Warehouse System

Abstract

A warehouse system according to the present invention comprises: a component accommodation container warehouse in which are stored a plurality of component accommodation containers for accommodating a plurality of components; a component supply unit warehouse in which are stored a plurality of component supply units used when components accommodated in the component accommodation containers are supplied to a component mounting machine; a component accommodation container loader which loads the component accommodation containers into the component supply units; and a conveyance robot which moves among the component accommodation container warehouse, the component supply unit warehouse, and the component accommodation container loader, and which conveys the component accommodation containers and the component supply units to the component accommodation container loader.

Description

Technical Field

[0001] This specification relates to a warehouse system used to assist a component mounting machine.

Background Art

[0002] Techniques for mass-producing substrate products by performing substrate work on substrates with printed wiring are widespread. Furthermore, it has become common to arrange a plurality of types of substrate work machines for performing substrate work to form a substrate work line. Among the substrate work machines, a component mounting machine uses a component supply unit loaded with a component storage container that houses a plurality of components. In many cases, the component storage container and the component supply unit are stored in a warehouse. Then, through the loading operation of loading the component storage container into the component supply unit, it is prepared for use. Technical examples related to the storage and preparation for use of the component storage container and the component supply unit are disclosed in Patent Documents 1 and 2.

[0003] Patent Document 1 discloses a manufacturing management system that controls an SMT line (substrate work line) to manufacture printed circuit boards (substrate products). This manufacturing management system includes a reel stocker, a cartridge stocker, and a control personal computer that manages both stockers. The control personal computer includes a database that stores various data files related to the manufacture of printed circuit boards, a setup support unit that instructs setup work, and a mounting data creation unit that creates mounting data for mounting components on the printed circuit board. According to this, it is said that even for SMT lines with different equipment specifications and configurations, setup work can be performed efficiently, and mounting data corresponding to the setup information can be created.

[0004] In addition, the component mounting system disclosed in Patent Document 2 includes a component storage for storing a plurality of feeder devices (one form of component supply unit) that accommodate a large number of components, a supply device for replenishing and collecting components from the feeder devices to the component mounting machine, and a transport means for transporting the supply device between the component storage and a plurality of component mounting machines. According to this, it is said that necessary components can be automatically and efficiently replenished, enabling labor saving and automation.

Prior Art Documents

Patent Documents

[0005]

Patent Document 1

Patent Document 2

Summary of the Invention

Problems to be Solved by the Invention

[0006] By the way, in Patent Document 1 and Patent Document 2, a function is realized in which component containers and component supply units stored in a warehouse (stockers, component storage) are shipped out and supplied according to instructions. However, the loading operation of loading component containers into the component supply unit is carried out by an operator. Also, although a device for automating the loading operation has been put into practical use, the loading of component containers and component supply units into the device is carried out by an operator. For this reason, it cannot be said that sufficient labor saving has been achieved.

[0007] In this specification, it is an issue to be solved to provide a warehouse system that uses the support of a component mounting machine and achieves further labor saving in the loading operation of loading component containers into a component supply unit compared to the prior art.

Means for Solving the Problems

[0008] This specification discloses a warehouse system including a parts container warehouse that stores a plurality of parts container for accommodating a plurality of parts, a parts supply unit warehouse that stores a plurality of parts supply units used when supplying the parts accommodated in the parts container to a parts mounting machine, a parts container loader that loads the parts container into the parts supply unit, and a transfer robot that moves between each of the parts container warehouse, the parts supply unit warehouse, and the parts container loader and transports the parts container and the parts supply unit to the parts container loader.

Effect of the Invention

[0009] In the warehouse system disclosed in this specification, the transfer robot transports the parts container stored in the parts container warehouse to the parts container loader and also transports the parts supply unit stored in the parts supply unit warehouse to the parts container loader. Further, the parts container loader loads the parts container into the parts supply unit. As a result, preparations for using the parts supply unit with the parts mounting machine are automatically made. Therefore, the operator is not involved in the loading work, and further labor saving is achieved compared to the prior art.

Brief Description of the Drawings

[0010]

Figure 1

Figure 2

Figure 3

Figure 4

Modes for Carrying Out the Invention

[0011] 1. Configuration of the Warehouse System 1 of the First Embodiment The configuration of the warehouse system 1 according to the first embodiment will be described with reference to FIG. 1. The warehouse system 1 is used for the purpose of assisting one or more component mounters 91 that constitute the substrate processing line 9. Further, the warehouse system 1 can assist the component mounters 91 of a plurality of substrate processing lines 9. The component mounter 91 performs a mounting operation of mounting components on a substrate using a component supply unit loaded with a component storage container. The warehouse system 1 is responsible for the storage of the component storage container and the component supply unit, as well as the operations related to assistance.

[0012] The component storage container stores a plurality of components. The component supply unit is used when supplying the components stored in the component storage container to the component mounter 91. The component supply unit does not necessarily have to be integrated, and may be configured as a separable type. In this specification, at least a part of the combination of the component storage container and the component supply unit, or either one of them is referred to as "equipment".

