Component mounting device and component supply method

Abstract

To provide a component mounting system capable of handling a carrier tape in which the distance from a pocket containing the last component to the end of the carrier tape is long, and a component supply method.SOLUTION: The component mounting system includes: an adsorption detection unit that detects whether or not a component is picked up by a mounting head; and a control unit that determines whether or not a continuous adsorption error has occurred based on the detection result by the adsorption detection unit. A tape feeder has a conveyance path, a tape transfer unit, and a tape detection unit that detects whether or not a carrier tape exists. The control unit is configured to, when determining that a continuous adsorption error has occurred, control the tape transfer unit to eject the current tape when the existence of the current tape is not detected, and control to feed the current tape a predetermined length when the existence of the current tape is detected. While the tape detection unit detects the existence of the current tape, the control unit controls the tape transfer unit to repeat feeding the current tape a predetermined length.SELECTED DRAWING: Figure 5

Description

Technical Field

[0001] The present disclosure relates to a component mounting apparatus including a tape feeder that conveys a carrier tape storing components and supplies the components to a component supply position, and a component supply method thereof.

Background Art

[0002] Conventionally, as a component supply device used in a component mounting apparatus for mounting components on a substrate, a tape feeder that conveys a carrier tape storing components and supplies the components to a predetermined component supply port is known. Recesses called pockets are formed in the carrier tape, and the components are stored in the pockets.

[0003] When all the components of the carrier tape set in the tape feeder are supplied, an autoload type tape feeder that automatically sets the next carrier tape is known. In this specification, the currently conveyed carrier tape is called the current tape, and the carrier tape conveyed after the current tape is discharged is called the next tape.

[0004] For example, the tape feeder of Patent Document 1 detects the tape end of the current tape first, and determines that the components of the current tape are out of stock by determining whether a nozzle adsorption error has occurred after the tape end is detected.

Prior Art Documents

Patent Documents

[0005]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0006] However, some carrier tapes have a long distance from the pocket where the last component is stored to the end of the carrier tape. In the electronic component mounting device described in Patent Document 1, the tape end is detected first, and then component failure is determined by a nozzle suction error. Therefore, if the distance from the position where the last component is stored to the end of the tape is long, nozzle suction errors will occur frequently before the tape end is detected, making it impossible to accurately detect component failure and preventing the current tape from being ejected and set on the next tape.

[0007] This disclosure aims to provide a component mounting device and component supply method that accommodates carrier tapes with a long distance from the position of the pocket containing the last component to the end of the carrier tape. [Means for solving the problem]

[0008] The component mounting apparatus of this disclosure is a component mounting apparatus that picks up components contained on a carrier tape at a component removal position and mounts them on a substrate, and comprises a tape feeder equipped with a current tape, which is transported first as a carrier tape and a next tape, which is transported after the current tape, each containing multiple components; a mounting head that picks up components transported to the component removal position; a pick-up detection unit that detects whether or not a component has been picked up by the mounting head; and a control unit that controls the transport drive of the carrier tape in the tape feeder and determines whether or not a continuous pick-up error has occurred based on the detection result of the pick-up detection unit. The tape feeder has a transport path through which the carrier tape is transported from an inlet where the carrier tape is inserted to the component removal position; a tape transport unit that transports the carrier tape along the transport path; and a tape detection unit that is located upstream of the component removal position in the tape transport path and detects whether or not a carrier tape is present. The control unit causes the tape transport unit to transport the current tape along the tape transport path, supplying the components contained in the current tape to the component retrieval position. After ejecting the current tape, the control unit transports the next tape along the tape transport path, thereby transporting the components contained in the next tape to the component retrieval position. When the control unit determines that a continuous suction error has occurred, it checks the detection result of the tape detection unit. If the tape detection unit does not detect the presence of the current tape, it controls the tape transport unit to eject the current tape. If the tape detection unit detects the presence of the current tape, it controls the tape transport unit to advance the current tape to a predetermined length. After the current tape has advanced to a predetermined length, the control unit controls the tape transport unit to eject the current tape if the tape detection unit does not detect the presence of the current tape. If the tape detection unit detects the presence of the current tape, it controls the tape transport unit to advance the current tape to a predetermined length again. The control unit repeats the process of causing the tape transport unit to advance the current tape to a predetermined length while the tape detection unit detects the presence of the current tape.

[0009] The component supply method of this disclosure is a component mounting device in which a tape transport unit transports a carrier tape containing multiple components along a tape transport path to supply components to a component removal position, and a mounting head picks up the components transported to the component removal position and mounts them on a substrate, wherein a current tape, which serves as the carrier tape, is transported, and then a next tape, which serves as the carrier tape, is transported continuously. The component supply method of this disclosure includes: a suction detection step in which a suction detection unit detects whether or not a component has been picked up by the mounting head; a first determination step in which a control unit determines whether or not a continuous suction error has occurred based on the detection result of the suction detection unit; a tape detection step in which, if it is determined in the first determination step that a continuous suction error has occurred, a tape detection unit located upstream of the component removal position in the tape transport path detects whether or not a current tape is present; an discharge step in which, if the presence of a current tape is not detected in the tape detection step, the tape transport unit discharges the current tape; a second determination step in which, if the presence of a current tape is detected in the tape detection step, the control unit determines whether or not the number of transports for which the current tape has been transported for a predetermined length has reached a predetermined number of times; and a transport step in which, if it is determined in the second determination step that the number of transports has not reached a predetermined number of times, the tape transport unit transports the current tape for a predetermined length. The tape detection step, the second determination step, and the transport step are repeated until the discharge step is performed or the number of transports is determined to have reached a predetermined number of times in the second determination step. [Effects of the Invention]

[0010] According to this disclosure, it is possible to provide a component mounting device and a component supply method that can accommodate a long carrier tape, where the distance from the position of the pocket containing the last component to the end of the carrier tape is long. [Brief explanation of the drawing]

[0011] [Figure 1] Side view of the main part of a component mounting system equipped with a component mounting device in one embodiment. [Figure 2]Plan view of the parts supply section of a parts mounting device in one embodiment. [Figure 3] Perspective view of a carrier tape in one embodiment [Figure 4] A diagram showing the configuration of a tape feeder in one embodiment. [Figure 5] Block diagram showing an example of the functional configuration of a component mounting device. [Figure 6] A diagram illustrating the transport of carrier tape within a tape feeder. [Figure 7] A diagram illustrating the transport of carrier tape within a tape feeder. [Figure 8] A diagram illustrating the transport of carrier tape within a tape feeder. [Figure 9] Flowchart showing the process of changing the carrier tape [Modes for carrying out the invention]

[0012] According to a first aspect of this disclosure, a component mounting device for attaching components contained on a carrier tape to a substrate by picking them up at a component removal position includes a tape feeder equipped with a current tape, which is transported first, and a next tape, which is transported after the current tape, each containing a plurality of components; a mounting head for picking up components transported to the component removal position; a pick-up detection unit for detecting whether or not a component has been picked up by the mounting head; and a control unit for controlling the transport drive of the carrier tape in the tape feeder and determining whether or not a continuous pick-up error has occurred based on the detection result of the pick-up detection unit. The tape feeder includes a tape transport path through which the carrier tape is transported from an inlet where the carrier tape is inserted to a component removal position; a tape transport unit for transporting the carrier tape along the tape transport path; and a tape detection unit positioned upstream of the component removal position in the tape transport path for detecting whether or not a carrier tape is present. The control unit causes the tape transport unit to transport the current tape along the tape transport path, supplying the components contained on the current tape to the component retrieval position. After ejecting the current tape, the control unit transports the next tape along the tape transport path, thereby transporting the components contained on the next tape to the component retrieval position. When the control unit determines that a continuous suction error has occurred, it checks the detection result of the tape detection unit. If the tape detection unit does not detect the presence of the current tape, it controls the tape transport unit to eject the current tape. If the tape detection unit detects the presence of the current tape, it controls the tape transport unit to advance the current tape to a predetermined length. After the current tape has advanced to a predetermined length, the control unit controls the tape transport unit to eject the current tape if the tape detection unit does not detect the presence of the current tape. If the tape detection unit detects the presence of the current tape, it controls the tape transport unit to advance the current tape to a predetermined length again. The control unit provides a component mounting device that repeatedly causes the tape transport unit to advance the current tape to a predetermined length while the tape detection unit detects the presence of the current tape.

