Tape feeder, feeder management device, and feeder management system

Abstract

This tape feeder can be detachably mounted on a component mounting machine to supply a component stored in a carrier tape. The tape feeder comprises: a tape feeding mechanism for performing a feeding operation for feeding the carrier tape in a predetermined feeding direction, and a returning operation for returning the carrier tape in a reverse direction; an operation unit for receiving an operation of an operator; and a control unit that, in an inactive mode in which power is supplied without the tape feeder being mounted on the component mounting machine, switches the tape feeder between a command receptive state in which the tape feeding mechanism is caused to perform the return operation upon receiving a predetermined return command, and a command rejection state in which the tape feeding mechanism is not caused to perform the return operation even upon receiving the return command, on the basis of the operation received by the operation unit.

Description

Tape feeder, feeder management device, and feeder management system

[0001] The present specification relates to a tape feeder that supplies components housed on a carrier tape, and a feeder management device and a feeder management system that manage the tape feeder.

[0002] A technology for mass-producing circuit board products by performing substrate-related operations on boards on which circuit patterns are formed is becoming widespread. A typical example of a substrate-related operation machine that performs substrate-related operations is a component placement machine that performs component placement operations. Many component placement machines are equipped with a tape feeder that supplies components housed on a carrier tape. The tape feeder changes the type of components supplied by replacing the reel on which the carrier tape is wound and unwinding and loading the carrier tape from the reel. Reel replacement operations and carrier tape loading operations have traditionally been performed by an operator. In recent years, devices have been developed that assist in reel replacement operations and reduce the workload of operators, and one technical example is disclosed in Patent Document 1.

[0003] Patent Document 1 discloses a tape feeder management device that holds replaceable reels around which carrier tape is wound and is detachably mounted on a component mounting machine, and that includes a recognition unit that recognizes electronic component types that will not be used in the next or subsequent board types when transitioning from one board type to the next, and a rewinding unit that rewinds the carrier tape that supplies the electronic component types that will not be used in the next or subsequent board types. This reduces the effort required to rewind the carrier tape, and is said to improve the efficiency of reel removal work.

[0004] Japanese Patent Application Laid-Open No. 2018-49972

[0005] The technical example of Patent Document 1 automatically rewinds carrier tape that will not be used for the next or subsequent substrate types, which is advantageous in that it reduces the operator's workload. However, determining whether to automatically rewind the carrier tape based solely on the condition that the carrier tape will not be used for the next or subsequent substrate types can have adverse effects. For example, reels that are not scheduled for use are not necessarily removed, and the tape feeder may be stored with the reel attached. Also, if the leading end of the carrier tape does not extend outside the tape feeder, there is no need to rewind the carrier tape. On the other hand, if the reel is removed, the next time the tape feeder is used, the reel attachment and carrier tape loading operations will be required, resulting in redundant work.

[0006] Therefore, the problem to be solved in this specification is to provide a tape feeder, a feeder management device, and a feeder management system that allow an operator to easily set whether or not to automatically perform the return operation of returning the carrier tape in the reverse direction.

[0007] This specification discloses a tape feeder that is detachably mounted on a component mounting machine and supplies components housed on a carrier tape, the tape feeder comprising: a tape feed mechanism that performs a feed operation to feed the carrier tape in a predetermined feed direction and a return operation to return the carrier tape in the opposite direction; an operation unit that accepts operations from an operator; and a control unit that, in a non-operational mode in which power is supplied and the tape feeder is not mounted on the component mounting machine, switches between a command acceptance state in which the tape feed mechanism performs the return operation when a predetermined return command is received, and a command rejection state in which the tape feed mechanism does not perform the return operation even when the return command is received, based on the operation accepted by the operation unit.

[0008] This specification also discloses a feeder management device that includes a power supply unit that supplies power to the tape feeder that has been removed from the component mounting machine, and a higher-level control unit that is communicatively connected to the control unit of the tape feeder and transmits the return command.

[0009] Furthermore, this specification discloses a feeder management system comprising: a tape feeder that is detachably mounted on a component mounting machine and supplies components housed on the carrier tape, the tape feeder having a tape feed mechanism that performs a feed operation to feed a carrier tape in a predetermined feed direction and a return operation to return the carrier tape in the opposite direction, and an operation unit that receives operation from an operator; and a control unit that, in a non-operational mode in which power is supplied and the tape feeder is not mounted on the component mounting machine, switches between a command acceptance state in which the tape feed mechanism performs the return operation when a predetermined return command is received, and a command rejection state in which the tape feed mechanism does not perform the return operation even when the return command is received, based on operation received by the operation unit.

[0010] This specification discloses the technical idea of ​​changing "the tape feeder according to any one of claims 1 to 3" in claim 6 originally filed to "the tape feeder according to any one of claims 1 to 5," and the technical idea of ​​changing "the tape feeder according to claim 6" in claim 8 originally filed to "the tape feeder according to claim 6 or 7." This specification also discloses the technical idea of ​​changing "the feeder management device according to claim 9" in claim 11 originally filed to "the feeder management device according to claim 9 or 10," and the technical idea of ​​changing "the feeder management device according to claim 9" in claim 12 originally filed to "the feeder management device according to any one of claims 9 to 11."

[0011] According to the disclosed configuration, when the tape feeder is in a non-operating mode, the operator can operate the operation unit to switch the control unit between a command acceptance state and a command rejection state. In the command acceptance state, the control unit causes the tape feeding mechanism to perform a return operation when a return command is received, and in the command rejection state, the control unit does not cause the tape feeding mechanism to perform a return operation even when a return command is received. Therefore, whether or not the tape feeder automatically performs a return operation to return the carrier tape in the reverse direction can be easily set, depending on whether or not the operator operates the operation unit.

