Component Mounting System

Abstract

To provide technique for determining an abnormality in a camera unit, such as lens contamination, when a component recognition abnormality occurs in component recognition processing.SOLUTION: A component mounting system 100 comprises a mounter main body 1 including a camera unit 18 that acquires an image of a component being held by suction by a mounting head 161, and an overall control unit 21 that performs component recognition processing to recognize a component pickup state on the basis of the image captured by the camera unit 18, and determines whether there is an abnormality in the camera unit when a component recognition abnormality occurs. The overall control unit 21 acquires a past normal state image G0 by the camera unit 18, compares this normal state image G0 with an abnormal state image G1, which is an image in which a component recognition abnormality has occurred, and determines the presence or absence of abnormality in the camera unit 18 on the basis of the difference point between the images.SELECTED DRAWING: Figure 2

Description

[Technical field]

[0001] The present invention relates to a component mounting system that produces component-mounted boards by picking up components from a component supply area, transporting the components onto a board, and mounting the components on the board. [Background technology]

[0002] Conventionally, there has been known a component mounting system including a mounting machine that produces a component-mounted board on which electronic components (hereinafter simply referred to as "components") are mounted on a board such as a printed circuit board. As described in Patent Document 1, the mounting machine is usually equipped with a mounting head that adsorbs and holds components from a component supply area and transports them onto the board, and a camera unit that captures the components adsorbed and held by the mounting head. After the components are taken out from the component supply area and before they are mounted on the board, the camera unit captures the components adsorbed and held by the mounting head. Based on the image, a component recognition process is performed to recognize the positional deviation (adsorption deviation) of the components relative to the mounting head. Then, when the components are mounted on the board, the position of the mounting head is corrected according to the recognition result, thereby ensuring the mounting position accuracy of the components relative to the board. On the other hand, if the components in the image cannot be recognized in the component recognition process or if there is an abnormality in the components in the image, the mounting machine stops with an error and the operator is notified of the component recognition abnormality. For example, a component recognition error occurs when the mounting head fails to pick up and hold a component due to a component pickup error, or when the posture of the component that was picked up and held is extremely poor (when the positional deviation of the component exceeds the tolerance). [Prior art documents] [Patent documents]

[0003] [Patent Document 1] JP 2015-130377 A Summary of the Invention [Problem to be solved by the invention]

[0004] In the above mounting machine, the camera unit includes a camera body equipped with an image sensor and a dedicated lighting device attached thereto, and is usually capable of capturing component images without being affected by the lighting environment around the mounting machine (the lighting environment in the factory). However, if an abnormality occurs, such as a dirty lens on the camera body or a drop in the brightness level of the lighting device due to a malfunction, the quality of the captured image may decrease, which may cause component recognition abnormalities.

[0005] In other words, even if a component is properly adsorbed and held on the mounting head, lens dirt or the like can hinder component recognition, which can lead to component recognition errors. Therefore, if it were possible to determine whether a component recognition error was caused by a camera unit error, such as lens dirt, a quick response would be possible and the error stop period of the mounting machine could be shortened, but Patent Document 1 makes no mention of such technology.

[0006] The present invention has been made in consideration of the above-mentioned circumstances, and aims to provide technology that makes it possible to determine an abnormality in the camera unit, such as lens dirt, when a component recognition abnormality occurs during component recognition processing in a mounting machine. [Means for solving the problem]

[0007] A component mounting system according to one aspect of the present invention comprises a mounting execution unit including a mounting head that performs a component mounting process of adsorbing, holding and removing components from a feeder that supplies components and mounting the components on a board, and a camera unit that acquires an image related to the state of the components being adsorbed and held by the mounting head; a recognition unit that performs a component recognition process that recognizes the state of the components adsorbed by the mounting head based on the image captured by the camera unit; and a judgment unit that judges whether or not there is an abnormality in the camera unit if a component recognition abnormality occurs in the component recognition process, wherein the judgment unit acquires a normal state image that is a past image captured by the camera unit and is an image of a normal component recognition state, compares this normal state image with an abnormal state image in which the component recognition abnormality occurred, and judges whether or not there is an abnormality in the camera unit based on the differences between these images.

[0008] In this component mounting system, when a component recognition abnormality occurs during component recognition processing by the recognition unit, the determination unit acquires a past normal state image (an image of a normal component recognition state) taken by the camera unit, compares this normal state image with an abnormal state image (an image in which a component recognition abnormality has occurred), and determines whether or not there is an abnormality in the camera unit based on the differences between these images. When there is an abnormality in the camera unit, such as a dirty lens or poor lighting, there is often a clear difference between the normal state image and the abnormal state image. Therefore, with this component mounting system, it becomes possible to determine whether or not there is an abnormality in the camera unit during component recognition processing.

[0009] In the above-mentioned component mounting device, each of the abnormal state image and the normal state image includes a component image consisting of a group of pixels indicating a component, and a background image consisting of a group of pixels indicating the surrounding area of ​​the component image, and the judgment unit judges the presence or absence of an abnormality in the camera unit based on the differences between the background image in the abnormal state image and the background image in the normal state image.

