Component mounting system

Abstract

This component mounting system includes an assessment unit that: executes first determination processing before and after a component is removed at a supply position; determines that first determination processing can be used by a determination unit, if the determination results of the first determination processing executed before removing a component are determination results indicating that a component is present and if the determination results of the first determination processing executed after removing the component are determination results indicating that a component is not present; executes second determination processing before and after removing the component at the supply position; determines that second determination processing can be used by the determination unit, if the determination results of the second determination processing executed before removing the component are determination results indicating that a component is present and if the results of the second determination processing executed after removing the component are determination results indicating that a component is not present; and on the basis of the results of determination as to whether use is possible or not, assesses the determination processing to be used by the determination unit.

Description

Component Mounting System

[0001] This specification discloses a component mounting system.

[0002] Conventionally, a component mounter has been proposed that determines whether a feeder is out of components (determines whether components are present in the feeder) when a pickup error occurs (see, for example, Patent Document 1). In this component mounter, if the component shape is a square chip and the component size is equal to or smaller than a predetermined size, an image is captured by an imaging device and pattern matching is performed to determine whether the component is out of components. In other cases, this component mounter detects the height of the feeder with an optical sensor having a light-emitting element and a light-receiving element and determines whether the component is out of components based on the detected height.

[0003] International Publication No. 2021 / 166179

[0004] However, if a component out-of-stock determination (determination of the presence or absence of components in a feeder) is performed using a method that is based on the component shape and component size, it may not be possible to accurately determine whether or not a component has run out in the feeder. For example, even if the component shape is other than a square chip and the component size is larger than a predetermined size, if diffuse reflection of light is likely to occur on the surface of the feeder or the component, the height measured by the optical sensor may be higher than the actual height even though there are no components in the feeder, resulting in a determination that there are components, or the height measured by the optical sensor may be lower than the actual height even though there are components in the feeder, resulting in a determination that there are no components.

[0005] A primary object of the present disclosure is to further improve the accuracy of determining whether a component is out of stock.

[0006] The present disclosure has adopted the following means to achieve the above-mentioned main object.

[0007] A component mounting system according to the present disclosure is a component mounting system that takes out and mounts components supplied from a feeder to a supply position, and includes: an imaging device that images the supply position from above; a detection sensor that can detect components at the supply position; and a determination unit that determines whether the feeder is out of components using a determined determination process from among a plurality of determination processes that include, during operation of the component mounting system, a first determination process that determines whether or not a component is present at the supply position based on an image of the supply position captured by the imaging device, and a second determination process that determines whether or not a component is present at the supply position based on the presence or absence of detection by the detection sensor. a determination unit that executes the first determination process before and after the part is removed from the supply position, and if the determination result of the first determination process executed before the part is removed is that the part is present and the determination result of the first determination process executed after the part is removed is that the part is absent, the determination unit determines that the first determination process is usable;

[0008] According to this component mounting system, it is possible to further improve the accuracy of determining whether a component is out of stock.

[0009] 1 is a schematic configuration diagram of a component mounting system 10 including a component mounter 20. FIG. 2 is a side view of a mounting head 25. FIG. 3 is a partial enlarged view of the vicinity of the component supply position of a feeder 40. FIG. 4 is a block diagram showing the electrical connection relationships of the component mounting system 10. FIG. 5 is a flowchart showing an example of a production process. FIG. 6 is an explanatory diagram showing an example of a pre-production processing screen Sc. FIG. 7 is a flowchart showing an example of a component presence / absence determination success / failure determination process. FIG. 8 is a flowchart showing an example of a component out-of-stock determination means determination process. FIG. 9 is an explanatory diagram showing a component out-of-stock determination means that is determined according to a combination of the component presence / absence determination result from the mark camera 26 and the component presence / absence determination result from the height sensor 27. FIG. 10 is an explanatory diagram showing an example of a pre-production processing screen Sc after the component out-of-stock determination means determination process has been executed.

[0010] Next, embodiments of the present disclosure will be described with reference to the drawings.

[0011] Fig. 1 is a schematic diagram of a component mounting system 10 including a component mounter 20. Fig. 2 is a side view of a mounting head 25. Fig. 3 is a partially enlarged view of the vicinity of the component supply position of a feeder 40. Fig. 4 is a block diagram showing the electrical connections of the component mounting system 10. The left-right direction (X-axis direction), front-back direction (Y-axis direction), and up-down direction (Z-axis direction) are as shown in Figs. 1 to 3.

[0012] The component mounting system 10 produces boards S on which components P are mounted. In the component mounting system 10, each of a plurality of component mounters 20 receives a supply of components P from a feeder 40 and sequentially mounts the components P on the board S, thereby producing boards S on which the components P are mounted. The component mounting system 10 includes a production line in which a printing device that prints solder on the board S, a print inspection device that inspects the condition of the solder printed by the printing device, a feeder storage that stores used feeders 40 and feeders 40 to be used, and a plurality of component mounters 20 and a mounting inspection device that inspects the mounting condition of the components P mounted by each component mounter 20 are arranged in this order along the conveyance direction of the board. The component mounting system 10 also includes a management device 80 that manages the entire production line. Furthermore, the component mounting system 10 also includes an exchange robot (loader) that moves in front of the feeder storage and the component mounter 20 along the transport direction of the board S and inserts and removes the feeder 40 in a direction perpendicular to the transport direction of the board S relative to the component mounter 20 and the feeder storage, thereby exchanging the feeder 40 between the component mounter 20 and the feeder storage.

