Production assistance device and production assistance method

Abstract

A production assistance device is applied to a component mounting machine for executing a mounting process using a bulk feeder, and comprises: a state detection unit that detects whether a shutter is in a closed state or an open state, in which at least a portion of an opening of a supply region is open, when the mounting process is paused; and a shutter control unit that transitions the shutter to the closed state when the shutter is detected to be in the open state.

Description

Production support device and production support method

[0001] The present invention relates to a production support device and a production support method.

[0002] The production support device supports the production process of product boards by a component placement machine using a bulk feeder. The bulk feeder supplies components in bulk form in a supply area (see Patent Document 1). In a placement process as part of the production process, the component placement machine moves a placement head to pick up components supplied by a feeder such as the bulk feeder and place the components in predetermined positions on the board.

[0003] International Publication No. 2022 / 162919

[0004] If foreign matter (including components of a different type from the components being supplied) gets into the supply area of ​​a bulk reader, it may affect the component picking operation of a component mounting machine. Therefore, there is a need to prevent foreign matter from getting into the supply area of ​​a bulk feeder in a mounting process by a component mounting machine that uses a bulk feeder.

[0005] The present specification aims to provide a production support device and a production support method that can prevent foreign matter from entering a bulk feeder used in a mounting process by a component mounting machine.

[0006] This specification discloses a production support device that is applicable to a component mounting machine that performs mounting processing using a bulk feeder, the bulk feeder having a shutter that is openable and closable relative to a supply area that supplies a plurality of components so that they can be picked up and that closes the supply area in a closed state, and that includes a state detection unit that detects whether the shutter is in the closed state or an open state that opens at least a portion of the opening of the supply area when the mounting processing is interrupted, and a shutter control unit that transitions the shutter to the closed state when it is detected that the shutter is in the open state.

[0007] This specification discloses a production support method that is applicable to a component mounting machine that performs mounting processing using a bulk feeder, the bulk feeder having a shutter that is openable and closable relative to a supply area that supplies a plurality of components so that they can be picked up and that closes the supply area in a closed state, the production support method comprising: a state detection step that detects whether the shutter is in the closed state or an open state that opens at least a portion of the opening of the supply area when the mounting processing is interrupted; and a shutter control step that transitions the shutter to the closed state when the shutter is detected to be in the open state.

[0008] This specification also discloses the technical idea of ​​changing "the production support device described in claim 2" in claim 6 at the time of filing to "the production support device described in any one of claims 2-5," and the technical idea of ​​changing "the production support device described in any one of claims 1-8" in claim 10 at the time of filing to "the production support device described in any one of claims 1-9."

[0009] With this configuration, if the mounting process is interrupted, the shutter is appropriately switched to the closed state, shortening the period during which the shutter is maintained in the open state and preventing foreign matter from getting in. As a result, it is possible to prevent errors in the picking operation due to foreign matter getting in and maintain the productivity of the component mounting machine.

[0010] FIG. 5 is a plan view schematically showing a component mounting machine. FIG. 6 is a top view schematically showing a mounting head. FIG. 7 is a side view schematically showing a mounting head. FIG. 8 is a side view schematically showing a part of a bulk feeder including a supply area. FIG. 9 is a plan view seen from direction V in FIG. 4. FIG. 10 is a perspective view showing the opening and closing operation of a shutter. FIG. 11 is a flowchart showing a mounting process by a component mounting machine. FIG. 12 is a block diagram showing a production support device. FIG. 13 is a flowchart showing a production support process. FIG. 14 is a side view showing a suction nozzle located in the supply area. FIG. 15 is a flowchart showing a modified mode of the production support process.

[0011] 1. Overview of the production support device 70 The production support device 70 supports the production processing of product boards by the component mounting machine 10 using the bulk feeder 30. In the embodiment, the production support device 70 is incorporated into the control device 16 of the component mounting machine 10. The production support device 70 prevents foreign matter from entering the bulk feeder 30 during the mounting processing performed as part of the production processing by the component mounting machine 10, thereby maintaining productivity.

[0012] The component mounting machine 10 described above performs a mounting process for mounting components on a board 91 as a predetermined substrate-related operation. The component mounting machine 10 is installed along with other substrate-related operation machines in the transport direction of the board 91 to form a production line. Each of the multiple substrate-related operation machines is communicably connected to a host computer 60 that controls the production line as a whole. The production line includes, for example, multiple substrate-related operation machines, such as a printing machine, the component mounting machine 10, a reflow oven, and an inspection machine.

