of component storage sections, a manual feeder device 7 that does not have an automatic loading function, and a reel holding device 6 that rotatably holds component supply reels 81 and 82 around which component storage tapes 85 and 86 are wound are arranged in a plurality of arrangement positions (first to ninth slots SL1 to SL9) arranged in a row on a common pallet 5 equipped in the component mounter 1. The component type placement calculation device places a plurality of component types at a plurality of placement positions, and can be configured to include a fixed setting unit that determines some of the plurality of placement positions (third to seventh slots SL3 to SL7) as fixed positions and sets automatic feeder device 9 to be placed at the fixed positions, and a simulation unit that performs a simulation of placing a plurality of component types at a plurality of placement positions under the condition that automatic feeder device 9 is not moved from the fixed position and manual feeder device 7 is movable to any placement position (first, second, eighth and ninth slots SL1, SL2, SL8, SL9) other than the fixed positions.

[0050] The functions and effects of the component type placement calculation device of this embodiment are the same as those of the component type placement method of the first embodiment.

[0051] (5. Component type arrangement method of the second embodiment) Next, a component type arrangement method according to the second embodiment will be described with reference to Figs. 6 and 7. The component type arrangement method according to the second embodiment is realized by the calculation processing function of the control device, as in the first embodiment, and the calculation processing flow in Fig. 3 is also similar. However, the second embodiment differs from the first embodiment in that a plurality of types of automatic feeder devices are used. Fig. 6 is a diagram of a feeder arrangement table showing an example of a calculation processing result obtained in the fixed setting step S1 when the calculation processing flow in Fig. 3 is executed in the second embodiment. Furthermore, Fig. 7 is a diagram of a feeder arrangement table showing an example of a calculation processing result obtained in the simulation step S4 when the calculation processing flow in Fig. 3 is executed in the second embodiment.

[0052] As a prerequisite, a case is assumed in which the component mounter 1 first produces a board K of the third board type B3, and then produces a board K of the fourth board type B4. Five types of components, eleventh to fifteenth component types P11 to P15, are mounted on the board K of the third board type B3, and these five types of components are supplied from the eleventh to fifteenth component supply reels R11 to R15. The eleventh and twelfth component types P11, P12 are classified into a small component group, the thirteenth and fourteenth component types P13, P14 are classified into a medium component group, and the fifteenth component type P15 is classified into a large component group.

[0053] Available feeder devices include the first and second small automatic feeder devices ALS1 and ALS2, the first and second medium automatic feeder devices ALM1 and ALM2, and the large automatic feeder device ALL. The five automatic feeder devices ALS1, ALS2, ALM1, ALM2, and ALL are structurally the same as the automatic feeder device 9 described in the first embodiment, with the dimensional specifications changed according to the size of the parts to be fed.

[0054] The first and second small automatic feeder devices ALS1, ALS2 can feed both the 11th and 12th component types P11, P12 belonging to the small component group. The first and second medium automatic feeder devices ALM1, ALM2 can feed both the 13th and 14th component types P13, P14 belonging to the medium component group. The large automatic feeder device ALL can feed the 15th component type P15 belonging to the large component group. However, each of the automatic feeder devices ALS1, ALS2, ALM1, ALM2, ALL cannot feed component types of different sizes from different groups.

[0055] In the fixed setting step S1 in the second embodiment, the control device sets the third to seventh slots SL3 to SL7 as fixed positions for each type of automatic feeder. Then, the control device sets the three types of automatic feeders ALS1, ALS2, ALM1, ALM2, and ALL to be disposed at fixed positions for each type. In an example of the calculation processing result in FIG. 6, the fourth and fifth slots SL4 and SL5 are set as fixed positions for small items, and the arrangement of the first and second small automatic feeders ALS1 and ALS2 is set. In addition, the sixth and seventh slots SL6 and SL7 are set as fixed positions for medium items, and the arrangement of the first and second medium automatic feeders ALM1 and ALM2 is set. Furthermore, the third slot SL3 is set as a fixed position for large items, and the arrangement of the large automatic feeder ALL is set.

[0056] In the next step S2, the worker actually installs the five automatic feeder devices ALL, ALS1, ALS2, ALM1, and ALM2 in the third to seventh slots SL3 to SL7 so as to match the settings.

[0057] In the next step S3, the control device sets the third board type B3 for the boards to be produced. This determines that the eleventh to fifteenth component types P11-P15 will be placed in the third to seventh slots SL3-SL7. It is then determined that the fifteenth large component type P15 will be placed in the third slot SL3 to which the large automatic feeder device ALL is fixed. The placement positions of the other eleventh to fourteenth component types P11-P14 have not yet been determined.

[0058] In the next simulation step S4, the control device arranges the eleventh to fourteenth component types P11-P14 in the fourth to seventh slots SL7-SL7 so that their positions can be changed within the range of the constraint conditions, and simulates the mounting cycle time required to produce one board under each arrangement condition. The control device adopts the arrangement of the eleventh to fourteenth component types P11-P14 that results in the shortest mounting cycle time. As a constraint condition, the four small and medium-sized automatic feeder devices ALS1, ALS2, ALM1, ALM2 are not moved from their fixed positions in the fourth to seventh slots SL4-SL7.

