Component placement machine and component placement method

Abstract

This component mounting machine is provided with: a mounting control unit that performs a mounting process on the basis of a control program in which the execution order of a PP cycle including a component picking operation and a mounting operation for mounting a component to a substrate is set; a supply control unit that, if a pickable number of components in a bulk feeder that supplies a plurality of components in a bulk state is less than a criterion value, causes the bulk feeder to perform a component supply operation along with the mounting operation; and an order adjusting unit that, if the required time for the mounting operation planned to be executed along with a next round of the supply operation on the basis of the current pickable number is shorter than the required time for the supply operation, adjusts the execution order of the PP cycle including the mounting operation.

Description

[Technical Field]

[0001] The present invention relates to a component mounting machine and a component mounting method. [Background technology]

[0002] A component mounting machine performs a mounting process in which components supplied by a feeder or the like are mounted onto a board. As shown in Patent Document 1, one type of feeder supplies components in a bulk state, with the components scattered in a supply area from which a suction nozzle can pick up the components. During the mounting process, the component mounting machine performs image processing to recognize the state of component supply by the bulk feeder, and controls the component suction operation using the suction nozzle based on the results of the image processing. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Laid-Open No. 2011-114084 Summary of the Invention [Problem to be solved by the invention]

[0004] In a placement process, if the number of components that can be picked up by a bulk feeder falls below the number required for a picking operation, some of the planned placement operations may not be executed or it may be necessary to wait for the bulk feeder's supply operation, which may result in a decrease in production efficiency. Thus, when performing a placement process using a bulk feeder, it is desirable to take into account the fact that the number of components that can be picked up by the bulk feeder is indefinite and to control the supply operation so that it is executed at an appropriate execution timing.

[0005] An object of the present specification is to provide a component mounting machine and a component mounting method that can suppress a decrease in production efficiency in a mounting process using a bulk feeder. [Means for solving the problem]

[0006] This specification discloses a first component mounting machine that includes a mounting control unit that executes mounting processing based on a control program in which an execution order of a PP cycle, including a component picking operation and a mounting operation for mounting the components on a board, is set; a supply control unit that, when the number of components that can be picked up in a bulk feeder that supplies multiple components in bulk falls below a reference value, causes the bulk feeder to execute a component supply operation in parallel with a mounting cycle that repeats the mounting operation multiple times; and a sequence adjustment unit that, when the required time for the mounting cycle scheduled to be executed in parallel with the next supply operation scheduled based on the current pickable number is shorter than the required time for the supply operation, adjusts the execution order of the PP cycle including the mounting cycle.

[0007] This specification discloses a second component mounting machine comprising: a component supplying device equipped with a bulk feeder that supplies multiple components in bulk and a tape feeder that supplies the components by feeding and moving a carrier tape that stores the same type of components as the bulk feeder; a mounting control unit that executes a mounting process based on a control program in which an execution order of a PP cycle that includes a component picking operation and a mounting operation that mounts the components on a board is set; and a supply control unit that causes the bulk feeder to execute a component supply operation in parallel with the PP cycle when the number of components that can be picked up by the bulk feeder falls below a reference value, and when executing the picking operation, if a wait time occurs while waiting for the bulk feeder to finish the component supply operation, the mounting control unit switches the target to be picked up to the components supplied by the tape feeder.

[0008] This specification discloses a component mounting method comprising: a mounting control step of executing a mounting process based on a control program in which an execution order of a PP cycle including a component picking operation and a mounting operation of mounting the components on a board is set; a supply control step of, when the number of components that can be picked up from a bulk feeder that supplies a plurality of the components in bulk falls below a reference value, having the bulk feeder execute a component supply operation in parallel with a mounting cycle that repeats the mounting operation multiple times; and an order adjustment step of, when the required time for the mounting cycle scheduled to be executed in parallel with the next supply operation scheduled based on the current pickable number is shorter than the required time for the supply operation, adjusting the execution order of the PP cycle including the mounting cycle. [Effects of the Invention]

[0009] According to the first component placement machine and component placement method, the execution order of multiple PP cycles is adjusted appropriately based on the required number and the available number of components. This prevents a shortage of the available number of components when executing a PP cycle and reduces the need to wait for the bulk feeder to complete its supply operation. As a result, a decrease in production efficiency can be prevented.

[0010] Furthermore, with the configuration of the second component mounting machine, when a bulk feeder supply operation is required, the components to be picked up are switched to those supplied by a tape feeder that can supply the same type of components as the bulk feeder, thereby reducing the time spent waiting for the bulk feeder to complete its supply operation, and as a result, reducing the decline in production efficiency. [Brief explanation of the drawings]

[0011] [Figure 1] FIG. 1 is a plan view schematically showing a component mounting machine according to a first embodiment. [Figure 2] FIG. 2 is a plan view showing a component supply area in the bulk feeder. [Figure 3] FIG. 2 is a block diagram showing a component mounting machine. [Figure 4]FIG. 10 is a diagram showing image data of an image of a supply region. [Figure 5] 5 is a diagram showing the results of a supply state recognition process for the image data in FIG. 4. FIG. [Figure 6] 10 is a table showing a control program and analysis results for each PP cycle. [Figure 7] 10 is a flowchart showing a mounting process performed by a component mounting machine. [Figure 8] 10 is a flowchart showing a component supply management process performed by a component mounting machine. [Figure 9] 10 is a timing chart showing the relationship between a PP cycle to be executed and an adjusted PP cycle. [Figure 10] 10 is a flowchart showing the adjustment process of the PP cycle by the component mounting machine. [Figure 11] FIG. 10 is an explanatory diagram of a cycle generation process performed by a component mounting machine. [Figure 12] 10 is a flowchart showing a component supply management process by a component mounting machine according to a second embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0012] 1. First embodiment The following describes, with reference to the drawings, a component mounting machine and a component mounting method that executes a component mounting process using bulk feeder 30. Bulk feeder 30 is equipped in component mounting machine 10 that mounts components on board 91, for example, and supplies components in a bulk state (loose, with each component having an irregular posture).