[0013] 2. Configuration of the component mounting machine 10 2-1. Board transport device 11, component supply device 12

[0014] As shown in FIG. 1 , the component mounting machine 10 includes a board transport device 11. The board transport device 11 sequentially transports boards 91 in a transport direction and positions the boards 91 at predetermined positions within the machine. The component mounting machine 10 also includes a component supply device 12. The component supply device 12 supplies components to be mounted on the boards 91. The component supply device 12 has feeders 122 set in multiple slots 121. For example, a tape feeder that feeds and moves a carrier tape containing a large number of components to supply the components so that they can be picked is used as the feeder 122. Furthermore, a bulk feeder 30 that supplies components stored in bulk so that they can be picked is used as the feeder 122. Details of the bulk feeder 30 will be described later.

[0015] 2-2. Component Transfer Device 13 The component mounting machine 10 is equipped with a component transfer device 13. The component transfer device 13 transfers components supplied by the component supply device 12 to predetermined mounting positions on the board 91. The component transfer device 13 is equipped with a head drive device 131, a movable table 132, and the mounting head 20. The head drive device 131 moves the movable table 132 in horizontal directions (X and Y directions) using a linear motion mechanism. The mounting head 20 is detachably fixed to the movable table 132 by a clamp member (not shown), and is provided so as to be movable horizontally within the machine.

[0016] As shown in Figures 2 and 3, the mounting head 20 has a rotary head 21 that is rotatable around an R axis parallel to a vertical axis (Z axis). The rotary head 21 supports a plurality of holders 22 so that they can move up and down and rotate around a rotation axis (Q axis) for each of the holders 22. Each of the holders 22 is fitted with a holding member that holds a component 92. In this embodiment, the holding member is a suction nozzle 23 that holds the component 92 by suction using supplied negative pressure air. Note that a chuck or the like that grips and holds a component may also be used as the holding member.

[0017] The mounting head 20 has an R-axis rotation device 24 that rotates the rotary head 21 around the R-axis. The R-axis rotation device 24 angles the rotary head 21 at a predetermined angle around the R-axis, thereby indexing one holder 22 to an elevation position where it is to be elevated or lowered by an elevation device 26, which will be described later. The mounting head 20 has a Q-axis rotation device 25 that rotates the holder 22 around the Q-axis. In this embodiment, the Q-axis rotation device 25 has a mechanism that rotates multiple holders 22 in unison, and is used to rotate the multiple holders 22. With the above configuration, when one holder 22 is angled at a predetermined angle around the Q-axis, the other multiple holders 22 are also angled at predetermined angles in unison.

[0018] The mounting head 20 has an elevator device 26 that raises and lowers a holder 22 that is indexed to a lift position by the rotation of the rotary head 21 among the plurality of holders 22. The elevator device 26 lowers and raises the holder 22, thereby lowering and raising the suction nozzle 23 attached to the holder 22. The mounting head 20 may be configured to have two or more lift positions and include a plurality of elevator devices that can be driven independently so as to raise and lower the holders 22 positioned at the respective positions.

[0019] The number of holders 22 supported by the mounting head 20 configured as described above may vary depending on the type of mounting head 20. The mounting head 20 may adopt various configurations in addition to the configuration in which multiple holders 22 are supported at equal intervals in a circular ring shape as in this embodiment. For example, the mounting head 20 may adopt a configuration in which multiple holders 22 are supported arranged in a line or in a matrix.

[0020] 2-3. Component Camera 14, Board Camera 15 The component mounting machine 10 is equipped with a component camera 14 and a board camera 15. The component camera 14 and the board camera 15 are digital imaging devices having imaging elements such as CMOS. The component camera 14 and the board camera 15 capture images based on control signals and send image data acquired by the images. The component camera 14 is configured to be able to capture images of the components held by the suction nozzles 23 from below. The board camera 15 is mounted on a moving stage 132 so as to be movable horizontally integrally with the mounting head 20. The board camera 15 is configured to be able to capture images of the board 91 from above.

[0021] Furthermore, in addition to capturing an image of the surface of the circuit board 91, the board camera 15 can also capture an image of various devices within the movable range of the movable stage 132. For example, in this embodiment, as shown in Fig. 5, the board camera 15 can capture an image of the supply area As to which the bulk feeder 30 supplies components and the reference mark 49 provided on the upper part of the bulk feeder 30 within the camera's field of view. In this way, the board camera 15 can be used to capture images of different objects in order to obtain image data to be used for various image processing.

[0022] 2-4. Control Device 16 The component mounting machine 10 is equipped with a control device 16. The control device 16 is mainly composed of a CPU, various memories, a control circuit, and a storage device. The storage device of the control device 16 stores various data, such as a control program used to control the mounting process and component data. The control program indicates the mounting position, mounting angle, and component type of components to be mounted on the board 91 in the mounting process in the planned mounting order. The component data indicates shape data, allowable movement speed, pick-up position, etc. for each type of component.

