Feeder setup device

Abstract

To provide a feeder setup device capable of efficiently performing tape feeder setup work.SOLUTION: A feeder setup device includes a feeder holding portion that holds a tape feeder, to which a reel with a carrier tape is attached and which feeds the carrier tape to supply components, in a vertical position at a work position, a reel holding portion that holds the reel in a horizontal position, and a reel attachment mechanism that removes the reel from the reel holding portion, changes the position to a vertical position, and further attaches the reel to the tape feeder at the work position.SELECTED DRAWING: Figure 7

Description

Technical Field

[0001] This specification relates to an apparatus and a system for performing setup work of a tape feeder equipped in a component mounting machine.

Background Art

[0002] Techniques for mass-producing substrate products by performing substrate work on a substrate on which a circuit pattern is formed have become widespread. As a representative example of a substrate working machine that performs substrate work, there is a component mounting machine that performs component mounting work. Many component mounting machines use a tape feeder that supplies components using a carrier tape. Conventionally, the setup work of setting the carrier tape on the tape feeder has been performed by an operator. In recent years, techniques for automating the setup work of the tape feeder have been developed, and technical examples thereof are disclosed in Patent Documents 1 and 2.

[0003] The component tape mounting device disclosed in Patent Document 1 targets a component supply device that conveys a component tape (carrier tape) from a first storage unit to a second storage unit via a component supply position. The robot unit sets a pre-use component tape in the first storage unit of the component supply device in a lying-down posture and collects the used component tape from the second storage unit. According to this, it is said that the component tape can be automatically replenished to the component supply device after use.

[0004] Further, the warehouse system disclosed in Patent Document 2 includes a reel warehouse, a feeder warehouse, a reel loader, and a transport robot. The transport robot transports the reel in the reel warehouse and the tape feeder in the feeder warehouse to the reel loader, and the reel loader loads the reel into the tape feeder. According to this, it is said that preparations for using the tape feeder in the component mounting machine are automatically made, the operator is not involved in the loading work, and labor saving is achieved more than before. [[ID=CO22]]

Prior Art Documents

Patent Documents

[0005] [Patent Document 1] Japanese Patent Publication No. 2019-204858 [Patent Document 2] International Publication No. 2021 / 106026 [Overview of the project] [Problems that the invention aims to solve]

[0006] Incidentally, in the technology described in Patent Document 1, the unused parts tape is pulled from the reel and sent to the parts supply device, where it is wound and held in place by a clip in the first storage section. However, because it is necessary to pull out the long parts tape and then rewind it, the setup process becomes complicated and inefficient. In addition, since one robot unit sequentially sets the unused parts tape and collects the used parts tape, the setup process takes a long time. Furthermore, in the technology described in Patent Document 1, the parts supply device is positioned horizontally, so when attaching it to the parts mounting machine, it is necessary to change the orientation of the parts supply device to vertical.

[0007] In contrast, the reel loader described in Patent Document 2 performs the task of replacing the reel on which the carrier tape is wound, thus streamlining the setup process. However, since Patent Document 2 is an invention relating to the components of a warehouse system and the transport between those components, the detailed configuration of the reel loader is not disclosed.

[0008] Therefore, the problem to be addressed in this specification is to provide a feeder setup device and a feeder setup system that can efficiently perform tape feeder setup work. [Means for solving the problem]

[0009] This specification discloses a feeder setup device comprising: a feeder holding unit that holds a tape feeder, to which a reel around which a carrier tape is wound and which supplies components by feeding the carrier tape, in a vertical position at a work location; a reel holding unit that holds the reel in a horizontal position; and a reel mounting mechanism that removes the reel from the reel holding unit, changes it to a vertical position, and further attaches the reel to the tape feeder at the work location.

[0010] Furthermore, this specification discloses a feeder setup system comprising: a feeder holding unit that holds a tape feeder, to which a reel around which a carrier tape is wound and which supplies parts by feeding the carrier tape, in a vertical position at a work execution location; a feeder housing unit that houses a plurality of the tape feeders in the vertical position and is detachably provided on the device housing; a feeder transport unit that transports the tape feeders between the feeder housing unit and the feeder holding unit; a reel holding unit that stacks and holds a plurality of the reels in a horizontal position and is detachably provided on the device housing; a reel mounting mechanism that removes the reels from the reel holding unit and changes them to a vertical position, and further attaches the reels to the tape feeder at the work execution location; and a transport vehicle that carries at least one of the feeder housing unit and the reel holding unit into the feeder setup device or unloads it from the feeder setup device. [Effects of the Invention]

[0011] In the disclosed feeder setup device and feeder setup system, the reel mounting mechanism performs the setup operation of changing a reel from a horizontal position to a vertical position and attaching it to the tape feeder. Therefore, the reel mounting mechanism can attach a reel held horizontally in the reel holding section to a tape feeder held vertically in the feeder holding section. At this time, since the reel, whose position and orientation are stabilized by being horizontal, can be easily picked up, the feeder setup device can perform the setup operation efficiently. In addition, since the tape feeder is set up in a vertical position, similar to when it is used in a component mounting machine, there is no need to change the orientation when transporting the tape feeder after setup by an operator or automated device and attaching it to a component mounting machine by an operator or automated device. Therefore, the operator or automated device can perform the work efficiently. [Brief explanation of the drawing]

[0012] [Figure 1] This is a schematic perspective view showing the feeder setup device of the embodiment. [Figure 2] This is a schematic plan view of the feeder setup device. [Figure 3] This is a schematic perspective view showing the configuration of the feeder holding section and the tape feeder. [Figure 4] This is a block diagram showing the configuration related to the control and drive of the feeder setup device. [Figure 5] This is a diagram illustrating the operation flow of the feeder setup device. [Figure 6] This is a plan view illustrating the operation of removing a reel from a tape feeder, and the simultaneous operation of preparing another reel. [Figure 7] This is a plan view illustrating the retrieval operation of a removed reel and the simultaneous installation operation of another reel. [Figure 8] This diagram illustrates the setup time in a feeder setup device. [Figure 9] A diagram for explaining the setup time in the prior art. [Figure 10] A perspective view schematically showing a reel holding part of a modified form. [Figure 11] A perspective view schematically showing a feeder setup system of an embodiment. [Figure 12] A perspective view of a feeder transport vehicle for transporting a feeder housing part. [Figure 13] A perspective view of a reel transport vehicle for transporting a reel holding part.