[0010] If the lens of the camera unit is dirty and appears in the background image, the dirt may be recognized as part of a part, which may cause a part recognition error. According to the above configuration, the presence or absence of an abnormality in the camera unit is determined based on the difference between the background image in the abnormal state image and the background image in the normal state image, so that when a part recognition error occurs due to lens dirt as described above, it is possible to determine with a high degree of accuracy that there is an abnormality in the camera unit.

[0011] In this case, the determination unit determines that there is an abnormality in the camera unit when the brightness of the background image in the abnormal state image is lower than the brightness of the background image in the normal state image.

[0012] If the entire lens of the camera unit is dirty due to the adhesion of dust or the like, or if there is an abnormality in the lighting, the entire image becomes dark and the contrast difference between the component image and the background image becomes small, which may result in the component becoming unclear and causing an abnormality in component recognition. According to the above configuration, the presence or absence of an abnormality in the camera unit is determined based on a comparison between the brightness of the background image in the abnormal state image and the brightness of the background image in the normal state image, so that in the case where the entire lens of the camera unit is dirty due to the adhesion of dust or the like as described above, it is possible to determine with a high level that there is an abnormality in the camera unit.

[0013] In this case, it is preferable that the determination section further determines that there is an abnormality in the camera unit when the brightness of the background image in the abnormal state image is equal to or lower than a threshold value.

[0014] According to this configuration, it is possible to more accurately determine an abnormality in the camera unit, such as when the entire lens of the camera unit is dirty due to the adhesion of dust or the like.

[0015] In the component mounting apparatus, it is preferable that the determination unit obtains, as the normal state image, an image in which a component of the same type as the component that is the subject of the abnormal state image is the subject.

[0016] According to this configuration, since the subject is the same, the reliability of determining whether or not there is an abnormality in the camera unit based on the differences between the abnormal state image and the normal state image is improved.

[0017] It is preferable that the component mounting apparatus further comprises a notification unit that notifies of an abnormality in the camera unit when the determination unit determines that an abnormality exists in the camera unit.

[0018] With this configuration, when a component recognition abnormality occurs, the operator can recognize that the cause is an abnormality in the camera unit, which saves the operator the trouble of investigating other causes and enables subsequent measures to be taken promptly, thereby shortening the period during which the mounting execution unit is stopped due to an error.

[0019] In addition, in the above-described component mounting system, when the determination unit determines that there is no abnormality in the camera unit, it may determine that a pickup error by the mounting head and / or a component abnormality has occurred, and the notification unit may be configured to notify that a pickup error by the mounting head and / or a component abnormality has occurred.

[0020] With this configuration, when a component recognition abnormality occurs, the operator can recognize that the cause is a pickup error by the mounting head and / or a component abnormality. This saves the operator the trouble of investigating the camera unit abnormality, and enables subsequent measures to be taken promptly, thereby shortening the period during which the mounting execution unit is stopped due to an error. Effect of the Invention

[0021] According to the component mounting device according to each of the above aspects, when a component recognition abnormality occurs in the component recognition process in the mounter, it becomes possible to determine an abnormality in the camera unit, such as lens dirt. [Brief description of the drawings]

[0022] [Figure 1]1 is a schematic plan view showing a component mounting system according to an embodiment of the present invention. [Diagram 2] FIG. 2 is a block diagram showing a configuration of the component mounting system. [Diagram 3] 2 is a plan view showing a mounter body of a mounter provided in the component mounting system. FIG. [Figure 4] 3 is a schematic front view showing a head unit and a camera unit provided in the mounting machine main body. FIG. [Diagram 5] 10 is a flowchart illustrating control of component recognition processing by a mounting control unit. [Figure 6] FIG. 13 is a diagram showing a normal state image acquired by the part recognition process. [Figure 7] FIG. 11 is a diagram showing an example of an abnormal state image acquired by the part recognition process. [Figure 8] FIG. 11 is a diagram showing another example of an abnormal state image acquired by the part recognition process. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0023] Hereinafter, an embodiment of the present invention will be described in detail with reference to the drawings.

[0024] [Component mounting system configuration] FIG. 1 is a schematic plan view showing a component mounting system 100 according to an embodiment of the present invention, and FIG. 2 is a block diagram showing the configuration of this component mounting system 100. As shown in FIG.

[0025] The component mounting system 100 includes a plurality of mounting machines (four mounting machines 101-104 in this example) and a management device 110 connected to these mounting machines 101-104 so as to be able to communicate data with them. The mounting machines 101-104 are devices that mount electronic components (hereinafter referred to as "components") on a board P (see FIG. 3) such as a printed wiring board to produce a component-mounted board. These mounting machines 101-104 are connected in series in the transport direction of the board P to form a component mounting line. The outlined arrow in the figure indicates the transport direction of the board P.