[0013] 1-1. Configuration of component placement machine 10 The component mounting machine 10 constitutes a production line for producing substrate products together with a plurality of types of substrate-related operation machines including, for example, other component mounting machines 10. The substrate-related operation machines that make up the production line may include a printing machine, an inspection device, a reflow oven, and the like.

[0014] 1-1-1. Substrate transport device 1, the component mounting machine 10 includes a board transport device 11. The board transport device 11 sequentially transports boards 91 in a transport direction and positions the boards 91 at predetermined positions within the machine.

[0015] 1-1-2. Parts supply device 12 The component mounting machine 10 is equipped with a component supply device 12. The component supply device 12 supplies components to be mounted on the board 91. The component supply device 12 is equipped with a feeder 122 for each of a plurality of slots 121. The feeder 122 may be, for example, a tape feeder that feeds and moves a carrier tape containing a large number of components to supply the components so that they can be picked. The feeder 122 may also be a bulk feeder 30 that supplies components stored in a bulk state so that they can be picked. Details of the bulk feeder 30 will be described later.

[0016] Furthermore, the feeder 122 is loaded with components and installed in the slot 121 so that it can supply the required type of components according to the placement process to be executed. If a component runs out during the placement process, the placement process will be temporarily stopped, resulting in a decrease in production efficiency. For this reason, in some placement processes, a spare feeder 61 that can supply the same type of components is installed in another slot 121.

[0017] 1-1-3. Parts transfer device 13 The component mounting machine 10 includes a component transfer device 13. The component transfer device 13 transfers components supplied by the component supply device 12 to predetermined mounting positions on the board 91. The component transfer device 13 includes a head drive device 131, a movable table 132, a mounting head 133, and a suction nozzle 134. The head drive device 131 moves the movable table 132 in horizontal directions (X and Y directions) using a linear motion mechanism. The mounting head 133 is detachably fixed to the movable table 132 by a clamp member (not shown), and is provided so as to be movable horizontally within the machine.

[0018] The mounting head 133 supports a plurality of suction nozzles 134 that are rotatable and movable up and down. The suction nozzles 134 are holding members that pick up and hold components supplied by the feeder 122. The suction nozzles 134 use supplied negative pressure air to pick up the components supplied by the feeder 122. A chuck or the like that grips and holds components can be used as the holding member attached to the mounting head 133.

[0019] 1-1-4. Component camera 14, board camera 15 The component mounting machine 10 is equipped with a component camera 14 and a board camera 15. The component camera 14 and the board camera 15 are digital imaging devices having imaging elements such as CMOS. The component camera 14 and the board camera 15 capture images based on control signals and send image data acquired by the images. The component camera 14 is configured to be able to capture images of the components held by the suction nozzle 134 from below. The board camera 15 is mounted on a moving stage 132 so as to be movable horizontally integrally with the mounting head 133. The board camera 15 is configured to be able to capture images of the board 91 from above.

[0020] Furthermore, in addition to capturing an image of the surface of the board 91, the board camera 15 can also capture an image of various devices within the movable range of the movable stage 132. For example, in this embodiment, as shown in Fig. 2, the board camera 15 can capture an image of the supply area As to which the bulk feeder 30 supplies components and the reference mark 344 provided on the upper part of the bulk feeder 30 within the camera's field of view. In this way, the board camera 15 can be used to capture images of different objects in order to obtain image data to be used for various image processing.

[0021] 1-1-5. Control device 20 As shown in Fig. 1, the component mounting machine 10 includes a control device 20. The control device 20 is mainly composed of a CPU, various memories, and a control circuit. As shown in Fig. 3, the control device 20 includes a storage unit 21. The storage unit 21 is composed of an optical drive device such as a hard disk drive, or a flash memory. The storage unit 21 of the control device 20 stores various data such as a control program M1 used to control the mounting process.

[0022] 6, the control program M1 indicates the placement positions, placement angles, and component types of components to be placed on the board 91 in the planned placement order during the placement process. Here, the placement process includes a process of repeating a PP cycle (pick-and-place cycle) including a pickup cycle and a placement cycle multiple times. The above-mentioned "pick-up cycle" refers to a process of repeating a pickup operation multiple times in which components supplied by the component supply device 12 are picked up by the suction nozzle 134.

[0023] The above-mentioned "placement cycle" refers to a process of repeating a plurality of times a placement operation in which a picked component is placed at a predetermined placement angle in a predetermined placement position on the board 91. In this way, the control program M1 has preset therein an execution order (PP1, PP2, ...) of a PP cycle made up of a plurality of picking operations and placement operations grouped in consideration of the number of suction nozzles 134 supported by the placement head 133, the movement distance of the placement head 133, etc.

[0024] The control device 20 includes a placement control unit 22. The placement control unit 22 executes placement processing based on a control program M1 in which the execution order of the PP cycle is set. The placement control unit 22 executes processing to recognize the holding state of components held by each of the multiple holding members (suction nozzles 134). Specifically, the placement control unit 22 processes image data acquired by imaging with the component camera 14, and recognizes the position and angle of each component relative to the reference position of the placement head 133. Note that the placement control unit 22 may also process image data acquired by, in addition to the component camera 14, a head camera unit integrally provided on the placement head 133, for example, capturing an image of the component from the side, below, or above.