Mode for Carrying Out the Invention

[0013] 1. Configuration of Feeder Setup Device 1 of Embodiment The configuration of the feeder setup device 1 of the embodiment will be described with reference to FIGS. 1 to 3. Each figure is a schematic explanatory diagram, and some members are omitted and drawn for easy viewing. As shown at the upper left of FIGS. 1 and 2, the front, rear, left, and right are defined for convenience. The feeder setup device 1 includes a reel attachment / detachment part 11, a reel supply part 13, and a feeder supply part 15.

[0014] The reel attachment / detachment part 11 is configured by assembling various members inside the device housing 12. The device housing 12 is a large rectangular parallelepiped-shaped case, and a part of the front side and the left side are open. The reel supply part 13 is arranged by being coupled to the front side of the reel attachment / detachment part 11. The reel supply part 13 is configured using a box-shaped pedestal 14 corresponding to a device housing smaller than the device housing 12. The feeder supply part 15 is arranged by being coupled to the left side of the reel attachment / detachment part 11. The feeder supply part 15 is configured using a device housing 16 that is smaller than the device housing 12 and has a storage space 161 at the upper part.

[0015] The reel attachment / detachment unit 11 includes a feeder holding unit 2, a reel attachment mechanism 3, a tape loading mechanism 4, and a reel removal mechanism 5. As shown in FIG. 2, the feeder holding unit 2 is disposed at a position near the left front inside the device housing 12. The feeder holding unit 2 holds the tape feeder 9 in a vertically placed posture at the work execution position. As shown in FIG. 3, the feeder holding unit 2 has a bottom plate 21 and a support plate 23. The bottom plate 21 has a groove-shaped slot 22 extending in the front-rear direction. The tape feeder 9 is inserted from the front side of the slot 22 toward the rear and held at the work execution position. The support plate 23 is provided so as to stand up from the bottom plate 21 and contacts the left side surface of the tape feeder 9 at the work execution position. The support plate 23 supports the lateral pressing load generated when attaching the reel R to the tape feeder 9.

[0016] Here, the outline of the configuration of the tape feeder 9 will be described with reference to FIG. 3. The tape feeder 9 is detachably equipped on the component mounting machine. The tape feeder 9 is attached with a reel R around which a carrier tape T is wound, and feeds the carrier tape T to supply components. Each of the reels R has an identification code for identifying the individual of the reel R displayed thereon. <(

[0017] The tape feeder 9 is formed in a thin type with a small width dimension in the left-right direction. The tape feeder 9 has a reel holding shaft 91 protruding rightward from the left side plate at a position approximately in the center when viewed from the side. The reel holding shaft 91 engages with the center hole formed in the center of the reel R to hold the reel R detachably and rotatably. The carrier tape T is provided with cavities for accommodating components at a constant pitch. Further, the carrier tape T is provided with a number of sprocket holes along one side edge. The right side plate 92 of the tape feeder 9 has a largely open central portion to facilitate the attachment and detachment of the reel R. Note that there are a plurality of types of reels R, with differences in the material of the carrier tape T, and further differences in the tape width dimension of the carrier tape T and the width dimension of the reel R, and there are also a plurality of types of corresponding tape feeders 9.

[0018] The tape feeder 9 further includes a supply position 93, a sprocket 94, and a tape peeling section (not shown). The supply position 93 is located near the rear end of the upper surface of the tape feeder 9. The sprocket 94 is rotatably mounted in front of the supply position 93. The teeth of the sprocket 94 engage with the sprocket holes in the carrier tape T. The sprocket 94 is intermittently driven by a drive motor (not shown) to feed the carrier tape T at a constant pitch. The tape peeling section allows the cover tape constituting the carrier tape T to pass through the supply position 93 with one side edge peeled from the base tape, enabling the removal of parts. After passing through the supply position 93, the carrier tape T is cut by a tape cutting device provided on the parts mounting machine.

[0019] Furthermore, each tape feeder 9 displays an identification code that identifies the individual tape feeder 9. The tape feeder 9 is also equipped with a feeder control unit (not shown). The feeder control unit stores the identification codes of the tape feeder 9 and the reel R, and controls the component supply operation. When the tape feeder 9 is held in the feeder holding unit 2, the connector (not shown) automatically mates, and the feeder control unit communicates with the main control unit 81, which will be described later.

[0020] Returning to the description of the feeder setup device 1, the reel mounting mechanism 3 is located to the right of the feeder holding unit 2. The reel mounting mechanism 3 includes the reel transfer mechanism 1A, which will be described later. The reel mounting mechanism 3 changes the horizontal position of the reel R to a vertical position and then attaches the reel R to the tape feeder 9 at the work position. The reel mounting mechanism 3 consists of a pair of guide rails 31, a mobile platform 32, a mounting material 33, a mounting area 34, and a temporary placement area 35. The reel mounting mechanism 3 may also be configured in a way that separates the mechanism for changing the horizontal position of the reel R to a vertical position from the mechanism for grasping the vertical position of the reel R and attaching it to the tape feeder 9.

[0021] A pair of guide rails 31 extend horizontally from the front edge of the device housing 12 and approximately in the center in the front-rear direction, and are arranged parallel to each other and spaced apart. The mobile platform 32 is formed from a member that is long in the front-rear direction and is mounted straddling the top of the pair of guide rails 31. The mobile platform 32 moves back and forth along the guide rails 31 between the rightward standby position shown in Figures 1 and 2 and the feeder holding unit 2.