[0013] A tape reel 71 can be exemplified as the component storage container, and a feeder device can be exemplified as the component supply unit (shown by a broken line in FIG. 1). A carrier tape in which a large number of components are enclosed at a predetermined pitch is wound and held on the tape reel 71. The feeder device supplies the components to the component mounting tool of the component mounter 91 by pulling out the carrier tape from the tape reel 71 and sending it to the component extraction position. The feeder devices are roughly classified into two types: an integrated type and a separable type.

[0014] The integrated feeder device 72 (shown by a broken line in FIG. 1) is installed in the component mounter 91 in the form of a prepared feeder device 73 loaded with the tape reel 71. Then, when all the components on the tape reel 71 are consumed, the entire prepared feeder device 73 is replaced. It should be noted that only the tape reel 71 may be replaced in some cases. On the other hand, the separable feeder device is composed of a feeder main body incorporating a carrier tape feeding mechanism and a reel cassette loaded with the tape reel 71. The feeder main body is permanently installed in the component mounter 91, and a separate reel cassette is arranged near the feeder main body. Then, when all the components on the tape reel 71 are consumed, the reel cassette is replaced.

[0015] As will be described later, the prepared feeder device 73 is prepared by the warehouse system 1. Similarly, the prepared reel cassette loaded with the tape reel 71 is prepared by the warehouse system 1. In FIG. 3, the case of using the integrated feeder device 72 is illustrated, and the illustration of the separable feeder device is omitted.

[0016] Also, a tray 75 can be exemplified as a component container, and a tray loading unit 76 can be exemplified as a component supply unit (shown by a broken line in FIG. 1). The tray 75 has a plurality of component storage parts for storing components respectively. Generally, the plurality of component storage parts are arranged in a two-dimensional grid pattern. The tray loading unit 76 is equipped in the component mounting machine 91 in the form of the prepared tray loading unit 77 loaded with the tray 75. Then, when the components in the tray 75 are completely consumed, the entire prepared tray loading unit 77 is replaced. Note that only the tray 75 may be replaced. As will be described later, the prepared tray loading unit 77 is prepared by the warehouse system 1. Further, the tray loading unit 76 may have a mechanism for stacking and loading a plurality of trays 75 and removing the trays 75 in which the components are completely consumed in order from the top.

[0017] The warehouse system 1 of the first embodiment is composed of a plurality of warehouse modules, a transfer robot 6, etc. As shown in FIG. 1, seven warehouse modules are provided side by side. That is, in order from the left side to the right side, the loading and information adding unit 55, the first component container warehouse 21, the second component container warehouse 22, the component supply unit warehouse 3, the reel loader 41, the tray loader 42, and the transfer vehicle stop unit 51 are provided side by side.

[0018] Each of the warehouse modules has a delivery port (not shown in the figure) for delivering the transfer robot 6 and tools at the front side. The arrangement and shape of the delivery ports in each of the warehouse modules are standardized. In FIG. 1, each of the warehouse modules is shown as a rectangular parallelepiped with different sizes, but the actual shape may be different from that of a rectangular parallelepiped. Also, arrangements where a plurality of warehouse modules are not arranged in a line and arrangements where a plurality of warehouse modules are separated from each other are allowed.

[0019] The transfer robot 6 is composed of a robot body 61 and a moving path 62, etc. The moving path 62 is laid so as to pass in front of all the warehouse modules. The robot body 61 has a moving mechanism such as a linear motor or traveling wheels and moves along the moving path 62. Therefore, the robot body 61 moves between each of the warehouse modules, and its moving range extends from the loading and information - attaching section 55 at the left end to the transfer vehicle stop section 51 at the right end.

[0020] Note that a plurality of robot bodies 61 may be provided. Also, the moving path 62 may be made into a double - track or circular shape, and may even be configured with a more complex moving path. The plurality of robot bodies 61 are controlled by a warehouse control unit 82 (see FIG. 2) described later and move while avoiding collisions.

[0021] A non - contact power transmission section 63 is provided at regular intervals near the upper surface of the moving path 62. On the other hand, a non - contact power receiving section 64 is provided at the lower part of the robot body 61. The robot body 61 is supplied with power by a configuration of a non - contact power supply section composed of the non - contact power transmission section 63 and the non - contact power receiving section 64. As the non - contact power supply section, a configuration of an electromagnetic coupling method using a coil can be exemplified, but it is not limited thereto.

[0022] The robot main body 61 has an arm (not shown) for gripping tools and performs the transfer operation of tools at the transfer port of the warehouse module. Specifically, the robot main body 61 grips the tools placed at the transfer port using the arm on the front side of a certain warehouse module. Next, the robot main body 61 transports the tools by moving to another target warehouse module. Finally, the robot main body 61 releases the arm and places the tools at the transfer port on the front side of another warehouse module. Note that each of the warehouse modules may have an arm, and the robot main body 61 may be equipped with only a transport function for transporting tools.