[0013] As shown in FIG. 1 , the component mounter 20 includes a mounter main body 21 and a feeder 40 that is detachable from the mounter main body 21 .

[0014] The mounting machine main body 21 includes a substrate transport device 22 that transports the substrate S, a mounting head 25 that is fixed (attached) to a slider 24 and that picks up components P supplied to a component supply position by a feeder 40 and mounts the components P on the substrate S, a head moving device 23 that moves the mounting head 25 together with the slider 24 in the front-to-back and left-to-right directions (X and Y directions), and a mounting control device 30 (see FIG. 4 ). The substrate transport device 22, head moving device 23, and mounting head 25 are disposed within a housing 21a that is provided on a base 21b. The mounting head 25 includes suction nozzles 25a that suction the components P. The mounting head 25 is configured, for example, as a rotary head that is rotatable and includes a head main body that holds multiple suction nozzles 25a in the circumferential direction and an elevator device that raises and lowers the suction nozzles 25a relative to the head main body. Each suction nozzle 25a is selectively connected to a negative pressure source or a positive pressure source via an electromagnetic valve (not shown). By operating the electromagnetic valve so that the suction nozzle 25a is connected to a negative pressure source, negative pressure is applied to the suction nozzle 25a, making it possible to pick up the component P. Furthermore, by operating the electromagnetic valve so that the suction nozzle 25a is connected to a positive pressure source, the component P picked up by the suction nozzle 25a can be mounted on the board S.

[0015] In addition, the mounting machine main body 21 also includes a mark camera 26, a height sensor 27, a parts camera 28, a side camera 29, and the like.

[0016] 2, the mark camera 26 and the height sensor 27 are attached to the lower surface of the slider 24 and moved in the X and Y directions by the head moving device 23. The mark camera 26 and the height sensor 27 may also be attached to the mounting head 25.

[0017] Mark camera 26 captures an image of a reference mark attached to board S from above. This captured image is used to confirm the position of board S carried into the machine by board transport device 22. In this embodiment, mark camera 26 also captures an image of the component supply position of feeder 40 from above. This captured image is used to confirm whether feeder 40 is out of components by determining whether or not a component P is captured in the captured image.

[0018] As shown in FIG. 2 , the height sensor 27 is a reflective distance sensor (e.g., a laser sensor or a photoelectric sensor) having a light-emitting portion 27a that emits light downward and a light-receiving portion 27b that receives reflected light. The height sensor 27 is used to measure the height (position in the Z direction) of the surface of the board S. In this embodiment, the height sensor 27 is also used to check whether the feeder 40 is out of components by measuring the height of the surface (upper surface) at the component supply position of the feeder 40. That is, when a component P is present at the component supply position, the height sensor 27 measures the height of the object higher by the thickness of the component P compared to when the component P is not present at the component supply position. Therefore, the measurement value of the height sensor 27 can be used to determine whether the feeder 40 is out of components, and thus it can be confirmed whether the feeder 40 is out of components.

[0019] 1, the part camera 28 is installed adjacent to the board transport device 22, and captures an image of the component P from below when the suction nozzle 25a that has picked up the component passes above the part camera 28. The captured image is used to determine whether or not the component P has been successfully picked up by the suction nozzle 25a, and to determine the amount of positional deviation of the component P picked up by the suction nozzle 25a.

[0020] 2, the side camera 29 is disposed on the mounting head 25 and captures an image of the tip of the suction nozzle 25a from the side after the suction operation. The captured image is used to determine whether or not the component P has been successfully picked up by the suction nozzle 25a, and to determine the suction posture of the component P picked up by the suction nozzle 25a.

[0021] 4, the mounting control device 30 is configured as a computer having a CPU 31, ROM 32, RAM 33, storage (for example, HDD or SSD) 34, etc. The mounting control device 30 inputs image signals from the mark camera 26, parts camera 28, and side camera 29, and detection signals from the height sensor 27, etc. The mounting control device 30 also outputs drive signals to the board transport device 22, head moving device 23, mounting head 25, mark camera 26, parts camera 28, side camera 29, etc.

[0022] As shown in FIGS. 3 and 4 , the feeder 40 includes a tape reel around which the tape 41 is wound, a tape feeding mechanism 43 that unwinds the tape 41 from the tape reel and feeds it to a component supply position, a connector 45, and a supply control device 46. As shown in FIG. 3 , the tape 41 has cavities 41a formed at predetermined intervals along its length, each capable of accommodating a component P. These components P are protected by a film covering the surface of the tape 41. The feeder 40 feeds the tape 41 by a predetermined amount and sequentially supplies the components P accommodated in the cavities 41a to the component supply position. The film is peeled off from the components P accommodated on the tape 41 just before the component supply position, exposing the components P at the component supply position and allowing them to be picked up by the suction nozzle 25a. The supply control device 46 includes a known CPU, ROM, RAM, etc., and outputs a drive signal to the tape feeding mechanism 43 (feed motor). Furthermore, when the feeder 40 is set in the mounting machine main body 21 , the supply control device 46 is connected to the mounting control device 30 via the connector 45 so as to be able to communicate with it.

