Reel management device and reel management method

Abstract

This reel management device is applied to an automated warehouse provided with a storage unit and a transfer device. The storage unit can store a reel around which a carrier tape for storing a component to be mounted on a substrate is wound. In the transfer device, the reel is carried into and stored in the storage unit at the time of warehousing, and carries the reel out from the storage unit at the time of delivery. The reel management device includes a measurement unit that measures, in the storage unit, the amount of warpage of the reel carried into the storage unit by the transfer device or the reel carried out from the storage unit by the transfer device.

Description

Reel management device and reel management method

[0001] This specification discloses a technique relating to a reel management device and a reel management method.

[0002] The storage facility described in Patent Document 1 is equipped with a second measuring device. The second measuring device measures the outer dimensions of an item stored in the receiving section from above the item. The storage facility also has multiple types of storage sections depending on the outer dimensions of the items. The moving section selects a storage section that matches the outer dimensions of the item acquired by the acquiring section, and can move the item stored in the receiving section to the selected storage section.

[0003] International Publication No. 2021 / 075049

[0004] For example, warping may occur in a reel depending on the dimensions, weight, material, etc. Furthermore, the amount of warping of a reel may differ when the reel is stored in a storage unit and when the reel is placed on a placement unit that can temporarily place incoming or outgoing reels, and there is a demand for knowing the amount of warping of reels stored in a storage unit.

[0005] In view of the above circumstances, this specification discloses a reel management device and a reel management method that are capable of measuring the amount of warpage of a reel in a storage section.

[0006] This specification discloses a reel management device applicable to an automated warehouse that includes a storage unit and a transfer device. The storage unit is capable of storing reels around which carrier tape containing components to be mounted on circuit boards is wound. The transfer device transports the reels into the storage unit and stores them therein when the reels are stored, and transports the reels from the storage unit when the reels are removed from the storage unit. The reel management device includes a measuring unit that measures, in the storage unit, the amount of warpage of the reels that are transported into the storage unit by the transfer device or the reels that are transported out of the storage unit by the transfer device.

[0007] This specification also discloses a reel management method applicable to an automated warehouse equipped with a storage unit and a transfer device. The storage unit is capable of storing reels around which carrier tape containing components to be mounted on circuit boards is wound. The transfer device transports the reels into the storage unit and stores them therein when the reels are received, and transports the reels from the storage unit when the reels are removed. The reel management method includes a measuring step in the storage unit to measure the amount of warpage of the reels transported into the storage unit by the transfer device or the reels transported out of the storage unit by the transfer device.

[0008] This specification discloses the technical idea of ​​changing "the reel management device according to claim 3" to "the reel management device according to claim 3 or claim 4" in claim 5 of the claims originally attached to the application (hereinafter referred to as the "initial claims"). Also, this specification discloses the technical idea of ​​changing "the reel management device according to claim 1" to "the reel management device according to any one of claims 1 to 6" in claim 7 of the original claims.

[0009] According to the reel management device, the amount of warpage of the reel can be measured in the storage section. The above description of the reel management device also applies to the reel management method.

[0010] 5A is a configuration diagram showing an example of the configuration of board production equipment. FIG. 5B is a plan view showing an example of a reel. FIG. 5C is a side view of the reel of FIG. 2A. FIG. 5D is a front view showing an example of an automated warehouse. FIG. 5E is a plan view of the automated warehouse of FIG. 3A. FIG. 5F is a perspective view of the automated warehouse of FIG. 3A. FIG. 5G is a side view of the automated warehouse of FIG. 3C as viewed in the direction of arrow IV. FIG. 5H is a perspective view showing an example of a storage section in which reels are stored. FIG. 5F is a front view of the storage section of FIG. 5A. FIG. 5G is a front view showing an example of the positional relationship between a normal reel and a gripping mechanism when a normal reel is stored in the storage section. FIG. 5H is a front view showing an example of the positional relationship between a reel with a warpage amount exceeding the allowable range and the gripping mechanism when a reel with a warpage amount exceeding the allowable range is stored in the storage section. FIG. 5I is a block diagram showing an example of a control block of a reel management device. FIG. 5I is a flowchart showing an example of a control flow by the reel management device. FIG. 5I is a view showing an example of a measurement state when measuring the warpage amount of a normal reel. FIG. 5I is a view showing an example of a measurement state when measuring the warpage amount of a reel that exceeds the allowable range. FIG. 5I is a perspective view showing an example of a storage case.

[0011] 1, a substrate production facility 80 according to an embodiment includes a substrate-related work line 10L, a receiving section 20, a transport vehicle 30, and an automated warehouse 40. A reel management device 50 is applied to the automated warehouse 40.

[0012] 1-1. Substrate-related Work Line 10L In the substrate-related work line 10L, predetermined substrate-related work is performed on the substrate 90. The type and number of substrate-related work machines 10 constituting the substrate-related work line 10L are not limited. As shown in Fig. 1, the substrate-related work line 10L of the embodiment is equipped with a plurality of (five) substrate-related work machines 10: a printer 10a, a print inspection machine 10b, a component mounting machine 10c, a reflow oven 10d, and a visual inspection machine 10e, and the substrate 90 is transported in this order by a substrate transport device.

[0013] The printer 10a prints solder at component mounting positions on the board 90. The print inspection machine 10b inspects the printing condition of the solder printed by the printer 10a. The component mounting machine 10c mounts multiple components on the board 90 on which the solder has been printed. There may be one or more component mounting machines 10c. When multiple component mounting machines 10c are provided, the multiple component mounting machines 10c can share the task of mounting multiple components on the board 90.

[0014] The component mounting machine 10c is equipped with a component supply device that supplies components to be mounted on the board 90. The component supply device can supply components using, for example, a feeder equipped with a reel 21a shown in Figures 2A and 2B, a tray on which components are arranged, or the like. As shown in Figure 2B, the reel 21a has a reel main body 21a1 around which a carrier tape 21a2 that contains the components to be mounted on the board 90 is wound. The reel 21a is rotatably and detachably provided on the feeder.