[0026] The basic configuration of each of the mounting machines 101 to 104 is the same. Below, the specific configuration will be described using one mounting machine 101 as an example. As shown in Fig. 2, the mounting machine 101 comprises a mounting machine main body 1, a mounting control unit 2, a mounting communication unit 3, a display unit 4, and an operation unit 5. The mounting machine main body 1 corresponds to the "mounting execution unit" of the present invention, and the display unit 4 corresponds to the "notification unit" of the present invention.

[0027] The mounting machine main body 1 performs a component mounting process for mounting components on the board P. The mounting communication unit 3 is an interface for performing data communication with the management device 110, and has a function of inputting and outputting various data and information to and from the management device 110. The mounting control unit 2 controls the component mounting process by the mounting machine main body 1 according to board data stored in a storage unit 22, which will be described later, and also controls data communication of the mounting communication unit 3. The display unit 4 displays various information related to the component mounting process. The operation unit 5 receives input operations of various commands to the mounting control unit 2 by the operator. The detailed configuration of each of these units will be described below.

[0028] Fig. 3 is a plan view showing the mounter main body 1 of the mounter 101, and Fig. 4 is a schematic front view showing the head unit 16 and the camera unit 18 provided in the mounter main body 1. Note that in Fig. 1, Fig. 3, and Fig. 4, directional relationships are shown using XYZ orthogonal coordinates.

[0029] The mounting machine main body 1 includes a base 10, a conveyor 12, a component supply unit 14, a head unit 16, and a camera unit 18. The base 10 is a mounting base for various devices provided in the mounting machine main body 1. The conveyor 12 is a transport line for the board P installed on the base 10 so as to extend in the X direction, and is composed of a pair of belt-type conveyors 12a. The conveyor 12 carries the board P from outside the machine to a predetermined work position, and after the mounting work, carries the board P from the work position to outside the machine. The position of the board P shown in FIG. 3 is the work position. The conveyor 12 is equipped with a clamp mechanism (not shown), and the board P is positioned and held at the work position by this clamp mechanism during the component mounting process.

[0030] The component supply units 14 are areas for supplying components, and are provided on both sides of the conveyor 12 in the Y direction. A plurality of feeders 14a are provided in the component supply units 14, and components are supplied by each feeder 14a. In this example, each component supply unit 14 is provided with a tape feeder that supplies components while unwinding a tape containing components (small surface mount components) at regular intervals.

[0031] The head unit 16 picks up a component from the feeder 14a in the component supply unit 14, moves to a working position, and mounts the component on the board P held by the clamp mechanism. As shown in FIG. 4, the head unit 16 has a plurality of mounting heads 161, each of which has a suction nozzle 161a at its tip (lower end). The mounting heads 161 can move forward and backward (up and down) in the Z direction and rotate around an axis by driving a motor not shown. When picking up a component from the feeder 14a, the mounting head 161 descends from a predetermined retreat position, sucks and holds the component with the suction nozzle 161a, and then rises to the retreat position. Then, when mounting the component on the board P, the mounting head 161 descends from the retreat position above the board P and releases the component by releasing the suction-holding state of the component. As a result, the component is mounted at the target mounting position set on the board P.

[0032] The head unit 16 can move in the horizontal direction (XY direction) at least in the space above the component supply unit 14 and the board P at the work position by operation of the head unit drive mechanism 17. As shown in FIG. 3, the head unit drive mechanism 17 includes fixed rails 171 fixed to a pair of elevated frames installed on the base 10, a beam member 172 that moves in the Y direction along the fixed rails 171, and a unit support part (not shown) that moves in the X direction along the beam member 172. The head unit 16 is attached to this unit support part. The beam member 172 and the unit support member each move by the driving force of a motor. The movement of the beam member 172 and the unit support member moves the head unit 16 in the XY direction.

[0033] The camera unit 18 is installed between the component supply unit 14 and the conveyor 12 on the base 10. The camera unit 18 is a device that performs a component imaging process to image the component to recognize the state of the component being sucked and held by the suction nozzle 161a. After the suction nozzle 161a of each mounting head 161 sucks and holds the component from the feeder 14a, the camera unit 18 passes above the camera unit 18 when the head unit 16 moves above the board P at the work position, and sequentially images the components sucked and held by each suction nozzle 161a from below. The image obtained in this manner is an image (sometimes called a suction process image) that can be used to check, in addition to the component suction failure by the suction nozzle 161a (a state in which the component is not sucked), for example, the posture, shape, and amount of deviation of the suction position of the component with respect to the suction nozzle 161a. When the component is mounted on the board P, the moving direction and amount of movement of the head unit 16 are corrected based on the posture and amount of deviation of the component. This ensures the accuracy of mounting the components at the target mounting positions.

