Kitting equipment

Abstract

To provide a kitting device that can automatically remove and process a parts container from a parts supply unit.SOLUTION: A kitting device includes a kitting execution unit that performs removal work to remove a component container from a component supply unit, and a sorting unit that separates the component container removed by the kitting execution unit into an empty component container in which all component have been consumed and a component container in which components still remain.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] This specification relates to a substrate production system that produces substrates using a substrate production line in which a plurality of substrate production machines including a component mounting machine are arranged.

Background Art

[0002] Techniques for mass-producing substrates equipped with electronic circuits by performing operations such as component mounting on substrates with printed wiring are widespread. Furthermore, it has become common to configure a substrate production line by arranging a plurality of types of substrate production machines that perform operations. Among the substrate production machines, the component mounting machine uses a component supply unit equipped with a component storage container that stores a plurality of components. A representative example of the component supply unit, the tape feeder, uses a reel around which a carrier tape is wound as the component storage container.

[0003] The kitting operation of setting a component storage container (reel) in a component supply unit (tape feeder) is required for component replenishment operations when components are completely consumed as production progresses and for setup change operations for changing the type of substrate (substrate type) to be produced. This type of kitting operation has conventionally been performed manually. Also, a method of preparing in advance a component supply unit that has completed the kitting operation and replacing the component supply unit when necessary is also used. Technical examples related to the kitting operation and replacement operation of the component supply unit are disclosed in Patent Documents 1 and 2.

[0004] Patent Document 1 discloses a tape reel supply robot that loads a tape reel onto a tape feeder set in a component mounting machine. According to this, it is said that automatic replacement of the tape reel can be performed and losses such as loss of operation time can be eliminated.

[0005] Furthermore, the component mounting line described in Patent Document 2 includes a unit storage facility for storing multiple component supply units, and a unit exchange device for exchanging component supply units attached to multiple component mounting machines with component supply units in the unit storage facility. According to this, component supply units used in any of the component mounting machines can be loaded and unloaded from the unit storage facility for replenishment and retrieval, thus providing a user-friendly unit storage facility. [Prior art documents] [Patent Documents]

[0006] [Patent Document 1] Japanese Patent Application Publication No. 5-175686 [Patent Document 2] International Publication No. 2017 / 033268 [Overview of the Initiative] [Problems that the invention aims to solve]

[0007] Incidentally, the tape reel supply robot described in Patent Document 1 is preferable because it can automate the kitting work that was previously performed manually. However, in the case of the aforementioned setup changeover work, the tape reel supply robot sequentially loads tape reels into each of the numerous tape feeders, which increases the working time. This leads to the problem of reduced production efficiency.

[0008] In contrast, the configuration described in Patent Document 2 allows for the storage of completed parts supply units in a unit storage facility beforehand, thereby shortening the work time and increasing production efficiency by replacing the parts supply units during setup changes. However, when automating the kitting process at a kitting station to reduce labor, a transport vehicle is required to transport the parts supply units between the kitting station and the unit storage facility, which are spaced apart. The constraints on the transport vehicle's movement may increase the work time for setup changes. Furthermore, the limitations on the number of spare parts supply units may make the replacement process inefficient.

[0009] Therefore, this specification aims to provide a circuit board production system that achieves high production efficiency by streamlining parts replenishment and setup change operations related to component mounting machines. [Means for solving the problem]

[0010] This specification discloses a circuit board production system comprising: a component mounting machine having a component supply area for arranging component supply units, which picks up components from the component supply units and mounts them onto a circuit board; a kitting station provided in a circuit board production line in which a plurality of circuit board production machines, including the component mounting machine, are arranged, which sets a component container for housing a plurality of the components onto the component supply unit; and a transport device which transports the component supply unit with the component container set by the kitting station to the component mounting machine. [Effects of the Invention]

[0011] In the circuit board production system disclosed herein, the kitting station is located on the circuit board production line. Therefore, when the transport device transports the component supply unit, which has component containers set up, from the kitting station to the component mounting machine, it only needs to travel a short distance, enabling transport in a short time. Consequently, component replenishment and setup change operations related to the component mounting machine can be made more efficient, and as a result, high production efficiency can be achieved. [Brief explanation of the drawing]

[0012] [Figure 1] This is a schematic plan view showing the configuration of the substrate production system according to the embodiment. [Figure 2] This is a schematic planar section cross-sectional view showing the lower part of the substrate production system. [Figure 3] This is a side cross-sectional view of the parts mounting machine, taken from the right. [Figure 4] This is a side cross-sectional view of the kitting station, seen from the right. [Figure 5] This is a schematic perspective view showing the kitting execution unit of a kitting station. [Figure 6] This is a perspective view of a feeder transport vehicle that carries magazine-type spare storage units. [Figure 7] This is a perspective view of a reel transport vehicle that carries reel magazines (parts storage magazines). [Figure 8] This is a block diagram showing the control configuration of the substrate production system according to the embodiment. [Figure 9] This diagram illustrates variations in the position where the initial waste tape is cut from the tip of the carrier tape. [Figure 10] This embodiment is a diagram illustrating a table showing guidelines for the storage position of the tape feeder. [Modes for carrying out the invention]