[0013] As a result, previously, when adsorption errors continuously occurred at the component extraction position by the mounting head, by detecting whether a tape exists or not by the tape detection unit, the determination accuracy of component depletion can be improved. Further, when it is detected by the tape detection unit that a tape exists, by repeating tape feeding of a predetermined length and tape detection, even when the distance from the position where the component is finally stored to the tape end is long, the frequency of detecting the tape end can be improved. Thereby, even for a current tape with a long length to the tape end, the frequency of automatically replacing to the next tape due to component depletion can be improved.

[0014] According to a second aspect of the present disclosure, in the component mounting device of the first aspect, when the control unit determines that a continuous adsorption error has occurred, while the tape detection unit detects the presence of the current tape, until a predetermined number of times is reached, the tape conveyance unit is repeatedly caused to feed the current tape by a predetermined length to stop the operation of the mounting head.

[0015] According to a third aspect of the present disclosure, the component mounting device of the first or second aspect includes a notification unit that notifies the stop of the operation of the mounting head.

[0016] According to a fourth aspect of the present disclosure, in the component mounting device of the third aspect, after the tape conveyance unit has fed the current tape by a predetermined length a predetermined number of times, if the presence of the current tape is detected by the tape detection unit, the control unit stops the drive of the tape conveyance unit and causes the notification unit to notify a warning.

[0017] According to a fifth aspect of the present disclosure, in the component mounting device of any one of the first to fourth aspects, when the mounting head fails to adsorb the component at the component extraction position a predetermined number of times in advance, the control unit determines that a continuous adsorption error has occurred.

[0018] According to a sixth aspect of the present disclosure, in the component mounting device of the fifth aspect, the predetermined number of times is smaller as the size of the component to be adsorbed is larger.

[0019] According to a seventh aspect of the present disclosure, in the component mounting device according to any one of the first to sixth aspects, the mounting head sucks a component conveyed to the component take-out position by negative pressure. The suction detection unit includes a negative pressure sensor that detects the value of the negative pressure at which the mounting head sucks the component, and a suction determination unit that determines whether or not the component is sucked to the mounting head by comparing the detection value of the negative pressure sensor with a threshold value.

[0020] According to an eighth aspect of the present disclosure, in the component mounting device according to any one of the first to sixth aspects, the suction detection unit is disposed in the middle of the conveyance path from the component take-out position to the substrate, and includes a camera that photographs the component suction side of the mounting head, and an image processing unit that determines whether or not the component is sucked to the mounting head based on the photographed image of the camera.

[0021] According to a ninth aspect of the present disclosure, in the component mounting device according to any one of the first to eighth aspects, the length of the current tape conveyed until a predetermined length reaches a predetermined number of times is longer than the length from the tape detection unit to the entrance of the tape conveyance path.

[0022] According to a tenth aspect of the present disclosure, in the component mounting device according to any one of the first to ninth aspects, it does not have a sensor that directly detects the component breakage of the current tape. Thereby, the number of components can be reduced and the cost can be reduced.

[0023] According to an eleventh aspect of the present disclosure, in the component mounting device according to any one of the first to tenth aspects, the content notified to the notification unit is output to a device outside the component mounting device. According to this, an operator in a remote location can also be informed of the content notified to the notification unit.

[0024] According to a twelfth aspect of this disclosure, in a component mounting device in which a tape transport unit transports a carrier tape containing a plurality of components along a tape transport path to supply components to a component removal position, and a mounting head picks up the components transported to the component removal position and mounts them on a substrate, a current tape as a carrier tape is transported, and then a next tape as a carrier tape is continuously transported. The component supply method of this disclosure includes: a suction detection step in which a suction detection unit detects whether or not a component has been picked up by a mounting head; a first determination step in which a control unit determines whether or not a continuous suction error has occurred based on the detection result of the suction detection unit; a tape detection step in which, if it is determined in the first determination step that a continuous suction error has occurred, a tape detection unit located upstream of the component removal position on the tape transport path detects whether or not a current tape is present; an discharge step in which, if the presence of a current tape is not detected in the tape detection step, the tape transport unit discharges the current tape; a second determination step in which, if the presence of a current tape is detected in the tape detection step, the control unit determines whether or not the number of transports for which the current tape has been transported for a predetermined length has reached a predetermined number of times; and a transport step in which, if it is determined in the second determination step that the number of transports has not reached a predetermined number of times, the tape transport unit transports the current tape for a predetermined length. The component supply method is provided which, after the transport step is performed, the tape detection step is performed again, and the tape detection step, the second determination step, and the transport step are repeated until the discharge step is performed or the number of transports is determined to have reached a predetermined number of times in the second determination step.

[0025] Hereinafter, exemplary embodiments of the component mounting device relating to this disclosure will be described with reference to the attached drawings. This disclosure is not limited to the specific configurations of the embodiments described below, but includes configurations based on similar technical ideas.

[0026] (Embodiment) First, the component mounting system 100 and component mounting device 1 of the embodiment of this disclosure will be described with reference to Figure 1. Figure 1 is a simplified side view of the main parts of the component mounting system 100, which includes the component mounting device 1.

[0027] The component mounting system 100 is a system for manufacturing a mounted circuit board by mounting components 5 onto a circuit board 4. The component mounting system 100 comprises a component mounting device 1, a management device 92, and a portable information terminal 95.

[0028] The component mounting device 1 is a device that repeatedly performs a series of component mounting operations, which involves mounting components 5 onto a substrate 4 brought in from other devices in the upstream process and then transporting the substrate to other devices in the downstream process. The component mounting device 1 comprises a main body 2 and a component supply unit 3.

[0029] In Figure 1, the main unit 2 comprises a base 11, a substrate transport unit 12, a mounting head 13, a head movement mechanism 14, an operation unit 16, a main unit control unit 17, and a camera 19. The substrate transport unit 12 is equipped with a conveyor mechanism and transports the substrate 4 received from the upstream process equipment horizontally to position it at a predetermined work position. In this embodiment, the transport direction of the substrate 4 in the component mounting device 1 is the X direction (horizontal direction), and the vertical direction is the Z direction. The direction perpendicular to both the X and Z directions is the Y direction (front-back direction). The operation unit 16 is installed on the side of the main unit 2. The operation unit 16 has a touch screen 16a on its surface, which displays information necessary for operating the component mounting device 1, as well as operation buttons, etc. The touch screen 16a also functions as a notification unit that displays information such as the working status and warnings of the component mounting device 1, and informs the operator of this information.

[0030] In Figure 1, the mounting head 13 is equipped with a plurality of nozzles 13a extending downward. Each nozzle 13a is connected to a negative pressure source (not shown) by a tube 13b, generating a vacuum suction force at the lower end of each nozzle 13a to attract the component 5. The negative pressure source is, for example, a vacuum pump. The head movement mechanism 14 is equipped with, for example, an XY table and moves the mounting head 13 in the XY plane. The head movement mechanism 14 is also equipped with a negative pressure sensor 13c that detects the pressure value of the negative pressure of the nozzles 13a. The negative pressure sensor 13c is, for example, a vacuum sensor. The negative pressure sensor 13c is connected to the main unit control unit 17 in a communicative manner and transmits the detected value to the main unit control unit 17.