[0034] As shown in FIG. 4, the camera unit 18 includes a camera body 181 and an illumination device 182. The camera body 181 includes an imaging element such as a CMOS (Complementary metal-oxide-semiconductor) or a CCD (Charged-coupled device), and an optical system including a plurality of lenses for forming an image of the component on the imaging element. The illumination device 182 includes a plurality of LEDs arranged in a dome shape, and irradiates illumination light from below onto the component sucked and held by the suction nozzle 161a. With this configuration, the camera unit 18 irradiates illumination light from below onto the component sucked and held by the suction nozzle 161a, and receives the light reflected by the component with the camera body 181a. In this way, an image of the component is captured.

[0035] Returning to Fig. 2, the display unit 4 is configured with, for example, a liquid crystal display or the like, and displays various information on the component mounting process by the mounting machine main body 1. The display operation of the display unit 4 is controlled by a display control unit 28, which will be described later. The operation unit 5 is configured with a keyboard, a mouse, or a touch panel provided on the operation unit 5, or the like. The operation unit 5 receives input operations of various commands to the mounting control unit 2 by the operator.

[0036] The mounting control unit 2 is composed of a CPU (Central Processing Unit), a ROM (Read Only Memory) that stores a control program, a RAM (Random Access Memory) used as a working area for the CPU, etc. The mounting control unit 2 includes, as main functional components, a general control unit 21, a storage unit 22, a transport control unit 23, a component supply control unit 24, a head control unit 25, an imaging control unit 26, an image processing unit 27, a display control unit 28, and a communication control unit 29, etc.

[0037] The overall control unit 21 performs overall control of the operation of the mounter 101, such as the component mounting process of the mounter main body 1 and the data communication of the mount communication unit 3, based on the mounting program and various data stored in the storage unit 22, and executes various calculation processes and judgment processes associated with the control. Specifically, the overall control unit 21 performs component recognition processes, such as detecting component suction errors by the suction nozzle 161a and determining the amount of deviation of the component suction position relative to the suction nozzle 161a, based on the image captured by the camera unit 18, and further causes the display unit 4 to display the results of the component recognition processes via the display control unit 28. In particular, in this example, when a component recognition abnormality occurs in the component recognition process, the overall control unit 21 also performs a process of determining whether or not there is an abnormality in the camera unit 18. This will be described in detail later. In this example, the overall control unit 21 is configured to function as the "recognition unit" and the "judgment unit" of the present invention.

[0038] The storage unit 22 stores a mounting program and various data. The various data includes board data referenced by the general control unit 21. This board data is data that is the basis of component mounting processing of the mounting machine main body 1 by the general control unit 21, and includes multiple parameter information, target suction position information, and target mounting position information. The parameter information is information such as the type and shape (dimension) of the component, the type of the mounting head, the type of the suction nozzle, and the type and arrangement of the feeder 14a. In addition, the target suction position information is information that indicates a target suction position (target suction position) when the suction nozzle 161a picks up the component. In addition, the target mounting position information is information that indicates a target mounting position of the component on the board P.

[0039] The transport control unit 23, the component supply control unit 24, the head control unit 25, the imaging control unit 26, the display control unit 28, and the communication control unit 29 control the operation of each unit based on a command from the general control unit 21. That is, the transport control unit 23 controls the transport operation of the board P by the conveyor 12. Also, the component supply control unit 24 controls the component supply operation by each of the feeders 14a arranged in the component supply unit 14. Also, the head control unit 25 controls the operation of the head unit 16 and the mounting head 161. Also, the imaging control unit 26 controls the component imaging operation by the camera unit 18. Also, the display control unit 28 controls the display operation by the display unit 4. Also, the communication control unit 29 controls the mounting communication unit 3 to control the data communication between the mounting machine 101 and the management device 110. Also, the image processing unit 27 performs a predetermined image processing on the image data input from the camera unit 18. Based on the image that has been subjected to this image processing, the general control unit 21 executes the component recognition processing and the determination processing of the presence or absence of an abnormality in the camera unit 18.

[0040] The above is the configuration of the mounting machine 101, but as described above, the other mounting machines 102 to 104 basically have the same configuration as this mounting machine 101.

[0041] The management device 110 is configured by, for example, a personal computer connected to be able to perform data communication with the mounting machine 101. The management device 110 includes a management control unit 111, a management communication unit 112, a management storage unit 113, a display unit 114, and an operation unit 115.

[0042] The management communication unit 112 is an interface for performing data communication with the mounting machines 101 to 104, and acquires management data MD (described later) input from the mounting machines 101 to 104. The management storage unit 113 accumulates and stores the management data MD acquired by the management communication unit 112. The display unit 114 is configured with, for example, a liquid crystal display, and displays information on the management data MD stored in the management storage unit 113. The operation unit 115 is configured with a keyboard, a mouse, or a touch panel provided on the management display unit 125. The operation unit 115 accepts input operations of various commands related to the display on the display unit 114 by an operator. The management control unit 111 controls the display unit 114 in accordance with the commands input to the operation unit 115. In addition, the management control unit 111 controls the management communication unit 112 in response to requests from the mounting machines 101 to 104, reads out the management data MD stored in the management memory unit 113, and executes processing to output the management data MD to the mounting machines 101 to 104 that have made the request.