[0012] 1 is a perspective view schematically showing the configuration of a main part of a component mounting machine to which a tape feeder of an embodiment is detachably mounted. FIG. 2 is a side view of the tape feeder of an embodiment. FIG. 3 is a plan view of an operation panel of the tape feeder. FIG. 4 is a diagram of a table briefly showing functions assigned to functional parts on the operation panel in an operating mode and a non-operating mode of the tape feeder. FIG. 5 is a diagram showing the configuration of a feeder management device of an embodiment and the actual shape of a pallet stand. FIG. 6 is an electrical connection diagram showing the connection between a feeder management device and multiple tape feeders. FIG. 7 is an operational flow diagram explaining the operation of a tape feeder and a feeder management device when not mounted on a component mounting machine. FIG. 8 is an operational flow diagram explaining the operation of a tape feeder and a feeder management device in a modified form which, unlike FIG. 7, is not restricted by power supply capacity.

[0013] 1. Configuration Example of Component Mounting Machine 9 The tape feeder 1 of this embodiment is detachably mounted on the component mounting machine 9 and supplies components housed on a carrier tape. First, the configuration of the component mounting machine 9 will be described with reference to FIGS. 1 and 5. In FIG. 1, the direction from the upper left to the lower right is the X-axis direction along which the board K is transported, the direction from the lower left (rear side) to the upper right (front side) is the Y-axis direction, and the vertical direction is the Z-axis direction. The component mounting machine 9 repeatedly performs component mounting operations. The component mounting machine 9 is configured by assembling a board transport device 92, a component supply device 93, a component transfer device 94, a component camera 95, a mounting control unit 96, and the like to a base 91.

[0014] The substrate transport device 92 is composed of a first guide rail 921, a second guide rail 922, a pair of conveyor belts, a clamp device 923, and the like. The first guide rail 921 and the second guide rail 922 extend in the X-axis direction across the center of the upper part of the base 91 and are attached to the base 91 so as to be parallel to each other. A pair of conveyor belts are arranged parallel to each other and spaced apart from each other along the first guide rail 921 and the second guide rail 922. The pair of conveyor belts rotate with the substrate K placed on the conveyor transport surface, transporting the substrate K into and out of a mounting position set in the center of the base 91. In addition, a clamp device 923 is provided below the mounting position. The clamp device 923 pushes up the substrate K, clamps it in a horizontal position, and positions it at the mounting position.

[0015] The component supply device 93 is disposed at the rear of the component mounting machine 9. The component supply device 93 is configured by arranging a plurality of tape feeders 1 on the upper surface of a pallet table 931. As shown in FIG. 5 , the pallet table 931 has a carriage 932 attached to the lower side for movement, and is detachably mounted at the rear of the component mounting machine 9. The pallet table 931 is supplied with power from a power source provided in the base 91, and is connected for communication with the mounting control unit 96.

[0016] The upper surface of the pallet base 931 is provided with a plurality of slots 933 extending in the front-rear direction and parallel to one another. A tape feeder 1 is replaceably set in each of the slots 933. A pair of upper and lower positioning holes (not shown) for positioning the tape feeder 1 is provided for each slot 933 on the rear surface of the front upright portion 934 of the pallet base 931. Furthermore, a receiving connector (not shown) that is electrically connected to the tape feeder 1 is provided between the upper and lower positioning holes. The receiving connector has the function of relaying power and communications. The same number of slots 933, pairs of upper and lower positioning holes, and receiving connectors are provided.

[0017] The component transfer device 94 is composed of a pair of Y-axis rails 941, a Y-direction moving table 942, a Y-axis motor 943, an X-direction moving table 944, an X-axis motor 945, and a mounting head 946. The pair of Y-axis rails 941 are provided from the front of the base 91 to above the component supply device 93 at the rear. The Y-direction moving table 942 is mounted on the pair of Y-axis rails 941 and is driven in the Y-axis direction by the Y-axis motor 943 via a ball screw mechanism. The X-direction moving table 944 is mounted on the Y-direction moving table 942 and is driven in the X-axis direction by the X-axis motor 945 via a ball screw mechanism.

[0018] The mounting head 946 is replaceably attached to the rear side of the X-direction moving platform 944. An axisymmetric rotary tool 947 is rotatably provided below the mounting head 946. A plurality of suction nozzles (not shown) are held below the rotary tool 947. The suction nozzles, which are set to their operating positions by the rotation of the rotary tool 947, are driven by a Z-axis motor 948 to move up and down. Negative and positive pressure air is selectively supplied to the suction nozzles, which mount components picked up from the tape feeder 1 onto the board K at the mounting position.

[0019] The board camera 949 is provided below the X-direction moving platform 944 and is arranged alongside the mounting head 946. The board camera 949 captures an image of a position mark provided on the positioned board K and processes the image data to detect the exact mounting position of the board K. The component camera 95 is provided on the upper surface of the base 91 between the board transport device 92 and the component supply device 93. The component camera 95 captures an image of a component held by the suction nozzle from below and detects the holding state of the component by processing the image data. Digital still cameras are used for the board camera 949 and the component camera 95.

[0020] The placement control unit 96 is configured using a computer device, and its location is not limited. The placement control unit 96 may be configured with its functions distributed across multiple computers. The placement control unit 96 controls the execution of the placement work based on placement work data created for each type of board K. The placement work data is data that describes detailed procedures and methods for the placement work. The placement control unit 96 sends various commands to the board transport device 92, component supply device 93, component transfer device 94, and component camera 95, and also receives information regarding the operating status and the like from these devices.

[0021] 2. Overall Configuration of Tape Feeder 1 of the Embodiment Next, the overall configuration of the tape feeder 1 of the embodiment will be described with reference to Figures 2 and 3. Tape feeder 1 pulls out carrier tape CT (shown by a thick dotted line in Figure 2) from reel RL, feeds it in a predetermined feed direction, and supplies components at component supply position 141 located above and downstream in the feed direction. The right side of Figure 2 is the upstream side in the feed direction, and the left side is the downstream side. Tape feeder 1 is composed of a feeder main body 11, a reel holding unit 12, a tape transport path 13, a tape guide 14, a tape feed mechanism 15, an ejection mechanism 16, a control unit 2, an operation panel 3, etc.

[0022] The feeder body 11 is formed primarily from a single side panel that is long in the front-to-rear direction. The width of the feeder body 11 is determined to match the tape width of one of the multiple types of carrier tape CT. A detachable rail 111 that protrudes downward is provided at the bottom of the feeder body 11. The detachable rail 111 is inserted into a slot 933 in the pallet base 931, thereby setting the tape feeder 1 on the pallet base 931.