[0031] The camera 19 is positioned along the transport path from the component removal position 23ba to the substrate 4 and captures images of the component-suction side of the nozzle 13a of the mounting head 13. The captured images are sent to the main unit control unit 17.

[0032] The management device 92 is connected to the component mounting device 1 in a communicative manner and manages the production information of the component mounting device 1 collectively. The management device 92 is, for example, a host computer and can be composed of circuits such as a microcontroller, CPU, MPU, GPU, DSP, FPGA, or ASIC. The functions of the management device 92 are realized by combining hardware and software. The management device 92 realizes predetermined functions by reading data and programs stored in the memory unit and performing various arithmetic operations.

[0033] The portable information terminal 95 communicates wirelessly with the control device 92, allowing the worker to check production information held by the control device 92 while carrying the portable information terminal 95. The portable information terminal 95 can be, for example, a tablet or a smartphone.

[0034] In Figure 1, the parts supply unit 3 includes a trolley 21 and a tape feeder 23. The trolley 21 is provided with a feeder base 31 and a reel holding unit 32.

[0035] The feeder base 31 is a component for mounting the tape feeder 23. The feeder base 31 has multiple mounting slots (not shown) for mounting the tape feeder 23, which are spaced at equal intervals in the X direction. The tape feeder 23 supplies components 5 to the mounting head 13 of the component mounting device 1.

[0036] The reel holding unit 32 mounts and holds the reel 22 on which the carrier tape 24 is wound and stored. The reel holding unit 32 is provided with multiple holders (not shown) for holding the reel 22. In this embodiment, the reel holding unit 32 is configured to hold two reels 22 for one tape feeder 23. As a result, the reel holding unit 32 can supply two carrier tapes 24 to one tape feeder simultaneously.

[0037] The reel 22 is fitted with a barcode 28 containing information about the parts packaged on the carrier tape 24 (hereinafter referred to as "parts information"). The barcode 28 is a type of identifier that encodes information including parts information, but it is not limited to a one-dimensional code; it may also be a two-dimensional code or other type of identifier.

[0038] Figure 2 is a schematic plan view showing a feeder base 31 with multiple tape feeders 23 mounted on it. As shown in Figure 2, multiple tape feeders 23 can be mounted on the feeder base 31 in a row in the X direction. Each tape feeder 23 is provided with a component supply port 23b, and components 5 supplied to the component supply port 23b are picked up by the mounting head 13 and mounted on the circuit board 4.

[0039] Each tape feeder 23 mounted on the feeder base 31 is a so-called autoload feeder, which transports the carrier tape 24 mounted on the tape feeder 23 forward and supplies the parts 5 held on the carrier tape 24 to the parts supply port 23b at a predetermined position.

[0040] As shown in Figure 1, the tape feeder 23 is capable of holding a next tape 24b to be used after the current tape 24a, in addition to the current tape 24a that it is currently transporting. When the component 5 of the current tape 24a runs out, the tape feeder 23 discharges the current tape 24a and automatically transports the next tape 24b, supplying the component 5 held in the next tape 24b to the component supply port 23b. In this specification, when the next tape 24b reaches the component supply port 23b, its designation is changed to the current tape 24a.

[0041] When the component mounting device 1 performs component mounting work, first the substrate transport unit 12 operates to bring in the substrate 4 from the outside and position it at a predetermined work position. Once the substrate 4 is positioned at the work position by the substrate transport unit 12, the tape feeder 23 repeatedly performs a mounting turn by coordinating the operation of supplying components 5 to the component supply port 23b with the operation of the head moving mechanism 14 moving the mounting head 13.

[0042] In one mounting turn, the mounting head 13 moves to a position above the tape feeder 23, picks up the component 5 with the nozzle 13a, then moves to a position above the substrate 4, and performs a series of operations to mount the component 5 onto the substrate 4. Once all the components 5 to be mounted on the substrate 4 have been mounted through repeated mounting turns, the substrate transport unit 12 operates to transport the substrate 4 to the downstream process equipment. This completes the component mounting work for one substrate 4.

[0043] Returning to Figure 1, the portable information terminal 95 is a component used to provide notifications from the management device 92 to the worker carrying it and to check the status of the component mounting device 1. The portable information terminal 95 is a type of information acquisition device that acquires component information of the reel 22 and carrier tape 24 used in the tape feeder 23. The portable information terminal 95 has, for example, a barcode reader capable of reading the barcode 28 provided on the storage body (reel or cassette) that houses the carrier tape 24. The portable information terminal 95 is wirelessly connected to the management device 92 via WiFi or the like and can communicate with the management device 92. The portable information terminal 95 may also be able to communicate with the component mounting device 1. The component information acquired by the portable information terminal 95 is transmitted to the management device 92. The portable information terminal 95 is equipped with a display panel 95a that displays information to be notified to the worker, etc. In this embodiment, the portable information terminal 95 is described as an example of an information acquisition unit, but any device with a barcode reader is acceptable. Furthermore, if wireless tags are used instead of barcode 28, any device that has a reader capable of reading the information on the wireless tags will suffice.

[0044] Carrier Tape Next, the carrier tape 24 will be described with reference to Figure 3. Figure 3 is a perspective view showing an enlarged portion of the carrier tape 24. The carrier tape 24 has a base tape 51 and a top tape 52. The base tape 51 has a number of pockets 53 that open upwards, arranged in a row at equal intervals along the longitudinal direction of the base tape 51, and each pocket 53 stores a component 5. The top tape 52 is attached to the upper surface of the base tape 51 and encloses the components 5 in the pockets 53. In this way, the carrier tape 24 packages the components 5. Multiple feed holes 54 are arranged in a row at equal intervals parallel to the row of pockets 53 on the base tape 51.

[0045] The top tape 52 of the carrier tape 24 has an extension portion 52a that extends from the tip of the base tape 51. The extension portion 52a is provided to allow the top tape 52 to be caught by the exposed portion 66, which will be described later. The length of the extension portion 52a from the tip of the base tape 51 is such that it is necessary for the tape to reach the exposed portion 66 from the tape transport path 60 and be caught. The tip of the carrier tape 24 is cut so as to divide the feed hole 54.

[0046] Tape feeder Next, the detailed configuration of the tape feeder 23 will be described with reference to Figure 4. Figure 4 is a schematic diagram of the tape feeder 23 in this embodiment.

[0047] The tape feeder 23 comprises a tape transport path 60, a tape transport section 61, a tape introduction section 62, a shutter unit 63, a unit control unit 64, and a unit-side connector 65. The tape feeder 23 also includes a tape inlet 23a for feeding the carrier tape 24 into the tape transport path 60, a component supply port 23b for supplying components, and an outlet 23c for discharging the carrier tape 24 from the tape transport path 60.

[0048] The main body 23d of the tape feeder 23 consists of a core unit 23da and a loading unit 23db, and the loading unit 23db is detachable from the core unit 23da. The loading unit 23db is required when using the tape feeder 23 as an auto-load feeder.

[0049] The tape transport path 60 is formed in the main body 23d of the tape feeder 23, and guides the carrier tape 24, which is pulled out from the reel 22 and inserted into the tape feeder 23 from the tape inlet 23a, through the inside of the tape feeder 23 to the parts removal position 23ba, which is the position of the parts supply port 23b, and further guides it to the discharge port 23c.