[0023] As shown in FIG. 4 , the management device 80 is configured as a computer including a CPU 81, a ROM 82, a RAM 83, a storage 84, and the like. The management device 80 is connected to an input device 88, such as a keyboard or a mouse, and a display device 89, such as a liquid crystal display or an organic electroluminescence (EL) display. The storage 84 stores a production program 85, feeder information 86, job information 87, and the like. The production program 85 determines which components P are to be mounted on which boards S, in what order, and how many boards S mounted in this manner are to be produced in each mounter 20. The feeder information 86 is information about the feeders 40 held by each mounter 20. The feeder information 86 includes the feeder ID, the type (component type) of components P held by the feeder 40, the component shape (e.g., square chip), the component size, and the remaining number of components. This information is registered in advance by the operator operating the input device 88. The job information 87 is information regarding mounting instructions for each mounter 20. The job information includes the type of suction nozzle 25a to be used, the type and size of the component P to be mounted, and the mounting position of the component P. The job information 87 also includes information regarding a component out-of-stock determination means to be used when checking whether the feeder 40 is out of components when the suction nozzle 25a fails to pick up the component P.

[0024] The management device 80 is communicatively connected to the mounting control device 30 and exchanges various information with each mounter 20. The management device 80 is also communicatively connected to the feeder 40 (supply control device 46) set in the mounter main body 21 via each mounter 20 (mounting control device 30). The management device 80 communicates with the supply control device 46 via the mounting control device 30 and acquires feeder information 86 corresponding to the feeder ID of the set feeder 40. The management device 80 also receives input signals when an operator operates an input device 88 and outputs image signals to a display device 89.

[0025] Next, a description will be given of the operation of each component mounting system 10. Fig. 5 is a flowchart showing an example of production processing executed by the CPU 31 of the mounting control device 30 of each component mounter 20. This processing is started after receiving mounting instructions including a production program 85, feeder information 86, and job information 87 from the management device 80.

[0026] In the production process, the CPU 31 of the mounting control device 30 first performs a suction operation to cause the suction nozzle 25a to pick up a component P supplied from the feeder 40 (S100). Specifically, the CPU 31 controls the head moving device 23 to move the suction nozzle 25a above the component supply position of the feeder 40, then controls the elevator device to lower the suction nozzle 25a and supplies negative pressure from a negative pressure source to the suction nozzle 25a. This causes the component P at the component supply position to be picked up by the suction nozzle 25a. Next, the CPU 31 controls the side camera 29 to capture a side image of the tip of the suction nozzle 25a after the suction operation and determines whether or not a component is present based on the captured image (S102). Specifically, the CPU 31 performs image processing, such as pattern matching using pre-registered component side shapes (shape data), and determines that the component is absent if the component P cannot be recognized in the side image. However, determines that the component is present if the component P is recognized in the side image. Next, the CPU 31 determines whether or not a component P is present in the side image (S104). If the CPU 31 determines that a component P is present in the side image, it determines that the pickup of the component P was successful and updates the remaining component count (S106). Specifically, the CPU 31 subtracts 1 from the remaining component count included in the feeder information 86 and sends an instruction to the management device 80 to update the remaining component count. Upon receiving the update instruction, the management device 80 subtracts 1 from the remaining component count included in the feeder information 86 stored in the storage 84. The CPU 31 then determines whether or not the required number of components P have been picked up (S108). If the CPU 31 determines that the required number of components P have not been picked up, it returns to S100 and performs the pickup operation for the next component P. On the other hand, if the CPU 31 determines that the required number of components P have been picked up, it mounts the components P at their respective mounting positions on the board S (S110). Specifically, the CPU 31 controls the head moving device 23 so that the suction nozzle 25a that has sucked the component P moves to above the component mounting position on the board S, and then controls the lifting device so that the suction nozzle 25a moves down, and supplies positive pressure from the positive pressure source to the suction nozzle 25a. This causes the component P to be mounted on the board S. Then, the CPU 31 ends the production process.

[0027] On the other hand, if the CPU 31 determines in S104 that the component P is not present in the side image, it determines that the pickup of the component P has failed and increments the value of a counter (pickup failure counter) C by 1 (S112). The counter C counts the number of times component pickup has failed, and its initial value is 0. Next, the CPU 31 determines whether the value of the counter C is equal to or greater than a specified number of times Cref (S114). The specified number of times Cref is a value predetermined for each type of component P. If the CPU 31 determines that the value of the counter C is less than the specified number of times Cref, it returns to S100 and re-executes the pickup operation of the component P. On the other hand, if the CPU 31 determines that the value of the counter C is equal to or greater than the specified number of times Cref, it performs a component out-of-stock determination process (S116 to S126). It may seem that it would be sufficient to determine whether a component has run out in the feeder 40 simply by referring to the remaining number of components included in the feeder information 86. However, if the worker makes a mistake in inputting the initial value of the remaining component quantity when creating the feeder information 86, or if the worker manually replaces the feeder 40 during production, the remaining component quantity may not be the correct quantity. Therefore, in this embodiment, the mounting control device 30 performs a component out-of-stock determination process when pickup errors occur consecutively a specified number of times Cref or more.