[0013] 1. PCB production line 2 and component mounting machine 22 The configuration of the substrate production system 1 according to the embodiment will be described with reference to FIGS. 1 to 7. Each figure has a scaled-out part and is a schematic explanatory diagram. As shown in the lower right of FIGS. 1 and 2, the front, rear, left, and right are defined for convenience. The substrate production system 1 includes, as a minimum configuration, a substrate production line 2 including a component mounting machine 22, a kitting station 3, and a transfer device 4. In the present embodiment, the substrate production system 1 further includes two types of transfer carts (feeder transfer cart 51, reel transfer cart 55), a waste tape recovery device 6, a setup control unit 7, a production plan storage unit 71, and the like in addition to the above.

[0014] The substrate production line 2 is configured by arranging a plurality of substrate production machines including a component mounting machine 22. For example, the substrate production line 2 shown in FIGS. 1 and 2 is configured by arranging a solder printer 21, a component mounting machine 22, and a substrate inspection machine 23 from left to right. Each of the plurality of substrate production machines has a transfer conveyor 24 extending in the left-right direction at a generally intermediate height position. Each of the transfer conveyors 24 is rotationally driven by a conveyor drive unit 25 disposed on the lower side. Thereby, the substrate K is sequentially transferred from the upstream solder printer 21 to the downstream substrate production machines.

[0015] As shown in FIG. 3, the component mounting machine 22 has a component supply area 221, a mounting head 222, a suction nozzle 223, and a second reserve storage section 224. The component supply area 221 is provided at a generally intermediate height position on the front side, and the tape feeders 91 used for current production are arranged side by side. The component supply area | region 221 is formed using the plate-shaped member in which several groove-shaped slots extending in the front-back direction are provided. [[ID=⑨]]

[0016] A plurality of tape feeders 91 are inserted from the front side into each of a plurality of slots in the component supply area 221 and are detachably arranged. The tape feeder 91 supplies components using a reel 92 (see FIGS. 5 and 9) around which a carrier tape 93 is wound. The carrier tape 93 has a plurality of cavities arranged in a row in the tape length direction. Each cavity houses a component. The tape feeder 91 is one form of the component supply unit, and the reel 92 is one form of the component storage container.

[0017] Labels representing individual identification codes are attached to the tape feeder 91 and the reel 92. These labels are read by the component mounter 22, the kitting station 3, etc., and the individuals of the tape feeder 91 and the reel 92 are identified. Without being limited to this, the individual identification codes of the tape feeder 91 and the reel 92 may be stored in the built-in memory of the tape feeder 91. In this configuration, when the tape feeder 91 is set in the component mounter 22 or the kitting station 3 and communication-connected, the individual identification code is transmitted and identified.

[0018] The component mounter 22 has a mounting head 222 near the upper part of the internal space. The mounting head 222 is driven by a horizontal drive mechanism (not shown) and moves in two horizontal directions. The mounting head 222 holds one or more suction nozzles 223 so as to be able to move up and down. The transport conveyor 24 crosses a position at approximately the middle height on the rear side of the component mounter 22. The transport conveyor 24 carries a substrate K on which cream solder has been printed by the solder printer 21 into the component mounter 22.

[0019] Then, the mounting head 222 moves above the tape feeder 91, and the suction nozzle 223 descends to pick up a component from the tape feeder 91 and rises. Next, the mounting head 222 moves above the circuit board K, and the suction nozzle 223 descends to mount the component onto the paste-like solder on the circuit board K. When this pickup and mounting operation is repeated, the components in the tape feeder 91 are consumed and the unit runs out. In this case, instead of replacing the reel 92, the tape feeder 91 is replaced. Also, when changing the type of circuit board K, multiple tape feeders 91 are often replaced during setup changes.

[0020] The parts mounting machine 22 has a second spare storage section 224 below the front parts supply area 221. The second spare storage section 224 consists of an upper and lower section, each having a structure similar to that of the parts supply area 221. The second spare storage section 224 can accommodate multiple tape feeders 91 not currently in use in the upper and lower sections, respectively. The tape feeders 91 stored in the second spare storage section 224 are ready for use, with the reels 92 already set, and are used for parts replenishment and setup changes. The second spare storage section 224 may consist of only one section or three or more sections.