[0023] Here, the mounting process includes a process of repeating a PP cycle (pick-and-place cycle), which includes a pickup cycle and a mounting cycle, multiple times. The above-mentioned "picking cycle" refers to a process of repeating a pickup operation multiple times, in which components supplied by the component supply device 12 are picked up by the suction nozzle 23. In a pickup cycle, the components to be picked up may be supplied by the bulk feeder 30. If the supply area As of the bulk feeder 30 is formed with cavities 45 (see FIG. 5) that individually accommodate components, the pickup cycle involves moving the mounting head 20 to sequentially pick up components accommodated in the multiple cavities 45.

[0024] The above-mentioned "mounting cycle" refers to the process of sequentially mounting picked components onto the board 91, and more specifically, to the process of repeating a mounting operation multiple times to mount components at a predetermined mounting position and angle on the board 91. In this way, the control program has preset therein the execution order of a PP cycle, which is made up of multiple picking operations and mounting operations grouped together, taking into consideration the number of suction nozzles 23 supported by the mounting head 20, the movement distance of the mounting head 20, etc.

[0025] The control device 16 executes a process for recognizing the holding state of the components held by each of the multiple holding members (suction nozzles 23). Specifically, the control device 16 processes image data acquired by image capture by the component camera 14, and recognizes the position and angle of each component relative to the reference position of the mounting head 20. Note that in addition to the component camera 14, the control device 16 may also process image data acquired by, for example, a head camera unit integrally provided on the mounting head 20 capturing an image of the component from the side, below, or above.

[0026] In the mounting process, the control device 16 controls the mounting operation by the mounting head 20 so that the component is mounted on the board 91 in a predetermined orientation. At this time, the control device 16 controls the mounting operation based on the recognized holding state of the component. In other words, the control device 16 corrects the position of the mounting head 20 and the angle of the suction nozzle 23 about the Q axis so as to correct any positional and angular deviations of the component held by the suction nozzle 23 relative to the Q axis (the axis of rotation of the suction nozzle 23). As a result, the component held by the suction nozzle 23 is mounted at a predetermined mounting position and angle instructed by the control program.

[0027] 3. Configuration of Bulk Feeder 30 Bulk feeder 30 is set in component mounting machine 10 and functions as part of component supply device 12. Bulk feeder 30 supplies components housed in component cases in a bulk state (loose, with each component in an irregular position) that is not packaged like a carrier tape. Therefore, unlike tape feeders, bulk feeder 30 does not use carrier tape, which has the advantage of eliminating the need to load carrier tape and collect used tape.

[0028] Some bulk feeders 30 supply components in irregular positions to a planar supply area, for example. However, if the components are so close together in the supply area that they touch each other, or if they are piled up (overlapping vertically), or if the components are positioned horizontally so that their widths are vertical, the component mounting machine 10 cannot pick these components. Therefore, to increase the percentage of components that can be picked, some bulk feeders 30 supply components in an aligned state in the supply area As. In this embodiment, a bulk feeder 30 of the aligned type will be described as an example.

[0029] 3-1. Feeder Body 31 The bulk feeder 30 has a track unit 40 attached to a flat, box-shaped feeder body 31 so that the track unit 40 can vibrate and be detachably attached to the feeder body 31. A connector 311 and two positioning pins 312 are provided at the front of the feeder body 31 (the right end in FIG. 4 ). When the feeder body 31 is set in the slot 121 of the component supply device 12, it is supplied with power via the connector 311 and is capable of communicating with the control device 16 of the component mounting machine 10. The two pins 312 are inserted into guide holes provided in the slot and are used to position the feeder body 31 when it is set in the slot.

[0030] 3-2. Track Unit 40 The track unit 40 includes a track member 41 that is detachably attached to the feeder body 31. The track member 41 is vibrated by the vibration device 34. The track member 41 defines a transport path R along which multiple components are transported, and a supply area As that is connected to the transport path R and opens upward so that multiple components can be picked up. Here, the "supply area As" refers to an area where components are supplied in bulk and from which the component mounting machine 10 can pick up the components. The "transport path R" refers to a path along which components circulated from the component case side to the track member 41 are transported to the supply area As.

[0031] The track member 41 is formed so as to extend in the front-to-rear direction (the left-to-right direction in FIG. 4 ) of the feeder body 31 as a whole. In this embodiment, as shown in FIG. 5 , an alignment member 42 is replaceably attached to the track member 41. The alignment member 42 is, for example, one or more plate-shaped members. In this way, the track unit 40 is unitized by attaching one of a plurality of types of alignment members 42 selected from a plurality of types corresponding to the shapes of a plurality of types of parts to the common track member 41.

[0032] 5, the alignment member 42 defines a plurality of cavities 45 arranged in a predetermined pattern (a staggered pattern in this embodiment). Each of the plurality of cavities 45 has a rectangular shape that is slightly larger than the outer shape of the components supplied by the bulk feeder 30. Thus, the bulk feeder 30 has a plurality of cavities 45 that store components in a supply area As that supplies the components so that they can be picked up, with the thickness direction of the components oriented vertically.