[0028] The out-of-component determination process is performed as follows. That is, CPU 31 references job information 87 and determines whether the out-of-component determination means to be used is mark camera 26 (S116) and whether the height sensor 27 is (S118). If CPU 31 determines that the out-of-component determination means to be used is neither mark camera 26 nor height sensor 27, it determines that the out-of-component determination means to be used is the remaining number of parts, and performs out-of-component determination based on the remaining number of parts (S120). Specifically, CPU 31 determines that an out-of-component has occurred if the remaining number of parts included in feeder information 86 is 0, and determines that an out-of-component has not occurred if the number is greater than 0. CPU 31 then proceeds to S128.

[0029] Furthermore, if the CPU 31 determines in S118 that the component-out-of-component determining means to be used is the height sensor 27 rather than the mark camera 26, it measures the height of the component supply position (cavity 41 a) with the height sensor 27 and determines the presence or absence of a component at the component supply position (cavity 41 a) based on the measured height (S122). Specifically, the CPU 31 controls the head moving device 23 to move the height sensor 27 above the component supply position (cavity 41 a) of the feeder 40 being determined, then measures the height of the surface of the component supply position by irradiating light downward from the light-projecting unit 27 a and receiving the reflected light with the light-receiving unit 27 b. If the measured height corresponds to the height of the bottom surface of the cavity 41 a, it determines that a component P is not present at the component supply position. If the measured height is higher than the bottom surface of the cavity 41 a by a predetermined value or more, it determines that a component P is present at the component supply position. The CPU 31 then determines whether a component P has been out of component based on the result of the component-out-of-component determination (S126) and proceeds to S128.

[0030] If the CPU 31 determines in S116 that the component out-of-stock determination means to be used is the mark camera 26, it controls the head moving device 23 to move the mark camera 26 above the component supply position of the feeder 40 being determined, then it captures a top view image of the component supply position (cavity 41 a) with the mark camera 26, and determines the presence or absence of a component at the component supply position (cavity 41 a) based on the captured image (S124). Specifically, the CPU 31 performs image processing on the top view image, and determines that there is no component P at the component supply position (cavity 41 a) if the component P cannot be recognized in the top view image by pattern matching using a pre-registered top view shape (shape data) of the component top face, and determines that there is a component P at the component supply position (cavity 41 a) if the component P can be recognized in the top view image. Then, the CPU 31 determines whether there is a component out-of-stock based on the result of the component presence / absence determination (S126), and proceeds to S128.

[0031] After S120 or S126, the CPU 31 determines whether a component has run out (S128). If the CPU 31 determines that a component has not run out, it determines that the tape 41 has repeatedly failed to pick up the component P even though the component P is present on the tape 41, notifies the error (S130), and ends the production process. On the other hand, if the CPU 31 determines that a component has run out, it requests the replacement robot to replace the feeder 40 (S132), and ends the production process.

[0032] During production processing, when the value of counter C reaches or exceeds the specified number of times Cref, a component out-of-stock determination is performed using the component out-of-stock determination means included in the job information 87. A default determination means is set for the component out-of-stock determination means depending on the combination of component shape and component size (horizontal and vertical dimensions). However, the default component out-of-stock determination means set depending on this combination may not be able to accurately determine whether a component out-of-stock has actually occurred. For this reason, in this embodiment, the appropriateness of each component out-of-stock determination means can be confirmed by using each component out-of-stock determination means (remaining component count, mark camera 26, or height sensor 27) to determine the presence or absence of components at the component supply position (cavity 41a) before or during an interruption of production processing.

[0033] When an application for executing pre-production processing is started, the CPU 81 of the management device 80 displays a pre-production processing screen Sc shown in Fig. 6 on the display device 89. The pre-production processing screen Sc includes an image capture button 90, a component presence / absence determination processing start button 91, a component presence / absence determination success / failure determination processing start button 92, a pull-down menu 93, etc.

[0034] The image capture button 90 is a button for instructing the taking of an image of the component supply position (cavity 41a). The component presence / absence determination process start button 91 is a button for instructing the start of component presence / absence determination process for determining whether or not a component P is present at the component supply position (current cavity 41a). The component presence / absence determination process is, for example, the process of S122 or S124 of the production process shown in FIG. 5. The component presence / absence determination correctness determination process start button 92 is a button for instructing the start of the component presence / absence correctness determination process. The pull-down menu 93 is a menu presenting options for the component shortage determination means used when performing the component presence / absence determination process and the component shortage determination means used when performing the component presence / absence correctness determination process. Options include default, mark camera, height sensor, and automatic determination.