[0023] An upper positioning pin 112, a connector 113, and a lower positioning pin 114 are provided in this order from the top to the bottom of the downstream end face of the feeder main body 11. The upper positioning pin 112 and the lower positioning pin 114 engage with positioning holes provided in the pallet base 931 to position the tape feeder 1. When the tape feeder 1 is positioned, the connector 113 automatically fits into the receiving connector of the pallet base 931. As a result, the tape feeder 1 is supplied with power from a power source provided in the base 91, and the control unit 2 is connected to the attachment control unit 96 for communication.

[0024] The reel holding unit 12 is provided at a position closer to the upstream side of the feeder main body 11. The reel holding unit 12 rotatably and replaceably holds a reel RL around which a carrier tape CT is wound. The reel holding unit 12 is composed of at least one of an outer periphery holding unit and a holding shaft (not shown). The outer periphery holding unit rotatably holds the outer periphery of the reel RL. The holding shaft is disposed to extend in the width direction of the feeder main body 11 and rotatably holds the center hole of the reel RL. The carrier tape CT is composed of a base tape BT (shown by a thick solid line in FIG. 2) in which multiple cavities for accommodating components are formed, and a cover tape VT (shown by a thick dashed line in FIG. 2) that is bonded to the base tape BT and covers the cavities.

[0025] The tape transport path 13 extends from near the reel RL held by the reel holding unit 12 to the upper downstream side and guides the carrier tape CT in a predetermined feed direction. The tape transport path 13 has, for example, a bottom plate, two side plates, and a ceiling plate, and is formed into a cylindrical shape with a rectangular cross section. A tape guide 14 is provided near the downstream end of the tape transport path 13. The tape guide 14 has a component supply position 141 that opens upward near its downstream end. The tape guide 14 is switched between a holding position in which it is swung downward and a release position in which it is swung upward by operating a lever (not shown). In the holding position, the tape guide 14 holds the base tape BT after the cover tape VT has been peeled off, pressing it against the bottom plate of the tape transport path 13. A cover tape fold-back portion 131 is provided upstream of the tape guide 14 on the tape transport path 13. The cover tape folded portion 131 is formed between the downstream end of the ceiling plate of the tape transport path 13 and the tape guide 14, and opens upward.

[0026] The tape feeding mechanism 15 performs a feeding operation to feed the carrier tape CT in a predetermined feeding direction and a returning operation to return the carrier tape CT in the opposite direction. The tape feeding mechanism 15 is composed of a sprocket 151, a motor 152, and the like. The sprocket 151 is disposed below the tape transport path 13, approximately directly below the tape guide 14, and is rotatably supported by the feeder body 11. The teeth of the sprocket 151 pass upward through grooves formed in the bottom plate of the tape transport path 13 and engage with feed holes in the base tape BT. The sprocket 151 is rotationally driven by the motor 152 via a gear mechanism (not shown).

[0027] When the tape guide 14 is in a holding state of the base tape BT, the motor 152 of the tape feeding mechanism 15 rotates a predetermined amount to feed the carrier tape CT by the pitch distance of the cavity, thereby performing a component supply operation. When the reel RL is removed, the motor 152 of the tape feeding mechanism 15 rotates in the reverse direction, automatically returning the carrier tape CT in the reverse direction. On the other hand, when the tape guide 14 is in the release position, a loading operation can be performed, in which the leading end of the base tape BT is loaded up to the component supply position 141. After the loading operation is completed, the lever is operated, and the tape guide 14 moves from the release position to the holding position, thereby holding the base tape BT.

[0028] During the component supply operation, the cover tape VT of the carrier tape CT is peeled off from the base tape BT near the cover tape fold-back portion 131. The peeled cover tape VT travels upward from the tape transport path 13 through the cover tape fold-back portion 131, makes a U-turn, and travels backward above the tape transport path 13. The cover tape VT is then discharged downward by a discharge mechanism 16 (described in detail below). Meanwhile, the base tape BT is fed to the component supply position 141 with the cavity open to supply components. The base tape BT is then discharged downstream or downward. The discharged base tape BT and cover tape VT are cut by a tape cutting mechanism provided on the base 91 of the component mounting machine 9 and collected in a tape collection box.

[0029] The discharge mechanism 16 discharges the cover tape VT. The discharge mechanism 16 is composed of a feed guide 161 and a discharge section 165. The feed guide 161 is located near the center of the feed direction near the top of the feeder body 11. The discharge section 165 is located slightly upstream of the feed guide 161 near the bottom of the feeder body 11. The feed guide 161 is formed by two guide rollers and applies tension to the cover tape VT traveling backward, guiding it toward the discharge section 165. The discharge section 165 is formed by two gears that mesh with each other and sandwich the cover tape VT. One gear is driven by the motor 152 of the tape feed mechanism 15 to rotate synchronously with the sprocket 151 and discharge the cover tape VT downward. The two gears are operated to move apart from each other using an operating lever (not shown), allowing the cover tape VT to be loaded.

[0030] When the tape feed mechanism 15 returns the carrier tape CT in the opposite direction, the cover tape VT is returned from the discharge mechanism 16 and is no longer constrained, and the carrier tape CT is returned from the tape feed mechanism 15 to an unloaded state. This makes it possible to remove the reel RL, or makes the removal process easier. Therefore, the tape feed mechanism 15 automatically performs the return operation, reducing the operator's workload. On the other hand, if the reel RL is removed, the next time the device is used, it will be necessary to attach the reel RL, as well as load the carrier tape CT into the tape feed mechanism 15 and load the cover tape VT into the discharge mechanism 16, which will result in double work.

[0031] The control unit 2 is configured using a computer device. The control unit 2 switches the control content between an active mode and a non-active mode. The active mode is a mode in which the tape feeder 1 operates when power is supplied and the tape feeder 1 is installed in the component mounting machine 9. On the other hand, the non-active mode is a mode in which the tape feeder 1 operates when power is supplied and the tape feeder 1 is not installed in the component mounting machine 9. In the active mode, the control unit 2 controls the tape feeding mechanism 15 based on commands from the mounting control unit 96 to proceed with the component supply operation. The control function of the control unit 2 in the non-active mode will be described in detail later.