[0015] The leading end of the carrier tape 21a2 is pulled out to a component removal section provided in the feeder, and the components are sequentially supplied. The reel 21a can supply relatively small components such as chip components. The components are arranged on a tray. The tray can supply relatively large components such as QFP (Quad Flat Package) and BGA (Ball Grid Array). The reflow furnace 10d heats the board 90 on which components have been mounted by the component mounting machine 10c, melting the solder and performing soldering. The visual inspection machine 10e inspects the mounting state of the components mounted by the component mounting machine 10c.

[0016] In this way, the substrate-related operation line 10L can produce substrate products by sequentially transporting substrates 90 and performing production processes including inspection processes using multiple (five) substrate-related operation machines 10. Note that the substrate-related operation line 10L can also be equipped with other substrate-related operation machines 10 as needed, such as a function inspection machine, a buffer device, a substrate supply device, a substrate reversing device, a shield mounting device, an adhesive application device, and an ultraviolet irradiation device.

[0017] The plurality (five) of substrate-related performing machines 10 constituting the substrate-related performing line 10L and the management device 19 are capable of communicating with each other via wired or wireless communication units. The management device 19 controls the plurality (five) of substrate-related performing machines 10 constituting the substrate-related performing line 10L and monitors the operating status of the substrate-related performing line 10L. The management device 19 stores various control data for controlling the plurality (five) of substrate-related performing machines 10. The management device 19 transmits the control data to each of the plurality (five) of substrate-related performing machines 10. Furthermore, each of the plurality (five) of substrate-related performing machines 10 transmits its operating status and production status to the management device 19.

[0018] 1-2. Receiving Section 20 and Transport Vehicle 30 When the item 21 used in the substrate-related processing machine 10 arrives at the receiving section 20, a predetermined receiving operation is performed. Then, the item 21 is loaded onto, for example, the transport vehicle 30 and transported to the automated warehouse 40. After being stored in the automated warehouse 40, the item 21 is supplied to the substrate-related processing line 10L as needed.

[0019] The item 21 may be any item that can be used in the substrate-related operating machine 10, and includes, but is not limited to, the reel 21a. For example, the item 21 may include, in addition to the reel 21a, a tray on which components are arranged, a container for storing solder, etc. The item 21 also has an item identification member 22 attached thereto that can identify the item 21. The item identification member 22 may have item identification information that can identify the item 21, and may be, for example, a one-dimensional code, a two-dimensional code, a wireless tag, or the like.

[0020] Specifically, when the item 21 arrives at the receiving section 20, the worker issues an item identification member 22 using, for example, an item management device. The worker can also use a reading device (for example, a barcode reader) to read the identification member 23 attached to the item 21 by the supplier (vendor). The worker can also obtain item information from a database in which item information about the item 21 is registered.

[0021] For example, a worker attaches the item identification member 22 to the surface of the item 21 and places the item 21 in a storage case. The worker loads the storage case containing the item 21 onto a transport vehicle 30. For example, the transport vehicle 30 can be towed by a worker. An automated transport vehicle capable of automatic travel can also be used as the transport vehicle 30. Note that the transport vehicle 30 can also transport the item 21 to the automated warehouse 40 without using a storage case.

[0022] Also, a worker can transport the item 21 to the automated warehouse 40 without using the transport vehicle 30. Furthermore, at least a part of the work performed by the worker described above can be automated using a transport device (e.g., a belt conveyor), an actuator (e.g., a robot arm), an item management device, etc.

[0023] 1-3. Automated Warehouse 40 The automated warehouse 40 may take various forms as long as it automates the loading and unloading of the articles 21, including the reels 21a. As shown in Figures 3A to 3C, the automated warehouse 40 of this embodiment is formed, for example, in the shape of an octagonal prism. Note that for ease of explanation, in Figure 3C, the top of the automated warehouse 40 is open, and the interior of the automated warehouse 40 is shown. Also, Figure 4 is a schematic diagram of the interior of the automated warehouse 40 as viewed from the direction of arrow IV shown in Figure 3C, and mainly illustrates the loading and unloading section 41 and the storage section 42.

[0024] The automated warehouse 40 of this embodiment includes an entry / exit section 41, a storage section 42, a control device 40a, a transfer device 40b, a reading device 40d, and a display device 40e. The entry / exit section 41 includes an opening 41a and a placement section 40c, through which items 21 are entered and removed. As shown in FIG. 3A , the opening 41a is provided on the front of the automated warehouse 40. The opening 41a is formed larger than the items 21 so that the items 21 can be entered and removed. Note that the automated warehouse 40 may also have an exit port provided at an opening different from the opening 41a through which the items 21 are entered.

[0025] As shown in FIGS. 3B and 4 , the placement section 40c is provided in the work space near the opening 41a. The item 21 is temporarily placed on the placement section 40c when the item 21 is being stored or removed from the warehouse. For example, the storing operation of the item 21, in which the item 21 is carried in and placed on the placement section 40c, can be performed by a worker. In addition, the item 21 to be removed from the warehouse is placed on the placement section 40c through the opening 41a. The removing operation of the item 21, in which the item 21 placed on the placement section 40c is removed, can be performed by a worker, similar to the storing operation. The storing and removing operations of the item 21 can also be automated using an actuator (e.g., a robot arm, etc.).

[0026] As shown in Fig. 4, a reading device 40d is provided above the mounting section 40c. The reading device 40d reads the item identification member 22 attached to the item 21 to obtain item identification information of the item 21. The reading device 40d can be a known reading device (for example, a code reader that reads one-dimensional codes or two-dimensional codes, a radio that can wirelessly communicate with a wireless tag, etc.). When the item 21 is stored through the opening 41a, the reading device 40d reads the item identification member 22 attached to the item 21 to obtain the item identification information.

[0027] The storage section 42 stores the item 21. The storage section 42 may take various forms as long as it is capable of storing the item 21. For example, when the item 21 is a reel 21a, the storage section 42 may include a storage main body 42a and a support member 42b, as shown in FIGS. 3C and 4 . The storage main body 42a is formed in a U-shape when viewed in the vertical direction (Z-axis direction). The support member 42b is provided so as to protrude upward at a predetermined angle relative to the storage main body 42a, and can store the reel 21a. The angle of the support member 42b is set so as to prevent the reel 21a from falling off.