[0023] The loading and information - attaching unit 55 is a form of the work - performing unit that performs predetermined work on the component storage container. Also, the loading and information - attaching unit 55 doubles as a loading unit where the component storage container is loaded. The loading and information - attaching unit 55 has a loading port 56 for the component storage container on its left side surface. The loading and information - attaching unit 55 moves the component storage container loaded into the loading port 56 to an internal work - performing unit (not shown). The work - performing unit performs an information - attaching operation of attaching individual identification information to the component storage container.

[0024] The individual identification information is attached to each of the component storage containers such as the aforementioned tape reel 71 and tray 75. Examples of the work content of the information - attaching operation include printing an individual identification number and attaching an individual - identification barcode. The loading and information - attaching unit 55 places the component storage container with the attached individual identification information at the transfer port to make it in a state where it can be transported. Thereby, the information - attaching operation and the unloading to the component storage container are automatically performed, achieving labor - saving.

[0025] The first component storage container warehouse 21 is a warehouse with a desiccator and stores a plurality of component storage containers. The first component storage container warehouse 21 preferentially stores, keeps, and ships out the component storage containers of components that dislike moisture. Examples of components that dislike moisture include IC components and LSI components, which are stored in the form of tape reels 71 and trays 75 respectively. Note that when there is spare storage space in the first component storage container warehouse 21, it may store other non - priority components, the feeder device 72, and the tray loading unit 76.

[0026] The second component storage warehouse 22 is a general-purpose warehouse, and there are no special restrictions on the plurality of component storage containers to be stored. The second component storage warehouse 22 receives, stores, and ships component storage containers such as tape reels 71 and trays 75. These component storage containers are conveyed from the loading and information-providing unit 55 by the transfer robot 6.

[0027] The component supply unit warehouse 3 receives, stores, and ships a plurality of component supply units such as an integrated feeder device 72, a reel cassette, and a tray loading unit 76. These component supply units are carried into the delivery port of the component supply unit warehouse 3 by an operator. Alternatively, these component supply units are conveyed by the transfer robot 6.

[0028] The internal configurations of the first component storage warehouse 21, the second component storage warehouse 22, and the component supply unit warehouse 3 are similar to each other. For example, these warehouses are composed of storage shelves and an in-warehouse transfer unit. The storage shelves have a plurality of storage positions arranged two-dimensionally in the width direction and the height direction, and tools are stored at each storage position. The in-warehouse transfer unit conveys tools between the storage positions and the delivery port. Without being limited to this, these warehouses may have, for example, a plurality of storage shelves provided in the front-rear direction.

[0029] The reel loader 41 and the tray loader 42 are each a form of a component storage container loader that loads a component storage container into a component supply unit. The reel loader 41 performs a loading operation of loading the tape reel 71 into the feeder device 72 or the reel cassette. Specifically, the reel loader 41 moves the tape reel 71 placed at the delivery port by the transfer robot 6 and the feeder device 72 or the reel cassette to an internal operation execution unit (not shown). The operation execution unit loads the tape reel 71 in a predetermined posture at a predetermined position of the feeder device 72 or the reel cassette. Thereby, the loading operation of the tape reel 71 is completed, and the preparation for use by the component mounting machine 91 is complete. The prepared feeder device 73 or the prepared reel cassette is placed at the delivery port or temporarily stored inside.

[0030] Note that the reel loader 41 may be provided with a function of separating the tape reel 71 from the prepared feeder device 73 or the prepared reel cassette. The separated tape reel 71 is returned to the second component storage warehouse 22 for storage. Further, the feeder device 72 or the reel cassette from which the tape reel 71 has been removed is returned to the component supply unit warehouse 3 for storage.

[0031] The tray loader 42 performs a loading operation of loading the tray 75 into the tray loading unit 76. Specifically, the tray loader 42 moves a predetermined number of trays 75 placed at the delivery port and the tray loading unit 76 by the transfer robot 6 to an internal work execution unit (not shown). The work execution unit loads the tray 75 in a predetermined posture at a predetermined position of the tray loading unit 76. Thereby, the loading operation of the tray 75 is completed, and preparations for use in the component mounting machine 91 are made. The prepared tray loading unit 77 (the tray loading unit 76 loaded with the tray 75) for which preparations are complete is placed at the delivery port or temporarily stored inside.

[0032] Note that the tray loader 42 may be provided with a function of separating the tray 75 from the prepared tray loading unit 77. The separated tray 75 is returned to the second component storage warehouse 22 for storage. Further, the tray loading unit 76 from which the tray 75 has been removed is returned to the component supply unit warehouse 3 for storage.

[0033] Here, stand-alone type information providing devices, reel loading devices, and tray loading devices have been conventionally used. However, in the stand-alone type, it was necessary for the operator to carry in and out the instruments. In the first embodiment, since the transfer robot 6 is provided, the carry-in and carry-out work of the operator is reduced, and further labor saving is achieved compared to the conventional case.

