Component mounting system and generating device

Abstract

This component mounting system comprises: an imaging device that is mounted on a component mounting machine for mounting components on a substrate and captures an image of a predetermined region in the component mounting machine; and a generating device that generates shape data pertaining to the component on the basis of images captured by the imaging device. This generating device comprises: a first acquisition unit that acquires, from the imaging device, a component-excluding image, which is an image of the predetermined region without the component having been positioned therein; a second acquisition unit that acquires, from the imaging device, a component-including image, which is an image of the predetermined region with the component positioned therein; and a data generation unit that generates shape data pertaining to the component using the difference between the component-excluding image acquired by the first acquisition unit and the component-including image acquired by the second acquisition unit.

Description

Component mounting system and generation device

[0001] The technology disclosed in this specification relates to a technology for generating shape data of a part based on an image.

[0002] Patent Document 1 discloses a chip mounter equipped with an imaging device that captures an image of a component picked up by a suction nozzle from below. The chip mounter determines, for example, the coordinate values ​​of the tip of a lead extending from the component by using a scanning line set on the image captured by the imaging device.

[0003] Japanese Patent Application Publication No. 8-340194

[0004] In the chip mounter of Patent Document 1, a scanning line is set on an image captured from below of a component picked up by a suction nozzle. For example, if part of the suction nozzle is captured in the image, the scanning line may be set to part of the suction nozzle, resulting in the coordinate values ​​of the edge of the suction nozzle being acquired instead of the tip of the lead. In other words, if an object exists in the background of the component, accurate shape data of the component may not be generated based on the image. This specification provides technology that can generate accurate shape data of a component regardless of the component's background.

[0005] The component mounting system disclosed in this specification is equipped to a component mounter that mounts components on a board, and includes: an imaging device that images a predetermined area within the component mounter; and a generation device that generates shape data of the component based on the image captured by the imaging device. The generation device includes a first acquisition unit that acquires, from the imaging device, a component-free image that is an image of the predetermined area in a state where the component is not placed; a second acquisition unit that acquires, from the imaging device, a component-present image that is an image of the predetermined area in a state where the component is placed; and a data generation unit that generates the shape data of the component by using a difference between the component-free image acquired by the first acquisition unit and the component-present image acquired by the second acquisition unit.

[0006] If an object that is not a component exists within a predetermined area, the object is included in both the image without components and the image with components. In contrast, the component is included only in the image with components. The component mounting system described above generates component shape data by utilizing the difference between the image without components and the image with components. This makes it possible to generate component shape data without being affected by objects included in both images. This makes it possible to generate accurate component shape data regardless of the background of the component.

[0007] The generating device constituting the component mounting system described above, the control method for controlling the generating device, and the computer program for the generating device are also novel and useful.

[0008] A side view of a component mounter according to an embodiment. A cross-sectional view taken along line II-II in Figure 1. A flowchart of shape data generation processing executed by a control device. An example of an image used in the shape data generation processing. A flowchart of scanning line setting processing executed by a control device. An example of an image used in the scanning line setting processing.

[0009] The main features of the embodiments described below are listed below. Note that the technical elements described below are independent technical elements that exhibit technical utility alone or in various combinations, and are not limited to the combinations described in the claims at the time of filing.

[0010] (Feature 1) In the component mounting system described above, the generation device may further include an image generation unit that generates a difference image indicating the difference. In this case, the data generation unit may generate the shape data based on the difference image generated by the image generation unit.

[0011] Even if an object exists within a predetermined region, the object is included in both the part-without image and the part-with image. The object can be removed from the difference image. Therefore, accurate shape data of the part can be generated based on the difference image.

[0012] (Feature 2) In the component mounting system described above, the imaging device may capture an image of the predetermined region by irradiating the predetermined region with at least one monochromatic light and acquiring, for each pixel, a luminance of the monochromatic light reflected from the predetermined region. In this case, the image generation unit may generate the difference image for each corresponding pixel by using a difference between a first luminance, which is the luminance of the component-absent image, and a second luminance, which is the luminance of the component-present image.

[0013] According to this configuration, the difference between the first luminance and the second luminance can be used to generate a difference image with relatively simple image processing, compared to a configuration in which the colors of corresponding pixels are compared, for example.

[0014] (Feature 3) In the component mounting system described above, the data generating unit may generate the shape data of the component by excluding brightness in an area where the first brightness is greater than the second brightness.