[0025] During the placement process, the placement control unit 22 controls the operation of the placement head 133 based on information output from various sensors, image processing results, the control program M1, etc. This controls the positions and angles of the multiple suction nozzles 134 supported by the placement head 133. As a result, the components held by the suction nozzles 134 are placed at the predetermined placement positions and at the predetermined placement angles instructed by the control program M1.

[0026] The control device 20 includes a state recognition unit 23. The state recognition unit 23 recognizes the supply state of multiple components in the supply area As of the bulk feeder 30 based on image data D1 (see FIG. 4) acquired by imaging with a camera (in this embodiment, the board camera 15). The supply state recognition process includes a process of recognizing whether or not there are any components that can be picked up in the supply area As, and, if there are any components that can be picked up, a process of recognizing the position and angle of the components. Then, the placement control unit 22 controls the operation of the placement head 133 in the picking operation based on the results of the supply state recognition process. The recognition process performed by the state recognition unit 23 will be described in detail below.

[0027] The control device 20 includes a supply control unit 24. The supply control unit 24 controls the supply of components by the component supply device 12. If the component supply device 12 is equipped with a bulk feeder 30, the supply control unit 24 controls the bulk feeder 30 to perform a supply operation at an appropriate timing during the execution of the mounting process. The control of the bulk feeder 30 by the supply control unit 24 will be described in detail later.

[0028] The control device 20 includes a sequence adjustment unit 25. The execution sequence of the PP cycles, which are repeated multiple times in the mounting process, is preset by the control program M1 as described above. However, in actual mounting processes, some of the mounting operations of the PP cycles may not be completed normally due to errors in the component picking operation or the inclusion of defective components. In such cases, the sequence adjustment unit 52 adjusts the execution sequence of the PP cycles.

[0029] For example, when a mounting operation does not end normally, the order adjustment unit 25 moves the set of mounting operations related to the unsuccessful mounting operation to the middle or end of the scheduled PP cycle. This causes the mounting control unit 22 to attempt the mounting operation again as a recovery process. In this embodiment, the order adjustment unit 25 adjusts the execution order of a predetermined PP cycle according to the progress of the supply operation and mounting process of the bulk feeder 30, in addition to the above circumstances. The PP cycle adjustment process performed by the order adjustment unit 25 will be described in detail later.

[0030] The control device 20 includes a cycle generation unit 26. When the execution order of some PP cycles is changed by the order adjustment unit 25, the cycle generation unit 26 groups predetermined mounting operations under predetermined conditions to generate a new PP cycle. As a result, for example, multiple mounting operations that are the target of recovery processing are grouped into one PP cycle. The PP cycle generation process by the cycle generation unit 26 will be described in detail later.

[0031] 1-2.Configuration of bulk feeder 30 Bulk feeder 30 is installed in component mounting machine 10 and functions as part of component supply device 12. Bulk feeder 30 supplies components stored in a bulk state that is not aligned like a carrier tape. Therefore, unlike tape feeders, bulk feeder 30 does not use carrier tape, which has the advantage of eliminating the need to load carrier tape and collect used tape.

[0032] Some bulk feeders 30 supply components in irregular positions to a planar supply area As. However, if the components are so close together in the supply area As that they touch each other, or if they are piled up (overlapping vertically), or if the components are positioned horizontally with their widths aligned vertically, the component mounting machine 10 cannot pick these components. Therefore, to increase the percentage of components that can be picked, some bulk feeders 30 supply components in an aligned state in the supply area As. In this embodiment, a bulk feeder 30 of the aligned type will be described as an example.

[0033] When bulk feeder 30 is set in slot 121 of component supply device 12, it is supplied with power via a connector and is capable of communicating with control device 20. Bulk feeder 30 has a feeder body 31 formed in a flat, box-like shape. A component case that stores multiple components in bulk is detachably attached to feeder body 31. Bulk feeder 30 also has a track member 34 that is mounted so as to be vibrable relative to feeder body 31. Track member 34 forms a conveying path R along which the multiple components are conveyed, and a supplying area As that communicates with conveying path R and opens upward so that the multiple components can be picked up.

[0034] The track member 34 is formed to extend in the front-rear direction (left-right direction in FIG. 2) of the feeder body 31. A pair of side walls 341 that protrude upward is formed on both edges of the track member 34 in the width direction (top-bottom direction in FIG. 2). The pair of side walls 341, together with a tip portion 342 of the track member 34, surrounds the periphery of the conveying path R and prevents leakage of parts being conveyed along the conveying path R. A pair of circular reference marks 344 that indicate the reference position of the supply area As are provided on the upper surface of the tip portion 342, one on the left and one on the right.

[0035] In this embodiment, an alignment member 50 is replaceably attached to the track member 34. The alignment member 50 has a plurality of cavities 51 that individually accommodate a plurality of components. Specifically, the cavities 51 are arranged in a zigzag pattern in the supply area As, with adjacent rows staggered in the conveying direction. For example, the alignment member 50 has a total of 64 cavities 51, with eight cavities 51 regularly arranged in the conveying direction and eight cavities 51 regularly arranged in the width direction of the conveying path R. Each of the cavities 51 opens upward and accommodates a component with its thickness direction aligned vertically. The cavities 51 may also be arranged in a matrix.

[0036] The opening of the cavity 51 is set to a dimension slightly larger than the outer shape of the part when viewed from above. The depth of the cavity 51 is set according to the type of part (shape, mass, etc.). One of various types of track members 34 is attached to the track member 34, selected based on the type of part, the required number of cavities 51, and functionality.