[0021] 2. Kitting Station 3 The kitting station 3 is located on the circuit board production line 2, and more specifically, to the left of the solder printing machine 21. However, it is not limited to this location; the kitting station 3 may also be located between the solder printing machine 21 and the component mounting machine 22, or to the right (downstream) of the component mounting machine 22. As shown in Figure 4, the kitting station 3 is formed with dimensions that are smaller at the bottom and larger at the top in the front-to-back direction, with space provided at the rear bottom. A conveyor belt 24 and a conveyor drive unit 25 are arranged within this space. The conveyor belt 24 receives the circuit board K to the left of the kitting station 3 and transfers it to the conveyor belt 24 of the solder printing machine 21. The kitting station 3 includes a kitting execution unit 31, a spare storage unit attachment / detachment unit 32, a magazine receiving unit 33, a magazine delivery unit 34, a reel disposal unit 35, a sorting unit 36, and a first spare storage unit 37.

[0022] The kitting execution unit 31 is located on the front right side of the large upper part in the front-to-back direction of the kitting station 3 (see Figures 1 and 4). The kitting execution unit 31 consists of a feeder holding unit 311 shown in Figure 5, and a work robot (not shown). At the start of the kitting work, the work robot holds the tape feeder 91 to be worked on in the feeder holding unit 311. Next, the work robot rotatably sets the reel 92 at a predetermined position approximately in the center of the tape feeder 91.

[0023] The robot then pulls the carrier tape 93 from the reel 92 and performs the predetermined loading operation. This drives the carrier tape 93 out by the sprocket 911, making it ready to be fed to the parts supply position 912. In other words, the tape feeder 91 is ready for use. During the loading operation of the carrier tape 93, a portion of the leading edge of the carrier tape 93 may be cut as needed (details will be described later).

[0024] Furthermore, the work robot holds the tape feeder 91, recovered from the parts supply area 221 of the parts mounting machine 22, in the feeder holding unit 311 and performs the removal operation of removing the reel 92. The work robot is composed of, for example, an arm-type robot having a movable arm. In addition, the work robot may be configured by combining a moving mechanism for moving the tape feeder 91 and the reel 92. The kitting execution unit 31 is controlled by the kitting control unit 72 (see Figure 8).

[0025] The spare storage unit attachment / detachment section 32 is located on the upper rear right side of the kitting station 3. The spare storage unit attachment / detachment section 32 is the part where the magazine-type spare storage unit 95 is detachably installed. The magazine-type spare storage unit 95 is formed in the shape of a box with an opening (see Figure 6). The magazine-type spare storage unit 95 houses multiple tape feeders 91 side by side. Bidirectional transfer of the tape feeders 91 is possible between the magazine-type spare storage unit 95 located in the spare storage unit attachment / detachment section 32 and the kitting execution unit 31.

[0026] The magazine receiving section 33 is located to the left of the spare storage section attachment / detachment section 32. The magazine receiving section 33 is the part that receives the reel magazine 96 (parts storage magazine). The reel magazine 96 consists of a circular bottom plate and a spindle extending upward from the center of the bottom plate (see Figure 7). The reel magazine 96 stores multiple reels 92 stacked vertically by engaging the spindle with the central hole of the reel 92. The reels 92 can be transferred from the reel magazine 96 located in the magazine receiving section 33 toward the kitting execution section 31.

[0027] The magazine delivery unit 34 is located at the upper rear left of the kitting station 3, to the left of the magazine receiving unit 33. The magazine delivery unit 34 is the part that delivers the reel magazine 96. The reels 92 can be transferred from the kitting execution unit 31 via the sorting unit 36 ​​toward the reel magazine 96 located in the magazine delivery unit 34. The magazine receiving unit 33 and the magazine delivery unit 34 constitute a magazine attachment / detachment unit with two positions for attaching and detaching the reel magazine 96. Note that the magazine receiving unit 33 and the magazine delivery unit 34 may be simplified to a magazine attachment / detachment unit with only one position.

[0028] The reel waste section 35 is located in front of the magazine delivery section 34. The reel waste section 35 is the part that collects empty reels 92 from which the carrier tape 93 has run out after all the parts have been consumed. The sorting section 36 is located slightly to the left of the rear of the kitting execution section 31. The sorting section 36 sorts the reels 92 that have been removed by the kitting execution section 31. That is, the sorting section 36 sends reels 92 that still have parts remaining and whose carrier tape 93 has been partially used to the magazine delivery section 34 for storage in the reel magazine 96. The sorting section 36 also sends empty reels 92 to the reel waste section 35. The sorting section 36 is controlled by the sorting control unit 73 (see Figure 8).

[0029] The first spare storage section 37 is located in a small lower part in the front-to-back direction of the kitting station 3 (see Figures 2 and 4). The first spare storage section 37 consists of an upper and lower section with a structure similar to that of the second spare storage section 224 of the component mounting machine 22. The first spare storage section 37 can accommodate multiple tape feeders 91 not currently used in production in its upper and lower sections, respectively. The first spare storage section 37 may have a structure different from that of the second spare storage section 224.