[0035] When the component presence / absence determination process start button 91 is operated with the default selected in the pull-down menu 93, the CPU 81 performs component presence / absence determination process for the component supply position (current cavity 41a) using the default component out-of-stock determination means. When the component presence / absence determination process start button 91 is operated with the mark camera selected in the pull-down menu 93, the CPU 81 performs component presence / absence determination process for the component supply position (current cavity 41a) using the mark camera 26. When the component presence / absence determination process start button 91 is operated with the height sensor selected in the pull-down menu 93, the CPU 81 performs component presence / absence determination process for the component supply position (current cavity 41a) using the height sensor 27. When the component presence / absence determination process start button 91 is operated with the automatic determination selected in the pull-down menu 93, the CPU 81 performs component presence / absence determination process for the component supply position (current cavity 41a) using both the mark camera 26 and the height sensor 27.

[0036] Furthermore, when the component presence determination success / failure determination process start button 92 is operated with the default selected in the pull-down menu 93, the CPU 81 executes the component presence determination process using the default component out-of-component determination means before and after the component pickup operation, and determines whether the determination results are normal or abnormal. Furthermore, when the component presence determination success / failure determination process start button 92 is operated with the mark camera selected in the pull-down menu 93, the CPU 81 executes the component presence determination process using the mark camera 26 before and after the pickup operation, and determines whether the determination results are normal or abnormal. When the component presence determination success / failure determination process start button 92 is operated with the height sensor selected in the pull-down menu 93, the CPU 81 executes the component presence determination process using the height sensor 27 before and after the pickup operation, and determines whether the determination results are normal or abnormal. When the component presence / absence determination correctness determination process start button 92 is operated with automatic determination selected in the pull-down menu 93, the CPU 81 executes the component presence / absence determination process using the mark camera 26 and the height sensor 27 before and after the suction operation, and determines whether the determination results are correct or not.

[0037] Below, we will explain the part presence / absence determination correctness judgment process when a part P is stored in the part supply position (cavity 41a), automatic determination is selected in the pull-down menu 93, and the worker operates the part presence / absence determination correctness judgment process start button 92.

[0038] When the CPU 31 starts the component presence / absence determination process, it captures an image of the top surface of the component supply position (cavity 41a) using the mark camera 26, similar to S124 of the production process, and determines whether a component is present at the component supply position (cavity 41a) based on the captured image (S200). Next, it measures the height of the component supply position (cavity 41a) using the height sensor 27, similar to S122 of the production process, and determines whether a component is present at the component supply position (cavity 41a) based on the measured height (S202). Next, it performs a suction operation on the component P located at the component supply position (cavity 41a) using the suction nozzle 25a, similar to S100 of the production process (S204). Then, it captures a side image of the tip of the suction nozzle 25a that performed the suction operation using the side camera 29, similar to S102 of the production process, and determines whether a component is present based on the captured image (S206). If the CPU 31 can recognize the component P in the side image (if the component P is present), it determines that the pickup is successful, and if it cannot recognize the component P in the side image (if the component P is not present), it determines that the pickup is unsuccessful. Furthermore, if the CPU 31 determines that the pickup is successful, it determines that the component P is present in the component supply position (cavity 41 a) before the pickup operation and that the component P is not present in the component supply position (cavity 41 a) after the pickup operation.

[0039] Next, the CPU 31 determines whether the determination result using the top image of the mark camera 26 and the determination result using the side image of the side camera 29 both indicate a component presence determination (S208). If the CPU 31 determines that the determination result using the top image of the mark camera 26 and the determination result using the side image of the side camera 29 both indicate a component presence determination, the CPU 31 determines that the component presence determination using the top image of the mark camera 26 is normal (S210). This is because if a component P is present in the side image, it can be confirmed that the component P was present at the component supply position (cavity 41a) before the suction operation. On the other hand, if the CPU 31 determines that the judgment result using the top image of mark camera 26 is a judgment that a part is present and the judgment result using the side image of side camera 29 is a judgment that a part is not present, or if the judgment result using the top image of mark camera 26 is a judgment that a part is not present and the judgment result using the side image of side camera 29 is a judgment that a part is present, or if the judgment result using the top image of mark camera 26 is a judgment that a part is not present and the judgment result using the side image of side camera 29 is a judgment that a part is not present, then the CPU 31 determines that the judgment of the presence or absence of a part using the top image of mark camera 26 is abnormal (S212).

[0040] After S210 or S212, CPU 31 determines whether the determination result using the height measured by height sensor 27 and the determination result using the side image taken by side camera 29 both indicate a component presence determination (S214). If CPU 31 determines that the determination result using the height measured by height sensor 27 and the determination result using the side image taken by side camera 29 both indicate a component presence determination, CPU 31 determines that the component presence determination using the height measured by height sensor 27 is normal (S216). On the other hand, if the CPU 31 determines that the judgment result using the height measured by the height sensor 27 is a judgment that a part is present and the judgment result using the side image of the side camera 29 is a judgment that a part is not present, or if the judgment result using the height measured by the height sensor 27 is a judgment that a part is not present and the judgment result using the side image of the side camera 29 is a judgment that a part is present, or if the judgment result using the height measured by the height sensor 27 is a judgment that a part is not present and the judgment result using the side image of the side camera 29 is a judgment that a part is not present, then the CPU 31 determines that the judgment of the presence or absence of a part using the height measured by the height sensor 27 is abnormal (S218).

