Feeder control device and feeder control method

Abstract

This feeder control device is applied to a bulk feeder that is set in a component mounting machine and supplies components. The bulk feeder comprises a vibratory device that imparts vibration to a structural member. The feeder control device comprises a damping unit that applies, to the structural member, damping vibration that dampens the vibration of the structural member caused by the operation of the vibratory device.

Description

Feeder control device and feeder control method

[0001] The present invention relates to a feeder control device and a feeder control method.

[0002] The feeder control device is applied to a bulk feeder that is set in a component mounting machine and supplies components. As shown in Patent Document 1, the bulk feeder is set with a component case that stores a large number of components in bulk, and supplies the components to the component mounting machine so that they can be picked by conveying the components discharged from the component case to a predetermined supply area.

[0003] International Publication No. 2021 / 095219

[0004] A bulk feeder may employ a vibration device that applies a predetermined vibration to the component supporting the parts during the parts feeding operation. Such bulk feeders require control of the vibration device to improve the efficiency of the parts feeding operation.

[0005] An object of the present specification is to provide a feeder control device and a feeder control method that can improve the efficiency of component supply operations.

[0006] This specification discloses a feeder control device that is applied to a bulk feeder that is set in a component mounting machine and supplies components, and that the bulk feeder is equipped with a vibration device that imparts vibration to a component member, and a damping unit that imparts damping vibration to the component member to attenuate vibration of the component member caused by operation of the vibration device.

[0007] This specification discloses a feeder control method that is applied to a bulk feeder that is set in a component mounting machine and supplies components, the bulk feeder including a vibration device that applies vibration to a component member, and a damping step that applies damping vibration to the component member to dampen vibration of the component member caused by operation of the vibration device.

[0008] This specification also discloses the technical idea of ​​changing "the feeder control device according to any one of claims 1 to 4" in claim 6 originally filed to "the feeder control device according to any one of claims 1 to 5," and the technical idea of ​​changing "the feeder control device according to any one of claims 1 to 4" in claim 7 originally filed to "the feeder control device according to any one of claims 1 to 6." This specification also discloses the technical idea of ​​changing "the feeder control device according to claim 8" in claim 11 originally filed to "the feeder control device according to any one of claims 8 to 10," and the technical idea of ​​changing "the feeder control device according to claim 8" in claim 12 originally filed to "the feeder control device according to any one of claims 8 to 11."

[0009] This configuration shortens the time it takes for the components to come to rest compared to conventional methods, improving the efficiency of the supply operation. Also, if another operation that is executed after the component supply operation requires the components to come to rest, the start time of the other operation can be advanced, improving production efficiency.

[0010] Fig. 3 is a perspective view showing the appearance of a bulk feeder. Fig. 4 is a side view schematically showing the main parts and component cases of the bulk feeder. Fig. 5 is a plan view seen from direction III in Fig. 2. Fig. 6 is a block diagram showing a bulk feeder to which a feeder control device is applied. Fig. 7 is a flowchart showing a component supply process. Fig. 8 is a flowchart showing a preparation process. Fig. 9 is a graph showing the relationship between a drive frequency and the amplitude of vibration of a component. Fig. 10 is a flowchart showing a component conveyance process. Fig. 11 is a time chart showing the vibration state of a component during a component conveyance process.

[0011] 1. Overview of the Feeder Control Device 60 The feeder control device 60 is applied to a bulk feeder 10 that is set in a component mounting machine 3 and supplies components. In this embodiment, the feeder control device 60 is incorporated into the bulk feeder 10 as shown in FIG. 1 and controls various operations performed by the bulk feeder 10. The component mounting machine 3 described above performs a mounting process for mounting components onto a board as a predetermined substrate-related operation. A plurality of substrate-related operation machines are installed, for example, in the direction in which the boards are transported to form a production line.

[0012] As shown in Fig. 4, the production system 1 is composed of the above-mentioned production line, a host computer 2, a parts warehouse (not shown), etc. The host computer 2 controls the entire production line. Each of the multiple substrate-related operation machines is connected to the host computer 2 so as to be able to communicate with each other. The production line includes multiple substrate-related operation machines, such as solder printing machines, multiple component placement machines 3, a reflow oven, and an inspection machine.

[0013] In this embodiment, a factory for producing substrate products may be configured with multiple production lines. The configuration of each of the multiple production lines may be appropriately added or modified depending on, for example, the type of substrate products to be produced. Specifically, the multiple production lines may be appropriately equipped with substrate-related operating machines such as a buffer device for temporarily holding transported substrates, a substrate supply device, a substrate inverting device, various inspection devices, a shield mounting device, an adhesive application device, and an ultraviolet irradiation device.

[0014] 2. Configuration of Bulk Feeder 10 As shown in Figure 1, the bulk feeder 10 is installed in the component mounting machine 3 and functions as part of the component supply device. The bulk feeder 10 supplies components stored in a bulk state (irregularly positioned components) that is not aligned like a carrier tape. Therefore, unlike a tape feeder, the bulk feeder 10 does not use a carrier tape, which has the advantage of eliminating the need to load a carrier tape and collect used tape.

[0015] Some bulk feeders 10 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 width direction is vertical, the component mounting machine 3 cannot pick these components. Therefore, to increase the percentage of components that can be picked, some bulk feeders 10 supply components in an aligned state in the supply area. In this embodiment, a bulk feeder 10 of the aligned type will be described as an example.

[0016] 2-1. Feeder Body 11, Bracket 12, and Support Base 13 As shown in FIG. 2, the bulk feeder 10 includes a feeder body 11. The feeder body 11 is formed in a flat box shape. A connector 111 and two pins 112 are provided at the front of the feeder body 11 (the right end in FIG. 2). When the feeder body 11 is set in a slot of the component supply device, it is powered via the connector 111 and is capable of communicating with the control device of the component mounting machine 3. The two pins 112 are inserted into guide holes provided in the slot and are used to position the feeder body 11 when it is set in the slot.