[0030] 3. Conveying device 4 The transport device 4 performs various transport operations, starting with transporting the tape feeder 91, on which the reel 92 has been set by the kitting station 3, to the component mounting machine 22. As shown by arrow M1 in Figure 1, the transport device 4 moves from the front of the kitting station 3 to the front of the component mounting machine 22.

[0031] More specifically, guide rails and contactless power supply units are provided on the front of each board production machine constituting the board production line 2, and on the front of the kitting station 3. Meanwhile, the transport device 4 has an engagement part and a contactless power receiving part on its rear side, and has a moving motor inside. The engagement part of the transport device 4 engages with the guide rails to guide the movement of the transport device 4. The contactless power receiving part of the transport device 4 receives power from the contactless power supply unit and supplies power to the moving motor. As a result, the transport device 4 is driven by the moving motor and moves in the left-right direction. The transport device 4 is not limited to the above configuration, and may, for example, have the structure of a self-propelled transport vehicle equipped with a storage battery.

[0032] As shown by the dashed arrows in Figure 3, the transport device 4 has the function of transferring the tape feeder 91 between the parts supply area 221 and the second spare storage area 224 of the parts mounting machine 22. Also, as shown by the dashed arrows in Figure 4, the transport device 4 has the function of transferring the tape feeder 91 between the kitting execution unit 31 and the first spare storage area 37 of the kitting station 3. Furthermore, the transport device 4 has the function of moving the received tape feeder 91 while holding it inside the device, and the function of raising and lowering the tape feeder 91 inside the device.

[0033] Therefore, the transport device 4 can perform a transport operation to transport the tape feeder 91 between the aforementioned parts. The transport device 4 is controlled by the setup control unit 7 (see Figure 8). The applicant has disclosed a detailed configuration example of the transport device 4 in Patent Document 2 under the name "exchange robot".

[0034] 4. Feeder transport vehicle 51 and reel transport vehicle 55 As shown in Figure 6, the feeder transport vehicle 51 travels carrying a magazine-type spare storage unit 95. Although not shown in Figure 6, the magazine-type spare storage unit 95 accommodates multiple tape feeders 91 side by side. The feeder transport vehicle 51 transports the magazine-type spare storage unit 95 between the spare storage unit attachment / detachment section 32 of the kitting station 3 and the feeder storage warehouse 53 (see arrow M2 in Figure 1). The feeder transport vehicle 51 has a roller device 52 on its upper surface that automatically replaces the magazine-type spare storage unit 95.

[0035] The feeder transport vehicle 51 can automatically replenish the number of tape feeders 91 at the kitting station 3 from the feeder storage warehouse 53 if the number of tape feeders 91 is insufficient. The feeder transport vehicle 51 can also automatically store any surplus tape feeders 91 generated at the kitting station 3 in the feeder storage warehouse 53. Furthermore, the feeder transport vehicle 51 can improve transport efficiency by transporting multiple tape feeders 91 stored in the magazine-type spare storage unit 95. However, the feeder transport vehicle 51 may also be configured to transport one or more tape feeders 91 without using the magazine-type spare storage unit 95.

[0036] As shown in Figure 7, the reel transport vehicle 55 travels carrying multiple reel magazines 96 (parts storage magazines). In the example in Figure 7, one reel magazine 96 is fully loaded with reels 92, while another reel magazine 96 is empty. The reel transport vehicle 55 transports the reel magazines 96 between the magazine receiving section 33 and the magazine dispensing section 34 of the kitting station 3 and the reel storage warehouse 57 (see arrow M3 in Figure 1). The reel transport vehicle 55 has an annular conveyor device 56 on its upper surface for adjusting the position of the reel magazines 96 and automating the transfer process.

[0037] The reel transport vehicle 55 can automatically replenish the reels 92 needed at the kitting station 3 from the reel storage warehouse 57. The reel transport vehicle 55 can also automatically store partially used reels 92 generated at the kitting station 3 in the reel storage warehouse 57. Furthermore, the reel transport vehicle 55 can improve transport efficiency by transporting multiple reels 92 loaded in the reel magazine 96. The reel transport vehicle 55 may also be configured to transport one or more reels 92 without using the reel magazine 96. The feeder transport vehicle 51 and the reel transport vehicle 55 are controlled by the setup control unit 7 (see Figure 8).

[0038] Multiple feeder transport vehicles 51 and reel transport vehicles 55 may be provided. Furthermore, the travel paths for the feeder transport vehicles 51 and reel transport vehicles 55 can be modified, such as by creating double tracks or loops. In addition, the feeder transport vehicles 51 and reel transport vehicles 55 may have the same shape, and may carry a magazine-type spare storage unit 95 and a reel magazine 96 together. Furthermore, the feeder storage warehouse 53 and the reel storage warehouse 57 may be a single, unified storage warehouse.