[0037] Here, the "supply area As" of the track member 34 is an area where components are supplied in bulk and where components can be picked up by suction nozzles 134 supported by mounting heads 133. The "transport path R" of the track member 34 is a path along which components circulated from the component case side to the track member 34 are transported to the supply area As. A cover 36 that covers the top of the transport path R is fixed to the track member 34.

[0038] The bulk feeder 30 is provided with a shutter 37 that is disposed above the track member 34 and that can close the opening of the supply area As. The bulk feeder 30 can prevent components from flying out or foreign objects from entering the supply area As by opening and closing the shutter 37. The shutter 37 can be switched between an open state, a closed state, and an intermediate state by opening and closing the shutter 37. The closed state of the shutter 37 is a state in which the shutter 37 contacts the track member 34 and completely closes the opening of the supply area As. In this state, the shutter 37 is located behind the pair of reference marks 344 on the track member 34 on the feeder body 31, as shown by the dashed lines in FIG. 2, making it possible to view and capture an image of the pair of reference marks 344 when viewed from above.

[0039] The open state of the shutter 37 refers to a state in which the opening of the supply area As is not blocked and the main range of the supply area As (the range where multiple cavities 51 are provided in this embodiment) is exposed. At this time, the suction nozzle 134 can perform a component pick-up operation on any of the cavities 51. The intermediate state of the shutter 37 refers to a state between the closed state and the open state, in which the shutter 37 is spaced apart from the track member 34 by at least the amplitude of the track member 34 vibrating due to excitation and prevents components from jumping out of the opening of the supply area As. The shutter 37 is opened and closed by a drive device (not shown), and is set to the closed state, open state, or intermediate state depending on the drive state of the drive device.

[0040] Bulk feeder 30 includes a vibration device (not shown) mounted on feeder body 31. The vibration device applies vibration to track member 34 so that multiple parts are transported along transport path R. When the vibration device applies vibration to track member 34, track member 34 moves in an elliptical motion when viewed from the side. As a result, multiple parts on transport path R are subjected to a forward and upward external force or a backward and upward external force depending on the rotation direction of the elliptical motion of track member 34. As a result, multiple parts are transported to the front or rear of track member 34. Bulk feeder 30 can vary the transport speed, degree of dispersion, and transport direction of the transported parts by controlling the frequency and amplitude of the vibration applied to track member 34 and the rotation direction of the elliptical motion caused by the vibration.

[0041] The bulk feeder configured as described above receives a command to supply components during the period from the end of the current picking operation to the start of the next picking operation while the component mounting machine 10 is performing the mounting process, and executes the component supply operation. The component supply operation is an operation of transporting components so that the components are accommodated in the multiple cavities 51. Specifically, the transport operation includes a feed operation in which a component located at the front end of the transport path R advances to the front end of the supply area As, and then a return operation in which the component retreats to the front end of the transport path R again.

[0042] If there is sufficient time before the start of the next collection operation, the transport operation may be configured to repeatedly execute the forward and return operations so that multiple parts are moved back and forth multiple times in the supply area As. In other words, the bulk feeder 30 can selectively execute one of multiple patterns for supplying parts, taking into consideration factors such as the allowable time and the number of parts that can be collected.

[0043] 1-3. Details of the state recognition unit 23 As described above, the state recognition unit 23 recognizes the supply state of the plurality of components 92 in the supply area As of the bulk feeder 30 based on the image data D1 (see FIG. 4) acquired by imaging with the board camera 15. More specifically, the state recognition unit 23 first performs a supply state recognition process based on the image data D1 acquired by imaging the supply area As in a state in which the bulk feeder 30 has conveyed the plurality of components 92 to the supply area As by vibration.

[0044] 4 is an example of image data D1. As such, there are many bulk components 92 in the supply area As, and some of them may be housed in the cavities 51 in the normal position, some may be outside the cavities 51, some may be in contact with each other or piled up, and some may be lying down. In this embodiment, the state recognition unit 23 first determines the state of each of the multiple cavities 51.

[0045] As a result, the multiple cavities 51 are classified into accommodating cavities that accommodate components 92 so that they can be picked ("OK" in FIG. 5), NG cavities that cannot be picked even though components 92 are present around them ("NG" in FIG. 5), and empty cavities that do not have components 92 present around them ("EMP" in FIG. 5). In FIG. 5, accommodating cavities are indicated by diagonal lines, NG cavities are indicated by diagonal X marks, and empty cavities are indicated only by dashed outlines. The state recognition unit 23 calculates the number (V1, V2, V3) of the states (OK, NG, EMP) of the multiple cavities 51 as shown in FIG. 5.

[0046] The status recognition unit 23 then recognizes the current supply status based on the above numbers (V1, V2, V3). This supply status may include the ratio of the number of containing cavities V1 to the total number of cavities 51, the addresses of the containing cavities (unique values ​​assigned to each of multiple cavities 51) as the locations of the pickable components 92, and the orientations of the components 92 in the containing cavities (the angles of the pickable components 92). Note that the ratio of the number of containing cavities V1 is used, for example, to switch between various patterns in the supply operation. Hereinafter, the "number of containing cavities V1" will also be referred to as the "pickable number V1" of components 92.

[0047] 1-4. Details of the supply control unit 24 As described above, when the component supply device 12 is equipped with the bulk feeder 30, the supply control unit 24 controls the bulk feeder 30 so that the supply operation is performed at an appropriate execution timing. Various aspects can be adopted for the execution timing of the supply operation. For example, the execution timing set differs depending on whether priority is given to reducing the number of executions of the supply operation or to reducing the number of executions of the PP cycle including the recovery process.