[0043] [Control of component recognition processing, etc. by mounting control unit 2] 5 is a flowchart showing control of component recognition processing and the like by the mounting control unit 2 (general control unit 21). This control is executed from when each mounting head 161 (suction nozzle 161a) of the head unit 16 performs a component suction process (a process of picking up a component from the feeder 14a) until the component sucked and held by each mounting head 161 is mounted on the board P.

[0044] The general control unit 21 first judges whether the component imaging process by the camera unit 18 has been completed (step S1), and if Yes, executes the component recognition process based on the suction processed image that has been subjected to predetermined image processing by the image processing unit 27 and that corresponds to the first mounting head 161 in the preset order (step S3).Then, it judges whether the result of the component recognition is normal (step S5).

[0045] In the process of step S5, if a component can be recognized in the pickup process image and the posture, shape, and pickup position deviation amount of the component are all within a predetermined allowable range, the general control unit 21 judges that the component recognition is normal. In this case, the general control unit 21 creates management data MD in which the parameter information, pickup position deviation amount data, and the like are associated with the pickup process image judged to be normal (referred to as a "normal state image"), and inputs this management data MD to the management device 110 via the mounting communication unit 3. The management device 110 accumulates and stores the management data MD input from each of the mounters 101 to 104 in the management storage unit 113 for each mounter (step S7).

[0046] Next, the central control unit 21 judges whether the component recognition process has been completed for all components, i.e., whether the component recognition process has been completed for the suction process images corresponding to all mounting heads 161 (step S9). If the answer is No, the process returns to step S1, and the component recognition process is executed based on the suction process image corresponding to the next mounting head 161. When it is finally judged that the component recognition process has been completed for all components (Yes in step S9), the central control unit 21 ends the control of this flowchart.

[0047] On the other hand, if it is determined in step S5 that the component recognition result is abnormal (No in step S5), that is, if the component cannot be recognized in the suction processing image or if any of the component's posture, shape, and suction position deviation amount exceeds the allowable range, the overall control unit 21 transitions the process to step S11.

[0048] In step S11, the central control unit 21 outputs an inquiry signal to the management device 110, and checks whether management data DM of its own machine, i.e., management data DM of the mounting machine including the central control unit 21, which includes a normal state image of the same component (component of the same type) as the component where the component recognition abnormality occurred, is stored in the management storage unit 113. If the answer is No, the central control unit 21 further outputs inquiry information to the management device 110, and checks whether management data DM of a machine other than its own machine, which includes a normal state image of the same component as the component where the component recognition abnormality occurred, is stored in the management storage unit 113 (step S13).

[0049] If the answer is No in step S13, that is, if there is no management data DM including a normal state image for either the mounter itself or the other mounters 101-104, the central control unit 21 controls the display unit 4 via the display control unit 28 to display a screen indicating the occurrence of a component recognition abnormality on the display unit 4, and further stops the operation of each feeder 14a via the component supply control unit 24 and stops the operation of the head unit 16 via the head control unit 25 (steps S15, S17). As a result, the occurrence of the component recognition abnormality is notified to the operator, and the component mounting process by the mounter main body 1 is interrupted (error stop).

[0050] After the error stop, the central control unit 21 waits for the operator to input a specified release operation via the operation unit 5 (step S19), and if the release operation is input (Yes in step S19), it releases the error stop and transitions to step S9.

[0051] On the other hand, if the processing in step S11 or step S13 is Yes, that is, if management data DM including a normal state image is stored in the management device 110, the general control unit 21 outputs a read command signal to the management device 110 and acquires the management data DM from the management device 110 (step S21).

[0052] When the general control unit 21 acquires the management data MD including the normal state image, it compares this normal state image with the abnormal state image (the suction processing image determined to be a component recognition abnormality in step S5) as follows (step S23).

[0053] FIG. 6 shows an example of a normal state image. As shown in the figure, the normal state image G0 includes a part image Ga0 consisting of a pixel group showing a part sucked and held by the suction nozzle 161a, and a background image Gb0 consisting of a pixel group showing a peripheral area of ​​the part image Ga0. In the process of step S23, the general control unit 21 obtains the brightness of the background image Gb0 of the normal state image G0 and the brightness of the image of the area of ​​the abnormal state image corresponding to the background image Gb0 of the normal state image G0 (i.e., the background image of the abnormal state image), and compares the brightness of these background images. In this case, for example, the average value of the gradation of each pixel in the pixel group showing the background image can be set as the brightness of the background image.

[0054] Then, the general control unit 21 judges whether or not the brightness B2 of the background image of the abnormal state image is lower than the brightness B1 of the background image of the normal state image G0 and whether or not the brightness B2 of the abnormal state image is equal to or lower than a preset threshold value Bt (step S25). The threshold value Bt is a value assuming a background image acquired in a state where, for example, dust or the like is attached to the camera body 181 and the entire lens is clouded (wide-area dirt), or in a state where the illumination light does not meet a specified brightness level due to a malfunction of the illumination device 182, and is a value based on, for example, a simulation result. That is, in step S25, it is judged whether or not the cause of the component recognition abnormality is an abnormality of the camera unit 18, such as a clouded lens (wide-area dirt) or poor illumination.