[0033] A pair of side walls 46 that protrude upward are formed on both edges of the track unit 40 in the width direction (vertical direction in FIG. 5 ). The pair of side walls 46, together with a tip 47 of the track unit 40, surround the periphery of the transport path R and prevent parts transported on the transport path R from leaking out. A cover 48 that covers the top of the transport path R is fixed above the track member 41. The cover 48 is configured to prevent parts from jumping out of the transport path R. A pair of circular reference marks 49, one on the left and one on the right, are provided on the upper surface of the tip 47 to indicate the reference position of the supply area As.

[0034] A shutter 50 is provided on the front end side of the track member 41. The shutter 50 is provided on the track member 41 so as to be able to open and close, and in the closed state, closes the opening of the supply area As. When the track unit 40 is attached to the feeder body 31, the shutter 50 is connected to the shutter drive device 35. The opening and closing operation of the shutter 50 is controlled by the shutter drive device 35. By opening and closing the shutter 50, the bulk feeder 30 can prevent components from flying out and foreign matter from entering the supply area As. The above-mentioned "foreign matter" includes different types of components that are different from the components supplied by the bulk feeder 30.

[0035] Shutter drive device 35 is a drive device that opens and closes shutter 50 when track unit 40 is attached to feeder body 31. Shutter drive device 35 switches shutter 50 between a closed state and an open state based on a command from feeder control device 36. The closed state of shutter 50 is a state in which shutter 50 contacts track member 41 and the opening of supply area As is completely closed, as shown by the dashed lines in Figures 5 and 6 .

[0036] The open state of the shutter 50 refers to a state in which the opening of the supply area As is not blocked and the main range of the supply area As (the range in which the multiple cavities 45 are provided in this embodiment) is exposed (see the solid line in FIG. 6). In this embodiment, the open state of the shutter 50 includes a state in which at least a portion of the opening of the supply area As is open and the suction nozzle 23, which is the holding member, can perform a component picking operation for any of the cavities 45.

[0037] The state of the shutter 50 includes an intermediate state between the closed state and the open state. The intermediate state of the shutter 50 is a state in which the shutter 50 is slightly spaced apart from the track member 41 (slightly spaced apart so as not to interfere with the vibration of the track member 41 and to prevent components from leaking through the gap). In this embodiment, the intermediate state is a state in which the suction nozzle 23 cannot access the supply area As and is a state in which entry of foreign matter can be prevented, so the intermediate state is considered to be included in the closed state.

[0038] 3-3. Feeder Control Device 36 The bulk feeder 30 is equipped with a feeder control device 36. The feeder control device 36 is mainly composed of a CPU, various memories, and control circuits. When the bulk feeder 30 is installed in a slot of the component mounting machine 10, the feeder control device 36 is supplied with power via the connector 311 and is able to communicate with the control device of the component mounting machine 10.

[0039] The feeder control device 36 controls the operation of the vibration device 34, the shutter drive device 35, etc. The feeder control device 36 controls the operation of the vibration device 34 based on, for example, preset parameters to execute the component supply process. As a result, vibration is applied to the track member 41, and the components on the conveying path R are conveyed by receiving an external force that moves them in the conveying direction. The feeder control device 36 also controls the operation of the shutter drive device 35, and switches the shutter 50 to a predetermined state.

[0040] 4. Mounting Process by Component Mounting Machine 10 The mounting process by the component mounting machine 10 will be described with reference to Fig. 7. Here, it is assumed that the bulk feeder 30 is set in the component supply device 12. In the mounting process, first, the board transport device 11 of the component mounting machine 10 executes a board 91 loading process (S11), as shown in Fig. 7. As a result, the board 91 is loaded into the machine and positioned at a predetermined position within the machine.

[0041] Next, the control device 16 executes a PP cycle. In the PP cycle, the control device 16 executes a pickup cycle in which the pickup operation of picking up components using the multiple suction nozzles 23 is repeated (S12). At this time, the control device 16 controls the operation of the mounting head 20 in the pickup operation so that the mounting head 20 is sequentially positioned according to the positions of the components that can be picked up. Furthermore, when the bulk feeder 30 is supplying the components to be picked up, the control device 16 positions the suction nozzle 23 by appropriately switching between the coordinate values ​​of the center of the cavity 45 or the coordinate values ​​of the reference position of the component as the position of the components that can be picked up.

[0042] Next, the control device 16 executes a process for recognizing the holding state of the components held by each of the plurality of suction nozzles 23 (S13). Specifically, the control device 16 moves the mounting head 20 above the component camera 14 and sends an image capture command to the component camera 14. The control device 16 processes the image data acquired by the component camera 14, and recognizes the orientation (position and angle) of the component held by each of the plurality of suction nozzles 23.