[0041] After S216 or S218, the CPU 31 captures an image of the top surface of the component supply position (cavity 41 a) using the mark camera 26, as in S200, and determines whether a component is present at the component supply position (cavity 41 a) after the pickup operation based on the captured image (S220). Next, the CPU 31 measures the height of the component supply position (cavity 41 a) using the height sensor 27, as in S202, and determines whether a component is present at the component supply position (cavity 41 a) after the pickup operation based on the measured height (S222). Next, the CPU 31 determines whether the determination result using the top surface image from the mark camera 26 is a component-absence determination and whether the determination result using the side image from the side camera 29 is a component-presence determination (S224). If the CPU 31 determines that the determination result using the top surface image from the mark camera 26 is a component-absence determination and that the determination result using the side image from the side camera 29 is a component-presence determination, it determines that the component-absence determination using the top surface image from the mark camera 26 is normal (S226). This is because, if a component P is present in the side image, it can be confirmed that a component P is not present at the component supply position (cavity 41 a) after the suction operation. On the other hand, if the CPU 31 determines that the determination result using the top image of mark camera 26 is a component presence determination and the determination result using the side image of side camera 29 is a component absence determination, or if the determination result using the top image of mark camera 26 is a component presence determination and the determination result using the side image of side camera 29 is a component presence determination, or if the determination result using the top image of mark camera 26 is a component absence determination and the determination result using the side image of side camera 29 is a component absence determination, then the CPU 31 determines that the determination of the component presence or absence using the image captured by mark camera 26 is abnormal (S228).

[0042] After S226 or S228, the CPU 31 determines whether the determination result using the height measured by the height sensor 27 is a component-absence determination and the determination result using the side image taken by the side camera 29 is a component-presence determination (S230). If the CPU 31 determines that the determination result using the height measured by the height sensor 27 is a component-absence determination and the determination result using the side image taken by the side camera 29 is a component-presence determination, the CPU 31 determines that the component-absence determination using the height measured by the height sensor 27 is normal (S232). On the other hand, if the CPU 31 determines that the judgment result using the height measured by the height sensor 27 is a judgment that a part is present and the judgment result using the side image of the side camera 29 is a judgment that a part is not present, or if the judgment result using the height measured by the height sensor 27 is a judgment that a part is present and the judgment result using the side image of the side camera 29 is a judgment that a part is present, or if the judgment result using the height measured by the height sensor 27 is a judgment that a part is not present and the judgment result using the side image of the side camera 29 is a judgment that a part is not present, then the CPU 31 determines that the judgment of the presence or absence of a part using the height measured by the height sensor 27 is abnormal (S234).

[0043] Then, after S232 or S234, the CPU 31 transmits to the management device 80 top surface images before and after the suction operation and success / failure information indicating whether the determination of the presence or absence of each component using the mark camera 26 and the height sensor 27 is normal or abnormal (S236), and terminates the process of determining the success or failure of the component presence determination.

[0044] Next, the out-of-component determination means selection process executed by the CPU 81 of the management device 80 will be described. The out-of-component determination means selection process is initiated after receiving information indicating the success or failure of each component presence / absence determination using the mark camera 26 and the height sensor 27 from the mounting control device 30. FIG. 8 is a flowchart illustrating an example of the out-of-component determination means selection process. When the CPU 81 of the management device 80 initiates the out-of-component determination means selection process, it first determines whether the component presence determination and component absence determination using the top-view image of the mark camera 26 are correct (S300). If the CPU 81 determines that the component presence determination and component absence determination using the top-view image of the mark camera 26 are correct, it then determines whether the component presence determination and component absence determination using the height measured by the height sensor 27 are correct (S302). If the CPU 81 determines that the component presence determination and component absence determination using the height measured by the height sensor 27 are correct, it then selects the default out-of-component determination means as the out-of-component determination means (S304). On the other hand, if the CPU 81 determines that at least one of the component presence determination and component absence determination using the height measured by the height sensor 27 is abnormal, it determines that the mark camera 26 is the component shortage determination means (S306).

[0045] If the CPU 81 determines in S300 that at least one of the component presence determination and component absence determination using the top view image of the mark camera 26 is abnormal, it determines whether the component presence determination and component absence determination using the height measured by the height sensor 27 are normal (S308). If the CPU 81 determines that the component presence determination and component absence determination using the height measured by the height sensor 27 are normal, it selects the height sensor 27 as the component shortage determination means (S310). On the other hand, if the CPU 81 determines that at least one of the component presence determination and component absence determination using the height measured by the height sensor 27 is abnormal, it selects the remaining number of components as the component shortage determination means (S312). The CPU 31 ends the component shortage determination means determination process after S304, S306, S310, or S312.

[0046] 9, when the presence or absence of parts can be normally determined using both the mark camera 26 and the height sensor 27, the CPU 81 determines the default out-of-component determination means as the out-of-component determination means. Furthermore, when the mark camera 26 can normally determine the presence or absence of parts but the height sensor 27 cannot, the CPU 31 determines the mark camera 26 as the out-of-component determination means regardless of the default out-of-component determination means. Furthermore, when the mark camera 26 cannot normally determine the presence or absence of parts but the height sensor 27 can normally determine the presence or absence of parts, the CPU 31 determines the height sensor 27 as the out-of-component determination means regardless of the default out-of-component determination means. Furthermore, when the presence or absence of parts cannot be normally determined using both the mark camera 26 and the height sensor 27, the CPU 31 determines the remaining number of parts as the out-of-component determination means.