[0015] Generally, the brightness of a component is greater than the brightness of a predetermined area when the component is not placed. Therefore, if there is an area where the first brightness of the component-free image is greater than the second brightness of the component-present image, it is estimated that the brightness difference between the two images in that area is caused by factors other than the component. With this configuration, the shape data is generated by excluding the brightness of the area where the first brightness is greater than the second brightness, so that accurate shape data can be generated without being affected by factors other than the component.

[0016] (Feature 4) In the component mounting system described above, the generation device may further include a display unit that displays the difference image, and a selection unit that accepts, from a user, a selection of a specific region from the difference image displayed on the display unit. In this case, when the selection unit accepts the selection of the specific region, the data generation unit may generate the shape data of the component while excluding the luminance of the specific region.

[0017] With this configuration, it is possible to generate shape data based on a user's instruction, for example, by excluding areas that are determined to be clearly not to be used in generating shape data of a part.

[0018] (Feature 5) In the component mounting system described above, the at least one monochromatic light may include three monochromatic lights. In this case, the imaging device may capture three images of the predetermined area by irradiating the predetermined area with each of the three monochromatic lights and acquiring, for each pixel, the luminance of each of the three monochromatic lights reflected from the predetermined area. Furthermore, the image generation unit may generate three difference images for each corresponding pixel in each of the three images of the predetermined area by using the difference between the first luminance and the second luminance, and the data generation unit may generate three pieces of shape data based on the three difference images generated by the image generation unit. Furthermore, the generation device may further include an identification unit that identifies one piece of shape data from the three pieces of shape data generated by the data generation unit.

[0019] Depending on the type of component, the color of the monochromatic light that is easily reflected may differ. With this configuration, three pieces of shape data corresponding to the three colors of monochromatic light are generated, and one piece of shape data can be identified from them. Therefore, for example, it is possible to identify the shape data from the three pieces of shape data that best reflects the shape of the component.

[0020] (Feature 6) In the component mounting system described above, the specifying unit may specify one of the three pieces of shape data selected by a user.

[0021] With this configuration, the user can select shape data from three types of shape data.

[0022] (Feature 7) In the component mounting system described above, the predetermined area may include a mounting area on the board where the component is to be mounted. In this case, the component-free image may be an image of the predetermined area before the component is mounted in the mounting area, and the component-present image may be an image of the predetermined area after the component is mounted in the mounting area.

[0023] In addition to the components, various objects are placed around the mounting area of ​​the board. With this configuration, regardless of the various objects placed around the mounting area on the board, it is possible to generate shape data of the components using images of the components before and after mounting.

[0024] (Feature 8) In the component mounting system described above, the imaging device may include a mark camera that captures an image of the board from above.

[0025] With this configuration, shape data can be created based on the difference between an image without components and an image with components captured from above by the mark camera. Therefore, shape data can be generated with a simpler configuration than, for example, a configuration that includes an imaging device dedicated to generating shape data.

[0026] (Feature 9) In the component mounting system described above, the shape data generated by the data generation unit may indicate a contour line of the component. In this case, the generation device may further include a setting unit that sets a plurality of scanning lines orthogonal to the contour line, and a first extraction unit that extracts, for each of the plurality of scanning lines set in the component-present image by the setting unit, at least one first edge that is a boundary between the component and a background based on a change in luminance of a pixel group along the scanning line.

[0027] According to this configuration, the first edge can be extracted using the generated shape data.

[0028] (Feature 10) In the component mounting system described above, the generating device may further include a second extraction unit that extracts, in the component-free image, a second edge that causes a predetermined luminance difference on the plurality of scanning lines set by the setting unit, and a determination unit that, when the second edge is extracted from the component-free image by the second extraction unit, determines whether the second edge is identical to the first edge.

[0029] When a second edge is extracted from the component-free image and the second edge is located at a position corresponding to a first edge in the component-containing image, the first edge may not be the boundary between the component and the background. With this configuration, it is possible to use the component-free image and the component-containing image to determine whether the extracted first edge accurately extracts the boundary between the component and the background.

[0030] (Feature 11) In the component mounting system described above, the generation device may further include a deletion unit that, when the determination unit determines that the second edge extracted by the second extraction unit is identical to the first edge, deletes the scanning line from which the first edge was extracted.

[0031] According to this configuration, scanning lines that do not properly extract the boundary between the part and the background are deleted, so that it is possible to prevent an inaccurate first edge from being extracted.