[0022] The mounting member 33 is generally formed from a rectangular bar-shaped member and extends upward from the right side of the mobile table 32. The mounting member 33 faces directly towards the reel holding shaft 91 of the tape feeder 9 at the work position. In other words, the mounting member 33 is positioned precisely to the right when viewed from the reel holding shaft 91. The mounting member 33 swings around a pivot shaft 331 located near the mobile table 32, to the upright position shown in Figures 1 and 2, and to a horizontal position tilted to the left (see arrow SW1 in Figure 1). A sampling section 332 is provided at the end of the mounting member 33 away from the pivot shaft 331. The sampling section 332 detachably samples the reel R. As the sampling section 332, a gripping mechanism that grips the claw portion formed on the reel R or the periphery of the reel R, or a suction mechanism that uses negative pressure to attract the reel R, can be used.

[0023] The mounting area 34 is located to the right between the pair of guide rails 31. The mounting area 34 is where the reel R to be installed next is placed in a sideways position. The temporary storage area 35 is located to the left of the mounting area 34 between the pair of guide rails 31. The temporary storage area 35 is where the reel mounting mechanism 3 can temporarily place the reel R in a sideways position to change the order of use of the reels R later. Reels R placed in the temporary storage area 35 may not be used as a result. The temporary storage area 35 can be made wide enough to temporarily store multiple reels R. The moving platform 32 and mounting material 33 move above the mounting area 34 and the temporary storage area 35.

[0024] The tape loading mechanism 4 is positioned close to the feeder holding unit 2, as shown in Figure 2 (it is omitted in Figure 1). The tape loading mechanism 4 loads the carrier tape T into the tape feeder 9 and makes it ready for feeding. The tape loading mechanism 4 is composed of, for example, a multi-joint robot, and specifically consists of a multi-joint arm 41, a camera 42, and a plurality of fingers 43.

[0025] The articulated arm 41 can freely rotate and bend, and the position and orientation of the camera 42 and fingers 43 can be freely adjusted. The camera 42 is located at the tip of the articulated arm 41. The camera 42 images the tape feeder 9 at the work position to detect the position and state of the reel R and carrier tape T. Multiple fingers 43 are located at the tip of the articulated arm 41 alongside the camera 42. In addition to gripping and releasing the work object, the multiple fingers 43 can perform operations such as movement and twisting.

[0026] Prior to the loading operation, the multiple fingers 43 peel off the retaining seal that secures the tip of the carrier tape T. The multiple fingers 43 then load the tip of the carrier tape T until it engages with the sprocket 94, making it ready to feed. The multiple fingers 43 can facilitate the peeling and loading operations by rotating the reel R around the reel holding shaft 91 as needed. The tape loading mechanism 4 assumes a retracted position with its articulated arm 41 bent so as not to obstruct the attachment and detachment of the reel R when not in operation.

[0027] The reel removal mechanism 5 is located to the right of the feeder holding section 2 and above the reel mounting mechanism 3. The reel removal mechanism 5 removes the reel R from the tape feeder 9 at the work position. The reel removal mechanism 5 consists of a guide rail 51, a mobile platform 52, a removal material 53, and a collection box 54, among other components.

[0028] The guide rail 51 is provided near the ceiling of the device housing 12 and extends in the front-rear direction. The mobile platform 52 is formed to be long in the left-right direction and is mounted below the guide rail 51. The mobile platform 52 moves back and forth along the guide rail 51 between the rearward standby position shown in Figures 1 and 2 and the feeder holding unit 2.

[0029] The removal member 53 is formed from a thick plate-shaped member that is longer than the movable base 52 and is provided extending horizontally from the lower side of the movable base 52. The removal member 53 swings around a pivot axis 531 provided near the left end of the movable base 52 to the horizontal position shown in Figures 1 and 2, and to a downward-hanging vertical position (see arrow SW2 in Figure 1). A sampling section 532 is provided at the end of the removal member 53 that is away from the pivot axis 531. The sampling section 532 detachably samples the reel R. The sampling method of the sampling section 532 may be the same as or different from that of the sampling section 332 of the reel mounting mechanism 3.

[0030] The collection box 54 is positioned below the removal material 53 when the mobile platform 52 moves to the standby position. The collection box 54 collects multiple removed reels R together. The collection box 54 is formed in a box shape with an upward opening. Therefore, the collection box 54 can automatically collect the reels R that fall when the collection section 532 of the removal material 53 is released.

[0031] The reel supply unit 13 is equipped with a detachable reel holding unit 6 and a reel transfer mechanism 1A. A pair of guide plates 141 extending in the front-rear direction are provided on the left and right sides of the upper surface of the base 14. The reel holding unit 6 is placed between the pair of guide plates 141 on the base 14. As shown in Figure 2, the front inner sides of the pair of guide plates 141 are tapered, and the distance between them at the front is wider than that at the rear. This makes it easy to insert the reel holding unit 6 from the front towards the base 14.

[0032] The reel holding unit 6 holds multiple (for example, 20) reels R in a horizontal position, stacked on top of each other. The reels R are not limited to new ones; they may be partially used, such as those with the carrier tape T partially used. The reel holding unit 6 comprises a horizontally positioned disc-shaped holding plate 61 and a round bar-shaped holding shaft 62 that extends upward from the center of the holding plate 61 and engages with the central hole of the reel R. Therefore, even if reels R with different diameters and widths are mixed, the reel holding unit 6 holds them with their central holes aligned, making it easy to remove the reels R. An identification code 63 is displayed near the outer circumference of the upper surface of the holding plate 61. The identification code 63 contains information that identifies each individual reel holding unit 6. The identification code 63 is provided by printing or by attaching a sticker.

[0033] Based on the work instruction data, the worker procures multiple reels R and performs the stacking operation, stacking them on the reel holding unit 6. The work instruction data instructs the content of the setup operation performed by the feeder setup device 1. In other words, the work instruction data is data that associates the type information of multiple reels R that are needed sequentially as the production progress of the parts mounting machine with the type information of multiple tape feeders 9 that can be applied to those reels R.