[0048] In this embodiment, the supply control unit 24 performs control that prioritizes reducing the number of times the supply operation is performed. Specifically, the supply control unit 24 first determines whether the number V1 of components 92 that can be collected from the bulk feeder 30 has fallen below a reference value Vc. In particular, the supply control unit 24 acquires the number V1 that can be collected that is included in the supply state recognized by the state recognition unit 23, and updates the number V1 that can be collected by subtracting the required number for the PP cycle (for example, the required number Ra of component type a) each time a PP cycle is performed. If the updated number V1 that can be collected falls below the reference value Vc, the supply control unit 24 commands the bulk feeder 30 to perform a supply operation.

[0049] The reference value Vc can be set as appropriate. In this embodiment, the reference value Vc is set to 1. That is, the supply control unit 24 commands the bulk feeder 30 to execute a supply operation when the collectable number V1 becomes 0. With this setting, if the placement control unit 22 is unable to collect the required number of components 92 from the bulk feeder 30 during the execution of a certain PP cycle, it skips part of the PP cycle and proceeds to the placement operation for the collected number of components 92. The placement control unit 22 executes the skipped part of the PP cycle (the collection operation and the placement operation) at a predetermined timing, similar to the recovery process.

[0050] Furthermore, when instructing the bulk feeder 30 to execute the supply operation as described above, the supply control unit 24 sends the command after the picking operation from the bulk feeder 30 is completed and the suction nozzle 134 has risen sufficiently. As a result, the supply operation by the bulk feeder 30 is executed in parallel with the mounting cycle of the PP cycle.

[0051] 1-5. Mounting process by component mounting machine 10 The mounting process by the component mounting machine 10 will be described with reference to Fig. 7. Here, it is assumed that the component supply device 12 is equipped with a plurality of feeders 122, namely, tape feeders and bulk feeders 30. After the bulk feeders 30 are set in the slots 121, the control device 20 executes a calibration process to recognize the positions of the plurality of cavities 51 within the machine.

[0052] In the above calibration process, the control device 20 first moves the substrate camera 15 above the pair of reference marks 344 on the bulk feeder 30 and acquires image data by capturing an image with the substrate camera 15. Then, the control device 20 recognizes the position of the bulk feeder 30 within the machine based on the positions of the pair of reference marks 344 included in the image data and the position of the substrate camera 15 at the time of capturing the image through image processing. The control device 20 can acquire the coordinate values ​​of each of the cavities 51 based on the results of the calibration process and the arrangement information of the cavities 51.

[0053] In the mounting process, first, the board transport device 11 of the component mounting machine 10 executes a board 91 loading process (S11), as shown in FIG. 7. This loads the board 91 into the machine and positions it at a predetermined position within the machine. After S11, or in parallel with S11, the supply control unit 24 causes the bulk feeder 30 to execute a supply operation (S21). By executing the supply operation, a state is created in which multiple components 92 are accommodated in at least some of the multiple cavities 51 of the bulk feeder 30. After the supply operation by the bulk feeder 30 is completed, the state recognition unit 23 executes a process to recognize the supply state of the components 92 (S22). This acquires the current pickable number V1 and the positions (addresses of the accommodation cavities) of the pickable components 92 as the supply state.

[0054] Next, the control device 20 executes a PP cycle. In the PP cycle, the operation control unit 41 executes a pickup cycle in which a pickup operation is repeated to pick up components 92 using multiple suction nozzles 134 (S12). At this time, the placement control unit 22 controls the operation of the placement head 133 in the pickup operation so that the placement head 133 is sequentially positioned according to the positions of the pickable components 92. At this time, the placement control unit 22 positions the suction nozzles 134 by appropriately switching between the coordinate values ​​of the center of the cavity 51 and the coordinate values ​​of the reference position of the components 92 as the positions of the pickable components 92.

[0055] Next, the control device 20 executes a process for recognizing the holding state of the components 92 held by each of the plurality of suction nozzles 134 (S13). Specifically, the control device 20 moves the mounting head 133 above the component camera 14 and sends an image capture command to the component camera 14. The control device 20 processes the image data acquired by the component camera 14, and recognizes the orientation (position and angle) of the components 92 held by each of the plurality of suction nozzles 134. The result of the holding state recognition process (S13) is recorded in the memory unit 21 as an operation result indicating whether or not a picking error occurred in the picking operation.

[0056] Thereafter, the control device 20 executes a mounting cycle (S14) in which the mounting operation of mounting components using the multiple suction nozzles 134 is repeated. In the mounting operation of this mounting cycle (S14), the control device 20 controls the operation of the mounting head 133 so that the components 92 are mounted at the mounting positions specified by the control program M1. Furthermore, the mounting head 133 controls the operation so that the suction nozzles 134 are positioned and angled relative to the mounting positions based on the results of the recognition process (S13).

[0057] Furthermore, the supply control unit 24 executes a supply management process in parallel with the above-described PP cycle. The supply management process includes setting the execution timing of the supply operation of the components 92 by the bulk feeder 30, issuing a command for the supply operation, and recognizing the supply status. For example, when the supply operation of the components 92 is executed, the supply operation by the bulk feeder 30 is executed in the period from the end of the collection cycle (S12) of the current PP cycle to the start of the collection cycle (S12) of the next PP cycle.

[0058] The control device 20 determines whether all PP cycles have been completed based on the control program M1 (S15). If all PP cycles have not been completed (S15: No), the control device 20 executes the PP cycles (S12-S14). If all PP cycles have been completed (S15: Yes), the control device 20 executes the unloading process of the board 91 (S16). In the unloading process of the board 91, the board transport device 11 unclamps the positioned board 91 and unloads the board 91 out of the component mounting machine 10.