[0017] As shown in Fig. 2, the bulk feeder 10 includes a bracket 12. The bracket 12 is provided so as to be vibrable relative to the feeder body 11. The bracket 12 is formed in a block shape extending in the front-to-rear direction of the feeder body 11, and supports a track member 31 of the transport unit 20 attached to the upper surface. A predetermined vibration is applied to the bracket 12 by a transport vibration device 50. The track member 31 supported by the bracket 12 is fixed by a locking member (not shown).

[0018] As shown in Fig. 2, the bulk feeder 10 includes a support table 13. The support table 13 is provided so as to be vibrable relative to the feeder body 11, and supports component cases 25 via case holders 21 of the transport unit 20. The support table 13 is formed in a block shape extending in the front-to-rear direction of the feeder body 11, and supports the case holders 21 attached to the top surface. A predetermined vibration is applied to the support table 13 by a discharge vibration device 40. In this embodiment, the case holders 21 supported by the support table 13 are fixed in place by a locking member (not shown).

[0019] 2-2. Transport Unit 20 As shown in FIG. 2, the bulk feeder 10 includes a transport unit 20. The transport unit 20 is detachably attached to the feeder body 11. In this embodiment, the transport unit 20 supports a set component case 25. The transport unit 20 is a unit for transporting components from an area (receiving section 211) that receives components discharged from the component case 25 to the supply area As.

[0020] After the bulk feeder 10 has been used for a predetermined mounting process, a type of maintenance is performed in which all components inside the feeder are removed in preparation for the next use. The transport unit 20 is configured as a unit so that the portion that functions as a component flow path can be removed from the feeder body 11 to improve workability, assuming such a removal process. In this embodiment, the transport unit 20 includes a case holder 21, a track unit 22, and a connecting member 23.

[0021] 2-2-1. Case Holder 21 The case holder 21 is provided so as to be vibrable relative to the feeder body 11. The case holder 21 is attached to the feeder body 11 via the support base 13. This allows vibration to be applied to the case holder 21 by the discharge vibration device 40 via the support base 13. The case holder 21 supports the set component cases 25. The case holder 21 has a receiving portion 211 that receives components discharged from the component cases 25. In this embodiment, the portion of the case holder 21 that receives components has an inclined surface that is inclined forward with respect to the horizontal plane. The case holder 21 has a component flow path that extends upward from the lower end of the inclined surface.

[0022] The component case 25 is an external device that stores a plurality of components 92 in bulk. The component case 25 is set in a detachable (replaceable) manner in the case holder 21 of the transport unit 20 of the bulk feeder 10. The component case 25 has an overall shape that is a flat box, similar to the feeder body 11. The component case 25 is set in the case holder 21 and is ready to discharge the components 92 from a discharge port 251 formed in the bottom.

[0023] 2-2-2. Track unit 22 Track unit 22 includes a track member 31 that is detachably attached to feeder body 11. Track member 31 is attached to feeder body 11 via bracket 12. As a result, track member 31 is vibrated by conveyance vibration device 50 via bracket 12. Track member 31 forms a conveyance path R along which a plurality of parts are conveyed, and a supply area As that communicates with conveyance path R and opens upward so that a plurality of parts can be picked up.

[0024] Here, the "supply area As" is an area where components are supplied in bulk and where components can be picked up by the component mounting machine 3. The "conveyance path R" is a path along which components circulated on the track member 31 from the case holder 21 side are transported to the supply area As.

[0025] The track member 31 is formed so as to extend in the front-to-rear direction (left-to-right direction in FIG. 2 ) of the feeder body 11 as a whole. In this embodiment, an alignment member 32 is replaceably attached to the track member 31. The alignment member 32 is, for example, one or more plate-shaped members. In this manner, the track unit 22 is unitized by attaching one of a plurality of types of alignment members 32 selected from a plurality of types corresponding to the shapes of a plurality of types of parts to the common track member 31.

[0026] The components 92 supplied by the bulk feeder 10 include chip components such as resistors and capacitors formed in chip form, and conductive ball components. In this embodiment, the components 92 are solder balls 92A formed in a spherical shape, as shown in Fig. 3. The solder balls 92A are used as a bonding material to bond a plurality of electrodes formed in a grid pattern on an electronic component such as a BGA (Ball Grid Array) to lands on a substrate.

[0027] As shown in FIG. 3 , the alignment member 32 defines a plurality of cavities 35 arranged in a predetermined pattern (a staggered pattern in this embodiment). Each of the plurality of cavities 35 has a circular shape slightly larger than the diameter of the solder ball 92A and is configured to accommodate the solder ball 92A transported to the supply area As. When the components supplied by the bulk feeder 10 are chip components, the cavity 35 has a rectangular shape slightly larger than the outer shape of the chip component and is configured to accommodate the chip component. Thus, the bulk feeder 10 includes a plurality of cavities 35 for accommodating components 92 in the supply area As. A pair of side walls 36 protruding upward are formed on both edges of the track unit 22 in the width direction (the vertical direction in FIG. 3 ). The pair of side walls 36, together with the tip 37 of the track unit 22, surround the periphery of the transport path R, preventing leakage of the components 92 transported along the transport path R.

[0028] The track unit 22 has a shutter 38 provided on the front end side of the track member 31. The shutter 38 is provided on the track member 31 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 22 is attached to the feeder body 11, the shutter 38 is connected to a shutter drive device (not shown). The opening and closing operation of the shutter 38 is controlled by the shutter drive device. By opening and closing the shutter 38, the bulk feeder 10 can prevent components 92 from jumping out and foreign objects from entering the supply area As.

[0029] 2-2-3. Connecting Member 23 The connecting member 23 connects the case holder 21 and the track unit 22 so that multiple components can flow between them. The connecting member 23 is tubular, allowing multiple components to flow through it. The connecting member 23 is flexible and deforms in response to the vibrations of the case holder 21 and the track unit 22, thereby absorbing the respective vibrations. In this way, the connecting member 23 reduces or blocks vibrations transmitted between the case holder 21 and the track unit 22, which vibrate independently of each other.