[0039] 5. Waste tape collection device 6 The waste tape collection device 6 collects the initial waste tape from the carrier tape 93. The initial waste tape is generated during the loading process when the kitting execution unit 31 of the kitting station 3 sets the reel 92 onto the tape feeder 91. Furthermore, the waste tape collection device 6 also collects the waste tape generated after the component mounting machine 22 has used the carrier tape 93. To clarify, the component mounting machine 22 is equipped with a tape cutting unit that cuts the used carrier tape 93 into predetermined lengths to create waste tape. As shown in Figure 1, the waste tape collection device 6 consists of a collection box 61, a waste tape conveyor 62, and a collection slope 63.

[0040] The collection box 61 is placed in a predetermined position set on the upper left side of the kitting station 3. The collection box 61 is formed in a box shape that opens upwards. The collection box 61 collects the initial waste tape and waste tape described above by housing them inside. The collection box 61 is removed from its predetermined position by the operator, and the initial waste tape and waste tape inside are discarded.

[0041] As shown in Figure 3, the waste tape conveyor 62 starts from the front upper part of the second spare storage section 224 of the component mounting machine 22. Waste tape is placed at the starting point of the waste tape conveyor 62 by the tape cutting section of the component mounting machine 22. The waste tape conveyor 62 extends from the starting point, passing in front of the solder printing machine 21, to the front upper part of the first spare storage section 37 of the kitting station 3 (see Figure 4). Furthermore, the waste tape conveyor 62 bends at the left front of the kitting station 3 and extends along the left side of the kitting station 3 to the collection box 61 (see Figure 1). The waste tape conveyor 62 operates in conjunction with the operation of the component mounting machine 22, transporting and collecting the waste tape into the collection box 61.

[0042] The collection slope 63 is formed as an inclined slope, with its upper starting point located inside the kitting execution unit 31 and its lower ending point located above the collection box 61. The collection slope 63 consists of an inclined bottom surface and two sides, or is formed as an inclined cylindrical shape. Initial waste tape is placed on the upper starting point of the collection slope 63 by the work robot of the kitting execution unit 31. The initial waste tape slides down along the inclination of the collection slope 63, falls towards the collection box 61, and is collected.

[0043] The configuration of the waste tape collection device 6 described above reduces the effort required for disposal by the operator compared to the case where disposal is performed separately at the kitting station 3 and the parts mounting machine 22. Furthermore, since the reel disposal unit 35 is located near the collection box 61, the operator can dispose of empty reels 92 at the same time as the waste tape, further reducing the effort. Alternatively, the collection slope 63 may be omitted, and the work robot of the kitting execution unit 31 may be used to load the initial waste tape into the collection box 61.

[0044] 6. Control Configuration of Substrate Production System 1 Next, the control configuration of the PCB production system 1 will be described with reference to Figure 8. As shown in Figure 8, the PCB production system 1 includes a setup control unit 7. The setup control unit 7 is connected to a production management device 79. The production management device 79 is connected to a line control unit 78. Furthermore, the line control unit 78 is connected to multiple types of PCB production machines, including a component mounting machine 22.

[0045] The production management device 79 manages the production plan and production progress of the circuit board K. The production plan includes information such as the type of circuit board K to be produced, the number to be produced, and the production order. The line control unit 78 controls the operation of the circuit board production line 2 based on the production plan received from the production management device 79. The line control unit 78 also sequentially transmits the production progress status of the circuit board production line 2 to the production management device 79. The production progress status includes information such as the actual number of circuit boards K produced and the number of components consumed by the component mounting machine 22.

[0046] The setup control unit 7 acquires the production plan for the circuit boards from the production management device 79 and stores it in the production plan storage unit 71. The setup control unit 7 also acquires the production progress status from the line control unit 78 via the production management device 79 as needed. Based on the production plan and production progress status, the setup control unit 7 performs control related to the setup of the tape feeder 91. The setup control unit 7 controls the transport operation of the transport device 4, as well as the travel and transfer operations of the feeder transport car 51 and the reel transport car 55. The setup control unit 7 also issues commands to the kitting control unit 72 and sorting control unit 73 of the kitting station 3 and transmits necessary information.

[0047] The kitting control unit 72 controls the progress of the kitting and removal operations of the reels 92 in the kitting execution unit 31. The kitting control unit 72 can improve the efficiency of the work based on the information received from the setup control unit 7. For example, the kitting control unit 72 receives information on the arrangement positions of multiple tape feeders 91 in the magazine-type spare storage unit 95 and information on the placement order of multiple reels 92 in the reel magazine 96, and can quickly and accurately select the tape feeders 91 and reels 92 to be worked on.