[0034] The reel transfer mechanism 1A is positioned on a plate base 142 that extends to the left from the bottom of the base 14. The reel transfer mechanism 1A functions as part of the reel mounting mechanism 3. The reel transfer mechanism 1A consists of a support column 1B, an arm 1C, and a sampling section 1E, etc. The support column 1B stands vertically upward from a position near the rear of the plate base 142. The arm 1C is provided so as to be able to move up and down relative to the support column 1B. Furthermore, the arm 1C is configured to be able to rotate in a horizontal plane around a rotation axis 1D provided near the support column 1B.

[0035] The sampling unit 1E is provided so as to be extendable and retractable relative to the arm 1C. The sampling unit 1E detachably collects data from the reel R on its lower side. The sampling method of the sampling unit 1E may be the same as or different from that of the sampling unit 332 of the reel mounting mechanism 3 and the sampling unit 532 of the reel removal mechanism 5. A code reader 1F (see Figure 4) is also attached to the sampling unit 1E. The code reader 1F reads the identification code 63 of the reel holding unit 6. Furthermore, the code reader 1F can read the identification code of the uppermost reel R.

[0036] As described above, the reel transfer mechanism 1A functions as part of the reel mounting mechanism 3. More specifically, the reel transfer mechanism 1A removes the reel R from the reel holding section 6 through the operation of the arm 1C and the sampling section 1E. Furthermore, the reel transfer mechanism 1A places the removed reel R in the placement area 34 or temporary placement area 35 in a horizontal position through the operation of the arm 1C and the sampling section 1E. The reel transfer mechanism 1A uses the multiple reels R stacked on the reel holding section 6 in order from the top.

[0037] The feeder supply unit 15 is equipped with a detachable feeder housing unit 7 and further includes a feeder transport unit 75. As shown in Figure 2, the storage space 161 at the top of the device housing 16 is open to the front, and two feeder housing units 7 can be stored side by side. Multiple roller conveyors 162 extending in the left-right direction are provided on the bottom surface that partitions the storage space 161 (see Figure 1), making it easy to store the feeder housing units 7.

[0038] The feeder housing section 7 is formed in the shape of a box with an open front. Multiple slots identical in shape to the slots 22 of the feeder holding section 2 are formed on the bottom surface of the feeder housing section 7. The feeder housing section 7 accommodates multiple (for example, 20) tape feeders 9 in a vertical orientation, arranged side by side. When multiple tape feeders 9 are housed in the feeder housing section 7 and the feeder housing section 7 is housed in the storage space 161, the connectors (not shown) automatically mate, and the multiple feeder control units communicate with the main control unit 81, which will be described later. Each feeder housing section 7 is marked with an identification code that identifies the individual feeder housing section 7. Based on the work instruction data described above, the worker procures the multiple tape feeders 9 to be used and performs the housing operation of housing them in the feeder housing section 7. The number of feeder housing sections 7 housed in the storage space 161 may be one or three or more.

[0039] A guide rail 163 is provided at the lower front of the storage space 161 of the device housing 16. The guide rail 163 extends almost the entire length of the storage space 161 in the left-right direction and further extends to the front of the feeder holding section 2. The feeder transport section 75 is mounted on this guide rail 163. The feeder transport section 75 moves back and forth between the feeder housing section 7 and the feeder holding section 2 along the guide rail 163.

[0040] The feeder transport unit 75 is formed in a box shape with an opening at the rear. The feeder transport unit 75 has an internal space for temporarily housing the tape feeder 9, and a feeder operation mechanism for inserting and removing the tape feeder 9 into the internal space via the opening. Therefore, the feeder transport unit 75 can pull out the tape feeder 9 from the feeder housing unit 7 and the feeder holding unit 2, or conversely, insert the tape feeder 9 into the feeder housing unit 7 and the feeder holding unit 2. It is preferable to provide an openable and closable safety fence (not shown) on the front side of the reel supply unit 13 and the feeder supply unit 15 to prevent workers from approaching them unintentionally.

[0041] 2. Configuration related to the control and drive of the feeder setup device 1 Next, the configuration related to the control and driving of the feeder setup device 1 will be explained with reference to Figure 4. The feeder setup device 1 has a main control unit 81, an installation control unit 82, a loading control unit 83, a removal control unit 84, a transfer control unit 85, and a transport control unit 86. The main control unit 81 is configured using a computer device having communication and human-machine interface functions. Other control units corresponding to lower control units may be provided together with the main control unit 81 or separately. In Figure 4, only one of the multiple tape feeders 9 that are connected to the main control unit 81 is shown as an example.

[0042] The main control unit 81 is connected to the feeder control unit of the tape feeder 9 held in the feeder holding unit 2. The main control unit 81 is also connected to the feeder control units of the multiple tape feeders 9 housed in the feeder housing unit 7. On the other hand, the main control unit 81 is connected to the higher control unit 89. The higher control unit 89 stores feeder correspondence data that associates the identification code of the feeder housing unit 7 with the identification codes of the multiple tape feeders 9 housed there. This feeder correspondence data is created during the aforementioned housing operation. The higher control unit 89 also stores reel correspondence data that associates the identification code of the reel holding unit 6 with the identification codes of the multiple reels R held there. This reel correspondence data is created during the aforementioned stacking operation. The higher control unit 89 stores feeder information that associates the identification code of the tape feeder 9 with the type information of the tape feeder. The higher control unit 89 also stores reel information that associates the identification code of the reel R with the type information of the reel R.

[0043] The main control unit 81 acquires work instruction data from the higher-level control unit 89 before starting the setup work. Furthermore, the main control unit 81 acquires feeder-related data and reel-related data along with the work instruction data. The main control unit 81 may also be equipped with a code reader (such as a two-dimensional code reader) to read the identification code of the feeder housing unit 7, and may query the higher-level control unit 89 with the read identification code to acquire the feeder-related data.

[0044] The main control unit 81 controls the mounting control unit 82, the loading control unit 83, the removal control unit 84, the transfer control unit 85, and the transport control unit 86. Here, the reel mounting mechanism 3 (including the reel transfer mechanism 1A), the tape loading mechanism 4, and the reel removal mechanism 5 are provided separately, have different drive sources, and operate independently of each other. Therefore, the main control unit 81 controls the reel mounting mechanism 3, the tape loading mechanism 4, and the reel removal mechanism 5 to operate separately and in parallel in order to perform the setup work efficiently, and to avoid interference between the mechanisms.