[0050] The tape inlet 23a opens on the upstream side in the tape feeding direction of the tape feeder 23. The discharge port 23c opens on the downstream side in the tape feeding direction. The tape transport path 60 is connected from the tape inlet 23a to the discharge port 23c. At the component removal position 23ba located downstream of the tape transport path 60, the mounting head 13 removes the component 5.

[0051] During the process of continuously performing the parts mounting work, multiple carrier tapes 24, each stored in a reel 22, are sequentially inserted from the tape inlet 23a and supplied to the tape feeder 23, with each carrier tape 24 serving as a unit lot.

[0052] The tape transport unit 61 transports the carrier tape 24 to the component removal position 23ba on the downstream side of the tape transport path 60. The tape transport unit 61 includes a first transport sprocket 61a that engages with the feed holes 54 of the carrier tape 24, a second transport sprocket 61b, a third transport sprocket 61c, and a drive unit 61d.

[0053] The first transport sprocket 61a, the second transport sprocket 61b, and the third transport sprocket 61c are arranged in order from the downstream side along the tape transport path 60.

[0054] The drive unit 61d includes, for example, a motor as a power source and a power transmission member that transmits the power from the power source to the first to third transport sprockets 61a to 61c. The power transmission member is, for example, a gear.

[0055] The tape introduction unit 62 sends the carrier tape 24 inserted into the tape feeder 23 from the tape inlet 23a to the tape transport unit 61. The tape introduction unit 62 is located on the upstream side of the tape transport path 60. The tape introduction unit 62 comprises a feed sprocket 62a, a tape support unit 62b, and a drive unit 62c.

[0056] The drive unit 62c has the function of rotating the feed sprocket 62a in the direction of arrow a1 and the function of moving the feed sprocket 62a and the tape support unit 62b in the direction of arrow a2. By driving the feed sprocket 62a to rotate in the direction of arrow a1, the inserted carrier tape 24 can be transported downstream along the tape transport path 60.

[0057] Near the upstream tape inlet 23a of the tape transport path 60, the tape transport path 60 widens considerably, and the tape support section 62b is positioned to divide the tape transport path 60 into two within this widened space. Therefore, the tape feeder 23 can transport another carrier tape 24 downstream along the bottom surface 60a of the tape transport path 60, with the leading edge of the carrier tape 24 supported by the tape support section 62b at the upstream end of the tape transport path 60. Furthermore, the drive unit 62c can move the input sprocket 62a and the tape support section 62b, thereby moving the carrier tape 24 supported by the tape support section 62b to the bottom surface 60a of the tape transport path 60.

[0058] The drive unit 62c includes, for example, a motor as a power source and a power transmission member that transmits power from the power source to the feed sprocket 62a. The power transmission member is, for example, a gear. It also includes a power transmission mechanism that combines a link mechanism, gears, elastic members, etc., to move the feed sprocket 62a and the tape support unit 62b in the direction of arrow a2 using power from another power source.

[0059] The tape transport section 61 and the tape introduction section 62 function as transport units that transport the carrier tape 24 along the tape transport path 60 and supply the parts 5 to the parts retrieval position 23ba.

[0060] The tape feeder 23 includes a first sensor PH1, a second sensor PH2, a third sensor PH3, and a fourth sensor PH4, which are arranged in order from the upstream side along the tape transport path 60.

[0061] The first sensor PH1 detects that the carrier tape 24 inserted into the tape support section 62b of the tape feeder 23 has reached the downstream end of the tape support section 62b, in this case, the shutter unit 63.

[0062] The second sensor PH2 detects the presence or absence of the carrier tape 24 downstream of the downstream end of the tape support section 62b, near the junction where it merges with the tape transport path 60 on the extension of the tape support section 62b.

[0063] The third sensor PH3 detects the presence or absence of the carrier tape 24 downstream of the confluence point and upstream of the exposed portion 66 of the tape transport path 60.

[0064] The fourth sensor PH4 detects the presence or absence of the carrier tape 24 downstream of the exposed portion 66 of the tape transport path 60 and upstream of the component removal position 23ba. The first sensors PH1 to the fourth sensors PH4 are optical sensors that directly or indirectly detect the presence or absence of the carrier tape 24 at their respective locations, and are, for example, reflective or transmissive photosensors.

[0065] The tape support section 62b supports the carrier tape 24 and maintains the orientation in which the carrier tape 24 is transported. The tape support section 62b can discharge the carrier tape 24 into the tape transport path 60. The carrier tape 24 discharged from the tape support section 62b moves to the bottom surface 60a of the tape transport path 60 below the tape support section 62b. Once the carrier tape 24 has detached from the tape support section 62b, the next carrier tape 24 (next tape 24b) can be inserted into the tape support section 62b at any time.

[0066] Shutter Unit Next, the shutter unit 63 will be described with reference to Figure 4. The shutter unit 63 prevents the carrier tape 24, supported by the tape support section 62b, from advancing further downstream on the tape transport path 60. The shutter unit 63 is equipped with a first sensor PH1.

[0067] When the carrier tape 24 is transported downstream along the tape transport path 60 and reaches the third transport sprocket 61c, the fourth sensor PH4 detects the carrier tape 24. The fourth sensor PH4 transmits a detection signal to the unit control unit 64 indicating that it has detected the carrier tape 24. Upon receiving the detection signal from the fourth sensor PH4, the unit control unit 64 recognizes that the downstream side of the carrier tape 24 is being transported to the third transport sprocket 61c. The unit control unit 64 then drives the drive unit 62c to move the input sprocket 62a and the tape support unit 62b in the direction of arrow a2. As a result, as described above, the carrier tape 24 falls from the tape support unit 62b and moves to the bottom surface 60a of the tape transport path 60.

[0068] The unit control unit 64 drives the drive unit 62c to move the tape support unit 62b, and then returns the tape support unit 62b to its original position.

[0069] When the carrier tape 24 falls from the tape support section 62b, the first sensor PH1 stops outputting a detection signal for the carrier tape 24 to the unit control unit 64. As a result, the unit control unit 64 recognizes that the carrier tape 24 is not supported by the tape support section 62b, or that the carrier tape 24 is not present at the position of the first sensor PH1.

[0070] As shown in Figure 7(b), when the carrier tape 24 moves downstream along the tape transport path 60, the second sensor PH2 detects the carrier tape 24 and transmits a detection signal to the unit control unit 64 and the main unit control unit 17. Also, in the state shown in Figure 6(a), the unit control unit 64 has not received a detection signal from the second sensor PH2, so it can determine that the carrier tape 24 has not reached the position of the second sensor PH2.

[0071] The exposed portion 66 is created by peeling the top tape 7b of the carrier tape 7 (see Figure 3) from the carrier tape 7 to expose the component 5 that is packaged on the carrier tape 7. In this embodiment, the exposed portion 80 employs a method of peeling the top tape 7b from the carrier tape 7 using air and rollers, but the component 5 may also be exposed by cutting open the top tape 7b with a cutter or the like. In the following description, after the top tape 52 has been peeled off the base tape 51, the base tape 51 from which the top tape 52 has been peeled off will also be referred to as the carrier tape 24.

[0072] The fourth sensor PH4 is positioned downstream of the location where the exposed portion 66 is located. The detection result from the fourth sensor PH4 is sent to the unit control unit 64. Alternatively, the fourth sensor PH4 may be equipped with a dog that can mechanically contact the leading edge of the carrier tape 24, and the leading edge of the carrier tape 24 may be detected by detecting the displacement of the dog that occurs when the carrier tape 24 comes into contact with the dog using an optical sensor. If the displacement of the dog is detected by an optical sensor, the carrier tape 24 can be reliably detected even if the carrier tape 24 is made of a light-transmitting material.