[0059] Due to the constraints, two possible cases are possible: a case where a small eleventh component P11 is placed in the fourth slot SL4 and a small twelfth component P12 is placed in the fifth slot SL5, and a case where the eleventh component P11 is placed in the fifth slot SL5 and the twelfth component P12 is placed in the fourth slot SL4. Similarly, two possible cases are possible: a case where a medium thirteenth component P13 is placed in the sixth slot SL6 and a medium fourteenth component P14 is placed in the seventh slot SL7, and a case where the thirteenth component P13 is placed in the seventh slot SL7 and the fourteenth component P14 is placed in the sixth slot SL6. Therefore, in the second embodiment, a simulation may be performed under a total of four conditions, 2 cases x 2 cases.

[0060] The simulation determines the placement of the eleventh to fourteenth component types P11-P14 in the fourth to seventh slots SL4-SL7. In the example of the calculation processing result in Fig. 7, the eleventh to fourteenth component types P11-P14 are placed in the fourth to seventh slots SL4-SL7, respectively. This determines the component types P11-P15 to be supplied from the five automatic feeder devices ALS1, ALS2, ALM1, ALM2, and ALL, respectively.

[0061] As a result of the above, the feeder layout table shown in Fig. 7 is completed. The control device displays the completed feeder layout table to the worker, and instructs the details of the changeover work. In step S5, the worker performs the changeover work in accordance with the feeder layout table. The worker sets each of the component supply reels R15, R11-R14 corresponding to each of the component types P15, P11-14 in the reel holding device 6, and attaches the reel holding device 6 to the rear of each of the automatic feeder devices ALL, ALS1, ALS2, ALM1, ALM2.

[0062] When the setup change operation is completed, in step S6, the control device carries out production of the third substrate type B3 substrates K. When production of a predetermined number of substrates K is completed, the control device returns the execution of the computation process flow to step S3.

[0063] Prior to the production of the next board K of the fourth board type B4, steps S3, S4, and S5 are performed again. Even if the board K to be produced is changed from the third board type B3 to the fourth board type B4, the five automatic feeder devices ALS1, ALS2, ALM1, ALM2, and ALL are not moved from their fixed positions in the third to seventh slots SL3 to SL7. Then, in response to the change in component type arrangement, only the reel holding device 6 or the eleventh to fifteenth component supply reels R11 to R15 are replaced.

[0064] (6. Aspects and Effects of the Second Embodiment) The component type arrangement method of the second embodiment has an automatic loading function for automatically loading component storage tapes 85, 86 when the component storage tapes 85, 86 storing components are inserted into a plurality of component storage sections, and when five automatic feeder devices ALL, ALS1, ALS2, ALM1, ALM2 of three types, small, medium, and large, corresponding to a plurality of component type groups classified based on differences in the plurality of component types of the components, and a reel holding device 6 for rotatably holding component supply reels 81, 82 around which the component storage tapes 85, 86 are wound, are arranged in a plurality of arrangement positions (first to ninth slots SL1 to SL9) arranged in a row on a common pallet 5 equipped in a component mounter 1, a plurality of component types P11 to P15 of the components are arranged in a plurality of arrangement positions (first to ninth slots SL1 to SL9) arranged in a row on a common pallet 5 equipped in a component mounter 1. The component type placement method includes a fixed setting step S1 for determining a plurality of placement positions (third to seventh slots SL3 to SL7) as fixed positions for each type of automatic feeder (the third slot SL3 is a fixed position for large-sized items, the fourth and fifth slots SL4 and SL5 are fixed positions for small-sized items, and the sixth and seventh slots SL6 and SL7 are fixed positions for medium-sized items) and setting the plurality of types of automatic feeders to be placed at the fixed positions for each type; and a simulation step S4 for performing a simulation of placing a plurality of component types of components at the plurality of placement positions under the condition that the plurality of types of automatic feeders are not moved from the fixed positions for each type, and the placement of component types P11 to P15 belonging to the corresponding component type group is changed within the range of the fixed positions for each type.

[0065] According to this, when a substrate K is produced using a total of five automatic feeders ALS1, ALS2, ALM1, ALM2, and ALL of three types, a fixed position for each type of automatic feeder is determined and used regularly. Therefore, multiple types of automatic feeders with good workability during changeover work can be effectively utilized. Furthermore, a simulation of component type placement is performed under the condition that the total of five automatic feeders of three types are not moved, and the placement of component types P11 to P15 is changed within the range of the fixed positions for each type (the third slot SL3 is for large components, the fourth and fifth slots SL4 and SL5 are for small components, and the sixth and seventh slots SL6 and SL7 are for medium components). According to this, when changing the component type at the fixed position for each type, the automatic feeder is not moved, and only the reel holding device 6 or the eleventh to fifteenth component supply reels R11 to R15 are replaced, thereby shortening the changeover work time. In addition, the mounting cycle time can be minimized. Therefore, production efficiency can be improved by comprehensively taking into account the changeover work time and the mounting cycle time.