[0030] 2-3. Air Supply Device 16 The bulk feeder 10 is equipped with an air supply device 16 that supplies positive pressure air to the transport unit 20. When the transport unit 20 is attached to the feeder body 11, the air supply device 16 supplies positive pressure air to the transport unit 20, and the transport unit 20 circulates multiple parts from the case holder 21 to the track unit 22 via the connecting member 23. In this embodiment, the air supply device 16 supplies or cuts off the positive pressure air supplied from the outside from below the case holder 21 based on commands from the feeder control device 60, which will be described later.

[0031] 2-4. Vibration Device Vb, Vibration Sensor Vs As shown in FIG. 2, the bulk feeder 10 includes a component Ns, a vibration device Vb, and a vibration sensor Vs used in the component supply operation. The component Ns is a member that supports multiple components. In this embodiment, the component Ns includes the case holder 21 of the transport unit 20 and the track member 31 of the track unit 22. The vibration device Vb is provided so as to be able to transmit vibration to the component Ns, and the vibrator Vb1 applies vibration to the component Ns (case holder 21, track member 31) in response to the supplied power. In this embodiment, the vibration device Vb includes a discharge vibration device 40 and a transport vibration device 50.

[0032] The vibration sensor Vs detects the amplitude of the vibration of the component Ns (case holder 21, track member 31) caused by the vibration of the vibration exciter Vb (discharge vibration exciter 40, transport vibration exciter 50). In this embodiment, the vibration sensor Vs includes a discharge vibration sensor 45 and a transport vibration sensor 55.

[0033] 2-4-1. Discharge Vibration Device 40 The bulk feeder 10 includes a discharge vibration device 40 provided in the feeder body 11. The discharge vibration device 40 is a vibration device that applies vibration to the case holder 21 that supports the component case 25, thereby discharging the component from the component case 25. In this embodiment, the discharge vibration device 40 applies vibration to the support base 13 to which the case holder 21 is integrally fixed, thereby applying vibration to the component case 25 via the case holder 21.

[0034] The ejection vibration device 40 has a vibrator that applies vibration to the case holder 21 in response to the supplied power. The ejection vibration device 40 may employ, for example, a configuration in which a solenoid 41 that is excited by power supply is used as the vibrator. The solenoid 41 is excited to generate a magnetic field only while power is being supplied from a power supply device 42. As a result, a vibrated part (not shown) provided on the support base 13 is attracted to the solenoid 41 and moves from its initial position.

[0035] Furthermore, when the power supply to the solenoid 41 by the power supply device 42 is cut off, the magnetic force disappears and the support base 13 moves back to its initial position. In this configuration, by supplying pulsed power to the solenoid 41 by the power supply device 42, the ejection vibration device 40 vibrates the support base 13, the case holder 21, and the component case 25 so that they move back and forth in the horizontal direction.

[0036] The discharge vibration sensor 45 is provided on the case holder 21 and detects a vibration value indicating the vibration state of the case holder 21 vibrating due to the vibration of the discharge vibration device 40. Examples of vibration values ​​that can be used to indicate the vibration state include amplitude, frequency, damping time, and vibration trajectory (the movement trajectory of a specific part caused by vibration). In this embodiment, the discharge vibration sensor 45 detects the actual vibration amplitude of the case holder 21 when the solenoid 41 is supplied with pulsed power to vibrate the case holder 21. Note that if the discharge vibration sensor 45 is not used in the component supply process described below, its installation on the bulk feeder 10 may be omitted.

[0037] 2-4-2. Conveyor Vibration Device 50 The bulk feeder 10 includes a conveyor vibration device 50 provided in the feeder body 11. The conveyor vibration device 50 is a vibration device that applies vibration to the track member 31 to convey parts on the conveying path R. In this embodiment, the conveyor vibration device 50 applies vibration to the bracket 12 to which the track member 31 is integrally fixed, thereby applying vibration to the track member 31 that forms the conveying path R.

[0038] Specifically, the conveying vibration device 50 has a plurality of support members 51, a plurality of piezoelectric elements 52, and a power supply device 53. The plurality of support members 51 directly or indirectly connect the feeder body 11 and the bracket 12 to support the bracket 12. In this embodiment, the plurality of support members 51 include forward support members 51A used for conveying components forward, and backward support members 51B used for conveying components rearward. The forward support members 51A and the backward support members 51B are inclined in different directions relative to the vertical direction.

[0039] The plurality of piezoelectric elements 52 are vibrators that vibrate at a frequency corresponding to the power supplied by the power supply device 53. The plurality of piezoelectric elements 52 are affixed to each of the plurality of support members 51. When at least some of the plurality of piezoelectric elements 52 vibrate, vibration is imparted to the track member 31 via the bracket 12. Furthermore, the amplitude of the track member 31 varies depending on the voltage applied to the piezoelectric elements 52. Of the plurality of piezoelectric elements 52, those affixed to the advance support member 51A are advance vibrators 52A that move components in the advance direction of the transport path R. Furthermore, of the plurality of piezoelectric elements 52, those affixed to the retreat support member 51B are retreat vibrators 52B that move components in the retreat direction of the transport path R.

[0040] The transportation vibration sensor 55 is provided in the transportation vibration device 50 and detects a vibration value indicating the vibration state of the vibrating track member 31. The vibration value indicating the vibration state may be amplitude, frequency, damping time, vibration locus (movement locus of a specific part due to vibration), etc. In this embodiment, the transportation vibration sensor 55 detects the actual vibration amplitude of the track member 31 when the piezoelectric element 52 is supplied with power and vibrates.

[0041] Furthermore, a transport vibration sensor 55 is provided on each of the plurality of support members 51 that support the brackets 12 that vibrate integrally with the track member 31. More specifically, a piezoelectric element 52 and a transport vibration sensor 55 are provided on each of the forward movement support member 51A and the backward movement support member 51B. The forward movement vibration sensor 55A provided on the forward movement support member 51A detects the actual amplitude as a vibration value when the piezoelectric element 52 (forward movement oscillator 52A) provided on this forward movement support member 51A is powered and applies vibration to the track member 31 via the bracket 12.