[0073] In Figure 4, the unit control unit 64 is connected to the drive unit 61d, the exposure unit 66, and the fourth sensor PH4 in a communication manner, and the unit control unit 64 controls the operation of the drive unit 61d and the exposure unit 66, respectively. In other words, the unit control unit 64 drives and controls the third transport sprocket 61c, thereby executing a tape transport operation in which the carrier tape 24 is transported along the tape transport path 60. At this time, the unit control unit 64 is capable of controlling the transport timing and transport amount of the carrier tape 24.

[0074] The unit control unit 64 is connected to the operation unit for communication, and the unit control unit 64 is further connected to the main body 2 of the component mounting device 1 for communication. The tape transport operation and tape feeding operation described above are performed by operation commands input from the operation unit and control commands transmitted from the main body 2.

[0075] The exposed component is transported by the tape transport unit 61 along with the carrier tape 24 to an opening formed downstream, i.e., the component removal position 23ba. An opening is formed at the position corresponding to the component removal position 23ba.

[0076] Next, the functional configuration of the component mounting device 1 will be described with reference to Figure 5. Figure 5 is a block diagram showing an example of the functional configuration of the component mounting device 1.

[0077] The component mounting device 1 can accommodate multiple tape feeders 23, each of which is equipped with a unit control unit 64. The unit control unit 64 comprises a tape transport control unit 64a and a storage unit 64b. The unit control unit 64 can be implemented using a circuit composed of semiconductor elements or the like. For example, the unit control unit 64 can be composed of a circuit such as a microcontroller, CPU, MPU, GPU, DSP, FPGA, or ASIC. The functions of the unit control unit 64 may be implemented using hardware alone, or by combining hardware and software. The unit control unit 64 reads data and programs stored in the storage unit 64b and performs various arithmetic operations to realize predetermined functions.

[0078] The unit control unit 64 is electrically connected to the first sensor PH1, the second sensor PH2, the third sensor PH3, the fourth sensor PH4, the drive unit 61d, and the drive unit 62c, and controls the operation of each component.

[0079] The tape transport control unit 64a controls the operation of the tape transport unit 61 based on commands from the main unit control unit 17, thereby controlling the feeding operation of the carrier tape 24 mounted on the tape feeder 23.

[0080] The storage unit 64b stores component information of the carrier tape 24 mounted on the tape feeder 23. The storage unit 64b also stores component information of the current tape 24a and the next tape 24b mounted on the tape feeder 23. The storage unit 64b can be implemented, for example, by a hard disk drive (HDD), SSD, RAM, DRAM, ferroelectric memory, flash memory, magnetic disk, or a combination thereof.

[0081] The unit-side connector 65 is connected to the main unit-side connector 10 via the connector on the feeder base 31, enabling communication between the unit control unit 64 and the main unit control unit 17. Alternatively, the unit-side connector 65 may be connected to a connector of an external setup device or maintenance device, etc., after the tape feeder 23 has been removed from the main unit 2, enabling communication between the unit control unit 64 and the external setup device or maintenance device, etc.

[0082] The main control unit 17 controls the component mounting operation in the main unit 2. The main control unit 17 includes a suction determination unit 17a, an image processing unit 17b, a continuous suction error determination unit 17c, a storage unit 17d, a head movement control unit 17e, and a tape transport control unit 17f. The main control unit 17 can be composed of circuits such as a microcontroller, CPU, MPU, GPU, DSP, FPGA, or ASIC. The functions of the main control unit 17 are realized by combining hardware and software. The main control unit 17 realizes predetermined functions by reading data and programs stored in the storage unit 17d and performing various arithmetic operations.

[0083] The suction determination unit 17a determines whether or not a suction error of the component 5 by the mounting head 13 has occurred by comparing the detected value of the negative pressure sensor 13c with a predetermined threshold value. If the detected value of the negative pressure sensor 13c is smaller than the threshold value, the nozzle 13a has suctioned the component 5 and the predetermined negative pressure state is maintained, so it can be determined that the suction was successful. If the detected value of the negative pressure sensor 13c is larger than the threshold value, the nozzle 13a has not suctioned the component 5, so it can be determined that the predetermined negative pressure state is not maintained and a suction error has occurred. The negative pressure sensor 13c and the suction determination unit 17a constitute the suction detection unit.

[0084] The image processing unit 17b determines, by image recognition based on the image captured by the camera 19, whether or not the component 5 has been attracted to the nozzle 13a of the mounting head 13. If the image processing unit 17b determines that the component 5 has not been attracted to the nozzle 13a of the mounting head 13, it recognizes that an attraction error has occurred. The image processing unit 17b also determines whether or not the orientation of the component 5 that has been attracted to the nozzle 13a falls within a predetermined range.

[0085] The continuous adsorption error determination unit 17c determines whether the number of times an adsorption error has been determined by the adsorption determination unit 17a or the image processing unit 17b has continuously exceeded a predetermined threshold. This threshold can be set in any way, but as an example, since large components 5 are less prone to adsorption errors and if adsorption errors occur continuously, there is a high possibility of component failure, the threshold may be changed according to the size of component 5. The threshold corresponding to small components 5 may be set higher than the threshold corresponding to large components 5. This can improve the efficiency of carrier tape replacement.

[0086] The continuous suction error determination unit 17c recognizes that a continuous suction error has occurred in the mounting head 13 if it determines that the number of times a suction error has been determined to have occurred is consecutively greater than a predetermined threshold. The continuous suction error determination unit 17c may count the number of continuous suction errors as the number of times both the suction determination unit 17a and the image processing unit 17b determine that a suction error has occurred, or it may count the number of continuous suction errors as the number of times at least one of them determines that a suction error has occurred.

[0087] The storage unit 17d has a counter 17da and also stores threshold values ​​used by the continuous adsorption error determination unit 17c. The storage unit 17d can be implemented, for example, by a hard disk (HDD), SSD, RAM, DRAM, ferroelectric memory, flash memory, magnetic disk, or a combination thereof.

[0088] The head movement control unit 17e controls the operation of the head movement mechanism 14, thereby moving the mounting head 13 to the corresponding position on the substrate 4 where the suctioned component 5 should be mounted.

[0089] The tape transport control unit 17f has the same function as the tape transport control unit 64a of the unit control unit 64, and controls the operation of the tape transport unit 61 directly from the main unit 2 to control the feeding operation of the carrier tape 24 mounted on the tape feeder 23. The operation of the tape transport unit 61 may be controlled by the unit control unit 64 of the tape feeder 23, or by the main unit control unit 17 of the main unit 2.

[0090] Next, with reference to Figures 6 to 8, the carrier tape transport operation by the tape feeder 23 will be explained.

[0091] Refer to Figure 6(a). The operator inserts the carrier tape 24 along the tape support 62b located at the tape inlet 23a of the tape feeder 23. If the current tape 24a is downstream of the tape transport path 60, the tape introduction unit 62 brings in the carrier tape 24 with the shutter unit 63 locked, and stops the input sprocket 62a when the carrier tape 24 is detected by the first sensor PH1. If the operator has inserted the carrier tape 24 to the position detected by the first sensor PH1, the tape introduction unit 62 will not operate. In either case, the carrier tape 24 cannot enter beyond the shutter unit 63. In this way, the carrier tape 24 waits at the standby position 23bb located upstream of the parts removal position 23ba, which will be described later.