[0045] The mounting control unit 82 controls the starting and stopping of the first motor that drives the movement of the movable platform 32 of the reel mounting mechanism 3, as well as the change in the direction of movement by switching the first motor between forward and reverse rotation. Furthermore, the mounting control unit 82 controls the swinging motion of the mounting material 33 and the sampling motion of the sampling unit 332.

[0046] The loading control unit 83 controls the movement of the articulated arm 41 and fingers 43 based on the detection results of the camera 42 of the tape loading mechanism 4. The removal control unit 84 controls the starting and stopping of the second motor that drives the movement of the movable platform 52 of the reel removal mechanism 5, as well as the change in the direction of movement by switching the second motor between forward and reverse rotation. Furthermore, the removal control unit 84 controls the swinging motion of the removal material 53 and the collection motion of the collection unit 532. The transfer control unit 85 controls the lifting and rotating motion of the arm 1C of the reel transfer mechanism 1A, and further controls the extension and retraction motion and collection motion of the collection unit 1E.

[0047] Furthermore, the transfer control unit 85 transmits the identification code 63 of the reel holding unit 6 read by the code reader 1F to the main control unit 81. The main control unit 81 queries the higher-level control unit 89 for the received identification code 63 to obtain reel-corresponding data and identifies each individual reel R of the reel holding unit 6. Alternatively, the code reader 1F may sequentially acquire the identification code displayed on each reel R, and the acquired identification codes may be transmitted from the transfer control unit 85 to the main control unit 81. The transport control unit 86 controls the starting and stopping of the third motor that drives the movement of the feeder transport unit 75, as well as the change in the direction of movement by switching the third motor between forward and reverse rotation.

[0048] The main control unit 81 acquires work instruction data, feeder information, and reel information from the upper control unit 89, obtains the identification code of the tape feeder 9 held in the feeder holding unit 2, and obtains the identification code of the reel holding unit 6 or the identification code of the reel R from the transfer control unit 85. Furthermore, based on the work instruction data, feeder information, reel information, and identification code, the main control unit 81 can select a tape feeder 9 applicable to the uppermost reel R of the reel holding unit 6. In other words, the main control unit 81 selects a tape feeder 9 of the type corresponding to the reel R based on the recognized identification information of the reel R and the identification information of the tape feeder.

[0049] 3. Operation of Feeder Setup Device 1 Next, the operation of the feeder setup device 1 will be explained with reference to Figures 5 to 7. Since multiple mechanisms operate in parallel in the feeder setup device 1, the operation flow consists of two parallel sequences as shown in Figure 5. This operation flow is carried out primarily by the main control unit 81 through coordinated control with the lower control units.

[0050] Prior to executing the operation flow shown in Figure 5, the operator places the first feeder housing 7, which contains the multiple tape feeders 9 to be set up, into the storage space 161. Furthermore, the operator places the empty second feeder housing 7 into the storage space 161. This operation involves gathering the set-up tape feeders 9 into the second feeder housing 7, ultimately leaving the first feeder housing 7 empty.

[0051] The system is not limited to the above; it may also be operated by using only one feeder housing 7 and returning the tape feeder 9, after the setup work is completed, to its original housing position. Alternatively, the tape feeders 9 can be housed without any gaps in two feeder housings 7 to perform the maximum number of setup operations. In this operation, when the setup work for the first feeder housing 7 is completed and the setup work for the second feeder housing 7 is being performed, the completed first feeder housing 7 can be replaced with the uncompleted third feeder housing 7. By repeating this process, uninterrupted setup operations can be performed.

[0052] The operator then places the reel holding unit 6, which holds multiple reels R used for the setup work, onto the base 14 of the reel supply unit 13. At this time, it is preferable that there is a one-to-one correspondence between the multiple tape feeders 9 housed in the feeder housing unit 7 and the multiple reels R held in the reel holding unit 6, with no excess or deficiency. By performing the aforementioned housing and stacking work based on the work instruction data, the operator ensures that the one-to-one correspondence is satisfied and that there is no excess or deficiency. The one-to-one correspondence is satisfied even when multiple types of tape feeders 9 and multiple types of reels R are used in combination.

[0053] In step S1 of Figure 5, the main control unit 81 controls the feeder transport unit 75 to transport the tape feeder 9 corresponding to the uppermost reel R of the reel holding unit 6. The feeder transport unit 75 pulls out the tape feeder 9 from the feeder housing unit 7, incorporates it, moves to the feeder holding unit 2 (see arrow M1 in Figure 6), and inserts the incorporated tape feeder 9 into the feeder holding unit 2. As a result, the tape feeder 9 is held in the working position, and its identification code is read by the main control unit 81.

[0054] In the exceptional case where there is no tape feeder 9 applicable to the uppermost reel R, the uppermost reel R is placed in the temporary storage area 35 by the reel transfer mechanism 1A, and the tape feeder 9 corresponding to the second reel R is inserted into the feeder holding unit 2. This exception occurs, for example, when an operator removes the tape feeder 9 from the feeder housing unit 7 for some reason. After this, the operation flow is divided into a first series of steps S2 to S5 and a second series of steps S11 to S14.

[0055] In step S2 of the first sequence, the main control unit 81 checks the status of the reel R of the tape feeder 9 based on the identification code of the tape feeder 9 or the identification code of the reel R read from the feeder control unit, and branches the operation flow. If the tape feeder 9 has been used in advance by the component mounting machine, the reel R may be in a partially used state with part of the carrier tape T already in use. In this case, in step S3, the tape loading mechanism 4 performs a process of securing the tip of the carrier tape T with retaining tape to suppress slack in the carrier tape T. At this time, the tape loading mechanism 4 can wind the carrier tape T onto the reel R as needed. After this, the tape loading mechanism 4 assumes a retracted position with the articulated arm 41 bent.