[0032] As shown in FIG. 2, the operation panel 3 is disposed on the upper portion of the feeder body 11 near the upstream end. The operation panel 3 has four functional parts as shown in FIG. 3, namely, a feed button 31, an origin button 32, a return button 33, and an indicator lamp 34. The feed button 31, the origin button 32, and the return button 33 are push buttons that can be pressed by an operator, and the pressing operation is detected by the control unit 2. The feed button 31 and the return button 33 distinguish between pressing within a predetermined time range and pressing and holding the button for longer than the predetermined time. The indicator lamp 34 changes its display color and lights up according to control from the control unit 2, and in this embodiment, it displays one of four states: off, green, yellow, and red.

[0033] The forward button 31, the origin button 32, and the return button 33 are a form of an operation unit that accepts operations from the operator. The indicator lamp 34 is a form of a notification unit that notifies the operator. The functions assigned to each of the forward button 31, the origin button 32, the return button 33, and the indicator lamp 34 by the control unit 2 differ depending on whether the button is in the operating mode or the non-operating mode.

[0034] 3. Detailed Functions of the Control Unit 2 and the Operation Panel 3 Next, detailed functions of the control unit 2 and the operation panel 3 will be described. The control unit 2 uses one of the following methods (1) to (3) as a method for determining the non-operating mode described above, but other methods may also be used. (1) When power is supplied and the device is started, and then connected for communication with the wearing control unit 96, the control unit 2 determines the operating mode. When the device is started but is not connected for communication with the wearing control unit 96, the control unit 2 determines the non-operating mode. (2) When the device is started, and then connected for communication with another control unit other than the wearing control unit 96, the control unit 2 determines the non-operating mode. (3) When a mode command indicating the non-operating mode is received from another control unit after the device has started, the control unit 2 determines the non-operating mode.

[0035] In the non-operating mode, the control unit 2 switches between a command acceptance state and a command rejection state based on an operation received by the operation panel 3. In the command acceptance state, the control unit 2 causes the tape feed mechanism 15 to perform a reverse operation when a predetermined reverse command is received. In the command rejection state, the control unit 2 does not cause the tape feed mechanism 15 to perform a reverse operation even when a reverse command is received. Furthermore, in the operating mode, the control unit 2 does not accept an operation of the operation panel 3 that switches between the command acceptance state and the command rejection state, and remains in the command rejection state.

[0036] Specifically, the control unit 2 assigns the function of switching between a command acceptance state and a command rejection state in the non-operation mode to the feed button 31, and does not distinguish between pressing and holding the feed button 31. Also, to enable correction of operator mistakes or erroneous operations, the control unit 2 alternately switches between the command acceptance state and the command rejection state each time the feed button 31 is pressed. Note that the control unit 2 may assign this state switching function to the origin button 32 or the return button 33.

[0037] Furthermore, the control unit 2 may be in either state when it is communicatively connected to a control unit other than the mounting control unit 96 and the higher-level control unit 6 of the feeder management device 4, which will be described later. For example, there is a case where the tape feeder 1 is brought into a feeder maintenance device and the control unit 2 is communicatively connected to a maintenance control unit. In this case, the control unit 2 may be fixed to the command acceptance state or the command rejection state, or may be switched between the command acceptance state and the command rejection state based on specific conditions.

[0038] The control unit 2 uses the indicator lamp 34 as an indicator that notifies the operator whether the tape feed mechanism 15 is in a command acceptance state or a command rejection state. Specifically, the control unit 2 assigns the command acceptance state notification function to red illumination of the indicator lamp 34, and the command rejection state notification function to green illumination of the indicator lamp 34. Furthermore, after the tape feed mechanism 15 has completed the reversing operation, the control unit 2 causes the indicator lamp 34 to notify that the reversing operation has been completed. Specifically, the control unit 2 assigns the end of the reversing operation notification function to extinguishing the indicator lamp 34. Note that the control unit 2 may also assign the command acceptance state, command rejection state, and end of the reversing operation notification functions to states other than those described above for the indicator lamp 34.

[0039] The functions of the operation panel 3 described above are shown in the non-operational mode column of the table shown in Fig. 4. As shown in the table, in the non-operational mode, the origin button 32, the return button 33, and the yellow lit indicator lamp 34 are not assigned any functions and remain unused. Also, as shown in the operation mode column in Fig. 3, in the operation mode, the operation panel 3 is assigned functions that differ from those in the non-operational mode.

[0040] More specifically, pressing the feed button 31 assigns a function to cause the tape feed mechanism 15 to feed the carrier tape CT by the pitch distance of the cavities. Pressing and holding the feed button 31 assigns a long feed function to cause the tape feed mechanism 15 to feed the carrier tape CT for the duration the button is pressed. In other words, the feed button 31 is assigned functions other than the function of switching between a command acceptance state and a command rejection state in the operating mode.

[0041] Furthermore, pressing the origin button 32 assigns to the tape feeding mechanism 15 a function of returning the carrier tape CT to a predetermined origin position. On the other hand, pressing the return button 33 assigns to the tape feeding mechanism 15 a function of reversing the carrier tape CT by a pitch distance. Furthermore, pressing and holding the return button 33 assigns to the tape feeding mechanism 15 a long return function of reversing the carrier tape CT for the duration of the button being pressed. In the operation mode, when the feed button 31, origin button 32, or return button 33 is operated, the control unit 2 controls the tape feeding mechanism 15 to realize the assigned function.