[0028] Each storage unit is provided with multiple pairs of support members 42b (15 pairs, or 30 in total, in FIG. 4), allowing multiple (15) reels 21a to be stored. Each of the multiple pairs (15 pairs) of support members 42b is provided with two support members 42b spaced apart from each other so as not to interfere with the transfer device 40b. Note that, for the sake of convenience, reference numerals are assigned to some but not all of the components in FIGS. 3C and 4.

[0029] 3B and 3C , the storage section 42 of the embodiment is arranged in an elliptical shape when viewed in the vertical direction (Z-axis direction). The storage section 42 of the embodiment includes two types of storage units: a first storage unit 42t1 and a second storage unit 42t2. Multiple first storage units 42t1 and multiple second storage units 42t2 are provided along the vertical direction (Z-axis direction). The first storage unit 42t1 is wider than the second storage unit 42t2 and can store larger reels 21a than the reels 21a that the second storage unit 42t2 can store.

[0030] As shown in Figures 3C and 4, the first storage units 42t1 are connected in the vertical direction (Z-axis direction) by connecting portions 42j. The second storage units 42t2 are also connected in the vertical direction (Z-axis direction) by connecting portions 42j. Adjacent first storage units 42t1 are connected to each other by connecting portions 42j, and adjacent second storage units 42t2 are also connected to each other by connecting portions 42j. Adjacent first storage units 42t1 and second storage units 42t2 are also connected to each other by connecting portions 42j.

[0031] The type, number, and arrangement of the storage units can be changed as appropriate. The shape and size (width, depth, and height) of the storage units can be set to suit the items 21 to be stored, and the storage sections 42 can also store items 21 other than reels 21a, such as trays. Furthermore, the storage sections 42 can also store storage cases 70, which will be described later. The items 21 may be stored in any suitable storage unit, and if the board production facility 80 includes multiple automated warehouses 40, the items 21 may be stored in any of the automated warehouses 40 that have suitable storage units.

[0032] The control device 40a includes a known arithmetic device and storage device, and a control circuit is configured. The control device 40a is configured to be able to communicate with and control the transfer device 40b, the reading device 40d, and the display device 40e. The control device 40a also includes a storage device that stores item information about the item 21, and can notify the management device 19 of the item information. For example, if the item 21 is a reel 21a, the item information may include the type of component contained in the reel 21a, the number of components (remaining number), reel diameter, reel thickness, model and supplier (vendor), humidity control level, expiration date, etc.

[0033] The transfer device 40b carries the item 21 into the storage section 42 and stores it when the item 21 is brought into the warehouse, and carries the item 21 out of the storage section 42 when the item 21 is undeliverable. Specifically, the transfer device 40b moves the item 21 placed on the placement section 40c during the warehousing operation of the item 21 to the storage section 42 and stores it there. Furthermore, when the item 21 is undeliverable, the transfer device 40b moves the item 21 stored in the storage section 42 to the placement section 40c, thereby enabling the undeliverable operation of the item 21.

[0034] As shown in Figures 3B and 3C, the transfer device 40b of this embodiment is located inside the storage units (first storage unit 42t1 and second storage unit 42t2) when viewed in the vertical direction (Z-axis direction). The transfer device 40b may take various forms as long as it can move the item 21. For example, the transfer device 40b may be a robot arm (articulated robot), a lifting and sliding mechanism, or the like. As shown in Figure 3C, the transfer device 40b of this embodiment includes a lifting mechanism 40b1 and a gripping mechanism 40b2.

[0035] The lifting mechanism 40b1 can rotate about an axis along the vertical direction (Z-axis direction) and can lift and lower the gripping mechanism 40b2 along the vertical direction (Z-axis direction). The gripping mechanism 40b2 can grip the article 21 and can move forward or backward at the same angle as the inclination angle θ1 of the placement unit 40c shown in Figure 4. The gripping mechanism 40b2 can also move forward or backward at the same angle as the inclination angle θ1 of the support member 42b of the storage unit 42.

[0036] As described above, in the automated warehouse 40 of the embodiment, the inclination angle θ1 of the placement section 40c matches the inclination angle θ1 of the support member 42b of the storage section 42. Therefore, in the automated warehouse 40 of the embodiment, an entry-time removal operation of removing items 21 from the placement section 40c and an entry-time storage operation of storing the removed items 21 in the storage section 42 can be performed by the lifting and lowering motions, turning motions, forward motions, and backward motions of the transfer device 40b. Also, in the automated warehouse 40 of the embodiment, an exit-time removal operation of removing items 21 from a storage unit and an exit-time sending operation of sending the removed items 21 to the placement section 40c can be performed by the lifting and lowering motions, turning motions, forward motions, and backward motions of the transfer device 40b.

[0037] The display device 40e may be a known display device, and displays various information so that the worker can visually recognize it. The display device 40e displays, for example, item information about the items 21 stored in the storage section 42 in response to an operation by the worker. Note that the display device 40e in this embodiment is configured as a touch panel, and also functions as an input device that accepts various operations by the worker.

[0038] The control device 40a can also store location information, entry / exit information, and storage information of the item 21 in the storage unit 42 in a storage device, and the display device 40e can also display this information. The location information indicates the storage location of the item 21. The entry / exit information indicates the entry date and time and the exit date and time of the item 21. The storage information includes, for example, information such as the ambient temperature and ambient humidity of the storage unit 42. The control device 40a stores the location information and entry date and time of the item 21 when the item 21 is stored. The control device 40a stores the storage information while the item 21 is in storage. The control device 40a stores the exit date and time of the item 21 when the item 21 is exited.

[0039] 1-4. Reel Management Device 50 For example, warping may occur in the reel 21a depending on the dimensions, weight, material, etc. of the reel 21a. Furthermore, the amount of warping AW0 of the reel 21a may differ between when the reel 21a is stored in the storage section 42 and when the reel 21a is placed on the placement section 40c, which can temporarily place the incoming reel 21a or the outgoing reel 21a.