[0034] The transfer cart stop unit 51 is where the transfer cart 52 that can move between the warehouse system 1 and the component mounting machine 91 stops. The transfer cart stop unit 51 performs the operation of loading the tools received from the transfer robot 6 onto the transfer cart 52. The transfer cart 52 travels along the transfer path 53 connecting the warehouse system 1 and the substrate processing line 9 as indicated by the arrow M1 in FIG. 1, and transports the loaded tools to the component mounting machine 91. Therefore, the transfer cart stop unit 51 functions as an unloading section from which at least one of the component containers and the component supply units is unloaded.

[0035] Furthermore, the transfer cart 52 transports the idle tools that have been used in the component mounting machine 91 and have no planned use in the immediate future in the reverse direction from the component mounting machine 91 to the transfer cart stop unit 51. The tools transported in the reverse direction are returned to either a warehouse or a loader by the transfer robot 6. Therefore, the transfer cart stop unit 51 functions as a loading section into which at least one of the component containers and the component supply units is loaded.

[0036] Note that a plurality of transfer carts 52 can be provided. Furthermore, in a configuration that supports a plurality of substrate processing lines 9, the transfer path 53 may be branched or looped in the middle, and a more complex transfer path may be configured. The plurality of transfer carts 52 are controlled by a transfer control unit 83 (see FIG. 2) described later and travel while avoiding collisions.

[0037] 2. Common Elements of the Warehouse Modules Here, the seven warehouse modules have common elements that are shared among them. This enables easy addition, deletion, modification, and rearrangement of the warehouse modules. In general, a "module" means a structural unit that has common elements and is easy to modify. The common elements include at least one of the following six items.

[0038] 1) Standardization of at least one of the external shape and the installation structure 2) Standardization of at least one of the power supply specifications and the power supply unit 3) Standardization of at least one of the communication specifications and the communication unit 4) Commonization of the control unit that controls the operation of the warehouse module 5) Commonization of the higher-level control unit that issues commands to the warehouse module 6) Commonization of the process of taking in and out equipment in the warehouse module These will be described in order below.

[0039] 1) In the first embodiment, although the outer shapes of the warehouse modules excluding the carrier stop unit 51 are different, the installation structures are commonized. For example, common bases or floor surfaces are provided with fixing seats at a certain pitch. On the other hand, installation seats of the same common shape are provided on the bottom surfaces of the respective warehouse modules at the same certain pitch. The installation seats of the warehouse modules are fixed to the fixing seats using the same fixtures, for example, bolts of the same thickness and length.

[0040] According to this, even if the total number of installation seats of the plurality of types of warehouse modules is different, they are installed on the same common base or floor surface by the same construction method. Therefore, the installation work of the warehouse module is simple. Furthermore, the additional installation work of adding a warehouse module and the relocation work of changing the arrangement order and position of the warehouse modules are as simple as the installation work.

[0041] 2) The power supply specifications of the plurality of types of warehouse modules are commonized. For example, the power supply specifications are commonized such as using both AC and DC for the power supply, or making the voltage levels different between the drive power supply and the control power supply. According to this, power can be supplied to a plurality of warehouse modules from a common power supply unit using power cables. Therefore, it is not necessary to provide a power supply unit for each of the warehouse modules, and simplification of the structure and cost reduction are achieved.

[0042] 3) The communication specifications and the configuration of the communication unit of the plurality of types of warehouse modules are commonized. According to this, since the same communication unit can be commonly applied to a plurality of warehouse modules, the hardware cost is reduced. Also, since the communication software is commonized, the software development cost is reduced.

[0043] Assume a case where the communication specifications are not unified due to differences in the manufacturers of multiple types of warehouse modules or due to the newness or oldness of the manufacturing time. In this case, an interface device is separately required to realize communication between the warehouse module and the warehouse control unit 82 (described later) and communication between the warehouse modules. This causes disadvantages such as an increase in cost and a decrease in communication reliability.

[0044] 4) The control units that control the operations of the warehouse modules are shared. For example, the algorithms for determining the storage positions in the three warehouses and the logic for controlling the in-warehouse transfer units are shared. As a result, the three warehouses are used efficiently. Also, for example, the handling conditions for handling equipment at the transfer ports of each warehouse module are shared. According to this, the transfer operations are shared regardless of the differences in the individual functions of the warehouse modules. Therefore, equivalent operation reliability regarding the transfer of equipment can be obtained for each warehouse module, and the software development cost is reduced.

[0045] 5) The warehouse control unit 82 is commonly provided as the upper control unit that issues commands to the warehouse modules. According to this, the transfer of equipment between the warehouse modules is centrally managed. Therefore, the transfer operations of the equipment and the operations in the work implementation unit are carried out in a timely and efficient manner.

[0046] 6) The processes of taking in and out equipment in each warehouse module, that is, the arrangement and shape of the transfer ports are shared. According to this, the transfer operations of the equipment by the transfer robot 6 are simplified and smoothed, and the operation reliability is improved.

[0047] 3. Functional Configurations of the Warehouse System 1 and the Production Management System 8 Next, the functional configuration of the warehouse system 1 of the first embodiment and the functional configuration of the upper-level production management system 8 will be described with reference to FIG. 2. As shown in FIG. 2, the production management system 8 is composed of a production management unit 81, a warehouse control unit 82, a conveyance control unit 83, and a line control unit 84. The production management unit 81 is located at a higher level of control. The warehouse control unit 82, the conveyance control unit 83, and the line control unit 84 are wired communication-connected to the production management unit 81 and are located at a lower level of the production management unit 81.