[0042] Furthermore, in the operation mode, the indicator lamp 34 is assigned the function of informing the operator of the current state of the tape feeder 1. More specifically, the indicator lamp 34 is naturally turned off when the power supply to the tape feeder 1 is turned off and no power is being supplied. In the operation mode, the indicator lamp 34 is assigned the function of informing the operator of a normal state in which power is being supplied to the tape feeder 1 when it is lit green. Furthermore, the indicator lamp 34 is assigned the function of informing the operator of a warning state in which some abnormality has occurred in the tape feeder 1 but the component supply operation does not need to be interrupted when it is lit yellow. Furthermore, the indicator lamp 34 is assigned the function of informing the operator of an error state in which the tape feeder 1 has interrupted the component supply operation when it is lit red. In other words, in the operation mode, the indicator lamp 34 is assigned functions other than the function of informing the operator of a command acceptance state or a command rejection state. The control unit 2 controls the indicator lamp 34 so that the function of informing the operator of the current state of the tape feeder 1 is properly performed in the operation mode.

[0043] 4. Configuration of Feeder Management Device 4 of the Embodiment Next, the configuration of feeder management device 4 that manages tape feeders 1 will be described with reference to FIGS. 5 and 6 . As shown in FIG. 5 , feeder management device 4 manages a plurality of tape feeders 1 that are set on a pallet table 931 that has been removed from a component mounting machine 9. Feeder management device 4 is composed of a housing 41, a power supply unit 5, a host control unit 6, a harness 7, and the like. Housing 41 is formed in the shape of a box made of metal or resin, for example. A setting unit 42 and a start button 43 are provided on the front or top surface of housing 41. Setting unit 42 and start button 43 are connected to host control unit 6.

[0044] The setting unit 42 variably sets the tape return amount by which the carrier tape CT is returned in the return operation performed by the tape feeding mechanism 15 in the non-operating mode. The setting unit 42 has, for example, a switch that allows the operator to increase or decrease the tape return amount, and a display unit that displays the currently set tape return amount. The currently set tape return amount is acquired by the upper level control unit 6. This makes it possible to variably adjust the tape return amount depending on, for example, differences in the model of the tape feeder 1.

[0045] The start button 43 is a component that instructs the host controller 6 to start the return operation performed by the tape feed mechanism 15. The start button 43 is, for example, a push button that is pressed by an operator. The pressing of the start button 43 is detected by the host controller 6. The setting unit 42 and the start button 43 may be replaced by another component, such as a touch panel, that has equivalent or greater functions.

[0046] The power supply unit 5 supplies power to the multiple tape feeders 1 set on the pallet stand 931. The power supply unit 5 is configured to include, for example, an AC / DC converter that converts commercial frequency AC power into DC power to be supplied to the tape feeders 1. The power capacity of the power supply unit 5 is set to be larger than the sum of the power capacity of four system power lines 52, which will be described later. A power line 51 drawn from the power supply unit 5 is connected to one end of the harness 7.

[0047] The host control unit 6 is configured using a computer device. The host control unit 6 is connected for communication with the control units 2 of the multiple tape feeders 1 set on the pallet stand 931. The host control unit 6 transmits a mode command indicating a non-operation mode to each of the multiple control units 2. The host control unit 6 also transmits a return command to at least some of the multiple control units 2. The control content of the host control unit 6 will be described in detail later in the explanation of the operation. A communication line 61 drawn from the host control unit 6 is connected to one end of a harness 7.

[0048] The harness 7 is configured using a multi-core cable having connectors on both ends. The connector at one end of the harness 7 is connected to the power line 51 and the communication line 61. The connector at the other end of the harness 7 is fitted into a connector on the pallet base 931 that is not visible in FIG. 5. Therefore, even if the power line 51 and the communication line 61 are considered to extend to the pallet base 931, the electrical connections are equivalent.

[0049] The connection state between the feeder management device 4 and multiple tape feeders 1 is shown in detail in Figure 6. In Figure 6, power lines responsible for supplying power are depicted with thick lines, and communication lines responsible for transmitting commands and information are depicted with thin, dashed lines. As shown in the figure, power line 51 branches into four system power lines 52 inside pallet table 931. Furthermore, each of system power lines 52 branches into multiple individual power lines 53. Each of individual power lines 53 is connected to a receiving connector provided for each slot 933. Therefore, individual power line 53 supplies power to the tape feeding mechanism 15 and control unit 2 of one tape feeder 1.

[0050] Here, the actual pallet stand 931 has 52 slots 933, and can accommodate up to 52 tape feeders 1. Each of the four system power lines 52 branches into 13 individual power lines 53, and each system supplies power to up to 13 tape feeders 1. The power capacity of the system power lines 52 is limited to a range that can cover the power of two tape feeding mechanisms 15 and 13 control units 2.

[0051] Additionally, in normal operation mode, one of the multiple tape feeders 1 is selected in turn to pick up components one by one, so there is little need for the tape feeding mechanisms 15 of three or more tape feeders 1 to operate simultaneously, and no problems arise even if the power capacity of the system power line 52 is limited. This makes it possible to use thinner power line 52 and reduce the capacity of protective breakers, fuses, connection terminals, etc., thereby reducing the cost of the power system in the pallet table 931. In addition, it becomes possible to reduce the capacity of the power supply for the component mounting machine 9.

[0052] Meanwhile, the communication line 61 branches inside the pallet base 931 and is connected to a receiving connector provided for each slot 933. This allows the host control unit 6 to perform simultaneous transmission to the control units 2 of up to 52 connected tape feeders 1. The host control unit 6 can also specify some of the control units 2 of the 52 tape feeders 1 as the communication destination addresses to perform one-to-many two-way communication.

[0053] The host control unit 6 performs control so as not to exceed the power capacity of the system power line 52. That is, the host control unit 6 limits the number of tape feeders 1 that simultaneously perform return operations to a predetermined number or less based on status information indicating whether the control units 2 of each of the multiple tape feeders 1 are in a command acceptance state or a command rejection state, and the limited power capacity of the system power line 52. That is, when three or more control units 2 in a command acceptance state are connected to one system (one system power line 52), the host control unit 6 limits the number of control units 2 that simultaneously send return commands to two or less per system. As a result, the number of tape feeders 1 that simultaneously perform return operations on the entire pallet table 931 is limited to eight or less. Note that in a configuration in which the power capacity of the power supply unit 5 or the power line 51, rather than the system power line 52, is limited, the host control unit 6 limits the number of tape feeders 1 that simultaneously perform return operations on the entire pallet table 931 so as not to exceed the power capacity.