[0059] 1-6. Supply management process by component placement machine 10 The supply management process by the component mounting machine 10 will be described with reference to Figure 8. The supply management process for components 92 is executed before the execution of a PP cycle or in parallel with some of the processes during the mounting process. First, the control device 20 determines the execution timing of the next supply operation (S31). The control device 20 adds up the required number of components 92 for each PP cycle scheduled to be executed in the order of execution of the PP cycle, and determines the execution timing of the next supply operation when the sum of the added value and a reference value Vc exceeds the current number V1 that can be picked up.

[0060] For example, as shown in FIG. 6, the control device 20 analyzes the control program M1 in advance and obtains the required quantities (Ra1, Rb1, . . .) of each component type in multiple PP cycles (PP1, PP2, . . .). FIG. 6 shows the required quantities Ra of component type (a) as required quantities Ra1, Ra2, . . ., RaN in each PP cycle (PP1, PP2, . . ., PPN). When component type (a) is supplied by the bulk feeder 30, the control device 20 accumulates the required quantities Ra during execution of, for example, the first PP cycle (PP1), and determines the timing for executing the next supply operation when the sum of the accumulated value (Ra1 + Ra2 + . . .) and a reference value Vc exceeds the collectable number V1.

[0061] Next, the control device 20 determines whether the required time TL of the attachment cycle scheduled to be executed in parallel with the next supply operation scheduled in S31 is shorter than the required time Ts of the supply operation (S32). Here, the required time Tt of each PP cycle can be obtained in advance as the sum of the required time TC of the collection cycle and the required time TL of the attachment cycle, as shown in Figure 6. Specifically, the required time Tt1 of the first PP cycle (PP1) corresponds to the sum of the required time TC1 of the collection cycle and the required time TL1 of the attachment cycle.

[0062] The time TC required for the collection cycle may vary depending on the movement distance of the placement head 133, which may be due to factors such as the number of components 92 to be collected and the installation position of the feeder 122 from which the components are being supplied. Furthermore, the time TL required for the placement cycle may vary depending on the movement distance of the placement head 133, which may be due to factors such as the number and placement positions of multiple components 92. The control device 20 analyzes the control program M1 to calculate various required times required for subsequent processing. While the required time Ts for the supply operation may vary depending on the supply operation pattern, the control device 20 may use a fixed value for the required time Ts for the supply operation in the above determination (S32).

[0063] 9, if the next scheduled supply operation SP is scheduled to be executed in parallel with the placement cycle (L3) of the third PP cycle (PP3), the respective required times Ts and TL3 are compared. For example, if the required time Ts for the supply operation SP is longer than the required time TL3 for the placement cycle (L3) (S32: Yes), and the next placement cycle (C4) of the fourth PP cycle (PP4) includes a picking operation for component type (a), a waiting time Tw will occur to wait for the completion of the supply operation SP.

[0064] Therefore, the order adjustment unit 25 executes an adjustment process of the PP cycles (S33). In the adjustment process, the order adjustment unit 25 adjusts the execution order of the multiple PP cycles included in the control program M1 under predetermined conditions to suppress or shorten the occurrence of the above-mentioned waiting time Tw. For example, the order adjustment unit 25 may adjust the third PP cycle (PP3), which will cause the waiting time Tw when executed as scheduled as described above, so that it is executed before the second PP cycle (PP2) that has not yet been executed.

[0065] In this embodiment, when adjusting the execution order of PP cycles, the order adjustment unit 25 adjusts the execution order of the PP cycles so that the PP cycle is later than the execution order set by the control program M1. According to this aspect, the order adjustment unit 25 can treat the PP cycle to be adjusted in the same way as a target for recovery processing, thereby simplifying various subsequent processes. Furthermore, the above-mentioned "predetermined condition" includes a condition that the order of execution among multiple PP cycles is fixed or recommended.

[0066] In this embodiment, it is assumed that there is no predetermined condition as described above, and the order adjustment unit 25 moves the PP cycle to be adjusted to the end of all PP cycles (S41), as shown in Fig. 10. As a result, as shown in the lower part of Fig. 9, the third PP cycle (PP3) is rescheduled to be executed at the end, as in the recovery process. Next, the next scheduled supply operation SP is scheduled to be executed in parallel with the mounting cycle of the PP cycle that was scheduled to be executed immediately after the moved PP cycle. The control device 20 determines whether the required time TL of this mounting cycle is shorter than the required time Ts of the supply operation (S42).

[0067] For example, as shown in the lower part of Fig. 9, the supply operation SP is scheduled to be executed in parallel with the mounting cycle (C4) of the fourth PP cycle (PP4). If the required time Ts for the supply operation SP is shorter than the required time TL4 for this mounting cycle (C4) (S42: Yes), there is a surplus time Tx equal to the difference, and no waiting time Tw occurs. If the required time Ts for the supply operation SP is longer than the required time TL for the next candidate PP cycle (S42: No), the above processes (S41-S42) are repeated with the next candidate PP cycle and the PP cycle to be adjusted, as long as the number of times the move-to-end process (S41) has been executed does not exceed a predetermined number (S43: Yes).

[0068] The above-mentioned specified number is set to a maximum value, which is the number of cycles from the next candidate PP cycle to the final PP cycle (PPN), and is set appropriately by an administrator or the like, taking into consideration the processing load, etc., or is set to a fixed value. If the number of times the movement process (S41) has been executed reaches the specified number (S43: No), the order adjustment unit 25 cancels up to the movement process (S41) of the PP cycle with the shortest waiting time Tw among the multiple PP cycles that have been subjected to adjustment, if the movement process (S41) has been executed multiple times, and completes the adjustment with some of the cycles restored to their original state (S44). The order adjustment unit 25 may also complete the adjustment with the movement process (S41) executed up to the specified number without canceling the movement process (S41).