[0055] FIG. 7 shows an example of an abnormal state image. The abnormal state image G1 shown in the figure includes a component image Ga1 and a background image Gb1, but the image appears dark overall due to lens fogging (wide-area dirt) or poor lighting in the camera unit 18. In the case of such an image, even if a component is properly suctioned and held by the suction nozzle 161a, the component image Ga1 may not be accurately recognized due to a small contrast difference between the component image Ga1 and the background image Gb1, and the component recognition may be determined to be abnormal in the process of step S5. Therefore, as described above, by comparing the brightness B1 of the background image Gb0 of the normal state image G0 with the brightness B2 of the background image Gb1 of the abnormal state image G1, it is possible to determine the presence or absence of an abnormality in the camera unit 18, such as fogging of the lens of the camera unit 18 (wide-area dirt) or poor lighting.

[0056] If the result of the process in step S25 is Yes, the central control unit 21 shifts the process to step S31. On the other hand, if the result of the process in step S25 is No, the central control unit 21 shifts the process to step S27, and further executes a process of detecting adhesion of a foreign substance to the lens of the camera unit 18 based on a comparison between the background image Gb0 of the normal state image G0 and the background image of the abnormal state image, thereby determining the presence or absence of adhesion of a foreign substance (step S29). In this case, the central control unit 21 can determine the presence or absence of adhesion of a foreign substance by, for example, binarizing each background image using a specific gradation as a threshold, finding the difference between the background image Gb0 of the normal state image G0 and the background image of the abnormal state image, and calculating the area of ​​the remaining black pixels.

[0057] FIG. 8 is another example of an abnormal state image, which is an abnormal state image G2 when a foreign object is attached to the lens of the camera unit 18. In this abnormal state image G2, a foreign object image Gf is captured in a position in the background image Gb2 relatively close to the component image Ga2. In such a case, the component image Ga2 and the foreign object image Gf are likely to be recognized as a single component in their entirety, and even if the component is properly suctioned and held by the suction nozzle 161a, a component recognition abnormality may be determined. Therefore, as described above, by comparing the background image Gb0 of the normal state image G0 with the background image Gb1 of the abnormal state image G1, it is possible to determine whether or not there is an abnormality in the camera unit 18, such as the attachment of a foreign object (narrow-area dirt) to the lens.

[0058] If it is determined in step S29 that no foreign matter is attached, i.e., if the process of step S29 returns No, the central control unit 21 makes a final determination that "there is no abnormality in the camera unit 18." On the other hand, if the processes of steps S25 and S29 return Yes, i.e., if it is determined that the lens is clouded (wide-area dirt) or that foreign matter is attached (narrow-area dirt), the central control unit 21 makes a final determination that "there is an abnormality in the camera unit 18."

[0059] If the result of the process in step S29 is Yes, the central control unit 21 proceeds to step S31. In step S31, the central control unit 21 controls the display unit 4 via the display control unit 28 to cause the display unit 4 to display a screen indicating the occurrence of a part recognition abnormality. In this case, if the result of the process in step S25 or step S29 is Yes, that is, if it is determined that there is an abnormality in the camera unit 18, the central control unit 21 controls the display unit 4 so that information indicating the part recognition abnormality and information indicating the abnormality in the camera unit 18 are displayed. In addition to the occurrence of the part recognition abnormality, the operator is notified that the cause of the part recognition abnormality is an abnormality in the camera unit 18.

[0060] If the result of the process in step S29 is No, that is, if it is determined that there is no abnormality in the camera unit 18, the general control unit 21 controls the display unit 4 so that information indicating the component pick-up failure by the mounting head 161 and the component abnormality are displayed together with information indicating the component recognition abnormality. A pick-up failure is a state in which the above-mentioned component is not picked up. A component abnormality is a state in which any of the posture, shape, and pick-up position deviation amount of the component exceeds the allowable range. When the cause of the component recognition abnormality is other than the camera unit 18, it is empirically determined that most of them are either a pick-up failure or a component abnormality. Therefore, in this example, if it is determined that there is no abnormality in the camera unit 18, the general control unit 21 causes the display unit 4 to display information indicating the component pick-up failure and / or the component abnormality.

[0061] The central control unit 21 further stops the operation of each feeder 14a via the component supply control unit 24, and stops the operation of the head unit 16 via the head control unit 25, thereby interrupting (error stop) the component mounting process by the mounting machine main body 1 (step S33). After the error stop, the central control unit 21 waits for the operator to input a predetermined release operation via the operation unit 5 (step S35), and when the release operation is input (Yes in step S35), the central control unit 21 releases the error stop and returns the process to step S9.