[0048] The sorting control unit 73 controls the sorting operation of the sorting unit 36. Based on the information received from the setup control unit 7, the sorting control unit 73 can perform sorting without errors. For example, based on information that the tape feeder 91 was recovered from the parts supply area 221 due to a parts shortage, the sorting control unit 73 can determine that the reel 92 removed from the tape feeder 91 is empty. This allows the sorting unit 36 ​​to correctly send the empty reel 92 to the reel disposal unit 35. In addition, based on information that the tape feeder 91 was recovered from the parts supply area 221 during a setup change operation due to a change in the type of circuit board, the sorting control unit 73 can determine that the reel 92 removed from the tape feeder 91 is partially used. This allows the sorting unit 36 ​​to correctly send the partially used reel 92 to the magazine delivery unit 34.

[0049] 7. Kitting process (including explanation of initial waste tapes) Next, the kitting operation at kitting station 3 will be explained with reference to Figure 9. In Figure 9, the carrier tape 93 is depicted as being thicker than it actually is. Based on the commands and information received from setup control unit 7, the kitting control unit 72 identifies the tape feeder 91 and reel 92 to be worked on and issues a command to the kitting execution unit 31.

[0050] The kitting execution unit 31 holds the tape feeder 91 without a reel 92 in the feeder holding unit 311 according to the command. The tape feeder 91 without a reel 92 is supplied from the magazine-type spare storage unit 95, or stored in the first spare storage unit 37 or the second spare storage unit 224 and transported to the kitting execution unit 31 by the transport device 4. Next, the kitting execution unit 31 takes a reel 92 from the reel magazine 96 and sets it in the tape feeder 91.

[0051] Next, the kitting unit 31 pulls out the carrier tape 93 from the reel 92 and performs a predetermined loading operation. At this time, the kitting unit 31 cuts a portion of the leading end of the carrier tape 93. The leading end of the carrier tape 93 consists of a base tape 931, a cover tape 932, an adhesive seal 933, and a seal gripper 934, as shown in Figure 9.

[0052] The base tape 931 has a row of cavities formed along its length for housing components. Some of the cavities near the tip are empty cavities that do not house components. The cover tape 932 is attached to the top surface of the base tape 931 so as to cover the cavities. The cover tape 932 extends forward of the tip of the base tape 931. The adhesive seal 933 is attached near the tip of the cover tape 932 and extends forward of the tip of the cover tape 932. The seal gripper 934 is attached to the tip portion of the adhesive seal 933.

[0053] The leading edge of the base tape 931 can be exemplified as the cutting position C1 of the carrier tape 93 (see Figure 9). Cutting generates initial waste tape beyond the cutting position C1. The kitting unit 31 places the initial waste tape at the upper starting point of the collection slope 63. As a result, the initial waste tape slides down the collection slope 63 and is collected in the collection box 61. The tape feeder 91, with the reel 92 set and ready for use, is discharged from the kitting unit 31 by the transport device 4.

[0054] 8. Operation and Mechanism of Substrate Production System 1 Next, the overall operation and function of the substrate production system 1 will be explained with reference to Figure 10. The setup control unit 7 prioritizes the setup of tape feeders 91 that are scheduled for use in production, and postpones the setup of tape feeders 91 that are not scheduled for use. The setup control unit 7 further prioritizes the setup of tape feeders 91 that are scheduled for use and have an earlier scheduled use date. Figure 10 shows five examples of cases in which guidelines for the storage location of the tape feeders 91 are defined according to whether or not they are scheduled for use and when they are scheduled for use.

[0055] The tape feeder 91 scheduled to be used earliest in production, in other words, the highest priority tape feeder 91, is the tape feeder 91 for supplying components in the event of a component shortage in the currently produced substrate type. The setup control unit 7 can determine the need for the component supply tape feeder 91 based on the production plan and production progress. The setup control unit 7 instructs the kitting control unit 72 to perform the kitting work on the component supply tape feeder 91 in advance, before a component shortage actually occurs. The kitting control unit 72, upon receiving the instruction, controls the execution of the kitting work.

[0056] Furthermore, the setup control unit 7 issues a command to the transport device 4 to move the tape feeder 91 for parts replenishment to the upper level of the second spare storage unit 224, which is the closest of the spare storage units to the parts supply area 221. Upon receiving the command, the transport device 4 transports the tape feeder 91 from the kitting station 3 to the upper level of the second spare storage unit 224 and stores it there. When a parts shortage actually occurs, the transport device 4 transports the tape feeder 91 from the upper level of the second spare storage unit 224 to the parts supply area 221 and inserts it into the slot. As a result, the transport distance of the tape feeder 91 is minimized, thus minimizing the work time required for parts replenishment.

[0057] The second highest priority tape feeder 91 is the changeover tape feeder 91 required when the currently produced substrate type is discontinued and production moves to the next substrate type. The setup control unit 7 can determine the need for the changeover tape feeder 91 based on the production plan. The setup control unit 7 instructs the kitting control unit 72 to perform the kitting work for the changeover tape feeder 91 in advance, before the changeover work actually occurs. The kitting control unit 72, upon receiving the instruction, controls the execution of the kitting work.