[0047] When the CPU 81 of the management device 80 completes the out-of-stock determination means selection process, it causes the pre-production processing screen Sc to display a top surface image Im2 before the suction operation, a top surface image Im3 after the suction operation, and the out-of-stock determination means, as shown in Fig. 10. In Fig. 10, it is assumed that the worker operates the image capture button 90 before operating the component presence / absence determination process start button 92, thereby displaying a top surface image Im1 of the component supply position (cavity 41a) before the component presence / absence determination process is executed. Furthermore, when the worker operates the input device 88 to create job information 87, the CPU 81 determines the out-of-stock determination means included in the job information 87 to be the out-of-stock determination means selected in the out-of-stock determination means selection process.

[0048] In this way, the component mounting system 10 creates job information 87 that reflects the results of the component presence / absence determination process. Therefore, a component out-of-stock determination means that can more reliably detect whether the feeder 40 is out of components is set in the job information 87, thereby improving the accuracy of component out-of-stock determination. Furthermore, the component mounting system 10 displays the component out-of-stock determination means on the display device 89. Therefore, the operator can easily determine the component out-of-stock determination means that is appropriate for determining whether the feeder 40 is out of components.

[0049] Here, the correspondence between the main elements of this embodiment and the main elements of the present disclosure will be described. Specifically, the component mounting system 10 of this embodiment corresponds to the component mounting system of the present disclosure, the mark camera 26 corresponds to the imaging device, the height sensor 27 corresponds to the detection sensor, the CPU 31 that executes the processes of S116, S118, S122, and S124 of the production process corresponds to the determination unit, and the CPU 31 that executes the component presence / absence determination process corresponds to the decision unit. The side camera 29 and the CPU 31 that executes the process of S206 of the component presence / absence determination process correspond to the success / failure determination unit. The storage 84 that stores job information 87 including a default component out-of-stock determination unit corresponds to the memory unit. The CPU 31 that executes the process of S106 of the production process corresponds to the remaining quantity management unit. The CPU 81 of the management device 80 that displays the top surface image Im2 before the pickup operation and the top surface image Im3 after the pickup operation on the pre-production processing screen Sc corresponds to the display control unit.

[0050] It goes without saying that the present disclosure is not limited to the above-described embodiments, and can be implemented in various forms as long as they fall within the technical scope of the present disclosure.

[0051] For example, in the above-described embodiment, the CPU 31 of the mounting control device 30 determines whether the component presence determination using the top surface images of the mark camera 26 before and after the pickup operation is normal or abnormal based on whether the component P is included in the side image in the component presence determination correctness determination process (S206 to S212, S224 to S228). However, this determination result may also be input by the operator. In this case, the CPU 31 may perform the following process instead of the processes of S206 to S212 and S224 to S228 in the component presence determination correctness determination process. That is, the CPU 31 displays the top surface images of the mark camera 26 before and after the pickup operation (S204) on the pre-production processing screen Sc. Furthermore, the CPU 31 displays on the pre-production processing screen Sc the results of the component presence / absence determination based on the top surface images before and after the pickup operation (S204) (the determination results of S200 and S220), a Correct button to be operated when the worker determines that the determination results are correct after looking at the top surface images, and an Incorrect button to be operated when the worker determines that the determination results are incorrect after looking at the top surface images. Then, the CPU 31 determines whether each determination result is correct or incorrect depending on whether the Correct button or the Incorrect button is operated for each determination result.

[0052] In the above-described embodiment, the CPU 31 of the mounting control device 30 captured a side image of the tip of the suction nozzle 25a with the side camera 29 and determined the presence or absence of a component based on the captured image in S102 of the production processing and S206 of the acceptability determination processing. However, the CPU 31 may replace at least one of these processes with a process of capturing a bottom image with the parts camera 28 and determining the presence or absence of a component based on the captured image. In this case, the CPU 31 may perform image processing on the bottom image and determine that a component is not present if the component P cannot be recognized in the bottom image by pattern matching or the like using a bottom surface shape (shape data) of the component bottom surface registered in advance, or determine that a component is present if the component P can be recognized in the bottom surface image.

[0053] In the above-described embodiment, steps S200 to S236 of the component presence / absence determination process are executed by the CPU 31 of the mounting control device 30. However, at least a part of these processes may be executed by the CPU 81 of the management device 80.

[0054] In the above-described embodiment, the out-of-stock determination means when the job information 87 is created is set to the out-of-stock determination means determined by the out-of-stock determination means determination process shown in Fig. 9. However, the job information 87 may be configured so that the worker can set an out-of-stock determination means other than the determined out-of-stock determination means.

[0055] In the above-described embodiment, the out-of-component determination means selection process is executed by the CPU 81 of the management device 80. However, the out-of-component determination means selection process may be executed by the CPU 31 of the mounting control device 30.