[0042] Furthermore, the reverse vibration sensor 55B provided on the reverse support member 51B detects the actual amplitude as a vibration value when the piezoelectric element 52 (reverse vibrator 52B) provided on this reverse support member 51B is powered and applies vibration to the track member 31 via the bracket 12. Here, when the conveying vibration device 50 applies vibration to the track member 31, the track member 31 moves in an elliptical motion when viewed from the side. As a result, a plurality of parts on the conveying path R are subjected to a forward and upward external force or a backward and upward external force depending on the rotation direction of the elliptical motion of the track member 31. As a result, the plurality of parts are conveyed to the front or rear of the track member 31.

[0043] Power supply device 53 varies the frequency and voltage of the power supplied to piezoelectric element 52 based on commands from feeder control device 60, which will be described later. This adjusts the frequency and amplitude of the vibration imparted to track member 31 and determines the rotation direction of the elliptical motion of track member 31. Fluctuations in the frequency and amplitude of the vibration of track member 31 and the rotation direction of the elliptical motion caused by the vibration will result in fluctuations in the conveying speed, degree of dispersion of the parts, conveying direction, etc.

[0044] Therefore, in order to improve conveying efficiency, the conveying vibration device 50 is set in advance to supply power (drive voltage, drive frequency) that corresponds to the vibration characteristics that vary among individual devices. For example, the bulk feeder 10 executes a preparatory process to set an initial drive voltage and drive frequency in a state in which the track member 31 to be used in the planned supply operation is attached, i.e., in a state in which the track member 31 is locked to the bracket 12 by the locking device. The details of setting the initial drive voltage and drive frequency will be described later.

[0045] 2-5. Feeder Control Device 60 The bulk feeder 10 is equipped with a feeder control device 60. The feeder control device 60 is mainly composed of a CPU, various memories, and control circuits. When the bulk feeder 10 is set in a slot of the component mounting machine 3, the feeder control device 60 is supplied with power via the connector 111 and is able to communicate with the control device of the component mounting machine 3. As shown in FIG. 4, the feeder control device 60 is equipped with a memory unit 61 and a transport control unit 62.

[0046] The storage unit 61 of the feeder control device 60 stores various data such as programs used to control the component supply process and transport parameters. The transport control unit 62 controls the operation of the air supply device 16, the discharge vibration device 40, the transport vibration device 50, etc. The above-mentioned "transport parameters" are parameters for controlling the operation of the transport vibration device 50 so that the vibration applied to the track unit 22 is appropriate when components are transported in the component supply process, and are set in advance in association with each type of component, for example.

[0047] 3. Component Supply Process of Bulk Feeder 10 The component supply process by the bulk feeder 10 configured as described above will be described with reference to FIG. 5. The feeder control device 60 first executes a preparation process (S10). The preparation process includes an initialization process that is performed first after the bulk feeder 10 is powered on, a calibration process for the vibration device Vb, and a process for setting the initial drive voltage and drive frequency. The preparation process will be described in detail later.

[0048] Next, the transport control unit 62 executes a process of replenishing parts to the transport path R formed on the track member 31 based on, for example, an external replenishment command (S20). This "replenishment process" is a process of replenishing parts discharged from the parts case 25 to the component Ns that supports the parts. More specifically, the transport control unit 62 executes an operation of discharging parts from the parts case 25 (S21). Note that this discharge operation may be executed after input of a replenishment command, or may be executed in advance for the next supply process after the previous supply process.

[0049] The transport control unit 62 controls the operation of the ejection vibration device 40 so that vibrations are applied to the component cases 25 via the case holder 21 and the support base 13. When the component cases 25 vibrate, the components are ejected from the ejection port 251. The ejected components fall onto the inclined portion of the case holder 21 located below the ejection port 251 and slide forward along the inclined surface of the inclined portion. As a result, the components are retained in the receiving portion 211 in front of the inclined portion.

[0050] In this state, the transfer control unit 62 performs a component blowing operation (S22). Specifically, the transfer control unit 62 commands the air supply device 16 to supply positive pressure air. The positive pressure air supplied by the air supply device 16 blows up the multiple components that have been retained and flows through the flow path formed in the case holder 21 together with the components. As a result, the positive pressure air and the multiple components flow from the case holder 21 through the connecting member 23 to the track unit 22 and reach the transfer path R of the track unit 22. Here, the positive pressure air is exhausted to the outside from an exhaust port formed in the cover of the track unit 22.

[0051] After the above-described process of replenishing components to the transport path R, the feeder control device 60 determines whether or not there is an external supply command (S31). If there is no supply command (S31: No), the transport control unit 62 suspends the execution of the component transport process. This maintains the current component supply state in the supply area As and enters a state of waiting for a supply command.

[0052] If a supply command is received (S31: Yes), the conveyance control unit 62 executes a component conveyance process (S32). In the component conveyance process, the conveyance vibration device 50 executes a conveyance operation (movement of moving the components forward and backward) to convey the components on the conveyance path R. As a result, some of the multiple components conveyed to the supply area As are accommodated in the cavities 35. When the shutters 38 are opened, the components accommodated in the multiple cavities 35 are supplied so that they can be picked by the component mounting machine 3. The opening and closing operation of the shutters 38 is executed based on an external command. Details of the component conveyance process will be described later.

[0053] Next, the feeder control device 60 executes an adjustment process (S33) to set and adjust the frequency of the vibration to be applied to the track member 31 in the next and subsequent part conveyance processes. This adjustment process (S33) adjusts the drive frequency as needed based on the amplitude of the track member 31 detected by the conveyance vibration sensor 55 as a result of executing the part conveyance process (S32).

[0054] After the component transport process (S32) and adjustment process (S33), the feeder control device 60 determines whether or not a component replenishment process (S20) is required (S34). The determination of whether or not a replenishment process is required is based on, for example, the presence or absence of an external command from the component mounting machine 3, or on the remaining number of components (including an estimated value) supported by the component Ns. For example, if the component mounting machine 3 captures an image of the supply area As immediately after the component supply process and the image data shows that the number of components is small, the component mounting machine 3 sends a replenishment command to the bulk feeder 10, indicating that a replenishment process is required.

[0055] Furthermore, if the component supply process has been performed a predetermined number of times since the previous resupply process, the component mounting machine 3 or the feeder control device 60 may determine that the remaining number of components supported by the component Ns has become low and that a resupply process is required. If a resupply process of components is required (S34: Yes), the resupply process of components is performed again (S20), and components are replenished onto the conveying path R. On the other hand, if a resupply process of components is not required (S34: No), the resupply process of components is omitted, and the machine waits for a supply command (S31).

