Calculation device and tray arrangement method

Abstract

To optimally arrange trays on pallets of a stocker.SOLUTION: An arithmetic device optimizes the tray arrangement in which trays in each of which a plurality of parts of the same type are stored are arranged on pallets of a stocker. The arithmetic device determines trays to be arranged on the pallets so that the number of surplus parts in trays storing other types of parts is less than the number of pallet parts, when the number of surplus parts indicating the remaining number of parts of a certain type in the stocker becomes zero, based on the number of pallet parts indicating the number of parts stored in a tray, and the mounting number indicating the number of parts to be mounted on a board determined for each type of parts.SELECTED DRAWING: Figure 2

Description

[Technical Field]

[0001] The technology disclosed in this specification relates to a computing device and a tray arrangement method. [Background technology]

[0002] In the production of electronic devices, component mounting devices are used to mount components on a board. As disclosed in Patent Document 1, there are cases in which components stored in a tray are mounted on a board. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Laid-Open No. 2006-140255 Summary of the Invention [Problem to be solved by the invention]

[0004] Each tray contains multiple parts of the same type. The trays are placed on each of the stocker's multiple pallets. To prevent a decline in work efficiency, there is a demand for technology that can optimally place trays on pallets.

[0005] The technology disclosed in this specification aims to optimally arrange trays on pallets in a stocker. [Means for solving the problem]

[0006] This specification discloses a computing device that optimizes the arrangement of trays containing multiple components of the same type on pallets in a stocker. The computing device determines the trays to be arranged on the pallet based on the pallet component count, which indicates the number of components stored on the tray, and the mount count, which indicates the number of components mounted on a board specified for each component type. When the surplus component count, which indicates the remaining number of components of a certain type in the stocker, reaches zero, the trays containing other types of components will have fewer surplus components than the pallet component count.

[0007] This specification also discloses a tray arrangement method for arranging trays containing multiple components of the same type on a pallet of a stocker. The tray arrangement method includes acquiring a pallet component count indicating the number of components stored on a tray, acquiring a mounting count indicating the number of components to be mounted on a board for each type of component, and determining a tray to be arranged on the pallet based on the pallet component count and the mounting count, such that when a surplus component count indicating the remaining number of components of a certain type in the stocker reaches zero, the number of surplus components in trays containing other types of components will be less than the pallet component count. [Effects of the Invention]

[0008] According to the technology disclosed in this specification, trays are optimally arranged on pallets in a stocker. [Brief explanation of the drawings]

[0009] [Figure 1] FIG. 1 is a diagram schematically showing a component mounting apparatus according to an embodiment. [Figure 2] FIG. 2 is a diagram schematically showing a stocker according to the embodiment. [Figure 3] FIG. 3 is a block diagram showing a computing device that performs optimization of tray placement according to the embodiment. [Figure 4] FIG. 4 is a diagram for explaining a tray arrangement method according to the embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0010] [Component mounting equipment] 1 is a diagram schematically illustrating a component mounting apparatus 1 according to an embodiment. The component mounting apparatus 1 includes a component supply device 2 and a mounting head 3.

[0011] The component supply device 2 has a stocker 5 having a plurality of pallets 4, a housing 6 that houses the stocker 5, and an elevator 7 that raises and lowers the stocker 5 inside the housing 6. The stocker 5 has a plurality of support members 8 arranged in the vertical direction. A pallet 4 is placed on each of the plurality of support members 8. A tray 10 is placed on each of the plurality of pallets 4. A plurality of the same type of components is stored in one tray 10.

[0012] The lifting device 7 raises and lowers the stocker 5 to adjust the height of the pallet 4. The pallet 4 arranged at a specified height is transported from the housing 6 to the supply position Pa. The trays 10 arranged on the pallet 4 are transported together with the pallet 4 from the housing 6 to the supply position Pa.

[0013] The mounting head 3 mounts components supplied from the component supply device 2 onto the board W. The board W is positioned at a mounting position Pb. The mounting head 3 is movable between a supply position Pa and a mounting position Pb. The mounting head 3 has a nozzle 9 that releasably holds components. The mounting head 3 mounts the components held by the nozzle 9 onto the board W. The mounting head 3 mounts a specified number of components of a specified type onto the board W based on predetermined mounting conditions.

[0014] [Stocker] FIG. 2 is a diagram schematically illustrating a stocker 5 according to an embodiment. The stocker 5 has a plurality of pallets 4. The plurality of pallets 4 are arranged in a vertical direction. A tray 10 is arranged on each of the plurality of pallets 4 of the stocker 5. One tray 10 is arranged on one pallet 4. In the example shown in FIG. 2, the stocker 5 has seven pallets 4. Seven trays 10 are arranged on one stocker 5.