[0062] [Effects, etc.] In the above-mentioned component mounting system 100, the general control unit 21 executes a component recognition process for recognizing the state of component suction by the mounting head 161 based on the image captured by the camera unit 18 (step S2 in FIG. 5). When the general control unit 21 determines that the component recognition is abnormal in this component recognition process (No in step S5 in FIG. 5), it acquires management data DM including a normal state image G0, which is a past suction process image by the camera unit 18 and is an image of a normal component suction state, from the management device 110, compares this normal state image G0 with the abnormal state image (G1, G2), which is the suction process image determined to be the component recognition abnormality, and determines whether or not there is an abnormality in the camera unit 18 based on the difference between these images (steps S25, S29). In detail, as described above, the general control unit 21 compares the brightness B1 of the background image Gb0 of the normal state image G0 with the brightness B2 of the background image Gb1 of the abnormal state image G1, and thereby determines whether or not there is a clouding of the lens (wide-area dirt) or poor lighting. In addition, the background image Gb0 and the background image Gb1 are compared to determine whether or not there is any foreign matter (narrow area dirt) attached to the lens.

[0063] Then, if it is determined that there is an abnormality in camera unit 18 (Yes in steps S25 and S29 in FIG. 5), central control unit 21 controls display unit 4 to display information indicating the abnormality in camera unit 18 together with information indicating the component recognition abnormality (step S31). Conversely, if there is no abnormality in camera unit 18 (No in step S29 in FIG. 5), central control unit 21 controls display unit 4 to display information indicating the component pickup failure by mounting head 161 and the component abnormality (step S31).

[0064] According to the component mounting system 100 of this embodiment, when the mounter main body 1 stops due to an error caused by a component recognition abnormality, the operator can determine whether the cause is the camera unit 18 or something else (a component pickup error or a component abnormality). This allows the operator to quickly begin work to resolve the error stop of the mounter main body 1. This leads to a shortened period of the error stop of the mounter main body 1, and ultimately contributes to improving the productivity of component mounting boards by the mounters 101-104.

[0065] Furthermore, because the presence or absence of an abnormality in camera unit 18 is judged each time a component suction abnormality occurs, the operator can check the condition of camera unit 18 and perform maintenance such as cleaning each time it is judged that there is an abnormality in camera unit 18. This prevents camera unit 18 abnormalities such as dirty lenses or poor lighting from being left unattended for a long period of time, and prevents erroneous recognition of a component recognition abnormality due to an abnormality in camera unit 18 even when the component suction state by mounting head 161 is normal. Furthermore, by suppressing the occurrence of such erroneous recognition, the number of parts discarded due to the erroneous recognition is reduced. This has the advantage of reducing the number of parts that are needlessly discarded.

[0066] Furthermore, in the component mounting system 100, when a component recognition abnormality occurs and management data DM is acquired from the management device 110 (step S21 in FIG. 5), the management data DM including a normal state image of the same component as the component in which the component recognition abnormality occurred is acquired, and the normal state image in the management data DM is compared with the abnormal state image (the adsorption processing image determined to have a component recognition abnormality). With this configuration, since the subject component is the same in both images, there is less error in the area of ​​the background images to be compared, and the background images can be compared more accurately. Therefore, the presence or absence of an abnormality in the camera unit 18 can be determined with high accuracy.

[0067] Furthermore, in the component mounting system 100, when obtaining management data DM including a normal state image from the management device 110, the management data DM of the own machine is obtained preferentially as described above (step S11 in FIG. 5), and when management data DM of the own machine does not exist, the management data DM of the mounting machines 101-104 other than the own machine is obtained (step S13 in FIG. 5), and the normal state image and abnormal state image of the management data DM are compared. Therefore, when a component recognition abnormality occurs, there is a high possibility that the management data DM including a normal state image can be obtained, and it becomes possible to more reliably determine whether or not there is an abnormality in the camera unit 18.

[0068] As described above, since the mounting machines 101-104 have the same basic configuration, even when acquiring the management data DM of the mounting machines 101-104 other than the own machine, it is possible to determine whether or not there is an abnormality in the camera unit 18 at a level comparable to that when acquiring the management data DM of the own machine. In this case, if the imaging conditions (e.g., the brightness level of the lighting device, etc.) of the camera unit 18 are different between the mounting machines 101-104, or if there are errors even if the imaging conditions are the same, the general control unit 21 may be configured to correct the acquired normal state image of the management data DM of the mounting machines 101-104 other than the own machine according to the difference in the imaging conditions, errors, etc., and to determine whether or not there is an abnormality in the camera unit 18 based on the corrected normal state image.

[0069] [Variations] The component mounting system 100 described above is one example of a preferred embodiment of the component mounting system according to the present invention, and the specific configuration can be appropriately changed without departing from the scope of the present invention. For example, the following configuration also belongs to the present invention.

[0070] (1) In the component mounting system 100 of the embodiment, management data DM is output from each of the mounting machines 101-104 to the management device 110, and is accumulated and stored in the management memory unit 113 of the management device 110. However, each of the mounting machines 101-104 may be configured to accumulate and store its own management data DM in its own memory unit 22.