[0043] Thereafter, the control device 16 executes a mounting cycle (S14) in which the mounting operation of mounting components using the plurality of suction nozzles 23 is repeated. In the mounting operation of this mounting cycle (S14), the control device 16 controls the operation of the mounting head 20 so that each component is mounted at a mounting position specified by the control program. Furthermore, the control device 16 controls the operation of the mounting head 20 so that the suction nozzles 23 are positioned and angled relative to the mounting positions based on the results of the recognition process (S13).

[0044] The control device 16 determines whether all PP cycles have been completed based on the control program (S15). If all PP cycles have not been completed (S15: No), the control device 16 executes the PP cycles (S12-S14). If all PP cycles have been completed (S15: Yes), the control device 16 executes the unloading process of the board 91 (S16). In the unloading process of the board 91, the board transport device 11 unclamps the positioned board 91 and unloads the board 91 from the component mounting machine 10.

[0045] 5. Production Support Device 70 The configuration of the production support device 70 will be described with reference to FIGS. 8 to 10. The production support device 70 supports the production process of product boards by the component mounting machine 10 using the bulk feeder 30. Here, the bulk feeder 30 supplies components in bulk form in the supply area As. Then, in the picking cycle of the mounting process (S12 in FIG. 7), the component mounting machine 10 moves the mounting head 20 to pick up components supplied by the feeder 122, such as the bulk feeder 30, and mounts the components in predetermined positions on the board 91.

[0046] The bulk feeder 30 is provided with an openable / closable shutter 50, and the shutter 50 can be closed to prevent the intrusion of foreign matter, for example, except during the period when the picking operation is being performed on the components supplied by the bulk feeder 30. However, the mounting process may be interrupted for some reason while being performed by the component mounting machine 10. The interruption of the mounting process may be a measure taken when an operator issues a stop instruction or when an abnormality is detected in the component mounting machine 10.

[0047] Specifically, the component placement machine 10 is provided with an emergency stop button (not shown). For example, an operator may discover a problem with the production process and press the emergency stop button. In this case, the component placement machine 10 will interrupt the current placement process, assuming that it has received a stop command. Furthermore, if the component placement machine 10 detects an abnormal operation of one of the components during the current placement process or if a certain number of predetermined operational errors (e.g., incorrect component picking) occur consecutively, it will interrupt the current placement process, assuming that an abnormality has been detected.

[0048] When the placement process is interrupted as described above, in principle, all of the component devices either maintain their current state and stop, or transition to a safe state as a fail-safe function and stop. Then, an operator or the control device 16 performs maintenance within the machine (including identifying the cause and removing the malfunction), after which the placement process is resumed. In such a case, if a foreign object gets into the bulk feeder 30, it could affect the subsequent component picking operation.

[0049] In particular, if a different type of component accidentally gets mixed into the supply area As of the bulk feeder 30, a component different from the supplied component will be fed, necessitating maintenance of the bulk feeder 30. Even if the different type of component can be detected by inspection of the board product, this will result in reduced productivity. Therefore, the production support device 70 of this embodiment employs a configuration that prevents the mixing of different types of components into the supply area As of the bulk feeder 30 during the production process of product boards using the bulk feeder 30.

[0050] In an embodiment, when the placement process is interrupted, the production support device 70 appropriately controls the operating state of the shutter 50 of the bulk feeder 30 to prevent foreign matter (including different types of components) from entering the supply area As. Specifically, as shown in FIG. 8 , the production support device 70 includes a state detection unit 71 and a shutter control unit 72. The production support device 70 may further include an interference determination unit 73, an evacuation command unit 74, and a regulation unit 75. When the placement process is interrupted as production processing, the production support device 70 executes the production support process of FIG. 9 using the production support method.

[0051] 5-2. Status Detection Unit 71 The status detection unit 71 executes a status detection step (S21). In the status detection step, the status detection unit 71 detects whether the shutter 50 is in a closed state or an open state that opens at least a portion of the opening of the supply area As when the mounting process is interrupted. Here, the feeder control device 36 of the bulk feeder 30 recognizes the operating state of the shutter 50. Specifically, the feeder control device 36 can recognize the operating state of the shutter 50 based on the command history to the shutter drive device 35. Alternatively, the feeder control device 36 may recognize the operating state of the shutter 50 based on the detection result of a sensor that can detect whether the shutter 50 is in a closed state or an open state.

[0052] In the state detection step, the state detection unit 71 inquires about the operating state of the shutter 50 from the feeder control device 36 of the bulk feeder 30, and detects whether the shutter 50 is open based on the response from the feeder control device 36. Alternatively, for example, if a camera capable of capturing images of the supply area As is provided inside the component mounting machine 10, the state detection unit 71 may detect the operating state of the shutter 50 based on image data acquired by capturing images of the camera.