[0092] If there is no carrier tape 24 downstream of the tape transport path 60, the shutter unit 63 is unlocked, and in this state, the tape introduction unit 62 transports the carrier tape 24. As a result, the carrier tape 24 passes through the shutter unit 63 and is fed into the tape transport path 60. As shown in Figure 6(b), when the carrier tape 24 is transported to a position where it hits the pin of the third transport sprocket 61c, the feeding by the loading sprocket 62a stops. The carrier tape 24 is transported further downstream by the third transport sprocket 61c, and when detected by the fourth sensor PH4, the tape transport unit 61 performs an operation to cause the exposed section 66 to capture the top tape 52.

[0093] When the exposed portion 66 catches the top tape 52, the exposed portion 66 and the third transport sprocket 61c peel off the top tape 52 while the carrier tape 24 is transported further downstream. When the pin of the second transport sprocket 61b is inserted into the feed hole 54 of the carrier tape 24, the drive unit 61d drives the second transport sprocket 61b to position the leading pocket 53 of the carrier tape 24 at the part removal position 23ba, as shown in Figure 7(a).

[0094] Next, a path change is performed at the tape introduction section 62. As shown in Figure 7(b), the carrier tape 24 passing through the tape introduction section 62 detaches from the tape introduction section 62 due to the path change and moves to the bottom surface 60a of the tape transport path 60 below it. The path change is performed when the carrier tape 24 is engaged with the second transport sprocket 61b and the third transport sprocket 61c of the tape transport section 61. When the path change is performed, the shutter unit 63 enters a locked state.

[0095] As shown in Figure 8(a), the operator can insert the next carrier tape 24 (next tape 24b) into the tape introduction section 62 that has become vacant due to the change in the track layout. The method for inserting the carrier tape 24 into the tape introduction section 62 is the same as the method described above.

[0096] As shown in Figure 8(b), when the second sensor PH2 detects that the end of the current tape 24a has passed, the tape transport unit 61 ejects the current tape 24a (tape ejection). Once the current tape 24a has been ejected, the shutter unit 63 is unlocked, and in this state, the tape introduction unit 62 transports the next tape 24b that was waiting at the standby position 23bb. As a result, the next tape 24b is fed into the tape transport path 60. When the next tape 24b is transported to a position where it hits the pin of the uppermost sprocket of the tape transport unit 61, the feeding by the feeding sprocket 62a stops. The path is changed, and the next tape 24b is transported as the current tape 24a.

[0097] Next, with reference to Figure 9, the carrier tape 24 replacement operation will be explained in more detail. Figure 9 is a flowchart showing the flow of carrier tape 24 replacement.

[0098] In step S1, the main unit control 17 receives the value detected by the negative pressure sensor 13c, and the suction determination unit 17a compares it with a predetermined threshold to determine whether or not a suction error has occurred. If the suction determination unit 17a determines that the value detected by the negative pressure sensor 13c is less than or equal to the threshold, it determines that no suction error has occurred (No in step S1) and continues to monitor the value detected by the negative pressure sensor 13c. If the suction determination unit 17a determines that the value detected by the negative pressure sensor 13c is greater than the threshold, it determines that a suction error has occurred (Yes in step S1) and sends information to the continuous suction error determination unit 17c indicating that a suction error has occurred. Furthermore, if a suction error occurs, the tape transport control unit 171 causes the tape transport unit 61 to advance the current tape 24a by the pitch of one component 5 and pick up the next component 5 onto the mounting head 13.

[0099] In step S2, when the continuous suction error determination unit 17c receives information indicating that a suction error has occurred, it counts the number of times a suction error has occurred and determines whether the consecutive count is greater than a predetermined threshold. If the continuous suction error determination unit 17c determines that the number of times a suction error has been determined to have occurred is consecutively less than or equal to the predetermined threshold, it determines that no continuous suction errors have occurred (No. in step S2) and returns to step S1. If the continuous suction error determination unit 17c determines that the number of times a suction error has been determined to have occurred is consecutively greater than a predetermined threshold, it determines that a continuous suction error has occurred in the mounting head 13 (step S2).

[0100] In step S3, the main unit control unit 17 sets the value n of the counter 17da in the storage unit 17d to 0. The value n of the counter 17da is the number of times the current tape 24a has been advanced to a predetermined length.

[0101] In step S4, the main control unit 17 refers to the detection result of the second sensor PH2 to check whether the second sensor PH2 has detected the current tape 24a. If the second sensor PH2 has not detected the presence of the current tape 24a (No. in step S4), the end of the current tape 24a is between the second sensor PH2 and the third sensor PH3, so the main control unit 17 recognizes that a component has run out in the current tape 24a. In step S5, the tape transport control unit 17f of the main control unit 17 drives the tape transport unit 61 to discharge the current tape 24a from the tape transport path 60. After that, as described above, the next tape 24b is transported as the current tape 24a.

[0102] In step S4, if the second sensor PH2 detects the presence of the current tape 24a (Yes in step S4), the end of the current tape 24a is upstream of the second sensor PH2.

[0103] In step S6, the main control unit 17 determines whether the tape feed count n of the counter 17da is equal to a predetermined number N. If the value n of the counter 17da is different from the predetermined number N (No in step S6), that is, if the value n of the counter 17da is less than the predetermined number N, in step S7, the tape transport control unit 17f drives and controls the tape transport unit 61 to transport the current tape 24a downstream for a predetermined length. This predetermined length is, for example, longer than the length of one pitch of the feed holes 54 of the carrier tape 24. After this, in step S8, the tape feed count n of the counter 17da is incremented (the value is increased by one).

[0104] After transporting the current tape 24a for a predetermined length in step S7, the main control unit 17 again checks in step S4 whether the second sensor PH2 has detected the current tape 24a by referring to the detection result of the second sensor PH2. If the second sensor PH2 has not detected the current tape 24a (No in step S4), the current tape 24a is ejected as described above. If the second sensor PH2 has detected the current tape 24a (Yes in step S4), steps S6, S7, and S8 are repeated again to transport the current tape 24a for a predetermined length. In this way, steps S4, S6, S7, and S8 are repeated until the second sensor PH2 no longer detects the current tape 24a in step S4, or until it is determined in step S6 that the tape feed count n has reached a predetermined number N. As a result, each time the presence of the current tape 24a is detected, the current tape 24a is transported and tape detection is performed again. This makes it easier to detect the end of the current tape 24a even if the current tape 24a is long from the position where the last component 5 is located to the end, thereby improving the accuracy of determining whether the current tape 24a is out of components.

[0105] In step S6, if the number of tape feeds n becomes equal to a predetermined number N, the continuous suction error of the mounted head 13 may be due to a reason other than a broken part in the current tape 24a. Therefore, in step S9, the tape transport control unit 17f stops driving the tape transport unit 61 and stops transporting the current tape 24a.

[0106] When the main control unit 17 confirms that the tape feed count n has become equal to a predetermined number N, in step S10, it transmits information to the touchscreen 16a, the external management device 92, and the portable information terminal 95 indicating a continuous suction error and that the current tape 24a has been transported a predetermined number of times. As a result, the error is displayed on the touchscreen 16a and the display panel 95a of the portable information terminal 95. By looking at this error display, the operator can check the status of the nozzle 13a of the mounted head 13 and take action to address the continuous suction error.

