Parts supply unit storage and retrieval system

Abstract

A component supply unit storage and retrieval system according to the present invention comprises: a unit container that contains a plurality of component supply units used when supplying a plurality of components to a component placement machine; a container holding platform that holds the unit container; a unit repository that stores more component supply units than the unit container; and a storage / retrieval robot that hands off the component supply units between the unit container and the unit repository.

Description

[Technical field]

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

[0002] A technology for mass-producing board products by performing board-related operations on boards with printed wiring has become widespread. Furthermore, it has become common to arrange a plurality of types of board-related operation machines for performing board-related operations side by side to form a board-related operation line. A component mounting machine among the board-related operation machines uses a component supply unit loaded with a component container that stores a plurality of components. The loading operation of loading the component container into the component supply unit, in other words, the setup operation of preparing the component supply unit for use, is often performed in a setup area away from the component mounting machine in operation (external setup). The set-up component supply unit is then transported to the component mounting machine and installed there (internal setup).

[0003] The above-mentioned loading work and installation work for the component mounting machine have conventionally been performed manually, requiring a lot of work. Furthermore, the loading work is performed ahead of schedule in order to ensure the achievement of the production plan, which increases the number of in-process component supply units that cannot be used for other purposes. This makes management complicated and requires even more work. In recent years, in order to save labor, container loaders that automate at least a part of the loading work have been put into practical use. One example of technology related to the automation of the loading work and installation work is disclosed in Patent Document 1.

[0004] The second embodiment of Patent Document 1 describes a configuration including a storage facility for storing reels (an example of a component container), a storage facility for storing feeders (an example of a component supply unit), a reel setting device, a transport device, and a management unit. The reel setting device performs a setup operation of setting reels in the feeders. The transport device transports the setup feeders to the component mounting machine. The management unit controls the removal of the reels and feeders, setup operations, transport operations, etc., and manages the production of the component mounting machine. It is said that this makes it easy to grasp the combination and location of reels and feeders, and makes it easy to manage them. [Prior art documents] [Patent documents]

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

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

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

[0008] This specification discloses a component supply unit storage and retrieval system comprising a unit storage container that stores a plurality of component supply units used when supplying a plurality of components to a component mounting machine, a storage container holding stand that holds the unit storage container, a unit warehouse that stores a greater number of the component supply units than the unit storage container can store, and an storage and retrieval robot that transfers the component supply units between the unit storage container and the unit warehouse. Effect of the Invention

[0009] In the component supply unit storage and retrieval system disclosed in this specification, the storage and retrieval robot automatically retrieves multiple component supply units from the unit warehouse and stores them in the unit storage container. The multiple component supply units stored in the unit storage container are then used together in the subsequent setup work or are installed together in the component mounting machine. This makes it possible to make the setup work more efficient compared to the conventional technology in which component supply units are setup one by one. [Brief description of the drawings]

[0010] [Figure 1] FIG. 1 is a perspective view showing a schematic configuration of a warehousing and shipping system for a component supply unit according to a first embodiment; [Diagram 2] FIG. 1 is a front view showing a schematic configuration of a component supply unit storage / retrieval system according to a first embodiment; [Diagram 3] FIG. 2 is a functional block diagram showing a control configuration in the first embodiment. [Figure 4] 4 is an operational flow diagram illustrating the control operation of the warehouse entry / exit control unit in the first embodiment. FIG. [Diagram 5] FIG. 13 is a plan view showing a schematic diagram of a loading / unloading system for a component supply unit according to a second embodiment. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

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

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

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

[0014] The feeder device is not limited to an integrated type, and there is also a separate type. A separate type feeder device is composed of a feeder main body having a carrier tape feeding mechanism, and a reel cassette in which a tape reel is loaded. The feeder main body is permanently installed in the component mounting machine 98, and a separate reel cassette is arranged near the feeder main body. As the component mounting operation progresses and the components on the tape reel are consumed, the reel cassette is replaced. The reel cassette corresponds to the component supply unit 92 in which the component container 91 is loaded.

[0015] In the following, a description will be given of a case where the component supply unit 92 is an integrated feeder device and a tape reel is already loaded as the component container 91. Note that a tray may be used as the component container 91, and a tray loading unit may be used as the component supply unit 92.

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

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

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

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

[0020] As shown in Figures 1 and 2, the storage container holder 3 is disposed adjacent to the left side of the unit warehouse 2. Without being limited thereto, the storage container holder 3 may be disposed on the right side of the unit warehouse 2. The storage container holder 3 holds the unit storage containers (41, 44) on the upper side. The storage container holder 3 is formed in a rectangular frame shape. An upper section guide 32 extending in the left-right direction is provided on the upper part of the front surface of the storage container holder 3. A lower section guide 33 extending in the left-right direction is provided on the lower part of the front surface of the storage container holder 3. The upper section guide 32 and the lower section guide 33 are disposed at the same height as the upper section guide 26 and the lower section guide 27 of the unit warehouse 2, and are formed in the same shape.