[0069] Furthermore, if the number of times the movement process (S41) has been executed reaches a predetermined number (S43: No), a waiting time Tw occurs while waiting for the completion of the supply operation SP when executing the picking operation of any PP cycle. In this embodiment, in such a case, the placement control unit 22 switches the picking target in the picking operation to the component 92 supplied by the spare feeder 61 (S45). As a result, the placement control unit 22 executes multiple PP cycles whose execution order has been adjusted, and when the supply operation SP is executed at the scheduled execution timing, picks up the same type of component 92 supplied by the spare feeder 61 instead of transitioning to a standby state.

[0070] This allows the system to transition to the mounting operation without incurring a standby time Tw. However, in a collection cycle using the spare feeder 61, the required time TL for the collection cycle may be extended because the placement head 133 must move to the spare feeder 61. Therefore, the placement control unit 22 may compare the expected standby time Tw with the extension of the required time TL due to the use of the spare feeder 61, and switch between waiting for the standby time Tw or picking up components supplied by the spare feeder 61. Furthermore, if the spare feeder 61 is not installed or if switching to the spare feeder 61 is not permitted, the above-mentioned switching process (S45) may be omitted.

[0071] The above-mentioned spare feeder 61 may be a bulk feeder or a tape feeder as long as it can supply the same types of components 92 as the bulk feeder 30. In this embodiment, the spare feeder 61 is a tape feeder that supplies components 92 by advancing a carrier tape that stores the components 92. Although a tape feeder can supply a smaller number of components 92 than the bulk feeder 30, it has the advantage of being able to shorten the time required for the supply operation to supply each component 92 and to supply the components 92 in a stable position, thereby eliminating the need for processing to recognize the supply state.

[0072] Subsequently, after the switching process (S45), or if the required time TL of the next candidate placement cycle is shorter than the required time Ts of the supply operation due to the movement process (S41) (S42: Yes), the cycle generation unit 26 determines whether the adjusted PP cycles include common operations after the final PP cycle (PPN) (S46). The determination of the presence or absence of common operations is a determination of whether the PP cycle whose execution order has been adjusted includes picking operations and placement operations for the same type of component 92 between consecutive PP cycles. The targets of this determination of the presence or absence of common operations (S46) may include PP cycles that have already been moved to the end by the previous adjustment process, and targets of recovery processes that have been partially moved to the end due to the execution of placement processes.

[0073] Specifically, as shown in the upper part of FIG. 11, three PP cycles (PP3, PP8, PP12) have been moved to the end through multiple movement processes (S41). Here, the third PP cycle (PP3) and the eighth PP cycle (PP8) include a picking operation and a placing operation for picking up the component (a) supplied by the bulk feeder 30, as shown in the lower part of FIG. 11, and therefore it is determined that there is a common operation (S46: Yes). The cycle generation unit 26 moves the set of the picking operation and the placing operation included in the eighth PP cycle (PP8) to the third PP cycle. As a result, the cycle generation unit 26 generates new PP cycles (PP31, PP81) as shown in the upper part of FIG. 11 (S47).

[0074] The control device 20 grasps the required number of each component (a) (Ra3 → Ra3 + Ra8, Ra8 → 0) in association with the new PP cycles (PP31, PP81). The cycle generation unit 26 may generate a new PP cycle if the new PP cycle (PP81) and the subsequent PP cycle (PP12) include common operations (picking and placing operations for the same type of component 92). According to this PP cycle generation process (S47), as shown in FIG. 11, the travel distance of the placing head 133 in the new PP cycles (PP31, PP81) can be shortened. As a result, the time required for the placing process can be shortened by the shortened time TR, improving the efficiency of the placing process.

[0075] If the adjusted multiple PP cycles do not include a common operation (S46: No), or if a new PP cycle cannot be generated because the predetermined condition is not met, the PP cycle generation process (S47) is not executed, and the PP cycle adjustment process (S33) ends. The above-mentioned "predetermined condition" includes, for example, a condition in which the order of execution of multiple mounting operations is fixed or recommended, or a condition in which the number of components 92 that can be picked up in one PP cycle is limited in relation to the number of suction nozzles 133.

[0076] After the above-described PP cycle adjustment process (S33) is completed, or if it is determined that the waiting time Tw will not occur (S32: No), the supply control unit 24 causes the bulk feeder 30 to execute a supply operation at the determined execution timing (S34). After the supply operation by the bulk feeder 30 is completed, the status recognition unit 23 executes a process to recognize the supply status of the components 92 (S35). The above-described supply operation (S34) and supply status recognition process (S35) are similar to S21 and S22 executed in parallel with the board 91 loading process (S11), and therefore detailed description thereof will be omitted.

[0077] 1-7. Effects of the configuration of the first embodiment According to the configuration of the component mounting machine 10 and the component mounting method (FIG. 7), the execution order of multiple PP cycles is adjusted appropriately based on the required number and the available number V1 (S33). This prevents the available number V1 from being insufficient when executing a PP cycle and the occurrence of a waiting time Tw for the bulk feeder 30 to complete its supply operation. As a result, a decrease in production efficiency can be prevented.

[0078] 2. Second embodiment A component mounting machine 10 and a component mounting method for mounting components 92 using a bulk feeder 30 will be described with reference to the drawings. The second embodiment differs from the first embodiment mainly in the configuration of the supply management process. The other configurations are substantially the same, so detailed description will be omitted.

[0079] 2-1. Supply management process by component placement machine 10 12, the steps (S51-S52, S54-S55) in the supply management process of the second embodiment are substantially the same as the steps (S31-S32, S34-S35) in the supply management process of the first embodiment, and the PP cycle adjustment process (S33 in FIG. 8) is omitted. In the supply management process, if the required time Ts for the supply operation SP is longer than the required time TL for the placement cycle (S52: Yes), the placement control unit 22 switches the collection target in the collection operation to the component 92 supplied by the spare feeder 61 (S53).