[0056] In the next step, S4, the reel removal mechanism 5 removes the reel R from the tape feeder 9. In detail, first, the mobile platform 52 moves from the standby position to the feeder holding unit 2 (see arrow M2 in Figure 6). Next, when the removal material 53 swings from a horizontal position to a vertical position, the sampling unit 532 contacts the reel R and collects the reel R. Then, when the removal material 53 returns from the vertical position to a horizontal position, the sampling unit 532 pulls the reel R from the reel holding shaft 91 and holds it in a horizontal position. At this time, the main control unit 81 deletes the identification code of the reel R from the memory unit of the feeder control unit of the tape feeder 9. Furthermore, the main control unit 81 transmits the identification code of the tape feeder 9 from which the reel R was actually removed to the higher control unit 89. At this time, the main control unit 81 may transmit the identification code of the removed reel R along with the identification code of the tape feeder 9 to the higher control unit 89.

[0057] In the next step, S5, the reel removal mechanism 5 retrieves the reel R. More specifically, first, the mobile platform 52 moves from the feeder holding unit 2 to the standby position (see arrow M4 in Figure 7). Next, the sampling unit 532 releases the reel R. As a result, the released reel R automatically falls into the retrieval box 54. After this, the operation flow proceeds to step S6, and the system waits until the operation of the second series is completed.

[0058] Furthermore, in step S2, reel R may be used up, meaning the entire carrier tape T has been used. In this case, the operation flow skips step S3 and proceeds to step S4, where reel R is immediately removed. Additionally, in step S2, there may be cases where reel R is not originally attached to the tape feeder 9 (i.e., there is none). In this case, the operation flow immediately proceeds to step S6.

[0059] Meanwhile, in step S11 of the second sequence, the reel transfer mechanism 1A uses the sampling unit 1E to sample the uppermost reel R from the reel holding unit 6 and places it on the placement area 34 (see arrow M3 in Figure 6). In the exceptional case where the uppermost reel R is placed on the temporary placement area 35, the reel transfer mechanism 1A places the second reel R on the placement area 34. After this, the reel transfer mechanism 1A returns the sampling unit 1E to the top of the reel holding unit 6.

[0060] In the next step, S12, the reel mounting mechanism 3 changes the orientation of the reel R in the mounting area 34. More specifically, first, when the mounting material 33 is tilted from an upright position to a horizontal position, the sampling unit 332 comes into contact with the reel R and samples the reel R. At this time, since the reel R is in a sideways position, its mounting position and orientation are stabilized. Therefore, the sampling unit 332 can easily sample the reel R. If the reel R were in a vertical position, there would be a risk of it rolling around or changing orientation.

[0061] Next, when the mounting material 33 returns from a horizontal position to an upright position, the sampling unit 332 changes the reel R from a sideways position to a vertical position and holds it. Note that when using the reel R in the temporary storage area 35, the moving platform 32 moves a predetermined distance to the left before the mounting material 33 falls over. After this, the execution of the operation flow is suspended until the termination condition, which signifies the end of step S4, is met. This is to avoid interference between the reel mounting mechanism 3 and the reel removal mechanism 5.

[0062] In step S13, after the termination conditions are met, the reel mounting mechanism 3 attaches the reel R to the tape feeder 9. More specifically, with the sampling unit 332 holding the reel R in a vertical position, the mobile platform 32 moves to the feeder holding unit 2. As a result, the reel R moves straight forward toward the reel holding shaft 91 (see arrow M5 in Figure 7) and is automatically attached to the reel holding shaft 91. The movement of the mobile platform 32 can be done simultaneously and in parallel with the movement of the mobile platform 52 to its standby position.

[0063] Once the reel R is installed, the main control unit 81 stores the identification code of the reel R in the feeder control unit of the tape feeder 9. Furthermore, the main control unit 81 associates the identification code of the tape feeder 9 that has been actually combined with the identification code of the reel R and transmits it to the higher control unit 89. After this, the mobile stand 32 returns to the standby position. In the next step S14, the tape loading mechanism 4 peels off the retaining tape from the tip of the carrier tape T and loads it until it engages with the sprocket 94.

[0064] In step S6, which is performed after step S14, the feeder transport unit 75 pulls out the tape feeder 9 from the feeder holding unit 2, incorporates it, moves to the feeder housing unit 7, and inserts the incorporated tape feeder 9 into the feeder housing unit 7. This completes the setup work for one tape feeder 9. In the next step S7, the main control unit 81 determines whether the setup work for all tape feeders 9 has been completed. If not, the operation flow returns to step S1, and the setup work for the next tape feeder 9 is repeated. If the setup work for all tape feeders 9 has been completed, the operation flow ends.

[0065] After this, the worker transports the feeder housing 7 containing the set-up tape feeder 9 to the component mounting machine and changes the setup of the tape feeder 9. If a reel R is temporarily placed in the temporary storage area 35, the worker places a tape feeder 9 applicable to that reel R into the feeder housing 7, and the reel is used. Furthermore, any reels R that remain in the temporary storage area 35 without being used are returned to the reel holding unit 6 by the reel transfer mechanism 1A and collected by the worker. In this embodiment, since the worker prepares the feeder housing 7 and the reel holding unit 6 in advance, the setup work for multiple tape feeders 9 is performed automatically, resulting in a significant labor saving effect.

[0066] Furthermore, the setup time in this embodiment is shown in Figure 8. In Figure 8, TA is the time required for securing the carrier tape T, TB is the time required for removing the reel R, TC is the time required for retrieving the reel R, TD is the time required for preparing another reel R (transferring and changing its orientation), TE is the time required for attaching the other reel R, and TF is the time required for loading the carrier tape T. Also, "loading" means inserting the tape feeder 9 into the feeder holding section 2, and "unloading" means pulling the tape feeder 9 out of the feeder holding section 2.

[0067] In this embodiment, there is a constraint that the termination condition of step S4, namely the removal of reel R (required time TB), must be met before the installation of another reel R (required time TE) can begin. Nevertheless, as shown in the figure, the securing process of the carrier tape T (required time TA) and the removal of reel R (required time TB) can be carried out in parallel with the preparation of another reel R (required time TD). Furthermore, the retrieval of reel R (required time TC) and the installation of another reel R (required time TE) and the loading of the carrier tape T (required time TF) can be carried out in parallel.