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

[0022] Of the three storage container holders 3 shown in Figures 1 and 2, a full-width unit storage container 41 is held on the upper side of the right-hand and central storage container holders 3. Also, two half-width unit storage containers 44 are held on the upper side of the left-hand storage container holder 3. The width dimension of the full-width unit storage container 41 is slightly smaller than the width dimension of the component mounting machine 98. The width dimension of the half-width unit storage container 44 is approximately half the width dimension of the full-width unit storage container 41.

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

[0024] The full-width unit storage 41 is mounted on the component mounting machine 98 and serves as a main part of the component supply device. Similarly, the two half-width unit storages 44 are mounted on the component mounting machine 98 and serve as a main part of the component supply device. Without being limited to this, the unit storages (41, 44) may not be mounted on the component mounting machine 98 and may be used to collectively perform setup work and transportation of the stored multiple component supply units 92, thereby improving efficiency.

[0025] The storage / retrieval robot 5 delivers a prepared part supply unit 92 with a part container 91 loaded therein between the unit storage container (41, 44) and the unit warehouse 2. The storage / retrieval robot 5 is formed vertically long. The storage / retrieval robot 5 is provided with a guide member and a moving drive unit on the rear side. The guide member engages with a moving guide consisting of a plurality of section guides (26, 27, 32, 33). As a result, the entire weight of the storage / retrieval robot 5 is supported by the moving guide and the moving direction is determined. The moving drive unit operates using, for example, a non-contact power supply device or a battery (not shown) as a power source. The moving drive unit is composed of, for example, a combination of a traveling wheel and a driving motor, or a moving mechanism that applies a linear motor. As a result, the storage / retrieval robot 5 moves along the moving guide in front of the unit storage container (41, 44) and the unit warehouse 2.

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

[0027] 2. Configuration related to control of storage / retrieval system 1 Next, a configuration relating to the control of the incoming / outgoing system 1 will be described. As shown in Fig. 3, the incoming / outgoing control unit 8 is communicatively connected to an efficiency improvement processing unit 95. The efficiency improvement processing unit 95 is communicatively connected to a line control unit 96. Furthermore, the line control unit 96 is communicatively connected to each of a plurality of types of substrate-related work machines constituting a substrate-related work line 97. The substrate-related work line 97 is a production line that mounts components on substrates to mass-produce substrate products. The component mounting machine 98 constituting the substrate-related work line 97 is equipped with a pre-set unit storage unit (41, 44) so ​​that it is possible to supply components.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Claims

1. a unit storage container for storing a plurality of component supply units, each of which is used in a state in which a tape reel is loaded when supplying a plurality of components to a component mounting machine, arranged in a predetermined direction; A container holder that holds the unit container; a unit warehouse arranged in line with the storage container holder in the predetermined direction and configured to store a greater number of the component supply units than the unit storage container can store; a storage / retrieval robot for transferring the part supply unit between the unit storage container and the unit warehouse; A moving guide is provided across the storage container holding table to the unit warehouse, the storage / retrieval robot moves in the predetermined direction along the movement guide to move between the storage container holder and the unit warehouse and store the part supply unit in a storage position on the unit storage container; The unit storage container is configured to be detachable from the storage container holding stand, and is loaded onto a cart or transport vehicle so that a plurality of the component supply units can be transported together from the storage container holding stand to the component mounting machine.

2. 2. The system for storing and retrieving parts supplying units according to claim 1, wherein the moving guide is configured such that section guides provided on the storage container holding table and the unit warehouse are aligned in the moving direction of the storing and retrieving robot.

3. 3. The part supply unit storing and retrieving system according to claim 2, wherein the number of said container holders can be increased.

4. 4. The component supply unit storing and retrieving system according to claim 1, wherein the unit storage container is mounted on the component mounting machine.

5. 5. The component supply unit storage / retrieval system according to claim 4, further comprising an entry / retrieval control unit that selects and controls a plurality of the component supply units to be retrieved from the unit warehouse based on the results of an efficiency improvement process that optimizes the storage positions of the plurality of the component supply units in the unit storage container in order to improve the efficiency of the component mounting work in the component mounting machine, and further controls the storage positions of the plurality of the retrieved component supply units in the unit storage container.

6. 6. The component supply unit warehousing and shipping system according to claim 5, further comprising a loading information storage unit that stores loading information that associates the individual tape reel with the individual component supply unit in which the tape reel is loaded.

7. The part supply unit inventory system according to any one of claims 1 to 6, wherein the part supply unit is a feeder device in which the tape reel on which a carrier tape containing a plurality of the parts is wound is loaded, or a reel cassette formed separately from a feeder main body having a feeding mechanism for the carrier tape and in which the tape reel is loaded.

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