[0058] Furthermore, the setup control unit 7 issues a command to the transport device 4 to temporarily move the tape feeder 91 for setup change to the lower level of the second spare storage unit 224, which is the second closest of the spare storage units to the parts supply area 221. Upon receiving the command, the transport device 4 temporarily transports the tape feeder 91 from the kitting station 3 to the lower level of the second spare storage unit 224 for storage.

[0059] Subsequently, the setup control unit 7 issues a command to the transport device 4 to move the tape feeder 91 for setup change to the parts supply area 221 at a predetermined timing based on the production plan, in other words, when setup change work becomes necessary. Upon receiving the command, the transport device 4 transports the tape feeder 91 from the lower section of the second spare storage unit 224 to the parts supply area 221 and inserts it into the slot. Here, since the lower section of the second spare storage unit 224 has a structure similar to that of the parts supply area 221, it can accommodate all of the tape feeders 91 used in setup change work. Therefore, the transport distance of the tape feeder 91 during setup change work is shortened, and the work time is reduced.

[0060] The third-highest priority tape feeder 91 is a tape feeder 91 for setup changeover corresponding to the next-next or later type of substrate to be produced. After the kitting work is performed, the third-highest priority tape feeder 91 is transported by the transport device 4 from the kitting execution unit 31 to the first reserve storage unit 37 below it and temporarily stored there.

[0061] After this, when production of the currently manufactured substrate type is completed, the next substrate type changes to the substrate type currently in production, and the substrate type after that changes to the next substrate type. At this time, the transport device 4 first transports the tape feeder 91 from the lower section of the second spare storage section 224 to the parts supply area 221 as part of the setup change operation. Then, the transport device 4 transports and stores the tape feeder 91 that is stored in the first spare storage section 37 and corresponds to the next substrate type into the empty space in the lower section of the second spare storage section 224. This transport operation can be performed using idle time.

[0062] Here, since the kitting station 3 is located on the circuit board production line 2, the transport device 4 only needs to travel a short distance when transporting the tape feeder 91 from the kitting station 3 to the component mounting machine 22. Therefore, compared to a conventional configuration where the kitting station is located away from the circuit board production line, the transport device 4 can transport the tape feeder 91 over a short distance and in a short time.

[0063] Furthermore, tape feeders 91 with reels 92 that are no longer planned for use in the parts mounting machine 22 are recovered from the parts supply area 221 by the transport device 4. The setup control unit 7 determines how to handle the recovered tape feeders 91. For example, if a tape feeder 91 has a partially used reel 92 and, considering production history, is expected to reuse that reel 92, the setup control unit 7 issues a command to the transport device 4 to maintain the reel 92's set state. Upon receiving the command, the transport device 4 transports the tape feeder 91 recovered from the parts mounting machine 22 to the first spare storage unit 37 for storage. At this time, the transport device 4 only needs to move a short distance, so transport can be completed in a short time.

[0064] Furthermore, for tape feeders 91 where it is unclear whether a reel 92 will be reused even if it has been partially used, the setup control unit 7 issues a command to the transport device 4 and the kitting control unit 72 to remove the reel 92. Upon receiving the command, the transport device 4 transports the recovered tape feeder 91 to the kitting execution unit 31. The kitting execution unit 31 removes the partially used reel 92 from the tape feeder 91 in accordance with the control from the kitting control unit 72.

[0065] After this, the tape feeder 91 is reused for kitting work on another reel 92. The tape feeder 91 can be efficiently reused by transporting it over a short distance and in a short time between the kitting station 3 and the component mounting machine 22. In contrast, in the conventional configuration, the tape feeder 91 is transported using a transport vehicle between the spaced-apart substrate production line and the kitting station, which limits the transport operation. In other words, the transport vehicle generally waits until multiple tape feeders 91 are ready in order to efficiently transport multiple tape feeders 91 together, making efficient reuse of the tape feeder 91 difficult. Therefore, according to this embodiment, the number of spare tape feeders 91 can be reduced compared to the conventional technology.

[0066] Furthermore, tape feeders 91 that do not need to be reused after the reel 92 has been removed are sent to the magazine-type spare storage unit 95 of the spare storage unit attachment / detachment unit 32, and are transported by the feeder transport vehicle 51 to the feeder storage warehouse 53 for storage. If there is space in the first spare storage unit 37 or the second spare storage unit 224, the storage of tape feeders 91 from which the reel 92 has been removed is permitted. On the other hand, partially used reels 92 are sent by the sorting unit 36 ​​to the reel magazine 96 of the magazine delivery unit 34, and are transported by the reel transport vehicle 55 to the reel storage warehouse 57 for storage.