[0015] One tray 10 stores multiple parts of the same type. The tray 10 has multiple pockets arranged in a matrix. One pocket stores one part. The pallet part number a, which indicates the number of parts stored in one new tray 10, is a predetermined value.

[0016] The outer shapes and dimensions of the multiple trays 10 are the same. Therefore, the smaller the dimensions of the parts, the more parts can be stored on one tray 10. The larger the dimensions of the parts, the fewer parts can be stored on one tray 10. The number of parts per pallet, a, is uniquely determined based on, for example, the dimensions of the parts. Note that the number of parts per pallet, a, may also be determined in advance by, for example, the parts manufacturer.

[0017] In order to maintain the quality of the parts, the trays 10 are supplied from the parts manufacturer in a packaged state. When the trays 10 are to be placed on the pallet 4, the packaging of the trays 10 is removed. After being unpackaged, the trays 10 are placed on the pallet 4.

[0018] In the example shown in Figure 2, in the initial state before the stocker 5 is loaded into the housing 6, the stocker 5 is arranged with three trays 10 for storing type A parts, two trays 10 for storing type B parts, and three trays 10 for storing type C parts.

[0019] After the stocker 5 is carried into the housing 6, the components stored in the tray 10 are mounted on the board W. The number b of components to be mounted on the board W is a predetermined value.

[0020] Components are mounted on the board W based on predetermined mounting conditions. The mounting conditions include a production program that specifies the type and number of components to be mounted on the board W. The number b to be mounted is determined based on the mounting conditions. The number b to be mounted is determined for each type of component based on the mounting conditions.

[0021] As the number of components to be mounted b increases, the number of remaining components f, which indicates the number of components remaining in the stocker 5, decreases.

[0022] In stocker 5, when the number of surplus parts f of a certain type of parts among type A parts, type B parts, and type C parts reaches zero, stocker 5 is removed from housing 6 to replace the tray 10 whose number of surplus parts f has reached zero with a new tray 10. For example, as shown in case 1 of FIG. 2, when the number of surplus parts f (remaining number) of type A parts in stocker 5 reaches zero, stocker 5 is removed from housing 6 even if type B parts and type C parts remain in stocker 5. In case 1 of FIG. 2, of two trays 10 storing type B parts, the number of surplus parts f (remaining number) of one tray 10 is 0, and the number of surplus parts f (remaining number) of the other tray 10 is 5. Of two trays 10 storing type C parts, the number of surplus parts f (remaining number) of one tray 10 is 1, and the number of surplus parts f (remaining number) of the other tray 10 is the same as the number of parts on the pallet a. That is, of the two trays 10 storing type C components, not a single component on the other tray 10 has been used for mounting.

[0023] If the combination of trays 10 placed on pallets 4 of stocker 5 is inappropriate, there is a possibility that a tray 10 will occur in which none of the stored components will be used for mounting, as shown in Case 1 of Figure 2. In other words, if the combination of trays 10 placed on pallets 4 of stocker 5 is inappropriate, when the number of remaining components f, which indicates the remaining number of type A components in stocker 5, becomes zero, the number of remaining components f in the other tray 10 storing type C components will be the same as the number of pallet components a.

[0024] The task of placing trays 10 containing components that will not be used for mounting on pallets 4 is a wasteful task. Furthermore, placing trays 10 containing components that will not be used for mounting on pallets 4 increases the frequency with which stocker 5 is removed from housing 6. Increasing the frequency with which stocker 5 is removed from housing 6 reduces the productivity of substrates W. Furthermore, as described above, trays 10 are placed on pallets 4 after being unpackaged. If components on unpackaged trays 10 are not used for mounting, the components will be exposed to the atmosphere for a long period of time. As a result, the quality of the components may deteriorate.

[0025] Therefore, in the embodiment, the arrangement of the trays 10 is optimized so that at least one component stored in each of the multiple trays 10 arranged on the pallet 4 of the stocker 5 is used for mounting between the time when the stocker 5 is carried into the housing 6 and the time when it is carried out from the housing 6. In other words, as shown in Case 2 in Fig. 2, the arrangement of the trays 10 is optimized so that a tray 10 in which no component is stored will be used for mounting is not arranged on the pallet 4.