[0053] 5-3. Shutter Control Device 72 The shutter control device 72 executes a shutter control step (S28). When the state detection unit 71 detects that the shutter 50 is in the open state (S22: Yes), the shutter control device 72 transitions the shutter 50 to the closed state (S28). Here, the shutter control device 72 can employ various control modes in addition to a mode in which the shutter 50 is alternatively transitioned to the closed state when the shutter 50 is in the open state. The various control modes will be described in detail below along with the interference determination unit 73 and the evacuation command unit 74.

[0054] 5-4. Interference determination unit 73 The interference determination unit 73 executes an interference determination step (S24). When the mounting process is interrupted and the shutter 50 is transitioned to the closed state while the mounting head 20 is stopped, the interference determination unit 73 determines whether interference will occur between the suction nozzle 23 and the shutter 50. If the mounting process is interrupted and the shutter 50 is not closed (S22: Yes), there is a possibility that a picking operation has been performed in which the suction nozzle 23 is lowered to pick up a component from the supply area As.

[0055] Therefore, if the shutter 50 is simply transitioned to the closed state, interference will occur between the descending suction nozzle 23 and the shutter 50, which may cause problems with the suction nozzle 23, the mounting head 20, the shutter 50, the shutter drive device 35, etc. Therefore, in this control mode, an interference determination is made before the shutter 50 is transitioned to the closed state (S28), and the operation of the shutter 50 is controlled based on the determination result.

[0056] Here, the interference determination unit 73 performs interference determination based on the position of the supply area As within the component mounting machine 10, the current position Pc of the mounting head 20, and the current height Hc of the suction nozzle 23 (see FIG. 10 ). Specifically, the interference determination unit 73 determines that no interference will occur between the suction nozzle 23 and the shutter 50 if the suction nozzle 23 is located outside the supply area As when viewed in the up-down direction. In other words, if the suction nozzle 23 is sufficiently far from the supply area As in the X and Y directions, the interference determination unit 73 determines that no interference will occur due to the operation of the shutter 50, regardless of the height of the suction nozzle 23.

[0057] Furthermore, when the current height Hc of the suction nozzle 23 is higher than the reference height Hs of the bulk feeder 30, the interference determination unit 73 determines that no interference will occur between the suction nozzle 23 and the shutter 50. The reference height Hs is set, for example, to the height at which the upper surface of the shutter 50 is located. When the suction nozzle 23 has risen to a sufficient height, the interference determination unit 73 determines that no interference will occur due to the operation of the shutter 50, regardless of the position of the suction nozzle 23 in the X and Y directions.

[0058] Furthermore, the interference determination unit 73 may perform interference determination based on the detection results of the detection device 55. For example, as shown in FIG. 10 , the bulk feeder 30 may be equipped with a detection device 55 capable of detecting the suction nozzle 23 that has descended to the reference height Hs of the bulk feeder 30 so as to pick up components supplied to the supply area As. The detection device 55 may be composed of, for example, a light projector that projects detection light in the horizontal direction and a light receiver that can detect the detector. When the light receiver of the detection device 55 does not detect the detection light, the interference determination unit 73 determines that the suction nozzle 23 is blocking the detection light and that switching the shutter 50 to the closed state will cause interference between the suction nozzle 23 present in the supply area As and the shutter 50.

[0059] The interference determination unit 73 performs interference determination by one or a combination of the various methods exemplified above. When the shutter 50 is detected to be in the open state (S22: Yes) and it is determined that no interference will occur between the suction nozzle 23 and the shutter 50 (S25: No), the shutter control unit 72 transitions the shutter 50 to the closed state (S28).

[0060] 5-5. Evacuation Command Unit 74 When the interference determination determines that interference between the suction nozzle 23 and the shutter 50 will occur (S25: Yes), the evacuation command unit 74 executes an evacuation command step (S26). Specifically, the evacuation command unit 74 commands the control device 16 to evacuate the suction nozzle 23 upward. As a result, the mounting head 20 drives the lifting device 26 to raise the suction nozzle 23, which has lowered below the initial height (the height of the raised end of the holder 22).

[0061] However, depending on the cause of the interruption of the mounting process, it is possible that the elevator device 26 is not operating or that the operation of the elevator device 26 is limited. In such a case, if the shutter 50 is closed after issuing a command to retract the suction nozzle 23, interference may occur between the shutter 50 and the suction nozzle 23 that has not been retracted. Therefore, in this embodiment, taking the above-mentioned circumstances into consideration, the shutter control unit 72 repeatedly determines whether the retraction of the suction nozzle 23 is complete (S27: No). After the retraction of the suction nozzle 23 is complete (S27: Yes), the shutter control device 72 switches the shutter 50 to the closed state (S28).

[0062] 5-6. Restriction Unit 75 The restriction unit 75 executes an operation restriction step (S23) and an operation restriction release step (S30). Here, if the series of processes (S25-S28) for closing the shutter 50 as described above is being executed, the shutter 50 has not yet been fully closed, and if maintenance is performed inside the device in parallel with this, the possibility of foreign matter entering the device increases. Therefore, the restriction unit 75 restricts a predetermined operation while the series of processes (S25-S28) for closing the shutter 50 is being executed.