[0056] 4. Detailed Configuration of Feeder Control Device 60 In the component supply process by the bulk feeder 10, it is necessary to stabilize the transport of components and improve the efficiency of the supply operation. To achieve this, appropriate control of the vibration device Vb is necessary. More specifically, in a configuration in which the vibrator Vb1 (solenoid 41, piezoelectric element 52) ​​applies vibration to the component Ns (case holder 21, track member 31) in response to the supplied power, as in this embodiment, it is preferable that the voltage (drive voltage) and frequency (drive frequency) of the power supplied to the vibration device Vb be appropriately set.

[0057] The drive voltage contributes to the amplitude of vibration, and the higher the drive voltage is set, the greater the amplitude of vibration of the component Ns, in principle. Here, the vibrating body including the component Ns has a predetermined natural frequency. The "vibrating body" mentioned above refers to a collection of members that vibrate integrally with the component Ns when excited by the vibration excitation device Vb. In this embodiment, the vibrating body excited by the transport vibration excitation device 50 includes the track member 31, the bracket 12, a locking device connecting these, and a cover attached to the track member 31. Furthermore, the vibrating body excited by the ejection vibration excitation device 40 includes the case holder 21, the support base 13, a locking device connecting these, and the component case 25 set in the case holder 21.

[0058] The vibrating body including the component Ns is assembled in contact with other members such as the connecting member 23 within the bulk feeder 10, and supports multiple parts to be conveyed. Therefore, the vibrating body is subjected to reaction forces from other members and multiple parts during vibration, and is in a vibration environment in which the reaction forces vary depending on the number of parts it supports. In such a vibration environment, the vibrating body resonates when vibrations of a frequency corresponding to its own natural frequency are applied. The frequency at which the vibrating body resonates in accordance with this vibration environment is hereinafter referred to as the "resonant frequency."

[0059] When vibrations are applied to the vibrating body including the component Ns by the vibrating device Vb supplied with power whose drive frequency is the resonant frequency, the vibrating body resonates and stably vibrates at the expected amplitude corresponding to the drive voltage. In other words, if the drive frequency deviates from the resonant frequency, the expected amplitude for the drive voltage may not be obtained, or the vibration may become unstable, such as by periodically increasing and decreasing the amplitude. If vibrations are continuously applied to the component Ns in an unstable state, the moving distance of the part per unit time may become shorter.

[0060] Therefore, in the preparation process (S10), an initial drive voltage and drive frequency are set so that the power supplied to the vibrator Vb during the component supply process is appropriate. Furthermore, because the resonance frequency may fluctuate with changes in the vibration environment, the feeder control device 60 performs an adjustment process (S33) of the drive frequency during production to maintain a good component supply process. Therefore, the feeder control device 60 includes a setting unit 64. In the preparation process (S10) and the adjustment process (S33), the setting unit 64 sets the frequency (drive frequency) of vibration that the vibrator Vb will apply to the component Ns from the next time onward.

[0061] Here, before executing a picking operation to pick up components supplied by the component supply process described above, the component mounting machine 3 executes a recognition process to recognize the supply status of components in the supply area As. This process recognizes which of the multiple cavities 35 contains a pickable component, and based on the result, sets the component to be picked. The recognition process also includes image processing of image data obtained by capturing an image of the supply area As. During this supply status recognition process and during the picking operation for a specific component, it is preferable that the component positioned in the supply area As in a pickable state be stationary.

[0062] In contrast, under the control of the vibrator Vb by the feeder control device 60, as shown by the standard line STN in Fig. 9 , the forward vibration BF is switched to the backward vibration BR at time T10, and even when the backward vibration BR is stopped at time T20, vibration remains in the component member Ns including the track member 31 for a predetermined damping period PdN. The residual vibration BS damps after the vibration by the vibrator Vb is stopped, and the amplitude becomes 0 (including a level at which the amplitude can be considered to be 0) after the damping period PdN has elapsed. Note that the wavy lines in Fig. 9 indicate the vibrations present during that period, but do not accurately indicate the amplitude or frequency.

[0063] The component mounting machine 3 can employ a control mode that waits until the residual vibration BS disappears (attenuates to the extent that the residual vibration BS no longer has any effect) when performing the supply status recognition process or component picking operation. However, the occurrence of wait time can contribute to a decrease in production efficiency. Therefore, the feeder control device 60 employs a configuration that improves the efficiency of the component supply operation by shortening the attenuation period Pd of the residual vibration BS. In this embodiment, the feeder control device 60 includes a damping unit 65. The following describes the preparation process, adjustment process, and component conveyance process related to the control of the conveyance vibration device 50.

[0064] In the preparation process (S10), the feeder control device 60 identifies the resonance frequency of the vibrator including the track member 31 based on the detection result by the conveyance vibration sensor 55. Specifically, as shown in Fig. 6, the feeder control device 60 searches for the resonance frequency of the vibrator when a predetermined drive voltage is applied (S11).

[0065] 7 shows the relationship between the drive frequency and the actual vibration amplitude of the track member 31 when the power supply device 53 applies a predetermined drive voltage to the forward piezoelectric element 52, with the vibrator in the reference state as the excitation target. As shown by the curve LSF, the vibration of the track member 31 reaches a maximum amplitude Tm (TmSF) at a predetermined resonance frequency Fr (FrSF). In this embodiment, the "reference state" when the vibrator to be excited includes the track member 31 is a state in which parts are removed from the track member 31.

[0066] In this embodiment, the feeder control device 60 first applies vibrations of multiple different frequencies to the track member 31 (vibrator). The drive voltage at this time is the drive voltage expected to be used in the component supply process, and is set to, for example, the maximum voltage that the power supply device 53 can apply. The multiple frequencies may be frequencies obtained by equally dividing a predetermined frequency band by a specified number, or may be frequencies obtained by adding or subtracting a specified number from the design frequency. In this embodiment, the frequency is set based on the amplitude detected by the conveyance vibration sensor 55 so that many samples (points on the curve LSF) are taken near the amplitude peak.