[0054] 5. Operation of Tape Feeder 1 and Feeder Management Device 4 Next, the operation of the multiple tape feeders 1 and feeder management device 4 set on the pallet table 931 when not mounted on the component mounting machine 9 will be described with reference to the operation flow in FIG. 7. Steps S11 to S22 in FIG. 7 are executed by the operator and the control unit 2 of the tape feeder 1, and steps S31 to S39 are executed by the operator and the upper control unit 6 of the feeder management device 4. As shown in the figure, the tape feeder 1 and the feeder management device 4 operate in parallel under the operation of the operator. Furthermore, steps S11 to S22 are executed in parallel for the multiple tape feeders 1 set on the pallet table 931. Note that commands and information sent and received between the tape feeder 1 and the feeder management device 4 are indicated by dashed arrows in FIG. 7.

[0055] 7, the operator removes the pallet table 931 that has been used by the component mounting machine 9 and moves it near the feeder management device 4. Next, the operator connects the harness 7 to the pallet table 931. This causes power to be supplied from the power supply unit 5 to the multiple tape feeders 1, and the control unit 2 of each tape feeder 1 starts up. After this, the operation flow branches into step S11 on the tape feeder 1 side and step S31 on the feeder management device 4 side.

[0056] In step S31, the upper control unit 6 of the feeder management device 4 simultaneously transmits a mode command indicating the non-operation mode to each control unit 2 of the multiple tape feeders 1. Then, in step S11, each control unit 2 receives the mode signal. In the next step S12, the control unit 2 determines that the mode is the non-operation mode and assigns the function in the non-operation mode column in FIG. 4 to the operation panel 3. In this embodiment, of the command acceptance state and the command rejection state, the former is set as the initial default state in the non-operation mode. Accordingly, the control unit 2 lights the indicator lamp 34 in red to notify that the command acceptance state is in effect.

[0057] In the next step S13, the operator presses the feed button 31 as necessary. That is, the operator presses the feed button 31 of the tape feeder 1 that does not require a return operation, without touching the tape feeder 1 that is to perform the return operation. Then, in the next step S14, the control unit 2 switches the command acceptance state to a command rejection state. Furthermore, in step S15, the control unit 2 switches the indicator lamp 34 from red to green to notify that the command rejection state is in effect. Steps S13 to S15 can be executed repeatedly, making it possible to correct any mistakes or operational errors made by the operator.

[0058] For example, if the feed button 31 of the tape feeder 1 that performs the return operation is pressed by mistake, the control unit 2 switches to the command rejection state, and the indicator lamp 34 changes from red to green. The operator notices the erroneous operation by visually checking the green light of the indicator lamp 34, and then simply presses the feed button 31 again in step S13. This switches the control unit 2 to the command acceptance state, and the indicator lamp 34 changes from green to red, correcting the erroneous operation.

[0059] In many cases, the majority of the tape feeders 1 set on the pallet table 931 are tape feeders 1 that perform the return operation. Therefore, by setting the command acceptance state to the default state, the number of tape feeders 1 that execute step S13 is reduced, thereby reducing the number of times the operator has to press the feed button 31. On the other hand, examples of tape feeders 1 that do not require the return operation include spare tape feeders 1 that have been loaded with carrier tape CT but have not been used by the component mounting machine 9, and tape feeders 1 in which the carrier tape CT has been cut with scissors or the like so that it does not extend beyond the feeder body 11 and is left on the pallet table 931.

[0060] The operator executes step S13 as necessary for all tape feeders 1 on the pallet table 931. After this, the operator moves to the side of the feeder management device 4. In step S32, the operator uses the setting unit 42 to set the tape return amount for the return operation performed by the tape feeding mechanism 15. In the next step S33, the operator presses the start button 43. In the next step S34, the upper control unit 6 broadcasts a request to send status information.

[0061] The control unit 2 determines in step S16 whether a transmission request has been received, and allows the repeated operations of steps S13 to S15 while a transmission request has not been received. When a transmission request has been received in step S16, the control unit 2 advances the operation flow to step S17. From this point onwards, the control unit 2 ignores any pressing of the forward button 31 and fixes the command acceptance state or the command rejection state. In step S17, the control unit 2 transmits state information indicating whether the state is the command acceptance state or the command rejection state.

[0062] In step S35, the host control unit 6 receives status information from each of the multiple control units 2. In the next step S36, the host control unit 6 determines the execution order of the return operations, etc., under the condition that the power supply capacity of the system power line 52 is not exceeded. For example, assume that the number of tape feeders 1 for which the control unit 2 is in a command acceptance state is two on the first system power line 52, three on the second system power line 52, six on the third system power line 52, and one on the fourth system power line 52.

[0063] In this case, the host control unit 6 selects, in the first execution order, two tape feeders 1 on the first system power line 52, two on the second system power line 52, two on the third system power line 52, and one on the fourth system power line 52. In the second execution order, the host control unit 6 selects the one tape feeder 1 remaining on the second system power line 52 and two other tape feeders 1 on the third system power line 52. Furthermore, in the third execution order, the host control unit 6 selects the two tape feeders remaining on the third system power line 52. In the next step S37, the host control unit 6 first transmits a return command to the control units 2 of the seven tape feeders 1 selected in the first execution order. At this time, the host control unit 6 also transmits the tape return amount that was set in step S32.

[0064] On the other hand, the control unit 2 checks its own status information after executing step S17. If the status information indicates a command rejection state, the operation flow of the control unit 2 immediately ends. If the status information indicates a command acceptance state, in step S19, the control unit 2 waits to receive a return command. In step S20 after receiving the return command, the control unit 2 causes the tape feed mechanism 15 to execute a return operation corresponding to the received tape return amount. In step S21 after the return operation is completed, the control unit 2 transmits end information indicating that the return operation is completed. In the next step S22, the control unit 2 switches the indicator lamp 34, which is lit red, to off to notify the completion of the return operation. This ends the operation flow of the control unit 2.