[0026] [Tray arrangement method] Next, a method for arranging the tray 10 will be described. FIG. 3 is a block diagram showing a calculation device 11 that optimizes the arrangement of the tray 10 according to this embodiment. The calculation device 11 includes a computer system. The calculation device 11 has a processor 11A such as a CPU (Central Processing Unit), a main memory 11B including a non-volatile memory such as a ROM (Read Only Memory) and a volatile memory such as a RAM (Random Access Memory), a storage 11C, and an interface 11D including an input / output circuit. The processor 11A reads a computer program from the storage 11C and loads it into the main memory 11B, and optimizes the arrangement of the tray 10 according to the computer program. The computer program may be distributed to the calculation device 11 via a network.

[0027] In the following explanation, the arrangement method of the tray 10 will be explained using the terms a, number of parts on the pallet, b, number of parts mounted, c, number of parts that can be produced, d, number of remaining parts, f, number of parts that are out of stock, e, and number of remaining parts when parts are out of stock, f.

[0028] The number of parts on a pallet a refers to the number of parts stored on one tray 10 in a brand new state. The number of parts on a pallet a is a predetermined value. The number of parts on a pallet a is uniquely determined, for example, based on the dimensions of the parts. Note that the number of parts on a pallet a may also be determined in advance, for example, by a parts manufacturer.

[0029] The mounting number b refers to the number of components mounted on one board W. The mounting number b is a predetermined value. The mounting number b is determined based on predetermined mounting conditions. The mounting conditions include a production program that specifies the type and number of components to be mounted on the board W. The mounting number b varies for each type of component depending on the mounting conditions.

[0030] The number of pallets c refers to the number of trays 10 placed in one stocker 5. In this embodiment, one tray 10 is placed on each of the multiple pallets 4 in the stocker 5. In other words, the number of trays 10 placed in one stocker 5 is equal to the number of pallets 4 placed in one stocker 5.

[0031] The producible number d refers to the number of substrates W that can be produced using the parts placed in one stocker 5. The producible number d is calculated based on the following formula (1). d = (a × c) / b … (1)

[0032] The number of remaining parts f refers to the number of parts remaining in the stocker 5 .

[0033] The number of out-of-stock parts e refers to the number of boards W produced when the number of surplus parts f of a certain type in stocker 5 becomes zero. The number of out-of-stock parts e is calculated based on the following formula (2). e=(a×c) / b...(2), but round up to the nearest integer.

[0034] The number of surplus parts f when a part is out of stock refers to the number of surplus parts f in trays 10 storing parts of a certain type when the number of surplus parts f of another type in stocker 5 becomes zero. The number of surplus parts f in trays 10 storing parts of a certain type when a part of another type is out of stock is calculated based on the following formula (3). f = (a × c) - (b × e) … (3)

[0035] The calculation device 11 acquires the pallet component number a, which indicates the number of components stored on the tray 10. The calculation device 11 also acquires the mounting number b, which indicates the number of components to be mounted on the board W, for each type of component. As described above, the pallet component number a and the mounting number b are each a predetermined value. Therefore, the calculation device 11 can acquire the pallet component number a and the mounting number b.

[0036] Based on the number of components on the pallet a and the number of components mounted b, the calculation device 11 determines which tray 10 to place on the pallet 4 so that when the number of remaining components f, which indicates the remaining number of a certain type of component in the stocker 5, reaches zero, the number of remaining components f in the tray 10 storing other types of components will be less than the number of components on the pallet a. The placement of the trays 10 is optimized by placing the trays 10 on the pallet 4 so that the number of remaining components f when a component runs out is less than the number of components on the pallet a.

[0037] The calculation device 11 determines the number of trays 10 to be placed in the stocker 5 so that a tray 10 is placed on each of the multiple pallets 4 in the stocker 5 and the number of remaining parts f of other types of parts is less than the number of parts a on the pallet.

[0038] The computing device 11 determines which trays 10 to place on the pallet 4 so that the number of remaining parts f in the trays 10 storing other types of parts is less than 100% of the number of parts a on the pallet.

[0039] A specific example will be described below with reference to Fig. 4. Fig. 4 is a diagram for explaining a method of arranging trays 10 according to an embodiment. Hereinafter, it is assumed that 40 pallets 4 are arranged in a stocker 5, and one tray 10 is arranged on each of the 40 pallets 4.

[0040] In the following description, type A parts will be referred to as "part A" as appropriate, and a tray 10 containing a plurality of type A parts will be referred to as "tray A 10" as appropriate. Type B parts will be referred to as "part B" as appropriate, and a tray 10 containing a plurality of type B parts will be referred to as "tray B 10" as appropriate. Type C parts will be referred to as "part C" as appropriate, and a tray 10 containing a plurality of type C parts will be referred to as "tray C 10" as appropriate.