[0048] The production management unit 81 promotes the production plan of the substrate products produced on the substrate working line 9 and manages the progress of production. Specifically, when starting the production of substrate products or switching the types of substrate products being produced, the production management unit 81 issues an instruction to the warehouse control unit 82 to prepare the necessary tools. In addition, the production management unit 81 issues an instruction to the conveyance control unit 83 to convey the prepared tools from the warehouse system 1 to the substrate working line 9.

[0049] When the necessary tools are conveyed to and mounted on the component mounter 91 of the substrate working line 9, the production management unit 81 issues an instruction to the line control unit 84 to start the production of the substrate products. Thereby, the substrate working line 9 performs the substrate work and advances the production of the substrate products. Information on the production results of the substrate products is appropriately notified from the line control unit 84 to the production management unit 81. Also, when components are consumed and decreased due to the progress of production, information on the decreased components is notified from the line control unit 84 to the production management unit 81. The production management unit 81 issues instructions to the warehouse control unit 82 and the conveyance control unit 83 to replenish the components.

[0050] The warehouse system 1 includes the warehouse control unit 82. The warehouse control unit 82 is wired communication-connected to each of the warehouse modules. Further, the warehouse control unit 82 is wirelessly (shown by a broken line) communication-connected to the robot body 61. The warehouse control unit 82 issues commands to each warehouse module and the robot body 61 based on the instructions received from the production management unit 81. On the other hand, the warehouse control unit 82 acquires information on the operation status from each warehouse module and the robot body 61.

[0051] However, regarding the loading of the component containers, the warehouse control unit 82 proceeds with the control without receiving instructions from the production management unit 81. That is, when a component container is loaded into the loading entrance 56, the warehouse control unit 82 instructs the implementation of the information attachment operation. Furthermore, based on the type and quantity of the loaded component containers, the warehouse control unit 82 selects the warehouse for storage and determines the storage location. After that, the warehouse control unit 82 instructs the robot body 61 to transport the component containers, and instructs the selected warehouse to receive and store the component containers. Furthermore, the warehouse control unit 82 notifies the production management unit 81 of the information regarding the stored component containers.

[0052] In controls other than the loading of the component containers, the warehouse control unit 82 instructs the first component container warehouse 21, the second component container warehouse 22, and the component supply unit warehouse 3 to receive, store, and ship out the tools. Also, the warehouse control unit 82 instructs the reel loader 41 and the tray loader 42 to perform the loading operation. Furthermore, the warehouse control unit 82 instructs the transport vehicle stop unit 51 to perform the loading and unloading operations of the tools onto the transport vehicle 52. Each of the warehouse modules performs the instructed operations and tasks, and notifies the warehouse control unit 82 of the progress status.

[0053] When the instruction from the production management unit 81 is the loading operation, the warehouse control unit 82 first instructs the robot body 61 to transport the component containers and the component supply units stored in one of the warehouses. Next, the warehouse control unit 82 instructs the reel loader 41 or the tray loader 42 to perform the loading operation. Then, the warehouse control unit 82 instructs the robot body 61 to transport the prepared tools to the transport vehicle stop unit 51.

[0054] Also, when the instruction is the transport operation of the tools to the component mounting machine 91, the warehouse control unit 82 instructs the robot body 61 to transport the tools stored in one of the warehouses to the transport vehicle stop unit 51. In both cases of the loading operation and the transport operation, the warehouse control unit 82 instructs the transport vehicle stop unit 51 to perform the loading operation of the tools onto the transport vehicle 52.

[0055] The transport control unit 83 is communicatively connected to the transport vehicle 52 wirelessly (indicated by a broken line). The transport control unit 83 controls the transport of tools by the transport vehicle 52. The transport control unit 83 receives an instruction from the production management unit 81 and stops the transport vehicle 52 at the transport vehicle stop unit 51. When the tools are loaded onto the transport vehicle 52, the transport control unit 83 drives the transport vehicle 52 from the warehouse system 1 to the component mounting machine 91. The tools transported by the transport vehicle 52 are mounted on the component mounting machine 91 and used. Note that the mounting operation and the removal operation of the tools onto / from the component mounting machine 91 are performed automatically or manually.

[0056] The line control unit 84 is communicatively connected to each of the substrate processing machines constituting the substrate processing line 9 by wire. The line control unit 84 controls the operation of each of the substrate processing machines. The line control unit 84 receives an instruction from the production management unit 81 and causes the substrate processing machines to perform substrate processing. The line control unit 84 notifies the production management unit 81 of information on the production results of the substrate products and information on the reduced components.

[0057] When the production of a certain type of substrate product is completed, idle tools that will not be used in the next production plan become apparent. The production management unit 81 issues an instruction to return the idle tools to the warehouse system 1 to the transport control unit 83 and the warehouse control unit 82. At this time, the transport control unit 83 controls the reverse transport from the component mounting machine 91 to the warehouse system 1. Also, the warehouse control unit 82 controls the reverse warehousing operation from the transport vehicle stop unit 51 to the warehouse or the loader.