[0040] Specifically, Figures 5A and 5B show an example of a storage section 42 in which the reel 21a is stored. These figures show a portion of the storage body 42a and support members 42b arranged along the vertical direction (Z-axis direction). As described above, the storage body 42a is formed in a U-shape when viewed in the vertical direction (Z-axis direction). Multiple pairs of support members 42b (three pairs, or six members, in Figures 5A and 5B) are provided, allowing multiple (three) reels 21a to be stored.

[0041] Each of the multiple pairs (three pairs) of support members 42b is provided with two support members 42b spaced apart so as not to interfere with the transfer device 40b. Specifically, the support members 42b are missing a portion to allow the gripping mechanism 40b2 to move forward and backward, and can support the reel 21a while contacting a portion of the reel 21a. For example, the larger the diameter of the reel 21a, the heavier the reel 21a tends to be. The thicker the reel 21a, the heavier the reel 21a tends to be. Thus, the larger the size of the reel 21a, the heavier the reel 21a tends to be.

[0042] 5B, the reel 21a shown by the solid line sags due to its own weight, causing warping, compared to the reel 21a shown by the dashed line. The same applies to the rigidity of the reel 21a as described above regarding size. In other words, the lower the rigidity of the reel 21a, the more likely it is that warping will occur in the reel 21a, and the more likely the warping amount AW0 of the reel 21a will increase. If the warping amount AW0 of the reel 21a increases, for example, when the transfer device 40b carries the reel 21a in, there is a possibility that the reel 21a will be carried back or that the reel 21a will jump out of the storage unit.

[0043] As shown in FIG. 3C , for example, the gripping mechanism 40b2 includes an upper gripper GP1 and a lower gripper GP2. The upper gripper GP1 is provided above the reel 21a in the storage unit 42 in the vertical direction (the Z-axis direction). The lower gripper GP2 is provided below the upper gripper GP1 in the vertical direction (the Z-axis direction). The upper gripper GP1 and the lower gripper GP2 grip the reel 21a by moving toward each other in the vertical direction (the Z-axis direction). Conversely, the upper gripper GP1 and the lower gripper GP2 release their grip on the reel 21a by moving away from each other in the vertical direction (the Z-axis direction).

[0044] The lower gripper GP2 is connected to the lifting mechanism 40b1. Therefore, the upper gripper GP1 can move in the vertical direction (in the Z-axis direction indicated by the arrow) relative to the lower gripper GP2. The upper gripper GP1 and the lower gripper GP2 can move forward or backward, and can also move up and down along the vertical direction (Z-axis direction) together with the lifting mechanism 40b1 and rotate around their axes. This allows the transfer device 40b to carry the reel 21a into the storage section 42, store it therein, and carry the reel 21a out of the storage section 42.

[0045] When the upper gripper GP1 and the lower gripper GP2 gripping the reel 21a move forward and enter a storage unit (first storage unit 42t1 or second storage unit 42t2) of the storage section 42 and release their grip on the reel 21a, the state shown in Fig. 6A, the state shown in Fig. 6B, or the like is obtained. Fig. 6A shows an example of the positional relationship between the gripping mechanism 40b2 and a normal reel 21n, which is a reel 21a with a warpage AW0 within a predetermined range, stored in the storage section 42. Fig. 6B shows an example of the positional relationship between the gripping mechanism 40b2 and a reel 21a with a warpage AW0 outside the allowable range stored in the storage section 42.

[0046] In the normal reel 21n shown in Fig. 6A, the lower surface 21d is in surface contact with the support member 42b and is spaced apart from the lower gripper GP2. Therefore, when the upper gripper GP1 and the lower gripper GP2 retract in this state, the normal reel 21n remains in the storage unit. In contrast, in the reel 21a shown in Fig. 6B, the lower surface 21d is spaced apart from the support member 42b and is in surface contact with the lower gripper GP2.

[0047] Therefore, when the upper gripper GP1 and the lower gripper GP2 retract in this state, the reel 21a may move together with the lower gripper GP2 from the storage unit, possibly resulting in the reel 21a being taken away. It is also conceivable that the reel 21a moves partway along with the lower gripper GP2 in the storage unit, and then, for example, due to vibration, the underside 21d of the reel 21a may move away from the lower gripper GP2 and be supported by the support member 42b. In this case, the reel 21a may protrude from the storage unit, where it is stored.

[0048] However, in the mounting section 40c, the reel 21a is mounted on a flat plate. Therefore, when the reel 21a is mounted on the mounting section 40c, the above phenomenon is unlikely to occur, and even if the amount of warpage AW0 of the reel 21a is measured while the reel 21a is mounted on the mounting section 40c, it may differ from the amount of warpage AW0 of the reel 21a stored in the storage section 42. Therefore, there is a demand to know the amount of warpage AW0 of the reel 21a stored in the storage section 42.

[0049] Therefore, in the embodiment, a reel management device 50 is provided. The reel management device 50 is applied to the automated warehouse 40 that includes a storage unit 42 and a transfer device 40b. As described above, the storage unit 42 is capable of storing the reels 21a around which the carrier tape 21a2 that contains the components to be mounted on the circuit board 90 is wound. The storage unit 42 may take various forms as long as it is capable of storing the reels 21a. The transfer device 40b carries the reels 21a into the storage unit 42 and stores them therein when the reel is brought into storage, and carries the reels 21a out of the storage unit 42 when the reel is undone. The transfer device 40b may take various forms as long as it is capable of moving the reels 21a as described above.

[0050] The reel management device 50 includes a measurement unit 51. The reel management device 50 may also include a determination unit 52. As shown in FIG. 7 , the reel management device 50 of this embodiment includes a measurement unit 51 and a determination unit 52. The measurement unit 51 and the determination unit 52 may be provided in various control devices, management devices, etc. For example, at least one of the measurement unit 51 and the determination unit 52 may be provided in the control device 40a of the automated warehouse 40. At least one of the measurement unit 51 and the determination unit 52 may also be provided in the management device 19.