[0080] As a result, the placement control unit 22 executes multiple PP cycles in the order set by the control program M1, and when a supply operation SP is executed at the scheduled execution timing, instead of transitioning to a standby state, picks up components 92 of the same type supplied by the spare feeder 61. This allows the placement operation to proceed without a standby time Tw. Furthermore, because the spare feeder 61 is a tape feeder, it can feed and supply components 92 individually so that they can be picked up by feeding and moving the carrier tape, thereby shortening the time required for the supply operation. Furthermore, because a tape feeder can supply components 92 in a stable position, there is the advantage that the supply status recognition process can be omitted.

[0081] Here, the placement control unit 22 switches to the spare feeder 30 (S53) depending on the result of the determination (S52) as to whether or not a waiting time Tw will occur. In contrast, the placement control unit 22 may compare the expected waiting time Tw with the extension of the required time TL by using the spare feeder 61, and switch between waiting for the waiting time Tw or picking up the parts supplied by the spare feeder 61.

[0082] 2-2. Effects of the configuration of the second embodiment According to the configuration of the component mounting machine 10 and the component mounting method (FIG. 12), when a supply operation of the bulk feeder 30 is required, the target to be picked up is switched to a component 92 supplied by a spare tape feeder that can supply the same type of components as the bulk feeder 30, thereby reducing the time spent waiting for the completion of the supply operation of the bulk feeder 30. As a result, a decrease in production efficiency can be reduced.

[0083] 3. Modifications of the First and Second Embodiments In the first and second embodiments, the bulk feeder 30 supplies components 92 to be mounted on the board 91 by the component mounting machine 10. In the first and second embodiments, a chip component that is rectangular when viewed in the thickness direction is exemplified as the component 92. However, the component 92 is used in a substrate-related operation machine that performs a predetermined operation on the board 91, such as the component mounting machine 10, and various items can be applied as long as they can be supplied in a state accommodated in the cavity 51 by the bulk feeder 30. For example, the bulk feeder 30 may supply solder balls that are formed into a spherical shape. [Explanation of symbols]

[0084] 10: component mounting machine, 11: board transport device, 12: component supply device, 122: feeder, 13: component transfer device, 20: control device, 21: memory unit, 22: mounting control unit, 23: status recognition unit, 24: supply control unit, 25: sequence adjustment unit, 26: cycle generation unit, 30: bulk feeder, 61: spare feeder (tape feeder), 91: board, 92: component, M1: control program

Claims

1. a placement control unit that executes placement processing based on a control program in which an execution sequence of a PP cycle, including a component picking operation and a placement operation for placing the component on a board, is set; a supply control unit that, when the number of components that can be picked up by a bulk feeder that supplies the plurality of components in a bulk state falls below a reference value, causes the bulk feeder to execute a supply operation of the components in parallel with a mounting cycle that repeats the mounting operation multiple times; an order adjusting unit that adjusts the order of execution of the PP cycles including the mounting cycle when the required time of the mounting cycle that is scheduled to be executed in parallel with the next supply operation that is scheduled based on the current collectable number is shorter than the required time of the supply operation; A component placement machine comprising:

2. 2. The component mounting machine according to claim 1, wherein the order adjusting unit adjusts the execution order of the PP cycle so that the PP cycle is placed later than the execution order set by the control program.

3. 3. The component mounting machine according to claim 1, further comprising a cycle generation unit that generates a new PP cycle from among a plurality of consecutive PP cycles that includes the picking operation and the placing operation for at least the same type of component when the PP cycle whose execution order has been adjusted includes the picking operation and the placing operation for the same type of component between consecutive PP cycles.

4. 4. The component mounting machine according to claim 1, wherein the reference value is set to 1.

5. a spare feeder capable of supplying the same type of parts as the bulk feeder; A component mounting machine as described in any one of claims 1 to 4, wherein when performing the collection operation, if a waiting time occurs while waiting for the bulk feeder to complete the supply operation of the component, the mounting control unit switches the collection target to the component supplied by the spare feeder.

6. 6. The component mounting machine according to claim 5, wherein the spare feeder is a tape feeder that feeds and moves a carrier tape that accommodates the components to supply the components.

7. a component supplying device equipped with a bulk feeder that supplies a plurality of components in bulk and a tape feeder that supplies the components by feeding and moving a carrier tape that contains the same type of components as the bulk feeder; a placement control unit that executes placement processing based on a control program in which an execution sequence of a PP cycle, including a component picking operation and a placement operation for placing the component on a board, is set; a supply control unit that, when the number of parts that can be picked up by the bulk feeder falls below a reference value, causes the bulk feeder to execute an operation of supplying the parts in parallel with the PP cycle; The component mounting machine, wherein when performing the collection operation, if a waiting time occurs for waiting for the bulk feeder to complete the supply operation of the component, the mounting control unit switches the collection target to the component supplied by the tape feeder.

8. a mounting control step of executing a mounting process based on a control program in which an execution sequence of a PP cycle including a component picking operation and a mounting operation of mounting the component on a board is set; a supply control step of causing the bulk feeder, which supplies the plurality of components in a bulk state, to execute a supply operation of the components in parallel with a mounting cycle in which the mounting operation is repeated a plurality of times when the number of components that can be picked up by the bulk feeder falls below a reference value; an order adjusting step of adjusting the order of execution of the PP cycle including the mounting cycle when the required time of the mounting cycle scheduled to be executed in parallel with the next supply operation scheduled based on the current collectable number is shorter than the required time of the supply operation; A component mounting method comprising:

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