[0067] The feeder control device 60 acquires the amplitude of the track member 31 to which vibrations of each frequency have been applied, and determines the frequency at which the track member 31 vibrates at the maximum amplitude Tm (TmSF) as the resonance frequency Fr (FrSF) (S12). If the forward and reverse resonance frequencies Fr have not been acquired (S13: No), the feeder control device 60 switches the forward and reverse frequencies and executes the acquisition process (S11-S12). As a result, the reverse resonance frequency FrSR is acquired, as shown by the curve LSR in FIG. 7. Note that the vibration of the track member 31 at the reverse resonance frequency FrSR has the maximum amplitude Tm (TmSR).

[0068] The forward resonance frequency FrSF and reverse resonance frequency FrSR obtained as described above are frequencies that cause resonance in the vibrating body including the track member 31 when predetermined drive voltages are applied to the forward and reverse piezoelectric elements 52, which are the vibrator Vb1, respectively, in the current vibration environment in which the track member 31 is in the reference state. The setting unit 64 sets the above drive voltages as the initial value of the drive voltage Ed used in the component supply process, and also sets the two types of resonance frequencies Fr as the initial value of the drive frequency Fd used in the component supply process (S14).

[0069] 4-2. Adjustment Process The resonant frequency Fr of the vibrator can vary depending on the replacement of the track member 31 or the alignment member 32, or the slot of the component mounting machine 3 in which the bulk feeder 10 is set. The resonant frequency Fr can also vary depending on an increase or decrease in the number of components supported by the component member Ns included in the vibrator. Specifically, the vibration characteristics shown by the curve LSF in FIG. 7 in the standard state decrease in both the resonant frequency and the maximum amplitude when the track member 31 is operating and supporting multiple components. Therefore, the feeder control device 60 performs an adjustment process (S33) of the drive frequency Fd as necessary during the component supply process.

[0070] Specifically, when the current amplitude detected by the vibration sensor Vs during the part transport process (S32) is not within a preset tolerance range, the setting unit 64 adjusts the drive frequency Fd based on the difference between the current amplitude and the target amplitude. The adjustment amount of the drive frequency Fd may be a constant value regardless of the magnitude of the difference, or may be a value increased or decreased by a predetermined amount from the previous adjustment amount. When the difference between the reference amplitude and the current amplitude is within the tolerance range, the setting unit 64 omits adjustment of the drive frequency Fd.

[0071] In the adjustment process (S33), the forward drive frequency Fd is set as described above, and the reverse drive frequency Fd is similarly set. Then, in the component supply process, after an external supply command is input (S31: Yes), the transport process (S32) is executed using the adjusted forward and reverse drive frequencies Fd. With this configuration, the drive frequency Fd is set so as to approach the resonance frequency Fr corresponding to the current vibration characteristics of the vibrating body including the component Ns (track member 31), so transport efficiency can be maintained and vibration can be stabilized.

[0072] 4-3. Component Conveyance Processing In the component conveyance processing (S32), as shown in FIG. 8, the conveyance control unit 62 first causes the conveyance vibration device 50 to apply forward vibration BF to the track member 31 via the bracket 12 (S51). As a result, multiple components are conveyed forward toward the supply area As, and some of the components are accommodated in the cavities 35. Next, the conveyance control unit 62 causes the conveyance vibration device 50 to apply backward vibration BR to the track member 31 (S52). As a result, the components that were not accommodated in the cavities 35 are retracted toward the conveyance path R and removed from the supply area As.

[0073] If the number of times the transport operation of reciprocating parts as described above has been performed has not reached the specified number of times (S53: No), the transport control unit 62 repeats S51-S52. The specified number of times may be a preset constant, or may be a value that varies depending on the type of parts, the type of alignment member 32, and the amount of parts supported by the track member 31. If the number of times the transport operation of reciprocating parts has been performed has reached the specified number of times (S53: Yes), the damping unit 65 performs damping processing to shorten the damping period of the residual vibration of the track member 31 (S54, damping step).

[0074] Here, as shown by the standard line STN in Figure 9, it has been found that when the damping process is not performed, the damping period PdN of the residual vibration BS tends to become longer as the frequency of the vibration (drive frequency Fd) applied to the vibrating body including the track member 31 approaches the resonance frequency Fr. This indicates that the vibrating body is vibrating efficiently, or in other words, that the vibrating body is in a state where it is difficult to damp. Therefore, in the damping process, the damping unit 65 applies damping vibration BD to the component member Ns to damp the vibration of the component member Ns.

[0075] In this embodiment, the damping unit 65 applies to the component Ns damping vibrations BD of a frequency (i.e., a non-resonant frequency Fn) different from the frequency (drive frequency Fd) of the vibrations (forward vibrations BF, backward vibrations BR) that the vibration exciter Vb applies to the component Ns during normal operation (transport operation in which parts are reciprocated). At this time, the damping unit 65 applies the damping vibrations BD to the component Ns through the damping operation of the vibration exciter Vb. In other words, the damping unit 65 attempts to quickly damp the vibration of the component Ns using the vibration exciter Vb that excites the component Ns.

[0076] Specifically, the damping unit 65 applies damping vibration BD to the track member 31 by the damping operation of the conveyance vibration excitation device 50 using the backward vibration element 52B. Note that while the damping operation can also be performed using the forward vibration element 52A, the backward vibration element 52B is used to prevent the part from moving forward due to the damping vibration BD applied thereby.

[0077] Furthermore, the damping unit 65 sets the drive voltage Ed of the power supplied to the retraction oscillator 52B during the damping operation of the conveyance vibration excitation device 50 to the drive voltage Ed of the power supplied to the retraction oscillator 52B during the retraction operation in which the conveyance vibration excitation device 50 moves the part in the retraction direction. The reason for setting it in this manner is to prevent the frequency of the damping vibration BD from unintentionally approaching the resonant frequency Fr corresponding to the changed drive voltage Ed, since changing the drive voltage Ed can cause the resonant frequency Fr to fluctuate.