[0051] At least one of the measurement unit 51 and the determination unit 52 may be provided in a control system higher than the management device 19. At least one of the measurement unit 51 and the determination unit 52 may be formed on the cloud. As shown in FIG. 7 , in the reel management device 50 of the embodiment, the measurement unit 51 and the determination unit 52 are provided in the control device 40a of the automated warehouse 40.

[0052] Furthermore, the reel management device 50 can execute control in accordance with, for example, the flowchart shown in FIG. 8. Specifically, the measurement unit 51 performs the processes shown in steps S11 to S13. The determination unit 52 performs the determinations and processes shown in steps S14 to S18. Note that the matters described in this specification can be selected and applied as appropriate. Similarly, the matters described in this specification can be combined as appropriate.

[0053] The measuring unit 51 measures the amount of warpage AW0 of the reel 21a that is carried into the storage unit 42 by the transfer device 40b or the reel 21a that is carried out from the storage unit 42 by the transfer device 40b, in the storage unit 42. The measuring unit 51 may take various forms as long as it can measure the amount of warpage AW0 of the reel 21a in the storage unit 42.

[0054] For example, as shown in Figures 6A, 6B, 9A, and 9B, the transfer device 40b includes a gripping mechanism 40b2 that can clamp and hold the reel 21a in the direction of the axis AX. The transfer device 40b may take various forms as long as it can grip the reel 21a as described above. For example, as already described, the transfer device 40b may include an upper gripper GP1 and a lower gripper GP2 shown in Figure 3C. This allows the transfer device 40b to clamp and hold the reel 21a in the direction of the axis AX using the upper gripper GP1 and the lower gripper GP2.

[0055] As described above, the storage section 42 includes a storage body 42a and a support member 42b. The storage body 42a is provided along the vertical direction (the Z-axis direction). The support member 42b is a partition member that divides the storage body 42a to allow the reels 21a to be stored individually. A portion of the support member 42b is missing to allow the gripping mechanism 40b2 to move forward and backward, and the support member 42b can support the reel 21a while in contact with a portion of the reel 21a. In the above embodiment, the measuring unit 51 may measure the amount of warpage AW0 of the reel 21a supported by the support member 42b. In this case, the measuring unit 51 can measure the amount of warpage AW0 of the reel 21a in the same state as when the reel 21a is stored in the storage section 42.

[0056] For example, the measurement unit 51 measures the height position H1 of a predetermined portion P0 of the reel 21a supported by the support member 42b. The predetermined portion P0 may be any portion capable of measuring the height position H1, and is not limited thereto. As shown in FIGS. 9A and 9B , the predetermined portion P0 may be, for example, the top surface 21u of the reel 21a. The measurement unit 51 can then determine the amount of warpage AW0 of the reel 21a as the deviation ΔH0 between the measured height position H1 of the predetermined portion P0 of the reel 21a and the height position H2 of the predetermined portion P0 of the normal reel 21n when the normal reel 21n is supported by the support member 42b.

[0057] A normal reel 21n refers to a reel 21a whose warpage AW0 is within a predetermined range. Because it is difficult to completely eliminate the warpage AW0 of the reel 21a, the predetermined range is set to be sufficiently smaller than the allowable range described below, such that the warpage AW0 can be ignored. FIG. 9A shows an example of a measurement state when measuring the warpage AW0 of a normal reel 21n. FIG. 9B shows an example of a measurement state when measuring the warpage AW0 of a reel 21a that exceeds the allowable range. FIG. 9A corresponds to FIG. 6A, and FIG. 9B corresponds to FIG. 6B. However, in FIG. 9B, the lower surface 21d of the reel 21a is spaced apart from the lower gripper GP2. As shown in FIG. 6B, the lower surface 21d of the reel 21a may come into surface contact with the lower gripper GP2.

[0058] As shown in Figures 9A and 9B, when both ends of the reel 21a in the radial direction (arrow RD direction) are supported by two support members 42b, the warp of the reel 21a is convex downward (downward in the plane of the paper) in the vertical direction (arrow Z axis direction), and is unlikely to be convex upward (upward in the plane of the paper) in the vertical direction (arrow Z axis direction). Furthermore, the upper surface 21u and the lower surface 21d of the reel 21a are formed of the same material, and the warp amount AW0 on the upper surface 21u of the reel 21a and the warp amount AW0 on the lower surface 21d of the reel 21a are generally equivalent. Therefore, as shown in Figure 9B, the deviation ΔH0 between the height position H1 of the predetermined portion P0 of the reel 21a to be measured and the height position H2 of the predetermined portion P0 of a normal reel 21n (a presumable fixed position) corresponds to the warp amount AW0 of the reel 21a. That is, the measuring unit 51 can determine the deviation ΔH0 as the amount of warpage AW0 of the reel 21a.

[0059] As already described, the gripping mechanism 40b2 includes the upper gripper GP1 that is provided above the reel 21a in the vertical direction (the Z-axis direction indicated by the arrow) when gripping the reel 21a in the storage unit 42, and the lower gripper GP2 that is provided below the upper gripper GP1 in the vertical direction (the Z-axis direction indicated by the arrow). In this case, for example, the measuring unit 51 can calculate the height position H1 using the distance sensor 61 provided in the upper gripper GP1 when the upper gripper GP1 and the lower gripper GP2 are separated by a predetermined distance in the storage unit 42 and the gripping of the reel 21a by the gripping mechanism 40b2 is released.

[0060] Specifically, the measurement unit 51 advances the upper gripper GP1 and the lower gripper GP2 gripping the reel 21a to enter the storage unit (first storage unit 42t1 or second storage unit 42t2) of the storage unit 42 (step S11 shown in FIG. 8 ). Next, the measurement unit 51 moves the upper gripper GP1 and the lower gripper GP2 away from each other in the vertical direction (the Z-axis direction) to release their grip on the reel 21a (step S12). The measurement unit 51 then measures the distance from the distance sensor 61 to the upper surface 21u of the reel 21a supported by the support member 42b, and calculates the height position H1 of the upper surface 21u of the reel 21a, which is the predetermined portion P0 of the reel 21a.