[0058] 4. Operation of the Warehouse System 1 of the First Embodiment Next, the operation of the warehouse system 1 of the first embodiment will be described with reference to the operation flow shown in FIG. 3. This operation flow is mainly advanced under the control of the warehouse control unit 82. In step S1 of FIG. 3, the warehouse control unit 82 checks whether a component container has been carried into the loading entrance 56. In step S2 when it has been carried in, the loading and information adding unit 55 performs an information adding operation.

[0059] In the next step S3, the warehouse control unit 82 selects a warehouse for storing the component storage container to which the individual identification information is assigned, and further determines the storage location. In the next step S4, the transfer robot 6 transports the component storage container to the selected warehouse. The selected warehouse receives the component storage container and stores it at the determined storage location. After step S4, and when the component storage container has not been carried in at step S1, the execution of the operation flow proceeds to step S5.

[0060] In step S5, the warehouse control unit 82 checks whether it has received an instruction from the production management unit 81. In step S6 when it has received an instruction, the warehouse control unit 82 investigates the content of the instruction and determines the branch destination of the operation flow. That is, when the instruction is a transfer operation, the warehouse control unit 82 branches to step S11, when it is a loading operation, it branches to step S21, and when it is a separation operation, it branches to step S31, respectively, as the branch destinations.

[0061] In step S11 for the transfer operation, the warehouse control unit 82 commands the warehouse module where the tools to be transferred are stored to ship them out. The warehouse module that has received the command ships the tools to the delivery port. Next, the warehouse control unit 82 commands the robot body 61 to transfer. The transfer robot 6 receives the tools from the delivery port of the warehouse module and transports them to the transfer vehicle stop unit 51.

[0062] Step S11 is executed when the remaining number of components decreases in the component mounting machine 91 and the tape reel 71 or the tray 75 is replaced. Also, step S11 is executed for the prepared feeder device 73 or the prepared reel cassette temporarily stored in the reel loader 41. Further, step S11 is executed for the prepared tray loading unit 77 temporarily stored in the tray loader 42. After step S11, the execution of the operation flow merges into step S24 (described later).

[0063] In step S21 in the case of the loading operation in step S6, the warehouse control unit 82 commands to convey the component storage container and the component supply unit that are the targets of the instructed loading operation. Hereinafter, the case where the tape reel 71 and the tray 75 are stored in the second component storage container warehouse 22 will be described. When the tape reel 71 and the tray 75 are stored in the first component storage container warehouse 21, the second component storage container warehouse 22 in the following description is replaced with the first component storage container warehouse 21.

[0064] When loading the tape reel 71 into the feeder device 72 or the reel cassette, the warehouse control unit 82 first commands the second component storage container warehouse 22 to release the tape reel 71, and then commands the robot main body 61 to convey it. The second component storage container warehouse 22 delivers the tape reel 71 to the delivery port according to the command. The robot main body 61 receives the tape reel 71 from the second component storage container warehouse 22 and conveys it to the reel loader 41.

[0065] Next, the warehouse control unit 82 commands the feeder device 72 or the reel cassette to be released from the component supply unit warehouse 3, and then commands the robot main body 61 to convey it. The component supply unit warehouse 3 delivers the feeder device 72 or the reel cassette to the delivery port according to the command. The robot main body 61 receives the feeder device 72 or the reel cassette from the component supply unit warehouse 3 and conveys it to the reel loader 41. Note that the robot main body 61 may convey the tape reel 71 and the feeder device 72 or the reel cassette together.

[0066] In the next step S22, the reel loader 41 performs an operation of loading the tape reel 71 into the feeder device 72 or the reel cassette. Subsequently, the reel loader 41 places the prepared feeder device 73 or the prepared reel cassette at the delivery port. Further, the reel loader 41 notifies the warehouse control unit 82 that the loading operation has been completed. In the next step S23, upon receiving the notification, the warehouse control unit 82 instructs the robot main body 61 to perform conveyance. The robot main body 61 receives the prepared feeder device 73 or the prepared reel cassette from the reel loader 41 and conveys it to the carrier stop unit 51.

[0067] In the next step S24, the warehouse control unit 82 instructs the carrier stop unit 51 to perform an operation of loading the prepared feeder device 73 or the prepared reel cassette onto the carrier 52. The subsequent conveyance to the component mounting machine 91 is carried out under the control of the conveyance control unit 83. After step S24, the execution of the operation flow returns to step S1. Also, when loading the tray 75 into the tray loading unit 76, the same operations as those from step S21 to step S24 described above are executed except that the tray loader 42 performs the loading operation.