[0067] Furthermore, regarding the tape feeder 91 from which the reel 92 has been recovered empty, the setup control unit 7 issues a command to the transport device 4 and the kitting control unit 72 to remove the empty reel 92. Upon receiving the command, the transport device 4 transports the recovered tape feeder 91 to the kitting execution unit 31. The kitting execution unit 31 removes the empty reel 92 from the tape feeder 91 in accordance with the control from the kitting control unit 72.

[0068] After this, the tape feeder 91 is reused after another reel 92 is kitted, or it is stored in the feeder storage warehouse 53 by the feeder transport vehicle 51. The empty reels 92 are sent to the reel disposal unit 35 by the sorting unit 36 ​​and discarded.

[0069] The operation of the transport device 4 described above is summarized below. The transport device 4 first transports the tape feeder 91 with the reel 92 set by the kitting station 3 to the second spare storage unit 224, and then, at a predetermined timing based on the production plan, transports the tape feeder 91 with the reel 92 set from the second spare storage unit 224 to the parts supply area 221.

[0070] Furthermore, based on the production plan, the conveying device 4 prioritizes transporting and storing tape feeders 91 with reels 92 that are not scheduled to be used in production to the first spare storage unit 37, and prioritizes transporting and storing tape feeders 91 with reels 92 that are scheduled to be used in production to the second spare storage unit 224. In addition, based on the production plan, the conveying device 4 prioritizes transporting and storing tape feeders 91 with reels 92 that are scheduled to be used later in the production order to the first spare storage unit 37, and prioritizes transporting and storing tape feeders 91 with reels 92 that are scheduled to be used earlier in the production order to the second spare storage unit 224.

[0071] In the PCB production system 1 of this embodiment, the kitting station 3 is located on the PCB production line 2. Therefore, when the transport device 4 transports the tape feeder 91 (component supply unit) with the reel 92 (component container) set on it from the kitting station 3 to the component mounting machine 22, it only needs to travel a short distance, enabling transport in a short time. Consequently, component replenishment and setup change operations related to the component mounting machine 22 can be made more efficient, resulting in high production efficiency. In addition, the short transport time allows for more efficient reuse of the tape feeder 91, thus easing the constraint on the number of spare tape feeders 91.

[0072] 9. Applications and Variations of Embodiments Furthermore, the method of using the first spare storage section 37 and the second spare storage section 224 is not limited to the above description or the guidelines shown in Figure 10, and can be appropriately changed according to the storage capacity of each spare storage section and the available number of spares for the tape feeder 91. Also, the combination of the component supply unit and the component storage container is not limited to the combination of the tape feeder 91 and reel 92 described in the embodiment, but may be, for example, a combination of a stick feeder and a component storage stick. Moreover, the configuration of the circuit board production line 2 can be modified in various ways. In addition, the embodiment can be applied and modified in various ways. [Explanation of symbols]

[0073] 1: PCB Production System 2: PCB Production Line 22: Component Mounting Machine 221: Component Supply Area 222: Mounting Head 223: Suction Nozzle 224: Second Reserve Storage Unit 3: Kitting Station 31: Kitting Execution Unit 32: Reserve Storage Unit Attachment / Detachment Unit 33: Magazine Receiving Unit 34: Magazine Dispensing Unit 35: Reel Disposal Unit 36: Sorting Unit 37: First Reserve Storage Unit 4: Conveying Device 51: Feeder Transport Vehicle 53: Feeder Storage Warehouse 55: Reel Transport Vehicle 57: Reel Storage Warehouse 6: Waste Tape Collection Device 61: Collection Box 62: Waste Tape Conveyor 63: Collection Ramp 7: Setup Control Unit 71: Production Plan Memory Unit 72: Kitting Control Unit 73: Sorting Control Unit 78: Line Control Unit 79: Production Management Device 91: Tape Feeder 92: Reel 93: Carrier Tape 95: Magazine-type spare storage compartment 96: Reel magazine K: Circuit board

Claims

1. A magazine attachment / detachment section on which a parts storage magazine for storing multiple parts storage containers can be attached and detached, A kitting execution unit that removes the parts container from the parts container magazine attached to the magazine attachment / detachment unit and sets the parts container in the parts supply unit, A kitting device equipped with the following features.

2. The kitting device according to claim 1, wherein the magazine attachment / detachment unit automatically transfers the parts storage magazine between itself and a transport vehicle that is traveling with the parts storage magazine on it.

3. The kitting apparatus according to claim 1 or 2, wherein the magazine attachment / detachment unit includes a magazine receiving unit that receives the parts storage magazine containing the parts storage units that the kitting execution unit sets in the parts supply unit.

4. The kitting apparatus according to any one of claims 1 to 3, wherein the magazine attachment / detachment unit includes a magazine delivery unit that delivers the parts storage magazine containing the partially used parts storage containers removed by the kitting execution unit from the parts supply unit.

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