[0078] 4-3-1. First Mode of Damping Process In the first mode of damping process, the damping unit 65 applies a damping vibration BD1 having a frequency lower than the resonant frequency Fr to the component Ns. The "frequency lower than the resonant frequency Fr" is a non-resonant frequency Fn, which is set to a value in the range of 10% to 30% of the resonant frequency FrSR for reverse travel (see the non-resonant frequency FnD in FIG. 7 ). As shown in FIG. 9 , when the damping vibration BD1 is applied during the period Pv1 from time T20, when the application of the reverse travel vibration BR is stopped, to time T22, the vibration of the track member 31 attenuates to approach the amplitude TnD of the damping vibration BD1, as indicated by the transition line St1, and reaches the amplitude TnD of the damping vibration BD1 at time T21.

[0079] When the application of the damping vibration BD1 is stopped at time T22, the vibration of the track member 31 damps from amplitude TnD to zero amplitude at time T31, which is earlier than usual. In the above example, the period Pv1 during which the damping vibration BD1 is applied was set to be longer than the period (T20-T21) until the vibration of the track member 31 damps to amplitude TnD, but it may also be set to be shorter than this period (T20-T21). In either case, the damping period Pd1 (T20-T31) from when the reverse vibration BR is stopped until the residual vibration BS disappears can be shortened compared to the damping period PdN (T20-T30) when the damping process is not executed.

[0080] The damping unit 65 may apply a damping vibration BD of a frequency higher than the resonant frequency Fr to the component Ns. The "frequency higher than the resonant frequency Fr" is a non-resonant frequency Fn, which is set to a value in the range of 10% to 30% of the resonant frequency FrSR for reverse travel (see the non-resonant frequency FnD2 in FIG. 7). This allows the damping vibration BD of an amplitude TnD similar to that of the damping vibration BD1 of a frequency lower than the resonant frequency Fr to be applied to the component Ns, thereby performing a similar damping process.

[0081] 4-3-2. Second Mode of Damping Process In the second mode of damping process, the damping unit 65 applies damping vibrations BD (BD2, BD3) of multiple different frequencies to the component Ns. The multiple frequencies are non-resonant frequencies Fn. For example, if there are two frequencies, the higher frequency is set to approximately 70% of the resonant frequency FrSR for reverse travel and the lower frequency is set to approximately 20% of the resonant frequency FrSR for reverse travel (see the non-resonant frequencies FnP and FnD in FIG. 7 ). Furthermore, as shown in FIG. 9 , the high-frequency damping vibration BD2 is applied during a period Pv21 from time T20, when application of the reverse vibration BR is stopped, to time T26, and the low-frequency damping vibration BD3 is applied during a period Pv22 from time T26 to time T28.

[0082] As a result, as shown by transition line St2, the vibration of the track member 31 attenuates to approach the amplitude TnP of the damping vibration BD2 on the high frequency side, and reaches the amplitude TnP of the damping vibration BD2 at time T25. The vibration of the track member 31 then further attenuates to approach the amplitude TnD of the damping vibration BD3 on the low frequency side, and reaches the amplitude TnD of the damping vibration BD3 at time T27. When the application of the low frequency damping vibration BD3 is stopped at time T27, the vibration of the track member 31 attenuates from the amplitude TnD and reaches zero amplitude at time T32, which is earlier than usual.

[0083] With this configuration, the vibration of the track member 31 can be damped in stages. This reduces the mechanical load caused by sudden damping and also reduces the deceleration applied to the components supported by the component Ns. In the second embodiment, the period Pv during which the vibration excitation device Vb performs the damping operation is a period Pv2 consisting of a period Pv21 during which high-frequency damping vibration BD2 is applied and a period Pv22 during which low-frequency damping vibration BD3 is applied. The periods Pv21 and Pv22 can be set appropriately, as in the first embodiment. With this configuration, the damping period Pd2 can be shortened compared to the normal damping period PdN.

[0084] 4-3-3. Third Mode of Damping Process In the third mode of damping process, the damping unit 65 applies to the component Ns a damping vibration BD having a frequency such that the frequency during the period Pv during which the damping vibration BD is applied is 1.0 or less. Specifically, the damping unit 65 applies a constant voltage to, for example, the oscillator Vb1 (in this embodiment, the retraction oscillator 52B) for a predetermined period Pv3. This maintains the piezoelectric element 52, which is the retraction oscillator 52B, in either a constant expanded state, a constant contracted state, or a constant state that is neither of these (e.g., a state in which the piezoelectric element 52 is deformed from its initial shape to a predetermined shape) during the predetermined period Pv3. In other words, one cycle (frequency of 1) is applied to the track member 31 over a period twice the predetermined period Pv3, i.e., an ultra-low frequency damping vibration BD4 having a frequency of 0.5 during the predetermined period Pv3.

[0085] Specifically, as shown in FIG. 9 , during the period Pv3 from time T20, when the application of the reverse vibration BR is stopped, to time T29, ultra-low frequency damping vibration BD4 is applied. This is thought to substantially change the vibration characteristics of the vibrating body, including the track member 31. As a result, as shown by the transition line St3, the vibration of the track member 31 is damped by the action of the oscillator Vb1, resulting in a faster damping rate than usual. The residual vibration BS of the track member 31 has an amplitude of zero at time T33. With this configuration, the damping period Pd3 can be shortened compared to the normal damping period PdN.

[0086] In the third mode of the damping process, the damping unit 65 may apply to the component Ns damping vibration BD at a frequency such that the frequency in the predetermined period Pv is 1.0. Furthermore, it is assumed that the actual frequency of the vibrator in the damping period Pd3 may be lower or higher than the resonant frequency Fr depending on the configuration of the vibrator.

[0087] Furthermore, when there are multiple types of oscillators Vb1 capable of imparting vibration to the track member 31, as in this embodiment, the damping unit 65 may impart ultra-low frequency damping vibrations BD4 in multiple patterns. The multiple patterns include the mode using the reverse oscillator 52B as exemplified, a mode using the forward oscillator 52A, and a mode using both. Which pattern is effective may be obtained from actual values ​​in preparatory processing, etc., taking into consideration that this may vary depending on the configuration of the vibrating body and the vibration environment.