[0107] As described above, the component mounting device 1 of this embodiment picks up components 5 contained on the carrier tape 24 at the component removal position 23ba and mounts them on the substrate 4. The component mounting device 1 comprises a tape feeder 23, a mounting head 13, a pick-up detection unit, and a main unit control unit 17. Each tape feeder 23 contains multiple components 5 and is equipped with a current tape 24a as the carrier tape 24 that is transported first, and a next tape 24b as the carrier tape 24 that is transported after the current tape 24a. The mounting head 13 picks up the components 5 that have been transported to the component removal position 23ba. The negative pressure sensor 13c, pick-up determination unit 17a, camera 19, and image processing unit 17b, which constitute the pick-up detection unit, detect whether or not the components 5 have been picked up by the mounting head 13. The main unit control unit 17 controls the transport drive of the carrier tape 24 in the tape feeder 23 and determines whether or not a continuous pick-up error has occurred based on the detection result of the pick-up detection unit. The tape feeder 23 includes a tape transport path 60 through which the carrier tape 24 is transported from a tape inlet 23a into which the carrier tape 24 is inserted to a parts retrieval position 23ba, a tape transport unit 61 that transports the carrier tape 24 along the tape transport path 60, and a second sensor PH2 positioned upstream of the parts retrieval position 23ba on the tape transport path 60 for detecting whether or not the carrier tape 24 is present. The main control unit 17 causes the tape transport unit 61 to transport the current tape 24a along the tape transport path 60, supplying the parts 5 contained in the current tape 24a to the parts retrieval position 23ba, and after discharging the current tape 24a, transports the next tape 24b along the tape transport path 60, thereby transporting the parts 5 contained in the next tape 24b to the parts retrieval position 23ba. When the main control unit 17 determines that a continuous suction error has occurred, it checks the detection result of the second sensor PH2, and if the presence of the current tape 24a is not detected by the second sensor PH2, it controls the tape transport unit 61 to eject the current tape 24a.If the presence of the current tape 24a is detected by the second sensor PH2, the main control unit 17 controls the tape transport unit 61 to feed the current tape 24a to a predetermined length. After the current tape 24a has been fed to the predetermined length, if the presence of the current tape 24a is not detected by the second sensor PH2, the main control unit 17 controls the tape transport unit 61 to eject the current tape 24a. If the presence of the current tape is detected by the second sensor PH2, the main control unit 17 controls the tape transport unit 61 to feed the current tape 24a to a predetermined length again. The main control unit 17 repeats the process of having the tape transport unit 61 feed the current tape 24a to a predetermined length while the second sensor PH2 detects the presence of the current tape 24a.

[0108] Furthermore, in the component supply method of this embodiment, a tape transport unit 61 transports a carrier tape 24 containing a plurality of components 5 along a tape transport path 60 to supply the components 5 to a component removal position 23ba, and a mounting head 13 picks up the components 5 transported to the component removal position 23ba and mounts them on a substrate 4. In this component mounting device 1, after transporting the current tape 24a as the carrier tape 24, a next tape 24b as the carrier tape 24 is continuously transported. The component supply method comprises a pick-up detection step, a first determination step, a tape detection step, an ejection step, a second determination step, and a transport step. In the pick-up detection step, the pick-up detection unit, which consists of a negative pressure sensor 13c, a pick-up determination unit 17a, a camera 19, and an image processing unit 17b, detects whether or not the components 5 have been picked up by the mounting head 13. In the first determination step, the control unit determines whether or not a continuous pick-up error has occurred based on the detection result of the pick-up detection unit. If it is determined in the first determination step that a continuous suction error has occurred, in the tape detection step, the second sensor PH2, located upstream of the component removal position 23ba in the tape transport path 60, detects whether or not a current tape 24a is present. If the presence of a current tape 24a is not detected in the tape detection step, the tape transport unit 61 ejects the current tape 24a in the ejection step. If the presence of a current tape 24a is detected in the tape detection step, the main unit control unit 17 determines in the second determination step whether or not the number of transports for which the current tape 24a is transported to a predetermined length has reached a predetermined number. If it is determined in the second determination step that the number of transports has not reached a predetermined number, the tape transport unit transports the current tape to the predetermined length in the transport step. After the transport step is performed, the tape detection step is performed again, and the tape detection step, the second determination step, and the transport step are repeated until the ejection step is performed or the number of transports is determined to have reached a predetermined number in the second determination step.

[0109] This allows for improved accuracy in detecting component failures by triggering the detection of tape presence by the second sensor PH2 when a series of suction errors by the mounted head 13 occur at the component removal position 23ba. Furthermore, if the second sensor PH2 detects the presence of tape, repeating tape feeding and tape detection for a predetermined length improves the frequency of tape end detection, even when the distance from the last stored component to the end of the tape is long. This improves the frequency of unattended tape replacement due to component failures, even with long current tapes.

[0110] Furthermore, when the main control unit 17 determines that a continuous suction error has occurred, while the second sensor PH2 is detecting the presence of the current tape 24a, it causes the tape transport unit 61 to repeatedly feed the current tape 24a to a predetermined length until a predetermined number of times is reached, and then stops the operation of the mounted head 13. By adjusting the predetermined number of times tape feeding and tape detection are repeated according to the trend of the length of the current tape to the end of the tape, the efficiency of replacing the tape with a next tape due to a component failure can be improved.

[0111] Furthermore, the parts mounting device 1 is equipped with a touchscreen 16a that notifies the operator when the mounting head 13 stops moving. This allows the operator to know when the mounting head 13 has stopped moving.

[0112] Furthermore, after the tape transport unit 61 has transported the current tape 24a for a predetermined length a predetermined number of times, if the presence of the current tape 24a is detected by the second sensor PH2, the main unit control unit 17 stops driving the tape transport unit 61 and displays a warning on the touchscreen 16a. As a result, the operator can receive a warning from the touchscreen 16a and learn that a continuous suction error has occurred and the end of the tape has not been detected even after transporting the tape for a predetermined length a predetermined number of times. This allows the operator to understand that it is highly likely that there is some kind of error in the suction of the mounted head 13 rather than a component shortage.

[0113] Furthermore, the main unit control unit 17 determines that a continuous pick-up error has occurred if the mounting head 13 fails to pick up the part 5 at the part pick-up position 23ba a predetermined number of times. This prevents accidental pick-up errors from being mistaken for part shortages.

[0114] Furthermore, the predetermined number of attempts decreases as the size of the component being held increases. By setting the number of attempts required to determine a continuous holding error in this way, the efficiency of replacing the carrier tape 24 in the event of a component failure can be improved.

[0115] Furthermore, the mounting head 13 uses negative pressure to attract the component 5 that has been transported to the component removal position 23ba. The attraction detection unit includes a negative pressure sensor 13c that detects the value of the negative pressure at which the mounting head 13 attracts the component 5, and an attraction determination unit 17a that determines whether or not the component 5 has been attracted to the mounting head 13 by comparing the detected value of the negative pressure sensor 13c with a threshold value. This makes it possible to appropriately detect component attraction errors in the mounting head 13.

[0116] Furthermore, the suction detection unit is positioned in the middle of the transport path from the component removal position 23ba to the substrate 4 and includes a camera 19 that photographs the component suction side of the mounting head 13, and an image processing unit 17b that determines whether or not the component 5 has been picked up by the mounting head 13 based on the image captured by the camera 19. This makes it possible to appropriately detect component suction errors of the mounting head 13.

[0117] Furthermore, the length of the current tape 24a that is transported for a predetermined number of times to reach a predetermined length is longer than the length from the second sensor PH2 to the tape inlet 23a of the tape transport path 60. As a result, even if the length of the current tape 24a from the position of the last component to the end of the tape is from the second sensor PH2 to the tape inlet 23a, the end of the tape can be detected, and the automatic replacement operation with the next tape 24b can be performed.

[0118] Furthermore, the component mounting device 1 does not have a sensor to directly detect component shortages in the current tape 24a. Even without a sensor to directly detect component shortages, it can accurately determine component shortages in the current tape 24a, thereby suppressing an increase in the number of components and preventing cost increases.