[0063] In this embodiment, when the mounting process is interrupted and the open state of the shutter 50 is detected (S22: Yes), the regulating unit 75 regulates at least one of the horizontal movement of the suction nozzle 23, the installation or removal of the feeders 122 including the bulk feeder 30, and the worker's access to the inside of the machine (S23). The reason for regulating the horizontal movement of the suction nozzle 23 is that if the suction nozzle 23 is moving horizontally while holding a component, the component may drop and become mixed in the supply area As.

[0064] The reason why the installation or removal of a feeder 122 is restricted is that it may cause parts to be scattered from the target feeder 122 and get into the supply area As of a bulk feeder 30 that is close to the target feeder 122. Furthermore, the reason why access by workers to the machine is restricted is that foreign matter attached to the worker's clothing may fall off, and that foreign matter may get scattered during maintenance by the worker and get into the supply area As.

[0065] The regulating unit 75 repeats the completion determination until the shutter 50 has completely transitioned to the closed state (S29: No). After the transition to the closed state is complete (S29: Yes), the regulating unit 75 cancels the restriction on the operations that were the subject of the restriction (S30). In this way, the regulating unit 75 restricts the predetermined target operations during the period until the shutter 50 is transitioned to the closed state by the shutter control unit 72. This makes it possible to prevent foreign matter from entering the shutter.

[0066] 6. Effects of the Configuration of the Embodiment According to the configuration of the embodiment, when the mounting process is interrupted, the shutter 50 is appropriately switched to the closed state, thereby shortening the period during which the shutter 50 is maintained in the open state and preventing foreign matter from entering. As a result, it is possible to prevent errors in the picking operation due to the entry of foreign matter, and maintain the productivity of the component mounting machine 10.

[0067] 7. Modified Embodiments 7-1. Production Support Processing In the embodiment, the production support device 70 determines whether the shutter 50 will interfere with the suction nozzle 23 when it is switched to the closed state (S24, S25). However, other aspects may be used to prevent malfunctions in the suction nozzle 23, etc. Specifically, the production support device 70 executes the production support processing shown in FIG. 11. However, steps that are substantially the same as the steps exemplified in the embodiment are assigned the same step numbers (S21-S23, S26-S27, S30), and detailed descriptions thereof will be omitted.

[0068] When the shutter control unit 72 detects that the shutter 50 is in the open state (S22: Yes), the shutter control unit 72 transitions the shutter 50 to the closed state at a speed slower than the movement speed of the shutter 50 during the mounting process (S41). As a result, the shutter drive device 35 moves the shutter 50 toward the closed state at a speed slower than normal. Note that the above-mentioned "movement speed" is set to a safe speed at which no malfunction will occur due to impact between the shutter 50 and the suction nozzle 23 even if the shutter 50 comes into contact with the suction nozzle 23.

[0069] The shutter control device 72 determines whether the shutter 50 has stopped due to interference with another component while moving at a low speed (S42). The shutter control device 72 repeats the above-described determination of whether the shutter 50 has stopped due to interference (S42) until the transition to the closed state is completed (S43: No). If the shutter 50 has not stopped due to interference and the transition to the closed state is completed (S43: Yes), restrictions on the predetermined target operation, etc. are released (S30), and the production support process ends.

[0070] On the other hand, if the shutter 50 stops due to interference with another component while transitioning to the closed state at low speed (S42: Yes), the retraction command unit 74 retracts the suction nozzle 23 upward (S26). The retraction command step (S26) and the completion determination step (S27) are the same as those described in the embodiment, and therefore detailed description thereof will be omitted. After the retraction of the suction nozzle 23 is completed (S27: Yes), the shutter control unit 72 transitions the shutter 50 to the closed state. The movement speed of the shutter 50 at this time is returned to the normal speed.

[0071] The shutter control device 72 repeats the completion determination until the transition to the closed state is complete (S46: No). When the transition to the closed state is complete (S46: Yes), restrictions on the specified target operation, etc. are released (S30), and the production support process ends. With this configuration, the shutter 50 can be safely transitioned to the closed state regardless of the position or height of the suction nozzle 23 or the detection results of the detection device 55. However, if there is a need to avoid interference between the suction nozzle 23 and the shutter 50 even at low speeds, the aspect exemplified in the embodiment is preferred.

[0072] 7-2. Other In the embodiment, the production support device 70 is configured to be incorporated into the component mounting machine 10. However, part or all of the production support device 70 may be incorporated into an external device of the component mounting machine 10, as long as it can acquire the operating state of the shutter 50 and can transition the shutter 50 to the closed state. For example, the production support device 70 may be incorporated into the bulk feeder 30 or the host computer 60, or may be a dedicated device installed on the production line.