[0088] 5. Effects of the Configuration of the Embodiment The configuration of the feeder control device 60 exemplified in the embodiment and the feeder control method including the damping process (S54, damping step) shorten the period until the component Ns comes to rest (damping period Pd) compared to the conventional method, thereby improving the efficiency of the feeding operation. Furthermore, if another operation executed after the component feeding operation requires the component Ns to come to rest, the start time of the other operation can be advanced, thereby shortening the time that the component mounting machine 3 waits for the residual vibration BS to disappear, for example. As a result, production efficiency can be improved.

[0089] Furthermore, as illustrated in this embodiment, when the components 92 are solder balls 92A, the position of the solder balls 92A within the cavity 35 is more likely to be unstable than when the components are chip components. Therefore, it is particularly useful to perform a damping process (damping step) that can quickly eliminate the residual vibrations BS of the components Ns, including the track member 31. Note that even when the components 92 are chip components, the supply area As is the subject of imaging in the supply state recognition process, and each chip component is the subject of collection, so quickly eliminating the residual vibrations BS of the components Ns is useful from the perspective of improving production efficiency.

[0090] 6. Modifications of the Embodiment 6-1. Application to Part Discharge Operation In the embodiment, the damping unit 65 shortens the damping period Pd of the residual vibration BS of the track member 31 during the transport operation. In contrast, the damping unit 65 may also be the target of damping processing that damps the residual vibration of the case holder 21 during the discharge operation. In this case, the setting unit 64 may set the frequency (drive frequency Fd) of the vibration that the discharge vibration device 40 applies to the case holder 21 during the next discharge operation executed in the replenishment process (S20).

[0091] Then, after the predetermined vibration is applied to the case holder 21 by the discharge vibration device 40 during the discharge operation, the damping unit 65 performs the damping process in the same manner as in the embodiment exemplified. This shortens the damping period until the residual vibration of the case holder 21 disappears. This makes it possible to prevent the residual vibration of the case holder 21 from being propagated via, for example, the feeder main body 11 and affecting the conveying operation or external devices such as other feeders.

[0092] 6-2. Application of Feeder Control Device 60 In the embodiment, the feeder control device 60 is configured to be incorporated into the bulk feeder 10. However, the damping unit 65 of the feeder control device 60 may be incorporated into a device external to the bulk feeder 10, as long as it can control the operation of the vibration device Vb that applies vibration to the component Ns. For example, the damping unit 65 of the feeder control device 60 may be configured to be incorporated into the control device of the component mounting machine 3 or the host computer 2.

[0093] 10: Bulk feeder, 20: Conveying unit, 21: Case holder (component), 22: Track unit, 31: Track member (component), 23: Connecting member, 25: Component case, 40: Discharge vibrating device, 41: Solenoid (vibrator), 50: Conveying vibrating device, 52: Piezoelectric element (vibrator), 52A: Forward vibrator, 52B: Backward vibrator, 55: Conveying vibration sensor, 60: Feeder control device, 61: Memory unit, 62: Conveying control unit, 65: Damping unit, 92: Component, 92A: Solder ball, As: Supply area, R: Conveying path, Ed: Driving voltage, Fd: Driving frequency, Fr: Resonant frequency, Fn: Non-resonant frequency, Ns: Constituent member, Vb: Vibrating device, Vb1: Vibrator

Claims

1. A feeder control device applied to a bulk feeder that is set in a component mounting machine and supplies components, the bulk feeder having a vibration device that imparts vibration to a component, and a damping unit that imparts damping vibration to the component to attenuate vibration of the component caused by the operation of the vibration device.

2. A feeder control device according to claim 1, wherein the damping section applies the damping vibration to the component member at a frequency different from the frequency of the vibration applied to the component member by the vibration applying device during normal operation.

3. A feeder control device as described in claim 2, wherein the vibration excitation device has a vibrator that is capable of transmitting vibration to the component and vibrates in response to supplied power, and the frequency of the vibration that the vibration excitation device applies to the component during normal operation is controlled by supplying power to the vibrator at a predetermined drive voltage, with the resonant frequency at which the amplitude of vibration of the component is maximized.

4. The feeder control device according to claim 3, wherein the damping section applies the damping vibration to the component member at a frequency lower than the resonant frequency.

5. A feeder control device according to any one of claims 1 to 4, wherein the damping section applies the damping vibrations of a plurality of different frequencies to the component members.

6. A feeder control device as claimed in any one of claims 1 to 4, wherein the damping section applies the damping vibration to the component member at a frequency such that the number of vibrations during the period in which the damping vibration is applied is 1.0 or less.

7. A feeder control device according to any one of claims 1 to 4, wherein the damping section applies the damping vibration to the component member by the damping operation of the vibration excitation device.

8. A feeder control device as described in claim 7, wherein the components include a track member that forms a transport path for the parts discharged from a parts case, and the vibration device includes a transport vibration device that applies vibration to the track member to transport the parts on the transport path.

9. A feeder control device as described in claim 8, wherein the conveying vibration excitation device is a vibrator that is capable of transmitting vibration to the component members and that applies vibration to the track members in response to supplied power, and has a forward vibrator and a backward vibrator that move the parts in the forward direction and backward direction of the conveying path, respectively, and the damping unit applies the damping vibration to the track members by the damping operation of the conveying vibration excitation device using the backward vibrator.

10. A feeder control device as described in claim 9, wherein the damping unit sets the drive voltage of the power supplied to the retracting vibrator during the damping operation to the drive voltage of the power supplied to the retracting vibrator during the retracting operation in which the conveying vibration device moves the part in the retracting direction.

11. A feeder control device as described in claim 8, wherein the track member is formed in a supply area that communicates with the conveying path and supplies the components so that they can be picked up by the component mounting machine, and has a plurality of cavities that can accommodate the components conveyed to the supply area.

12. The feeder control device of claim 8, wherein the component is a solder ball formed in a spherical shape.

13. A feeder control method applied to a bulk feeder that is set in a component mounting machine and supplies components, the bulk feeder including a vibration device that applies vibration to a component, and a damping step that applies damping vibration to the component to dampen vibration of the component caused by operation of the vibration device.

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