[0071] In this case, the overall control unit 21 is configured to obtain the management data DM by reading it out from the storage unit 22 of its own machine, and determine the presence or absence of an abnormality in the camera unit 18 based on the normal state image contained in the management data DM. Furthermore, if the management data DM including the normal state image is not stored in the storage unit 22 of its own machine, the overall control unit 21 is configured to obtain the management data DM including the normal state image from the mounting machines 101-104 other than its own machine, and determine the presence or absence of an abnormality in the camera unit 18 based on the normal state image in the management data DM. In the configuration of such a modified example, each of the mounting machines 101-104 constitutes the component mounting system of the present invention.

[0072] (2) In the component mounting system 100 of the embodiment, in the process of step S23 in Fig. 5, when the brightness B2 of the background image of the abnormal state image is lower than the brightness B1 of the background image of the normal state image G0 and the brightness B2 of the abnormal state image is equal to or lower than a preset threshold value Bt, the central control unit 21 determines that there is an abnormality in the camera unit 18 (step S25). However, when either brightness B2<brightness B1 or brightness B2<threshold value Bt is satisfied, it may be determined that there is an abnormality in the camera unit 18. However, in order to more accurately determine the presence or absence of lens fogging (wide-area dirt) or poor lighting, the configuration as in the embodiment is considered to be desirable.

[0073] (3) In the component mounting system 100 of the embodiment, when it is determined in the process of step S29 in Fig. 5 that there is no abnormality in the camera unit 18, the overall control unit 21 controls the display unit 4 in the process of step S33 so that information indicating a component pickup error by the mounting head 161 and a component abnormality is displayed together with information indicating a component recognition abnormality. However, when the overall control unit 21 can distinguish between a component pickup error and a component abnormality, the display unit 4 may be configured to display either the pickup error or the component abnormality, whichever is applicable.

[0074] (4) In the embodiment, an application example of the present invention has been described in which it is determined whether or not there is an abnormality in the camera unit 18 that images a component that is sucked and held by the suction nozzle 161a of the mounting head 161 from below. However, the present invention is also applicable to a case where it is determined whether or not there is an abnormality in a camera unit that images a component that is sucked and held by the suction nozzle 161a from the side. [Explanation of symbols]

[0075] 1. Mounting machine main body (mounting execution unit) 14 Parts supply area 14a Feeder 16 Head Unit 161 Mounting Head 18 Camera unit 181 Camera body 182 Lighting Equipment 2. Mounting control section 21 General Control Unit 22 Memory section 4 Display section (alarm section) 5 Control section 100 Component Mounting System 101, 102, 103, 104 Mounting machine 110 Management device G0 Normal state image G1, G2 Abnormal condition images

Claims

1. a mounting execution unit including a mounting head that performs a component mounting process of suction-holding and removing components from a feeder that supplies components and mounting the components on a board, and a camera unit that captures an image relating to the state in which the components are sucked and held by the mounting head; a recognition unit that performs a component recognition process to recognize a state in which the component is picked up by the mounting head based on an image captured by the camera unit; a determination unit that determines whether or not there is an abnormality in the camera unit when a component recognition abnormality occurs in the component recognition process, The component mounting system is characterized in that the judgment unit acquires a normal state image that is a past image captured by the camera unit and is an image of a normal component recognition state, compares this normal state image with an abnormal state image that is an image in which the component recognition abnormality has occurred, and judges whether or not there is an abnormality in the camera unit based on the differences between these images.

2. 2. The component mounting system according to claim 1, each of the abnormal state image and the normal state image includes a part image made up of a pixel group representing a part, and a background image made up of a pixel group representing a peripheral area of ​​the part image; The component mounting system according to claim 1, wherein the determination unit determines whether or not there is an abnormality in the camera unit based on differences between the background image in the abnormal state image and the background image in the normal state image.

3. 3. The component mounting system according to claim 2, A component mounting system characterized in that the judgment unit judges that there is an abnormality in the camera unit when the brightness of the background image in the abnormal state image is lower than the brightness of the background image in the normal state image.

4. 4. The component mounting system according to claim 3, The component mounting system according to claim 1, further comprising: a determination unit that determines that there is an abnormality in the camera unit when the brightness of the background image in the abnormal state image is equal to or lower than a threshold value.

5. 5. The component mounting system according to claim 1, A component mounting system, characterized in that the determination unit acquires an image of a component of the same type as the component that is the subject of the abnormal state image as the normal state image.

6. 6. The component mounting system according to claim 1, A component mounting system, further comprising a notification unit that notifies of an abnormality in the camera unit when the determination unit determines that an abnormality exists in the camera unit.

7. 7. The component mounting system according to claim 6, When the determination unit determines that there is no abnormality in the camera unit, the determination unit determines that a pickup error by the mounting head and / or a component abnormality has occurred, The component mounting system according to claim 1, wherein the notification unit notifies the occurrence of a pickup error by a mounting head and / or a component abnormality.

Images