[0056] According to the component mounting system of the present disclosure described above in detail, it is possible to improve the accuracy of determining whether a component is out of stock.

[0057] In the component mounting system of the present disclosure, the determination unit may execute the process before the component mounting system is put into operation.

[0058] This specification also discloses the technical idea of ​​changing "the component mounting system according to claim 1 or 2" to "the component mounting system according to any one of claims 1 to 3" in claim 4 as originally filed. This specification also discloses the technical idea of ​​changing "the component mounting system according to claim 1 or 2" to "the component mounting system according to any one of claims 1 to 4" in claim 5 as originally filed. This specification also discloses the technical idea of ​​changing "the component mounting system according to claim 1 or 2" to "the component mounting system according to any one of claims 1 to 5" in claim 6 as originally filed. This specification also discloses the technical idea of ​​changing "the component mounting system according to claim 1 or 2" to "the component mounting system according to any one of claims 1 to 6" in claim 7 as originally filed.

[0059] The present disclosure is applicable to the component mounting system manufacturing industry and the like.

[0060] 10 Component mounting system, 20 Component mounter, 21 Mounting machine main body, 21a Housing, 21b Base, 22 Board transport device, 23 Head moving device, 24 Slider, 25 Mounting head, 25a Suction nozzle, 26 Mark camera, 27 Height sensor, 27a Light projecting unit, 27b Light receiving unit, 28 Parts camera, 29 Side camera, 30 Mounting control device, 31 CPU, 32 ROM, 33 RAM, 40 Feeder, 41 Tape, 41a Cavity, 43 Tape feeding mechanism, 45 Connector, 46 Supply control device, 80 Management device, 81 CPU, 82 ROM, 83 RAM, 84 Storage, 85 Production program, 86 Feeder information, 87 Job information, 88 Input device, 89 Display device, 90 Imaging button, 91 Component presence / absence determination process start button, 92 Button to start the process of determining whether or not parts are present, 93 pull-down menu, P parts, S board, Sc production pre-processing screen.

Claims

1. A component mounting system that takes out and mounts components supplied from a feeder to a supply position, comprising: an imaging device that images the supply position from above; a detection sensor that can detect components at the supply position; and a determination unit that, while the component mounting system is in operation, determines whether the feeder is out of components using a determined determination process from among a plurality of determination processes, including a first determination process that determines whether or not a component is present at the supply position based on an image of the supply position captured by the imaging device, and a second determination process that determines whether or not a component is present at the supply position based on the presence or absence of detection by the detection sensor. a determination unit that determines the judgment process to be used by the determination unit based on the judgment result of whether the first judgment process executed before the component is removed from the supply position or not, and the judgment unit determines that the first judgment process is usable based on the judgment result of whether the first judgment process executed before the component is removed is that the component is present and the judgment result of whether the first judgment process executed after the component is removed is that the component is absent, and the determination unit determines that the second judgment process is usable based on the judgment result of whether the second judgment process executed before the component is removed is that the component is present and the judgment result of the second judgment process executed after the component is removed is that the component is absent, and the determination unit determines that the second judgment process is usable based on the judgment result of whether the second judgment process is usable or not.

2. A component mounting system according to claim 1, wherein the determination unit executes processing before the component mounting system is put into operation.

3. A component mounting system according to claim 1 or 2, comprising a success / failure determination unit that executes a success / failure determination process to determine whether a component has been successfully removed from the feeder, wherein the decision unit determines that the first determination process can be used if the determination result of the first determination process executed before the component is removed is that a component is present and the determination result of the first determination process executed after the component is removed is that a component is absent and the determination result of the success / failure determination process is that removal was successful, and determines that the second determination process can be used if the determination result of the second determination process executed before the component is removed is that a component is present and the determination result of the second determination process executed after the component is removed is that a component is absent and the determination result of the success / failure determination process is that removal was successful.

4. A component mounting system as described in claim 1 or 2, comprising a memory unit that stores a default judgment process, wherein the determination unit, when determining that the first judgment process is usable and the second judgment process is unusable, determines the first judgment process as the judgment process to be used by the judgment unit, when determining that the first judgment process is unusable and the second judgment process is usable, determines the second judgment process as the judgment process to be used by the judgment unit, and when determining that the first judgment process and the second judgment process are usable, determines the default judgment process as the judgment process to be used by the judgment unit.

5. A component mounting system as claimed in claim 1 or 2, comprising a remaining quantity management unit that manages the remaining number of components held by the feeder by subtracting the number each time a component is taken out of the feeder, and when the determination unit determines that the first determination process and the second determination process are unusable, it determines that the determination process to be used by the determination unit is a third determination process that determines whether the feeder is out of components based on the remaining number.

6. A component mounting system as claimed in claim 1 or 2, comprising a success / failure determination unit that executes a success / failure determination process to determine whether or not components have been successfully removed from the feeder, and the determination unit performs the determination process when it is determined in the success / failure determination process that removal of components has failed multiple times in succession.

7. A component mounting system as described in claim 1 or 2, comprising a display processing unit that displays the captured images captured during each of the first judgment processes executed before and after component removal on a display unit.

Images