[0068] In step S31 in the case of the separation operation in step S6, the warehouse control unit 82 instructs the reel loader 41 or the tray loader 42 to return the tools returned from the component mounting machine 91. For example, in the case of the separation operation of removing the tape reel 71 from the prepared feeder device 73 or the prepared reel cassette, the warehouse control unit 82 first instructs the carrier stop unit 51 to unload the prepared feeder device 73 or the prepared reel cassette from the carrier 52, and subsequently instructs the robot main body 61 to perform conveyance. The carrier stop unit 51 unloads the prepared feeder device 73 or the prepared reel cassette according to the instruction and places it at the delivery port. The robot main body 61 receives the prepared feeder device 73 or the prepared reel cassette from the carrier stop unit 51 and conveys it to the reel loader 41.

[0069] In the next step S32, the reel loader 41 performs a separation operation to remove the tape reel 71 from the prepared feeder device 73 or the prepared reel cassette. Subsequently, the reel loader 41 places the separated tape reel 71 and the feeder device 72 or the reel cassette at the delivery port. Further, the reel loader 41 notifies the warehouse control unit 82 that the separation operation has been completed.

[0070] In the next step S33, upon receiving the notification, the warehouse control unit 82 instructs the robot body 61 to perform transportation. The robot body 61 receives the tape reel 71 and the feeder device 72 or the reel cassette from the reel loader 41. Next, the robot body 61 returns the tape reel 71 to the second component storage warehouse 22 and returns the feeder device 72 or the reel cassette to the component supply unit warehouse 3. After step S33, the execution of the operation flow returns to step S1. Also, in the case of the separation operation of removing the tray 75 from the prepared tray loading unit 77, the same operations as those from step S31 to step S33 are executed except that the tray loader 42 performs the separation operation.

[0071] Note that the above-described separation operation is not essential. That is, the prepared feeder device 73 or the prepared reel cassette returned from the component mounter 91 may be stored in the reel loader 41 or the component supply unit warehouse 3 while being in a usable state. According to this storage method, in the combination of the tape reel 71 and the feeder device 72 or the reel cassette that are intermittently used with a pause period in between, the removal operation and the reloading operation of the tape reel 71 can be reduced. Similarly, the prepared tray loading unit 77 returned from the component mounter 91 may be stored in the tray loader 42 or the component supply unit warehouse 3 while being in a usable state.

[0072] In addition, there may be multiple instructions from the production control department 81. For example, when the loading operation for three feeder devices 72 or reel cassettes is instructed, the warehouse control unit 82 repeats the execution from step S21 to step S24 three times. As a result, the transport vehicle 52 can transport three prepared feeder devices 73 or three prepared reel cassettes together.

[0073] Furthermore, there may be a case where the transport vehicle 52 returns the idle instruments from the component mounting machine 91 to the transport vehicle stop section 51 and then transports the prepared instruments to the component mounting machine 91. In this case, the warehouse control unit 82 executes in advance the steps from step S21 to step S24 corresponding to the instruments to be prepared, and executes later the steps from step S31 to step S33 corresponding to the returned instruments. According to this, since the unloading operation of the returned instruments and the loading operation of the prepared instruments are continuously performed without delay after the transport vehicle 52 stops at the transport vehicle stop section 51, it is efficient.

[0074] In the warehouse system 1 of the first embodiment, the transport robot 6 transports the component containers (tape reels 71, trays 75) stored in the second component container warehouse 22 to the component container loaders (reel loaders 41, tray loaders 42), and also transports the component supply units (feeder devices 72, reel cassettes, tray loading units 76) stored in the component supply unit warehouse 3 to the component container loaders. In addition, the component container loader loads the component containers into the component supply units. As a result, the preparation for using the component supply units in the component mounting machine 91 is automatically completed. Therefore, the operator is not involved in the loading operation, and further labor saving is achieved compared with the conventional case.

[0075] In addition, since the seven warehouse modules have common elements, it is easy to add more warehouse modules. Therefore, it is easy to cope with an increase in the storage amount of the instruments, and the cost required for coping is also low. In addition, since the warehouse system 1 can be configured by freely combining multiple types of warehouse modules, it is possible to add operation execution functions such as information attachment work in addition to the storage function, and further labor saving is achieved compared with the conventional case.

[0076] 5. Warehouse System 1A of the Second Embodiment The warehouse system 1A of the second embodiment will be described with reference to FIG. 4. As shown in FIG. 4, in the warehouse system 1A of the second embodiment, a plurality of warehouse modules are arranged by being divided into a lower stage and an upper stage in the height direction. The types and arrangements of the lower-stage warehouse modules are the same as those in the first embodiment. The types and arrangements of the upper-stage warehouse modules are such that the carrier stop section 51 is omitted from the lower-stage configuration.

[0077] In addition, the transfer robot 6A is composed of two sets of robot bodies 61 and moving paths 62 each responsible for the lower stage and the upper stage, an elevator 65, and the like. The robot body 61 responsible for the upper stage can move to the lower-stage moving path 62 using the elevator 65 and can move to the carrier stop section 51 provided only in the lower stage. The two robot bodies 61 are controlled by the warehouse control unit 82 and move while avoiding collisions.