[0065] The host control unit 6 receives the end information in step S38. When the host control unit 6 receives the end information from all seven tape feeders 1 to which it sent return commands, it advances the operation flow to step S39. In step S39, the host control unit 6 determines whether all execution sequences have been completed, and if not, returns the operation flow to step S37. At this point, the second execution sequence and the third execution sequence still remain, so the operation flow returns to step S37. In the second step S37, the host control unit 6 sends a return command to the control unit 2 of each of the three tape feeders 1 selected for the second execution sequence. Then, the control unit 2 of the tape feeder 1 that is different from that in the first execution sequence executes steps S19 to S22.

[0066] The host control unit 6 executes step S38 for the second time, and because the third execution order still remains in step S39 for the second time, returns the operation flow to step S37 again. In step S37 for the third time, the host control unit 6 sends a return command to the control unit 2 of each of the two tape feeders 1 selected for the third execution order. Then, the control unit 2 of the tape feeder 1 that is different from that in the first execution order and the second execution order executes steps S19 to S22. The host control unit 6 executes step S38 for the third time, and determines in step S39 for the third time that all execution orders have been completed. This marks the end of the operation flow of the host control unit 6.

[0067] The operator can visually check the indicator lamps 34 and efficiently proceed with the setup work for the pallet table 931. That is, the operator first removes some of the tape feeders 1 whose indicator lamps 34 are lit green, and moves and stores them with the carrier tape CT loaded. The operator also leaves the remaining tape feeders 1 whose indicator lamps 34 are lit green on the pallet table 931, making them available for the next use. The operator then removes the tape feeders 1 whose indicator lamps 34 are extinguished, and then removes the reels RL from the removed tape feeders 1. These operations are possible even if the tape feeders 1 whose indicator lamps 34 are lit red remain. In other words, the operator can sequentially remove the tape feeders 1 whose indicator lamps 34 have changed from lit red to extinguished, thereby making the setup work more efficient. After this, the operator sets the separately set-up tape feeders 1 on the pallet table 931, preparing for the next use.

[0068] In conventional tape feeders, the return operation has been performed for each tape feeder by pressing and holding the return button 33. However, with this conventional technology, operating each tape feeder one by one takes a long time, and the operator has to repeatedly press the return button 33, which is cumbersome. Furthermore, the amount of tape returned varies from tape feeder to tape feeder. Furthermore, in conventional feeder management devices, a return command has been sent simultaneously to all tape feeders set on the pallet table 931. However, with this conventional technology, the carrier tape CT is returned even for tape feeders that do not require a return operation, resulting in the redundant work of reloading the carrier tape CT.

[0069] In contrast to the above-described conventional technology, in the embodiment, when the tape feeder 1 is in the non-operation mode, the operator can press the return button 33 to switch the control unit 2 between a command acceptance state and a command rejection state. In the command acceptance state, the control unit 2 causes the tape feeding mechanism 15 to perform a return operation upon receiving a return command. In the command rejection state, the control unit 2 does not cause the tape feeding mechanism 15 to perform a return operation even upon receiving a return command. Therefore, depending on whether the operator presses the return button 33, it is easy to set whether the tape feeder 1 automatically performs a return operation to return the carrier tape CT in the reverse direction. Furthermore, with the tape feeder 1 and feeder management device 4 of the embodiment, the return operation is automatically performed in the tape feeder 1 in which the control unit 2 is in the command acceptance state, thereby reducing the operator's workload. Furthermore, because unnecessary return operations are not performed in the tape feeder 1 in which the control unit 2 is in the command rejection state, the redundant loading of the carrier tape CT is avoided.

[0070] Furthermore, in the tape feeder 1 of the embodiment, different functions are assigned to the operation panel 3 in the non-operating mode and the operating mode, which simplifies the structure and reduces costs compared to a configuration in which separate operation units and notification units are provided for the non-operating mode and the operating mode. In addition, the configuration of the embodiment can be realized simply by updating the software of the control unit 2 of a conventional tape feeder and the upper control unit 6 of a conventional feeder management device. Therefore, the embodiment can be easily applied to conventional devices used in users' factories, etc.

[0071] 6. Operation in a Modified Form with No Power Supply Capacity Constraints Next, we will explain the operation of the tape feeder 1 and the feeder management device 4 in a modified form in which there are no power supply capacity constraints on the power supply unit 5, power line 51, and system power line 52. In a modified form in which there are no power supply capacity constraints, the sending and receiving of the status information and end information described in the embodiment is unnecessary, and the operation flow is simplified as shown in Figure 8. Step S01, steps S11 to S15, and steps S31 to S33 in Figure 8 are the same as those described in the embodiment and in Figure 7, so their explanation will be omitted.

[0072] 8, the operator presses the start button 43 of the feeder management device 4. In the next step S37A, the host control unit 6 simultaneously transmits a return command to each of the control units 2 of the multiple tape feeders 1 on the pallet table 931. At this time, the host control unit 6 also transmits the tape return amount that was set in step S32. This completes the operation flow of the host control unit 6.

[0073] Meanwhile, in step S16A, the control unit 2 of the tape feeder 1 determines whether a return command has been received, and allows the repeated operations of steps S13 to S15 while a return command has not been received. When a return command has been received in step S16A, the control unit 2 advances the operation flow to step S18. From this point onwards, the control unit 2 ignores any pressing of the feed button 31 and fixes the command acceptance state or the command rejection state. In step S18, the control unit 2 checks whether it is in the command acceptance state or the command rejection state. If it is in the command rejection state, the operation flow of the control unit 2 immediately ends.

[0074] In step S20 when the command is accepted, the control unit 2 causes the tape feeding mechanism 15 to perform a return operation corresponding to the received tape return amount. In step S22 after the return operation is completed, the control unit 2 turns off the indicator lamp 34, which has been lit red, to notify the completion of the return operation. This completes the operation flow of the control unit 2. In this modified form, as in the embodiment, it is possible to easily set whether or not the tape feeder 1 automatically performs the return operation, and the workload on the operator is reduced.