[0041] 25 pieces of A parts are stored in one A tray 10. 70 pieces of B parts are stored in one B tray 10. 100 pieces of C parts are stored in one C tray 10. In this case, as shown in FIG. 4, the number of parts a on a pallet for A parts is 25, the number of parts a on a pallet for B parts is 70, and the number of parts a on a pallet for C parts is 100. As described above, the number of parts a on a pallet is a predetermined value.

[0042] Three A components are mounted on one board W. Six B components are mounted on one board W. Two C components are mounted on one board W. In this case, as shown in FIG. 4, the number b of A components mounted is 3, the number b of B components mounted is 6, and the number b of C components mounted is 2. As described above, the number b is a predetermined value.

[0043] Suppose 21 A trays 10 are placed in one stocker 5. Suppose 15 B trays 10 are placed in one stocker 5. Suppose 4 C trays 10 are placed in one stocker 5. In this case, as shown in FIG. 4, the number of pallets c of A tray 10 is 21, the number of pallets c of B tray 10 is 15, and the number of pallets c of C tray 10 is 4. One stocker 5 will have the same number of trays 10 as the number of pallets 4 placed therein.

[0044] From the above formula (1), the producible quantity d of part A is 175, the producible quantity d of part B is 175, and the producible quantity d of part C is 200.

[0045] 4, as the process of mounting components onto the board W progresses, the number of remaining components f of components A and B simultaneously becomes zero. From the above-mentioned formula (2), the number of out-of-component components e, which is the number of boards W produced when the number of remaining components f of components A and B becomes zero, is 175.

[0046] According to the above formula (3), when the number of surplus parts f of parts A and B becomes zero and parts are out of stock, the number of surplus parts f of part C is 50.

[0047] 4, the number of remaining parts f of parts C when parts A and B are out of stock is less than the number of parts a on the pallet for parts C, so the arrangement of trays 10 is optimized. In the example shown in FIG. 4, the number of remaining parts f of parts C is 50, and the number of parts a on the pallet for parts C is 100, so the arrangement of trays 10 is optimized.

[0048] For example, the smaller the number f of remaining parts C when parts A and B are out of stock, the more optimized the arrangement of trays 10 becomes. The calculation device 11 optimizes the arrangement of trays 10 so that the number f of remaining parts C when parts A and B are out of stock is less than the number a of parts on the pallet for parts C. In the example shown in Fig. 4, the number f of remaining parts C when parts A and B are out of stock is 50, and the number a of parts on the pallet for parts C is 100, so the number f of remaining parts C when parts A and B are out of stock satisfies the condition that it is less than 100% of the number a of parts on the pallet for parts C.

[0049] On the other hand, if the number f of remaining parts C when parts A and B are out of stock is equal to or greater than the number a of parts C on the pallet, the arrangement of the trays 10 is not optimized.

[0050] The calculation device 11 repeatedly performs the above-mentioned calculation process while changing the number of pallets c for each of parts A, B, and C so that, for each of parts A, B, and C, when a certain type of part runs out, the number of surplus parts f in tray 10 storing other types of parts is less than the number of pallet parts a, the total number of pallets c does not exceed the capacity of stocker 5, and the producible number d is maximized.

[0051] Based on the number of pallets c calculated by the calculation device 11, tray A 10, tray B 10, and tray C 10 are placed on each of the multiple pallets 4 in the stocker 5. The stocker 5 with the multiple trays 10 placed therein is carried into the housing 6. The mounting head 3 of the component mounting device 1 mounts the components supplied from the trays 10 onto the board W.

[0052] [effect] As described above, according to the embodiment, the number of pallets c, which indicates the number of trays 10 to be placed on a pallet 4, is determined based on the predetermined number of components per pallet a and the predetermined number of components b for each type of component, so that when the number of remaining components f becomes zero when a certain type of component runs out in the stocker 5, the number of remaining components f in trays 10 storing other types of components becomes less than the number of components per pallet a. This allows the trays 10 to be optimally placed on the pallets 4 of the stocker 5. For example, this reduces the need to place trays 10 storing components that will not be used for mounting on the pallets 4, which is unnecessary. Furthermore, because trays 10 storing components that will not be used for mounting are not placed on the pallets 4, this reduces the frequency of removing the stocker 5 from the housing 6. This reduces a decrease in productivity of the boards W. This also reduces the exposure of unpackaged components on the trays 10 to the atmosphere for a long period of time. This reduces a decrease in the quality of the components.