[0078] In the second embodiment, the structure and functions of each warehouse module, the operation of the transfer robot 6A, etc. are the same as those in the first embodiment. Since the warehouse modules in the warehouse system 1A of the second embodiment are arranged in two upper and lower stages, the storage capacity of the instruments can be increased by about twice without increasing the installation space as compared with the first embodiment. Furthermore, the warehouse modules can be arranged in three or more stages, and a large number of instruments can be stored with higher space efficiency.

[0079] 6. Application and Modification of the Embodiment Note that the carrier stop section 51, the carrier 52, and the transfer path 53 may be omitted, and the operator may carry the prepared instruments to the component mounting machine 91. Also, the separation operation performed by the reel loader 41 may be performed by a separate reel unloader. Similarly, the separation operation performed by the tray loader 42 may be performed by a separate tray unloader.

[0080] In addition, the first component storage warehouse 21, the second component storage warehouse 22, and the component supply unit warehouse 3 may store raw materials for substrates, unfinished substrate products with some components not yet mounted, substrate products that have been determined to be non-conforming by a substrate inspection machine and require repair, and the like. Further, the warehouse system (1, 1A) may store solder used in the solder printing apparatus and tools such as screens and squeegees, and be capable of transporting them from the carrier stop section 51 to the solder printing apparatus. Additionally, the first and second embodiments can be applied and modified in various ways.

Explanation of Reference Numerals

[0081] 1, 1A: Warehouse system 21: First component storage warehouse 22: Second component storage warehouse 3: Component supply unit warehouse 41: Reel loader 42: Tray loader 51: Carrier stop section 52: Carrier 53: Conveyor path 55: Loading and information adding section 56: Loading port 6: Conveyor robot 61: Robot body 62: Movement path 63: Non-contact power transmission section 64: Non-contact power reception section 65: Elevator 71: Tape reel 72: Feeder device 73: Prepared feeder device 75: Tray 76: Tray loading unit 77: Prepared tray loading unit 8: Production management system 81: Production management section 82: Warehouse control section 83: Conveyor control section 84: Line control section 9: Substrate working line 91: Component mounting machine

Claims

1. A parts container warehouse for storing a plurality of parts containers that store a plurality of parts, a parts supply unit warehouse for storing a plurality of parts supply units used when supplying the parts stored in the parts containers to a parts mounting machine, a parts container loader for loading the parts containers into the parts supply units, a transfer robot that moves between each of the parts container warehouse, the parts supply unit warehouse, and the parts container loader, and conveys the parts container received from the parts container warehouse and the parts supply unit received from the parts supply unit warehouse to the parts container loader and delivers them to the parts container loader, wherein the parts container warehouse, the parts supply unit warehouse, and the parts container loader are provided side by side in one direction, and have a delivery port on the front side for delivering at least one of the parts container and the parts supply unit to and from the transfer robot, and the transfer robot moves along the one direction on the front sides of the parts container warehouse, the parts supply unit warehouse, and the parts container loader. A warehouse system.

2. The warehouse system according to claim 1, wherein the parts container warehouse, the parts supply unit warehouse, and the parts container loader have common elements in common with each other and can be increased, decreased, changed, and arranged.

3. The common elements include 1) commonalization of at least one of the outer shape and the installation structure 2) commonalization of at least one of the power supply specifications and the power supply unit 3) commonalization of at least one of the communication specifications and the communication unit 4) commonalization of the control unit for controlling the operation 5) commonalization of the upper control unit that issues commands 6) commonalization of the process of taking in and out the parts containers and the parts supply units The warehouse system according to claim 2, including at least one of the above.

4. The transfer robot performs delivery of at least one of the parts container and the parts supply unit in the parts container warehouse, the parts supply unit warehouse, and the parts container loader. The warehouse system according to any one of claims 1 to 3.

5. The warehouse system according to any one of claims 1 to 4, further including at least one of a loading section where at least one of the parts container and the parts supply unit is loaded, and an unloading section where at least one of the parts container and the parts supply unit is unloaded within the movement range of the transfer robot.

6. The warehouse system according to claim 5, wherein at least one of the loading unit and the unloading unit is a carrier stop section where a carrier capable of moving between the warehouse system and the component mounting machine while carrying at least one of the component containers and the component supply unit stops.

7. The warehouse system according to any one of claims 1 to 6, further comprising a work execution section for performing operations other than loading on at least one of the component container and the component supply unit within the moving range of the transfer robot.

8. The warehouse system according to claim 7, wherein the work execution section also serves as a loading section where the component container is loaded, and is a loading and information - providing section for providing individual identification information to the loaded component container.

9. The component container loader according to any one of claims 1 to 8 is a reel loader for loading a tape reel, which is the component container, onto a feeder device that is the component supply unit or a reel cassette constituting the feeder device.

10. The component container loader according to any one of claims 1 to 9 is a tray loader for loading a tray, which is the component container, onto a tray loading unit that is the component supply unit.

11. The component container warehouse, the component supply unit warehouse, and the component container loader according to any one of claims 1 to 10 are arranged by being divided into a plurality of stages in the height direction.

12. The warehouse system according to any one of claims 1 to 11, wherein the transfer robot is powered by a non - contact power supply unit.

Images