[0061] The distance sensor 61 may be any known distance sensor capable of measuring the distance, such as an ultrasonic sensor or an optical sensor. When an ultrasonic sensor is used as the distance sensor 61, the distance sensor 61 transmits and receives ultrasonic waves from the upper gripper GP1. Specifically, the distance sensor 61 transmits ultrasonic waves in the vertical direction (the Z-axis direction indicated by the arrow) from the upper gripper GP1 toward the top surface 21u of the reel 21a. The head of the distance sensor 61 then receives the ultrasonic waves reflected by the top surface 21u of the reel 21a.

[0062] The distance sensor 61 measures the time from transmitting ultrasonic waves to the top surface 21u of the reel 21a to receiving the ultrasonic waves reflected by the top surface 21u of the reel 21a, thereby measuring the distance from the head to the top surface 21u of the reel 21a. The measurement unit 51 then subtracts the measured distance from the height position of the head of the distance sensor 61 to calculate the height position H1 of the top surface 21u of the reel 21a. The distance sensor 61 can measure the distance at any location on the top surface 21u of the reel 21a.

[0063] 9A and 9B , for example, the distance sensor 61 can measure the distance at the center of the upper surface 21u of the reel 21a in the radial direction (direction of arrow RD) of the reel 21a. Note that, as shown in FIGS. 2A and 5A , a hole 21h is formed in the center of the reel 21a. Therefore, when the reel 21a is gripped by the upper gripper GP1 and the lower gripper GP2, the distance sensor 61 can measure the distance at a position spaced a predetermined distance from the hole 21h in the advancing / retreating direction of the upper gripper GP1 and the lower gripper GP2.

[0064] The distance sensor 61 can measure the distance at multiple points by sequentially moving a head along the radial direction (direction of arrow RD) on the top surface 21u of the reel 21a, or by providing multiple heads. In this case, the measurement unit 51 can even detect the warpage of the reel 21a. Note that what has been described above about the ultrasonic sensor also applies to, for example, an optical sensor (e.g., a photoelectric sensor, a laser sensor, etc.) that has a light emitter and a light receiver.

[0065] The distance sensor 61 can also be provided on the lower gripper GP2, etc. However, in this configuration, foreign matter is more likely to adhere to the distance sensor 61. For this reason, it is preferable to provide the distance sensor 61 on the upper gripper GP1. Once the height position H1 of the upper surface 21u of the reel 21a is measured in this manner, the measurement unit 51 calculates the deviation ΔH0 between the measured height position H1 of the upper surface 21u of the reel 21a and the height position H2 (a fixed position that can be estimated in advance) of the upper surface 21u of a normal reel 21n. The measurement unit 51 can then determine the calculated deviation ΔH0 as the amount of warpage AW0 of the reel 21a (step S13).

[0066] The measuring unit 51 can also use the imaging device 62 to calculate the height position H1 of the predetermined portion P0 of the reel 21a when the upper gripper GP1 and the lower gripper GP2 are separated by a predetermined distance in the storage unit 42 and the gripping mechanism 40b2 releases the grip of the reel 21a. The imaging device 62 may be any known imaging device as long as it can capture an image of the reel 21a supported by the support member 42b in a radial direction (direction of arrow RD) perpendicular to the axis AX. For example, the imaging device 62 shown by the dashed lines in FIGS. 9A and 9B is provided on the base end side of the upper gripper GP1 and the lower gripper GP2. In this case, the imaging device 62 can capture an image of the reel 21a supported by the support member 42b in a normal direction perpendicular to the plane of the drawings.

[0067] The measurement unit 51 can perform image processing on the image of the reel 21a captured by the imaging device 62 to calculate the height position H1 of the predetermined portion P0 of the reel 21a. The predetermined portion P0 is not limited as long as it can be recognized by image processing. For example, as with the distance sensor 61, the predetermined portion P0 can be the top surface 21u of the reel 21a. Alternatively, the predetermined portion P0 can be the bottom surface 21d of the reel 21a. Furthermore, the measurement unit 51 can calculate the height position H1 of any location on the top surface 21u or bottom surface 21d of the reel 21a. As shown in FIGS. 9A and 9B , for example, the measurement unit 51 can calculate the height position H1 of the top surface 21u of the reel 21a at the center of the reel 21a in the radial direction (direction of arrow RD).

[0068] The image processing method is not limited, and any known method can be used. The measurement unit 51 can recognize the external shape of the reel 21a by, for example, binarization processing, and calculate the height position H1 of the predetermined portion P0 of the reel 21a. For example, the measurement unit 51 calculates the distance between a reference position (e.g., the center of the image, a portion whose height position is known) in the image of the reel 21a captured by the imaging device 62 and the predetermined portion P0 of the reel 21a recognized from the image. The measurement unit 51 can then calculate the height position of the location moved by the above distance from the reference position as the height position H1 of the predetermined portion P0 of the reel 21a.

[0069] The measurement unit 51 can also use the distance sensor 61 to calculate the height position H1 of the predetermined portion P0 of the reel 21a, and can also use the imaging device 62 to calculate the height position H1 of the predetermined portion P0 of the reel 21a. The measurement unit 51 can then calculate the height position H1 of the predetermined portion P0 of the reel 21a based on multiple calculation results. For example, the measurement unit 51 can calculate the average of the multiple calculation results and use the calculated average as the height position H1 of the predetermined portion P0 of the reel 21a.

[0070] Additionally, in both cases where the distance sensor 61 and the imaging device 62 are used, the measuring unit 51 sets the upper gripper GP1 and the lower gripper GP2 to a predetermined distance apart in the storage unit 42, thereby releasing the gripping mechanism 40b2 from the gripping of the reel 21a. The shorter the predetermined distance separating the upper gripper GP1 and the lower gripper GP2, the more likely it is that the lower surface 21d of the reel 21a will come into contact with the lower gripper GP2, as shown in FIG. 6B .