[0119] Furthermore, the information displayed on the touchscreen 16a is output to a portable information terminal 95 located outside the component mounting device 1. This allows workers located away from the component mounting device 1 to be notified of information from the device and to be aware of warnings due to continuous suction errors.

[0120] While this disclosure is adequately described in relation to preferred embodiments with reference to the accompanying drawings, various variations and modifications will be obvious to those skilled in the art. Such variations and modifications should be understood to be included within the scope of this disclosure as defined by the attached claims. Furthermore, variations in combinations and sequences of elements in each embodiment can be realized without departing from the scope and spirit of this disclosure.

[0121] Furthermore, by appropriately combining any embodiment or modification from among the various embodiments and modifications, the effects of each can be achieved. [Industrial applicability]

[0122] The component mounting device and component supply method relating to this disclosure are applicable to component mounting systems that supply components using a carrier tape that stores the components. [Explanation of Symbols]

[0123] 1. Component mounting device 2 Main body 3. Parts Supply Department 4 circuit boards 5 parts 10 Main unit side connector 11 Base 12. Substrate transport section 13 Mounted Heads 13a Nozzle 14. Head movement mechanism 16 Control section 16a Touchscreen 17 Main Unit Control 17a Adsorption judgment part 17b Image Processing Unit 17c Continuous adsorption error determination unit 17d Storage section 17da counter 17e Head movement control unit 17f Tape transport control unit 18. Control Panel 19 Cameras 21 bogies 22 reels 23 Tape feeder 23a Tape entrance 23b Parts supply port 23ba Component removal location 23c outlet 23d Main unit 23da Core Unit 23dB Loading Unit 24 Carrier Tapes 24a Current Tape 24b Next Tape 28 barcodes 31 Feeder Base 32 Reel holding section 51 Base Tape 52 Top Tape 52a Extension 52b Tip 53 pockets 54 feed holes 60 Tape transport path 60a Bottom 60b top surface 61 Tape transport section 61a First conveyor sprocket 61b Second transport sprocket 61c Third conveyor sprocket 61d Drive unit 62 Tape input section 62a Delivery sprocket 62b Tape support section 62c drive unit 63 Shutter Unit 64 Unit Control Unit 64a Tape transport control unit 64b Storage section 65 Unit-side connector 66 Exposed part 92 Management device 95 Portable Information Terminals 95a Display Panel PH1 First Sensor PH2 Second Sensor PH3 Third Sensor PH4 Fourth Sensor

Claims

1. In a component mounting device that picks up components contained in a carrier tape at a component removal position and mounts them to a substrate, Each tape feeder houses multiple of the aforementioned components and is equipped with a current tape, which serves as the carrier tape to be transported first, and a next tape, which serves as the carrier tape to be transported after the current tape. A mounting head that picks up the part that has been transported to the part removal position, A suction detection unit that detects whether or not a component has been attracted by the mounted head, The tape feeder includes a control unit that controls the transport drive of the carrier tape and determines whether or not a continuous adsorption error has occurred based on the detection result of the adsorption detection unit, The aforementioned tape feeder is A tape transport path from the entrance into which the carrier tape is inserted to the component removal position, A tape transport unit that transports the carrier tape along the tape transport path, It has a tape detection unit positioned upstream of the component removal position in the tape transport path, which detects whether or not the carrier tape is present, The control unit causes the tape transport unit to transport the current tape along the tape transport path, supplying the components contained in the current tape to the component retrieval position, and after discharging the current tape, transports the next tape along the tape transport path, thereby transporting the components contained in the next tape to the component retrieval position. When the control unit determines that the continuous suction error has occurred, it checks the detection result of the tape detection unit, If the tape detection unit does not detect the presence of the current tape, the tape transport unit is controlled to eject the current tape. If the tape detection unit detects the presence of the current tape, the tape transport unit is controlled to advance the current tape to a predetermined length. After the current tape has been fed for the predetermined length, the control unit will: If the tape detection unit does not detect the presence of the current tape, the tape transport unit is controlled to eject the current tape. If the tape detection unit detects the presence of the current tape, the tape transport unit is controlled to advance the current tape again to the predetermined length. The control unit repeatedly causes the tape transport unit to advance the current tape to a predetermined length while the tape detection unit detects the presence of the current tape. Component mounting device.

2. When the control unit determines that the continuous suction error has occurred, while the tape detection unit is detecting the presence of the current tape, it causes the tape transport unit to repeatedly feed the current tape to the predetermined length until a predetermined number of times has been reached, and then stops the operation of the mounted head. The component mounting device according to claim 1.

3. The system includes a notification unit that notifies when the operation of the mounted head stops. The component mounting device according to claim 2.

4. If the tape transport unit has transported the current tape for a predetermined length a predetermined number of times, and the tape detection unit has detected the presence of the current tape, the control unit stops driving the tape transport unit and causes the notification unit to issue a warning. The component mounting device according to claim 3.

5. The control unit determines that a continuous suction error has occurred if the mounting head fails to pick up the part at the part pick-up position a predetermined number of times. The component mounting device according to claim 1.

6. The predetermined number of times mentioned above decreases as the size of the component being adsorbed increases. The component mounting device according to claim 5.

7. The aforementioned mounting head uses negative pressure to attract the parts that have been transported to the parts removal position. The adsorption detection unit is, A negative pressure sensor detects the value of the negative pressure at which the mounting head attracts the component, The system includes an adsorption determination unit that determines whether or not the component has been adsorbed onto the mounting head by comparing the detected value of the negative pressure sensor with a threshold value. The component mounting device according to claim 1.

8. The adsorption detection unit is, A camera is positioned in the middle of the transport path from the component removal position to the substrate and captures the component suction side of the mounting head, The system includes an image processing unit that determines whether or not the component has been attracted to the mounting head based on the image captured by the camera. The component mounting device according to claim 1.

9. The length of the current tape that is transported for a predetermined number of times is longer than the length from the tape detection unit to the tape entrance of the tape transport path. The component mounting device according to claim 2.

10. It does not have a sensor that directly detects a broken component in the current tape. The component mounting device according to claim 1.

11. The content to be notified to the notification unit is output to an external device of the component mounting device. The component mounting device according to claim 3.

12. In a component mounting apparatus in which a tape transport unit transports a carrier tape containing multiple components along a tape transport path to supply the components to a component removal position, and a mounting head picks up the components transported to the component removal position and mounts them to a substrate, in a component supply method in which a next tape, which serves as the carrier tape, is continuously transported after the current tape, which serves as the carrier tape, A suction detection step in which the suction detection unit detects whether or not a component has been picked up by the mounted head, A first determination step in which the control unit determines whether or not a continuous adsorption error has occurred based on the detection result of the adsorption detection unit, If it is determined in the first determination step that a continuous suction error has occurred, a tape detection step is performed in which a tape detection unit located upstream of the component removal position in the tape transport path detects whether or not a current tape is present. If the presence of the current tape is not detected in the tape detection step, the tape transport unit ejects the current tape in an ejection step, If the presence of the current tape is detected in the tape detection step, a second determination step is performed to determine whether the number of times the control unit has transported the current tape for a predetermined length has reached a predetermined number of times, If it is determined in the second determination step that the number of transports has not reached the predetermined number, the system includes a transport step in which the tape transport unit transports the current tape for the predetermined length, After performing the transport step, the tape detection step is performed again, and the tape detection step, the second determination step, and the transport step are repeated until the ejection step is performed or the second determination step determines that the number of transports has reached a predetermined number. Parts supply method.

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