[0066] In addition, since the five automatic feeder devices ALS1, ALS2, ALM1, ALM2, and ALL are used regularly, the number of replacement feeder devices 7 and 9 is reduced, thereby suppressing equipment costs.

[0067] Furthermore, the reel holding device 6 rotatably holds the eleventh to fifteenth component supply reels R11 to R15, on which the component storage tapes used for the five automatic feeder devices ALS1, ALS2, ALM1, ALM2, and ALL are wound, or multiple types of component supply reels 81, 82, and in a fixed setting step S1, sets the five automatic feeder devices ALS1, ALS2, ALM1, ALM2, and ALL to be arranged together in a continuous range of multiple slots (the third to seventh slots SL3 to SL7).

[0068] According to this, during a changeover operation, the worker only needs to mount the reel holding devices 6, which is fewer than the five automatic feeder devices ALS1, ALS2, ALM1, ALM2, and ALL. Therefore, the changeover operation is further reduced.

[0069] The component type placement method of the second embodiment can also be implemented as a component type placement calculation device. This component type placement calculation device may be realized by the calculation processing function of a control device (host computer) (not shown) that manages a board production line that includes the component mounter 1, but is not limited to this, and may also be realized by a control device 16 of the component mounter 1 or a separately installed computer device that shares various data such as mounting sequence data. That is, the component type placement calculation device of the embodiment has an automatic loading function for automatically loading component storage tapes 85, 86 when component storage tapes 85, 86 storing components are inserted into a plurality of component storage sections, and also has a function for automatically loading the component storage tapes 85, 86 when the component storage tapes 85, 86 storing components are inserted into a plurality of component storage sections, and has a function for automatically loading the component storage tapes 85, 86 when the component storage tapes 85, 86 store components in the plurality of component storage sections. The component type placement calculation device can be configured to include a fixed setting unit that defines a plurality of placement positions (third to seventh slots SL3 to SL7) as fixed positions for each type of automatic feeder (the third slot SL3 is a fixed position for large items, the fourth and fifth slots SL4 and SL5 are fixed positions for small items, and the sixth and seventh slots SL6 and SL7 are fixed positions for medium items) and sets the plurality of types of automatic feeders to be placed at the fixed positions for each type, and a simulation unit that performs a simulation to place a plurality of component types of components at the plurality of placement positions under the condition that the plurality of types of automatic feeders are not moved from the fixed positions for each type, and the placement of component types P11 to P15 belonging to the corresponding component type group is changed within the range of the fixed positions for each type.

[0070] The functions and effects of the component type placement calculation device of this embodiment are the same as those of the component type placement method of the second embodiment.

[0071] (7. Applications and Modifications of the First and Second Embodiments) In the first and second embodiments, the slots SL1 to SL9 are simplified to nine, and in reality, many more manual feeder devices 7 and automatic feeder devices 9 are often used. In the first and second embodiments, the automatic feeder devices 9 do not necessarily need to be arranged in a range of continuous slots. For example, in the second embodiment, the eleventh to fourteenth component types P11 to P14 may be mounted in the first component mounting cycle, and the fifteenth component type P15 may be mounted in the second component mounting cycle. In this case, the large automatic feeder device ALL may be arranged away from the other automatic feeders ALS1, ALS2, ALM1, and ALM2.

[0072] Furthermore, in the second embodiment, when more than five types of parts are to be supplied, manual feeder device 7 is used in addition to three types (a total of five automatic feeders ALL, ALS1, ALS2, ALM1, ALM2). In this case, the position of manual feeder device 7 can be varied within the range of first, second, eighth, and ninth slots SL1, SL2, SL8, SL9, and a simulation can be performed using the method of the first embodiment in addition. The present invention can be applied in many other ways and modified in many different ways. [Explanation of symbols]

[0073] 1: component mounter, 5: common pallet, 51: feeder mounting section, 55: reel mounting section, 6: reel holding device, 7: manual feeder device, 81, 82: first and second component supply reels, 85, 86: first and second component storage tapes, 9: automatic feeder device, SL1 to SL9: first to ninth slots (installation positions), P1 to P9, P11 to P15: first to ninth and eleventh to fifteenth component types, ALF1 to ALF5: first to fifth automatic feeder devices, ALS1, ALS2: first and second small automatic feeder devices, ALM1, ALM2: first and second medium automatic feeder devices, ALL: large automatic feeder device, M1 to M4: first to fourth manual feeder devices

Claims

1. A board production method comprising: an automatic loading function for automatically loading a component storage tape, each of which stores components, into a plurality of component storage sections when the component storage tape is inserted; and mounting, onto a board, components that are picked up by suction from a plurality of automatic feeders arranged in a row on a pallet equipped to a component mounter, the method comprising: a determination step of setting a board type of a board to be produced and determining a plurality of component types of a plurality of components to be arranged at the plurality of arrangement positions; a simulation step of arranging a plurality of component types of the components at the plurality of placement positions under the condition that the plurality of automatic feeders are not moved; A substrate production method comprising the steps of:

2. 2. The method of claim 1, wherein said plurality of automatic feeders are a plurality of types of automatic feeders respectively corresponding to a plurality of component type groups classified based on the size of the component type to be fed.

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