[0068] On the other hand, in the configuration exemplified in Patent Document 1, which includes a single robot unit, as shown in Figure 9, each process of the setup work is performed sequentially and cannot be processed in parallel. Therefore, according to this embodiment, the setup time from loading to unloading of the tape feeder 9 can be significantly reduced compared to the conventional technology.

[0069] In the feeder setup device 1 of this embodiment, the reel mounting mechanism 3 performs a setup operation in which the reel R, which is in a horizontal position, is changed to a vertical position and attached to the tape feeder 9. Therefore, the reel mounting mechanism 3 can attach the reel R, which is held in a horizontal position by the reel holding part 6, to the tape feeder 9, which is held in a vertical position by the feeder holding part 2. At this time, since the reel R, whose position and orientation are stabilized by being in a horizontal position, can be easily picked up, the feeder setup device 1 can perform the setup operation efficiently. In addition, since the tape feeder 9 is set up in a vertical position, just as when it is used in a component mounting machine, there is no need to change the orientation when transporting the tape feeder 9 after setup by an operator or automated device and attaching it to a component mounting machine by an operator or automated device. Therefore, the operator or automated device can perform the work efficiently.

[0070] If the reel R is stored vertically in a storage box that opens upwards to prevent it from rolling, it becomes difficult to remove the reel R. In particular, if reels R of different diameters and widths are mixed together, it becomes even more difficult to remove the reel R. Furthermore, in Patent Document 1, the tape feeder 9 is in a horizontal position, raising concerns about parts falling off after loading a partially used carrier tape T. In contrast, in this embodiment, the setup work of the tape feeder 9 is performed in the same vertical position as when in use, so the area near the peeled tip of the carrier tape T is in a generally horizontal position at the supply position 93, and parts falling off is suppressed.

[0071] 4. Transformation Form Next, a modified form of the reel holding part 6A with a different shape will be explained with reference to Figure 10. The modified form of the reel holding part 6A consists of a base plate 64, a holding plate 65, and a holding shaft 66. The base plate 64 is the part that rests on the base 14 and is formed in a wide rectangle for stability. The holding plate 65 is provided upright from one side of the base plate 64. The holding shaft 66 is provided vertically from the holding plate 65 and extends horizontally above the base plate 64. The holding shaft 66 engages with the central holes of multiple reels R, in other words, it holds multiple reels R in a vertical position. An identification code 67 is displayed near the outer edge of the holding plate 65.

[0072] In the modified configuration, the sampling unit 1E of the reel transfer mechanism 1A is transformed into an upright position and samples the reel R from the reel holding unit 6A while it remains in a vertical position. Furthermore, the sampling unit 1E transfers the reel R, while it remains in a vertical position, to the sampling unit 332 of the reel mounting mechanism 3 in mid-air. The configuration and operation of the other parts in the modified configuration are generally the same as in the embodiment. In the modified configuration, as in the embodiment, setup work can be performed efficiently.

[0073] 5. Feeder setup system 1S of the embodiment Next, the feeder setup system 1S of the embodiment will be described with reference to Figures 11 to 13. The feeder setup system 1S is configured by adding a feeder transport vehicle 9A and a reel transport vehicle 9C to the feeder setup device 1. As shown in Figure 12, the feeder transport vehicle 9A travels carrying the feeder housing unit 7. The feeder transport vehicle 9A has a roller device 9B on its upper surface for transferring the feeder housing unit 7. The feeder transport vehicle 9A travels and performs the transfer operation according to wireless commands 9G from the transport control unit 9F. The feeder transport vehicle 9A and the reel transport vehicle 9C are unmanned transport vehicles, also known as AGVs.

[0074] As shown in Figure 13, the reel transport vehicle 9C travels carrying multiple reel holders 6. In the example in Figure 13, one reel holder 6 is fully loaded with reels R, while another reel holder 6 is empty. The reel transport vehicle 9C has an annular conveyor device 9D on its upper surface for adjusting the position of the reel holders 6 and automating the reel transfer. The reel transport vehicle 9C travels and performs the transfer operation according to wireless commands 9G from the transport control unit 9F. Note that the reel transport vehicle 9C may also be a smaller version that travels carrying only one reel holder 6.

[0075] As shown in Figure 11, the target travel points for the feeder transport vehicle 9A and the reel transport vehicle 9C are four locations: the feeder setup device 1, the inlet / outlet 9K of the warehouse 9J, the external setup area 9L, and the component mounting machine 9N that constitutes the substrate work line 9M. The warehouse 9J is where equipment such as tape feeders 9 and components such as reels R are received, stored, and shipped out. The external setup area 9L is where workers perform various setup tasks related to the substrate work line 9M. Note that no safety fences are provided in front of the reel supply unit 13 and the feeder supply unit 15 of the feeder setup device 1. The feeder transport vehicle 9A and the reel transport vehicle 9C travel along the travel path 9P between the four target travel points. The travel path 9P is not limited to physical rails or the like, but may be virtually set on the floor.

[0076] Next, we will describe examples of transport using the feeder transport vehicle 9A and the reel transport vehicle 9C. The feeder transport vehicle 9A retrieves multiple tape feeders 9 in their individual state from the warehouse 9J and transports them to the external setup area 9L. The reel transport vehicle 9C retrieves multiple reels R in their individual state from the warehouse 9J and transports them to the external setup area 9L. In the external setup area 9L, the worker performs the task of hoisting the multiple tape feeders 9 into the feeder housing section 7. Furthermore, the worker performs the task of stacking the multiple reels R onto the reel holding section 6.

[0077] Next, the feeder transport vehicle 9A transports the feeder housing unit 7, which has been set up in the external setup area 9L, to the feeder setup device 1 and stores it in the storage space 161 of the feeder supply unit 15. The reel transport vehicle 9C also transports the reel holding unit 6, which has been set up in the external setup area 9L, to the feeder setup device 1 and places it on the base 14 of the reel supply unit 13. At this time, the main control unit 81 and the transport control unit 9F of the feeder setup device 1 work together to control the loading of the feeder housing unit 7 and the reel holding unit 6.