[0071] Furthermore, the storage unit 42 includes a storage body 42a and a support member 42b, and can store multiple reels 21a in the vertical direction (in the Z-axis direction). Therefore, a reel 21a may be stored one level above or below the reel 21a whose warpage amount AW0 is to be measured in the vertical direction (in the Z-axis direction). The longer the predetermined distance separating the upper gripper GP1 and the lower gripper GP2, the more likely the upper gripper GP1 and the lower gripper GP2 will interfere with reels 21a already stored.

[0072] Therefore, it is preferable that the measuring unit 51 sets the predetermined distance by which the upper gripper GP1 and the lower gripper GP2 are separated to the maximum separation amount that prevents interference between the upper gripper GP1 and the lower gripper GP2 and reels 21a other than the reel 21a for which the warpage amount AW0 is being measured. This makes it possible to increase the number of reels 21a that can be stored while suppressing interference between the upper gripper GP1 and the lower gripper GP2 and reels 21a that are already stored.

[0073] 1-4-2. Determination Unit 52 The determination unit 52 determines whether the warpage AW0 of the reel 21a measured by the measurement unit 51 exceeds the allowable range (step S14 shown in FIG. 8). The determination unit 52 can set the allowable range for the warpage AW0 based on various criteria. For example, as described above, if the warpage AW0 of the reel 21a increases, there is a possibility that the reel 21a will be carried back or will jump out of the storage unit when the transfer device 40b carries the reel 21a in.

[0074] Therefore, the allowable range of the warpage AW0 can be set to a range that can prevent the reel 21a from being taken home and from jumping out of the storage unit. Specifically, the allowable range of the warpage AW0 can be set to a range that prevents the lower surface 21d of the reel 21a from coming into contact with the lower gripper GP2 due to the warpage of the reel 21a supported by the support member 42b. Furthermore, the allowable range of the warpage AW0 can also be set to a range that is allowable for the reel 21a based on the required quality of the reel 21a.

[0075] If the warpage amount AW0 of the reel 21a is within the allowable range (Yes in step S14), the determination unit 52 causes the upper gripper GP1 and the lower gripper GP2 to retract while the gripping mechanism 40b2 in the storage unit 42 is released from gripping of the reel 21a (step S15). As described above, the upper gripper GP1 and the lower gripper GP2 in the storage unit 42 move away from each other by a predetermined distance, thereby releasing the gripping of the reel 21a by the gripping mechanism 40b2. In this state, the determination unit 52 causes the upper gripper GP1 and the lower gripper GP2 to retract. This completes the transport and storage of the reel 21a by the transfer device 40b. Then, control by the reel management device 50 is temporarily terminated.

[0076] If the warpage AW0 of the reel 21a exceeds the allowable range (No in step S14), the reel 21a may be carried back or may jump out of the storage unit, and therefore it is not preferable to retract the upper gripper GP1 and the lower gripper GP2 in this state. Furthermore, the automated warehouse 40 of this embodiment includes a placement unit 40c on which a stored reel 21a or a reel 21a to be shipped can be temporarily placed. Therefore, if the warpage AW0 of the reel 21a exceeds the allowable range, the determination unit 52 may use the transfer device 40b to move the reel 21a to the placement unit 40c.

[0077] Specifically, the determination unit 52 retracts the upper gripper GP1 and the lower gripper GP2 while the gripping mechanism 40b2 grips the reel 21a in the storage unit 42 (step S16). As described above, the upper gripper GP1 and the lower gripper GP2 move toward each other in the storage unit 42, thereby gripping the reel 21a. In this state, the determination unit 52 retracts the upper gripper GP1 and the lower gripper GP2. Then, the determination unit 52 moves the upper gripper GP1 and the lower gripper GP2 gripping the reel 21a to the placement unit 40c. Once the reel 21a has moved to the placement unit 40c, the determination unit 52 releases the gripping mechanism 40b2 from gripping the reel 21a. As a result, the reel 21a moves to the placement unit 40c (step S17).

[0078] The reel 21a moved to the mounting section 40c and having a warpage AW0 that exceeds the allowable range is difficult to store in the automated warehouse 40 in this state. Therefore, when the warpage AW0 of the reel 21a exceeds the allowable range, the determination section 52 can notify the operator that the warpage AW0 of the reel 21a exceeds the allowable range (step S18). This allows the operator to recognize the presence of the reel 21a whose warpage AW0 exceeds the allowable range.

[0079] The determination unit 52 may take various forms as long as it can provide notification that the warpage AW0 of the reel 21a exceeds the allowable range. For example, the determination unit 52 can use the display device 40e of the automated warehouse 40 to display a message that the warpage AW0 of the reel 21a exceeds the allowable range. The determination unit 52 can also provide audio guidance that the warpage AW0 of the reel 21a exceeds the allowable range. Furthermore, the determination unit 52 can transmit a message that the warpage AW0 of the reel 21a exceeds the allowable range to a portable terminal carried by the worker.

[0080] The determination unit 52 can also guide the user to store the reel 21a whose warpage amount AW0 exceeds the allowable range in a storage case 70 capable of stacking and accommodating multiple reels 21a in the storage unit 42 (step S18). FIG. 10 shows an example of the storage case 70. The storage case 70 shown in the figure includes a box-shaped case main body 71 and a pin member 72 protruding upward in the vertical direction (in the direction of the arrow Z) from the bottom surface of the case main body 71. By positioning the reel 21a so that the pin member 72 passes through the hole 21h of the reel 21a, multiple reels 21a can be stacked and accommodated in each of multiple storage areas (four in the figure).

[0081] For example, the worker removes the reel 21a whose warpage AW0 exceeds the allowable range that has been moved to the mounting section 40c, and stores the removed reel 21a in the storage case 70. Then, the worker places the storage case 70 that stores the reel 21a whose warpage AW0 exceeds the allowable range on the mounting section 40c. The automated warehouse 40 uses the transfer device 40b to move the storage case 70 to the storage section 42 and stores the storage case 70 in a storage unit that can store the storage case 70. In this way, the automated warehouse 40 can store the reel 21a whose warpage AW0 exceeds the allowable range.