[0073] 10: component mounting machine, 12: component supply device, 122: feeder, 13: component transfer device, 20: mounting head, 23: suction nozzle (holding member), 16: control device, 30: bulk feeder, 50: shutter, 55: detection device, 60: host computer, 70: production support device, 71: status detection unit, 72: shutter control unit, 73: interference determination unit, 74: evacuation command unit, 75: regulation unit, 91: board, 92: component, As: supply area, R: transport path, Pc: current position (of holding member), Hc: current height (of holding member), Hs: reference height (of bulk feeder)

Claims

1. A production support device applied to a component mounting machine that performs a mounting process using a bulk feeder, wherein the bulk feeder has a shutter that is openable and closable relative to a supply area that supplies a plurality of components so that they can be picked up, and that closes the supply area when in a closed state; the production support device comprising: a state detection unit that detects whether the shutter is in the closed state or an open state that opens at least a part of the opening of the supply area when the mounting process is interrupted; and a shutter control unit that transitions the shutter to the closed state when the shutter is detected to be in the open state.

2. The production support device described in claim 1, wherein the component mounting machine is provided with a mounting head that is movable horizontally and that supports a holding member that can be raised and lowered to hold the components picked up from the bulk feeder, and further includes an interference determination unit that determines whether interference will occur between the holding member and the shutter when the mounting process is interrupted and the mounting head is stopped and the shutter is transitioned to the closed state, and the shutter control unit transitions the shutter to the closed state when it is detected that the shutter is in the open state and it is determined that no interference will occur between the holding member and the shutter.

3. A production support device as described in claim 2, wherein the interference determination unit performs the interference determination based on the position of the supply area within the component mounting machine, the current position of the mounting head, and the current height of the holding member.

4. The production support device of claim 2, wherein the interference determination unit determines that no interference will occur between the holding member and the shutter when the holding member is located outside the supply area when viewed from above or below, or when the current height of the holding member is higher than the reference height of the bulk feeder.

5. The production support device according to claim 2, wherein the bulk feeder is equipped with a detection device capable of detecting the holding member that has descended to a reference height of the bulk feeder so as to pick up the parts supplied to the supply area, and the interference determination unit performs the interference determination based on the detection results of the detection device.

6. A production support device as described in claim 2, further comprising an evacuation command unit that retracts the holding member upward when the interference determination determines that interference will occur between the holding member and the shutter, and the shutter control unit transitions the shutter to the closed state after the retraction of the holding member is complete.

7. The production support device of claim 1, wherein when the shutter control unit detects that the shutter is in the open state, the shutter transitions to the closed state at a speed slower than the movement speed of the shutter during execution of the mounting process.

8. A production support device as described in claim 7, further comprising an evacuation command unit that causes a holding member that holds the parts picked up from the bulk feeder to retract upward if the shutter stops due to interference with another member while the shutter is transitioning to the closed state at a low speed, and the shutter control unit causes the shutter to transition to the closed state after the retraction of the holding member is complete.

9. A production support device as described in any one of claims 1 to 8, further comprising a regulating unit that, when the mounting process is interrupted and the open state of the shutter is detected, regulates at least one of the horizontal movement of a holding member that holds the parts picked up from the bulk feeder, the installation or removal of feeders including the bulk feeder, and worker access to the interior of the machine during the period until the shutter control unit transitions to the closed state.

10. A production support device according to any one of claims 1 to 8, wherein the suspension of the mounting process is a measure taken due to receipt of a stop instruction from an operator or detection of an abnormality in the component mounting machine.

11. A production support method applied to a component mounting machine that performs mounting processing using a bulk feeder, wherein the bulk feeder is provided with a shutter that is openable and closable relative to a supply area that supplies a plurality of components so that they can be picked up, and that closes the supply area when it is closed, the method comprising: a state detection step that detects whether the shutter is in the closed state or an open state that opens at least a part of the opening of the supply area when the mounting processing is interrupted; and a shutter control step that transitions the shutter to the closed state when it is detected that the shutter is in the open state.

12. The production support method of claim 11, wherein the component mounting machine comprises a mounting head that is movable horizontally and that supports a holding member that can be raised and lowered to hold the components picked up from the bulk feeder, and further comprises an interference determination step that determines whether interference will occur between the holding member and the shutter when the mounting process is interrupted and the mounting head is stopped and the shutter is transitioned to the closed state, and the shutter control step transitions the shutter to the closed state when it is detected that the shutter is in the open state and it is determined that no interference will occur between the holding member and the shutter.

13. A production support method as described in claim 12, further comprising an evacuation command step for retracting the holding member upward when the interference determination determines that interference will occur between the holding member and the shutter, and the shutter control step transitions the shutter to the closed state after the retraction of the holding member is complete.

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