[0078] Therefore, the feeder housing 7 being delivered will not collide with the feeder transport unit 75, nor will another feeder housing 7 already exist at the planned delivery location. Also, when the reel transport vehicle 9C arrives at the feeder setup device 1, there may be empty reel holding units 6 remaining on the base 14. In this case, the reel transport vehicle 9C first removes the empty reel holding unit 6 from the base 14, and then places the transported reel holding unit 6 onto the base 14.

[0079] With this, the feeder setup device 1 is ready to operate and performs the setup work on the multiple tape feeders 9. The reel holding unit 6 becomes empty as a result of the setup work, with no reels R inside. The reel transport vehicle 9C unloads the empty reel holding unit 6 and transports it to the external setup area 9L.

[0080] Meanwhile, the feeder transport vehicle 9A unloads the feeder housing unit 7 containing the set-up tape feeder 9 and transports it to the vicinity of the component mounting machine 9N. The worker removes the tape feeder 9 that will not be used in the next production run from the component mounting machine 9N and performs a setup change operation by attaching the tape feeder 9 that will be used in the next production run from the feeder housing unit 7 to the component mounting machine 9N. The removed tape feeder 9 is stored in the feeder housing unit 7. The feeder transport vehicle 9A transports this feeder housing unit 7 to the feeder setup device 1 to enable the replacement of the tape feeder 9 reel R. Alternatively, the feeder transport vehicle 9A transports this feeder housing unit 7 to the external setup area 9L.

[0081] Other transport operations are also possible. For example, the feeder transport vehicle 9A may store tape feeders 9 that are not scheduled to be used in warehouse 9J, and the reel transport vehicle 9C may store partially used reels R in warehouse 9J. Furthermore, the feeder transport vehicle 9A and the reel transport vehicle 9C may be used interchangeably by a single transport vehicle. In addition, the feeder transport vehicle 9A and the reel transport vehicle 9C may also be used interchangeably to transport various tools and materials used in the substrate work line 9M. Conversely, some of the transport operations described above may be performed by an operator, or one of the feeder transport vehicle 9A or the reel transport vehicle 9C may be omitted.

[0082] In the feeder setup system 1S of this embodiment, the loading and unloading of the feeder housing section 7 and the reel holding section 6 into and out of the feeder setup device 1 is performed automatically. Therefore, by adding a feeder transport vehicle 9A and a reel transport vehicle 9C to the feeder setup device 1, the labor-saving effect can be further enhanced.

[0083] 6. Applications and Variations of Embodiments The minimum configuration of the feeder setup device is the same as the configuration of the embodiment, but with the reel supply unit 13, feeder supply unit 15, and tape loading mechanism 4 omitted. In the minimum configuration, the operator inserts the tape feeder 9 into the feeder holding unit 2 and places the reel R on the mounting area 34 in a horizontal position. This automatically attaches the reel R to the tape feeder 9. The operator then removes the tape feeder 9 with the reel R attached, loads the carrier tape T, and completes the setup work.

[0084] Furthermore, the tape loading mechanism 4 can perform more complex loading operations than those described above. For example, a new reel R has a guide tape attached to the tip of the carrier tape T. When a new reel R is attached to the tape feeder 9, the tape loading mechanism 4 can cut the guide tape at a predetermined position and load the tape until the cut end engages with the sprocket 94. In addition, a reel holding unit 6 may be placed instead of the collection box 54, and the removed reel R may be collected in the reel holding unit 6, and the reel holding unit 6 may be unloaded by the reel transport vehicle 9C. Moreover, the embodiment can be applied and modified in various ways. [Explanation of Symbols]

[0085] 1: Feeder setup device 11: Reel attachment / detachment unit 13: Reel supply unit 15: Feeder supply unit 1A: Reel transfer mechanism 1B: Support column 1C: Arm 1E: Sampling unit 1S: Feeder setup system 2: Feeder holding unit 3: Reel mounting mechanism 31: Guide rail 32: Mobile platform 33: Mounting material 332: Sampling unit 34: Placement area 35: Temporary placement area 4: Tape loading mechanism 41: Multi-joint arm 42: Camera 43: Finger 5: Reel removal mechanism 51: Guide rail 52: Mobile platform 53: Removal material 532: Sampling unit 54: Collection box 6, 6A: Reel holding unit 61: Holding plate 62: Holding shaft 64: Bottom plate 65: Holding plate 66: Holding shaft 7: Feeder housing unit 75: Feeder transport unit 81: Main control unit 89: Upper control unit 9: Tape feeder 91: Reel holding shaft 94: Sprocket 9A: Feeder transport vehicle 9C: Reel transport vehicle 9F: Transport control unit R: Reel T: Carrier tape

Claims

1. A reel holding section that stacks and holds multiple reels with carrier tape wound around them in a horizontal position, A feeder housing section that accommodates multiple tape feeders, A feeder transport unit that transports the tape feeder corresponding to the uppermost reel of the reel holding unit from the feeder housing unit to the work position, A reel mounting mechanism that uses the multiple reels stacked in the reel holding section in order from the top to attach the reels to the tape feeder that has been transported to the work position, A feeder setup device equipped with the following features.

2. A reel holding section that stacks and holds multiple reels with carrier tape wound around them in a horizontal position, A feeder housing section that accommodates multiple tape feeders, A control unit that selects the tape feeder applicable to the uppermost reel of the reel holding unit based on reel information corresponding to the uppermost reel of the reel holding unit and feeder information corresponding to each tape feeder, A feeder transport unit that transports the selected tape feeder from the feeder storage unit to the work position, A reel mounting mechanism for attaching the uppermost reel of the reel holding unit to the tape feeder that has been transported to the aforementioned work position, A feeder setup device equipped with the following features.

3. The feeder setup device according to claim 1 or 2, wherein the reel mounting mechanism places the uppermost reel of the reel holding unit in a temporary storage area if there is no tape feeder applicable to the uppermost reel of the reel holding unit.

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