[0053] The number of pallets c for each of the multiple types of components is determined so that a tray 10 is placed on each of the multiple pallets 4 in the stocker 5, and the number of surplus components f of other types of components is less than the number of components a on the pallet. Therefore, all of the pallets 4 in the stocker 5 are used effectively. Furthermore, because the stocker 5 is fully loaded with trays 10, the frequency of unloading the stocker 5 from the housing 6 is suppressed. Therefore, a decrease in productivity of the substrates W is suppressed.

[0054] When the number of remaining parts f becomes zero when a certain part runs out, the smaller the number of remaining parts f in trays 10 storing other types of parts, the more optimized the arrangement of trays 10. By determining the number of pallets c so that the number of remaining parts f in trays 10 storing other types of parts is less than the number of parts a on the pallet, the arrangement of trays 10 is further optimized.

[0055] It is also preferable that the trays 10 to be arranged on the pallets 4 are determined so that the total number of pallets c does not exceed the capacity of the stacker 5 and the producible number d is maximized. [Explanation of symbols]

[0056] 1...component mounting device, 2...component supply device, 3...mounting head, 4...pallet, 5...stocker, 6...casing, 7...lifting device, 8...support member, 9...nozzle, 10...tray, 11...arithmetic unit, 11A...processor, 11B...main memory, 11C...storage, 11D...interface, Pa...supply position, Pb...mounting position, W...board.

Claims

1. A computing device that optimizes tray placement for placing trays containing multiple parts of the same type on a pallet in a stocker, comprising: One tray is placed on one pallet, The trays include an A tray storing a plurality of A type components, a B tray storing a plurality of B type components, and a C tray storing a plurality of C type components, a plurality of A trays, a plurality of B trays, and a plurality of C trays are arranged on each of the plurality of pallets of the stocker, The number of parts stored in one tray in a new state is defined as the number of parts in the pallet, a. The number of components mounted on one board, which is determined for each type of component, is defined as a mounting number b, The number of trays placed in one stocker is the number of pallets c, When the remaining number of parts in the stocker is the number of remaining parts f, Based on the number of pallet parts a and the number of parts mounted b, the trays to be placed on the pallets are determined by repeating the calculation process while changing the number of pallets c for each of the A, B, and C types of parts, so that when the number of surplus parts f for the A and B types of parts becomes zero, the number of surplus parts of the C type parts in tray C storing the C type parts will be less than the number of pallet parts a for the C type parts, so that when one type of part runs out, the number of surplus parts f in tray storing the other type of parts will be less than the number of pallet parts a, and so that the total number of pallets c does not exceed the capacity of the stocker. Computing device.

2. determining trays to be placed on the pallets so that the total number of pallets, which indicates the number of pallets to be placed on one stocker, does not exceed the capacity of the stocker and the producible number, which indicates the number of boards that can be produced using the parts placed on one stocker, is maximized; The computing device of claim 1 .

3. A tray arrangement method for arranging trays containing a plurality of parts of the same type on a pallet of a stocker, comprising the steps of: One tray is placed on one pallet, The trays include an A tray storing a plurality of A type components, a B tray storing a plurality of B type components, and a C tray storing a plurality of C type components, a plurality of A trays, a plurality of B trays, and a plurality of C trays are arranged on each of the plurality of pallets of the stocker, obtaining a pallet part count indicating the number of parts stored in the tray; Obtaining a mounting number indicating the number of components mounted on the board for each type of component; determining, based on the number of components on the pallet and the number of components to be mounted, a tray to be placed on the pallet so that when the number of remaining components, which indicates the remaining number of components of a certain type in the stocker, reaches zero, the number of remaining components in the tray storing the other types of components becomes less than the number of components on the pallet; The number of parts stored in one tray in a new state is defined as the number of parts in the pallet, a. The number of components mounted on one board, which is determined for each type of component, is defined as a mounting number b, The number of trays placed in one stocker is the number of pallets c, When the remaining number of parts in the stocker is the number of remaining parts f, Based on the number of pallet parts a and the number of parts mounted b, the trays to be placed on the pallets are determined by repeating the calculation process while changing the number of pallets c for each of the A, B, and C types of parts, so that when the number of surplus parts f for the A and B types of parts becomes zero, the number of surplus parts of the C type parts in tray C storing the C type parts will be less than the number of pallet parts a for the C type parts, so that when one type of part runs out, the number of surplus parts f in tray storing the other type of parts will be less than the number of pallet parts a, and so that the total number of pallets c does not exceed the capacity of the stocker. How to arrange the trays.

4. determining trays to be placed on the pallets so that the total number of pallets, which indicates the number of pallets to be placed on one stocker, does not exceed the capacity of the stocker and the producible number, which indicates the number of boards that can be produced using the parts placed on one stocker, is maximized; The tray arrangement method according to claim 3.

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