[0075] 7. Applications and Modifications of the Embodiments It is possible to configure a system in which the control unit 2 is located outside the tape feeder 1, for example on the pallet table 931. In other words, it is possible to configure a feeder management system that includes: a tape feeder that is detachably mounted on a component mounting machine 9 and supplies components accommodated on the carrier tape CT, the tape feed mechanism 15 having a feeding operation that feeds the carrier tape CT in a predetermined feeding direction and a returning operation that returns the carrier tape CT in the opposite direction, and an operation panel 3 that accepts operations from an operator; and a control unit 2 that, in a non-operating mode in which power is supplied while the tape feeder is not mounted on the component mounting machine 9, switches between a command acceptance state in which the tape feed mechanism 15 performs a return operation when a predetermined return command is received, and a command rejection state in which the tape feed mechanism 15 does not perform a return operation even when a return command is received, based on operations accepted by the operation panel 3.

[0076] Furthermore, when multiple models of tape feeders 1 with different tape retraction amounts are mixed on the pallet table 931, the operator can set the tape retraction amount separately for each model and have the tape feeding mechanism 15 perform the retraction operation for each model. The host control unit 6 may also use a different control method that does not exceed the power capacity of each of the four system power lines 52. For example, if the number of tape feeders 1 for which the control unit 2 is in a command receiving state is six on the third system power line 52, the host control unit 6 may send a retraction command to two of the six tape feeders, and each time it receives completion information from one tape feeder, it may send a retraction command to another tape feeder, repeating this process. Furthermore, a dedicated operation unit and notification unit for use in the non-operation mode may be provided in addition to the operation panel 3 used in the operation mode. Various other applications and modifications of the embodiment are possible.

[0077] 1: Tape feeder 11: Feeder body 12: Reel holding section 13: Tape transport path 14: Tape guide 15: Tape feeding mechanism 16: Discharge mechanism 2: Control section 3: Operation panel 31: Feed button 32: Home button 33: Return button 34: Indicator lamp 4: Feeder management device 42: Setting section 43: Start button 5: Power supply section 51: Power line 52: System power line 53: Individual power line 6: Upper control section 61: Communication line 9: Component placement machine 93: Component supply device 931: Pallet table 933: Slot CT: Carrier tape BT: Base tape VT: Cover tape RL: Reel

Claims

1. A tape feeder detachably equipped on a component mounting machine for supplying components housed in a carrier tape, the tape feeder comprising: a tape feeding mechanism configured to perform a feeding operation for feeding the carrier tape in a predetermined feeding direction and a returning operation for returning the carrier tape in the reverse direction; an operation unit configured to receive an operator's operation; and a control unit configured to switch between a command reception state in which, when a predetermined return command is received based on the operation received by the operation unit in a non-operating mode in which power is supplied while the tape feeder is not equipped on the component mounting machine, the tape feeding mechanism is caused to perform the returning operation, and a command rejection state in which the tape feeding mechanism is not caused to perform the returning operation even when the return command is received.

2. The tape feeder according to claim 1, wherein the control unit determines that the tape feeder is in an operating mode when the tape feeder is communicatively connected to a mounting control unit included in the component mounting machine, and determines that the tape feeder is in the non-operating mode when the tape feeder is not communicatively connected to the mounting control unit.

3. The tape feeder according to claim 1, wherein the control unit determines that the tape feeder is in the non-operating mode when the tape feeder is communicatively connected to another control unit other than the mounting control unit included in the component mounting machine, or when the tape feeder receives a mode command indicating the non-operating mode from the other control unit.

4. The tape feeder according to any one of claims 1 to 3, wherein in an operating mode in which power is supplied while the tape feeder is equipped on the component mounting machine, the control unit does not receive an operation on the operation unit for switching between the command reception state and the command rejection state, and fixes the tape feeder in the command rejection state.

5. The tape feeder according to claim 4, wherein in the operating mode, functions other than the function of switching between the command reception state and the command rejection state are assigned to the operation unit.

6. The tape feeder according to any one of claims 1 to 3, further comprising a notification unit configured to notify the operator of the command reception state or the command rejection state in the non-operating mode.

7. The tape feeder according to claim 6, wherein when the control unit receives the return command in the command reception state in the non-operating mode, after the tape feeding mechanism finishes the returning operation, the control unit causes the notification unit to notify that the returning operation has ended.

8. The notification unit is an indicator lamp to which a function other than the function of notifying the operator of the command reception state or the command rejection state is assigned in an operating mode in which power is supplied with the tape feeder being equipped in the component mounter, the tape feeder according to claim 6.

9. A feeder management device comprising: a power supply unit that supplies power to the tape feeder according to any one of claims 1 to 3 removed from the component mounter; and a host control unit that is communicatively connected to the control unit of the tape feeder and transmits the return command.

10. The host control unit according to claim 9, which transmits a mode command indicating the non-operating mode to the control unit.

11. The host control unit according to claim 9, which transmits a tape return amount that can be changed in setting in the return operation to the control unit.

12. The power supply unit and the host control unit are connected to each of a plurality of the tape feeders via a pallet stand on which the plurality of the tape feeders are set to be replaceable and detachably equipped on the component mounter, the feeder management device according to claim 9.

13. The host control unit according to claim 12, which transmits the return command to each of the control units of the plurality of the tape feeders all at once.

14. The host control unit is based on state information indicating whether each of the control units of the plurality of the tape feeders is in the command reception state or the command rejection state, and the power capacity of the power supply line connecting the power supply unit and the plurality of the tape feeders or the power capacity of the power supply unit, and regulates the number of the tape feeders that perform the return operation all at once to be equal to or less than a predetermined number, the feeder management device according to claim 13.

15. A tape feeder that is detachably mounted on a component mounter, has a tape feeding mechanism that performs a feeding operation for feeding a carrier tape in a predetermined feeding direction and a returning operation for returning it in the reverse direction, and an operation unit that receives an operator's operation, and supplies a component housed in the carrier tape. In a non-operating mode in which power is supplied while the tape feeder is not mounted on the component mounter, based on the operation received by the operation unit, when a predetermined return command is received, a command reception state for causing the tape feeding mechanism to perform the returning operation, and a control unit that switches between a command rejection state in which the tape feeding mechanism is not caused to perform the returning operation even when the return command is received. A feeder management system comprising:

Images