[0082] In the embodiment described above, the measuring unit 51 measures the warpage AW0 of the reel 21a that is carried into the storage unit 42 by the transfer device 40b, in the storage unit 42. Similarly, the measuring unit 51 can also measure the warpage AW0 of the reel 21a that is carried out from the storage unit 42 by the transfer device 40b, in the storage unit 42. In this embodiment, since the reel 21a is already stored in the storage unit 42, there is no problem with carrying the reel 21a back. However, there may be cases where it is desired to confirm, for example, whether the warpage AW0 of the reel 21a that is to be delivered from the automated warehouse 40 satisfies the required quality of the reel 21a (whether the reel 21a can be used for production). Therefore, the measuring unit 51 can also measure the warpage AW0 of the reel 21a that is carried out from the storage unit 42 by the transfer device 40b, in the storage unit 42.

[0083] 2. Reel Management Method What has been described above regarding the reel management device 50 also applies to the reel management method. Specifically, the reel management method is applied to an automated warehouse 40 that includes a storage unit 42 and a transfer device 40b. The reel management method includes a measurement process. The measurement process corresponds to the control performed by the measurement unit 51. The reel management method can also include a judgment process. The judgment process corresponds to the control performed by the judgment unit 52.

[0084] 3. Example of Effects of the Embodiment According to the reel management device 50, it is possible to measure the amount of warpage AW0 of the reel 21a in the storage section 42. What has been described above about the reel management device 50 also applies to the reel management method.

[0085] 21a: reel, 21a2: carrier tape, 21n: normal reel, 21u: upper surface, 40: automated warehouse, 40b: transfer device, 40b2: gripping mechanism, GP1: upper gripper, GP2: lower gripper, 40c: placement section, 42: storage section, 42a: storage main body, 42b: support member, 50: reel management device, 51: measurement section, 52: judgment section, 61: distance sensor, 62: imaging device, 70: storage case, 90: substrate, AW0: amount of warpage, P0: specified portion, H1: height position, H2: height position, ΔH0: deviation, AX: axis, arrow RD direction: radial direction, arrow Z axis direction: vertical direction.

Claims

1. A reel management device applicable to an automated warehouse comprising: a storage section capable of storing reels around which a carrier tape that contains components to be mounted on a board is wound; and a transfer device that carries the reel into and stores it in the storage section when the reel is brought into the warehouse and removes the reel from the storage section when the reel is removed from the warehouse, wherein the reel management device further comprises a measuring unit that measures, in the storage section, the amount of warping of the reel carried into the storage section by the transfer device or the reel removed from the storage section by the transfer device.

2. The transfer device is equipped with a gripping mechanism capable of gripping the reel by clamping it in the axial direction, the storage section is equipped with a storage main body arranged along the vertical direction, and a partition member that divides the storage main body to allow the reels to be stored individually, and a support member that is missing a part to allow the gripping mechanism to move forward and backward and is capable of supporting the reel in a state of contact with a part of the reel, and the measuring section is a reel management device as described in claim 1, which measures the amount of warping of the reel supported by the support member.

3. A reel management device as described in claim 2, wherein the measuring unit measures the height position of a specified portion of the reel supported by the support member, and the amount of warping of the reel is determined to be the deviation between the measured height position of the specified portion of the reel and the height position of the specified portion of a normal reel, which is a reel whose warping amount is within a specified range and is supported by the support member.

4. The gripping mechanism comprises an upper gripper that is arranged above in the vertical direction when gripping the reel in the storage section, and a lower gripper that is arranged below in the vertical direction compared to the upper gripper, and the measurement unit uses a distance sensor provided on the upper gripper to measure the distance from the distance sensor to the top surface of the reel supported by the support member when the upper gripper and the lower gripper are separated by a predetermined distance in the storage section and the gripping mechanism is released from the gripping of the reel, and calculates the height position of the top surface of the reel, which is the predetermined portion of the reel. A reel management device as described in claim 3.

5. The gripping mechanism comprises an upper gripper that is arranged above in the vertical direction when gripping the reel in the storage section, and a lower gripper that is arranged below the upper gripper in the vertical direction, and the measurement unit uses an imaging device to image the reel supported by the support member from a radial direction perpendicular to the axial direction when the upper gripper and the lower gripper are separated by a predetermined distance in the storage section and the gripping mechanism is released from gripping the reel, and performs image processing on the image of the imaged reel to calculate the height position of the specified portion of the reel. A reel management device as described in claim 3.

6. A reel management device as described in claim 4 or claim 5, wherein the measurement unit sets the specified distance by which the upper gripper and the lower gripper are separated to the maximum separation amount at which the upper gripper and the lower gripper do not interfere with other reels other than the reel for which the amount of warping is being measured.

7. A reel management device according to claim 1, further comprising a determination unit that determines whether the amount of warping of the reel measured by the measurement unit exceeds an allowable range.

8. The reel management device of claim 7, wherein the automated warehouse is provided with a placement section on which the incoming reel or the outgoing reel can be temporarily placed, and the judgment section uses the transfer device to move the reel to the placement section when the amount of warping of the reel exceeds the allowable range.

9. A reel management device as described in claim 7 or claim 8, wherein the judgment unit, when the amount of warping of the reel exceeds the allowable range, provides a notification to the effect that the amount of warping of the reel exceeds the allowable range.

10. A reel management device as described in claim 9, wherein the judgment unit guides the reel whose warpage exceeds the allowable range to be stored in a storage case capable of carrying and storing multiple reels, and stores the storage case in the storage unit.

11. A reel management method applicable to an automated warehouse comprising: a storage section capable of storing reels around which carrier tape that contains components to be mounted on a board is wound; and a transfer device that carries the reels into and stores them in the storage section when the reels are received and removes the reels from the storage section when the reels are removed from the storage section, the reel management method comprising a measurement step of measuring, in the storage section, the amount of warping of the reels carried into the storage section by the transfer device or the reels removed from the storage section by the transfer device.

Images