[0032] (Example) A component mounting system 100 according to an example embodiment will be described with reference to the drawings. The component mounting system 100 includes a component mounter 10 and a control device 22. The component mounter 10 is a device that mounts components 4 on a surface 3 of a circuit board 2. The component mounter 10 is also referred to as an electronic component mounting device or a chip mounter. The board 2 is a circuit board, and the components 4 are electronic components. Typically, the component mounter 10 is installed alongside other devices such as a solder printer and a board inspection device to form a continuous mounting line. The control device 22 is located outside the component mounter 10 and controls the operation of the component mounter 10. In a modified example, the control device 22 may be located within the component mounter 10.

[0033] The structure of the component mounter 10 will be described with reference to Figures 1 and 2. The component mounter 10 includes a touch screen 11, a component feeder unit 12, a feeder holder 14, a head unit 15 including a mounting head 16 and a head moving device 18, a downward camera 21, a mark camera 30, and a board conveyor 20. The touch screen 11 displays, for example, information related to the component mounter 10 and accepts operations from the user. In a modified example, the component mounter 10 may include a display and an operation unit (e.g., a mouse and a keyboard) instead of the touch screen 11.

[0034] 2 in particular, the component feeder unit 12 has a plurality of feeders arranged in the +X direction (i.e., the upward direction on the paper surface of FIG. 2), and each feeder stores a plurality of components 4. Each feeder of the component feeder unit 12 is detachably attached to a feeder holder 14 and supplies components 4 to the mounting head 16.

[0035] 1, the mounting head 16 of the head unit 15 has a cylindrical nozzle 6 that picks up components 4. The mounting head 16 is capable of moving the nozzle 6 along the Z axis (i.e., up and down on the paper surface of FIG. 1) to move the nozzle 6 toward and away from each feeder of the component feeder unit 12 or the surface 3 of the board 2. Note that the mounting head 16 is not limited to one having a single nozzle 6, and may have multiple nozzles 6.

[0036] The head moving device 18 of the head unit 15 moves the placement head 16 and the mark camera 30 between each feeder of the component feeder unit 12 and the board 2. As an example, the head moving device 18 of this embodiment is an XY robot that moves a moving base 18a along the XY plane, and the placement head 16 and the mark camera 30 are fixed to the moving base 18a. Note that the placement head 16 is not limited to being fixed to the moving base 18a, but may also be detachably attached to the moving base 18a.

[0037] 2, marks 2M and a plurality of mounting areas 40 are arranged on the surface 3 of the substrate 2. The marks 2M have a circular shape and are used as a reference for aligning the substrate 2 in a plan view when mounting components 4 on the surface 3 of the substrate 2. The mounting areas 40 are areas where the components 4 are fixed by solder, and include, for example, conductor portions 44 (see FIG. 4) that electrically connect the components 4 to circuits included in the substrate 2.

[0038] The lower camera 21 is disposed between the component feeder unit 12 and the board conveyor 20. The lower camera 21 has a lens disposed facing upward. The lower camera 21 captures a suction image of the component 4 picked up by the nozzle 6 from below. The lower camera 21 is configured to be able to communicate with the control device 22. The lower camera 21 captures the suction image based on an imaging instruction transmitted from the control device 22, and transmits image data of the captured suction image to the control device 22. Based on the transmitted suction image, the control device 22 can determine, for example, whether the component 4 is properly picked up by the nozzle 6.

[0039] As shown in FIG. 1 , the mark camera 30 is fixed to the movable base 18a and moves integrally therewith. The mark camera 30 includes an illumination light source 32 and a prism (not shown). The mark camera 30 captures, for example, an image of the surface 3 of the substrate 2 (e.g., a mark image of the mark 2M on the substrate 2) from above. The mark camera 30 is, for example, a CCD camera. The illumination light source 32 is, for example, composed of LEDs and includes a red (R) light source, a green (G) light source, and a blue (B) light source. Therefore, the mark camera 30 can capture a color image of the substrate 2 by adjusting the intensity of each light source. Furthermore, the mark camera 30 can capture monochromatic images of R, G, and B by irradiating the surface 3 with monochromatic light of each color (R, G, and B) using the illumination light source 32 and acquiring the brightness of each monochromatic light. The prism aligns the optical axis of the mark camera 30 with the target. For example, the illumination light source 32 illuminates the mark 2M on the board 2 through a filter, and the reflected light is reflected by a prism and guided to the mark camera 30, which then images the mark 2M on the board 2. The mark camera 30 is configured to be able to communicate with the control device 22, and image data captured by the mark camera 30 is sent to the control device 22. Note that the mark camera 30 does not need to be movable together with the mounting head 16, and may be fixed in a position where it can capture an image of the surface 3 of the board 2, for example.

[0040] The board conveyor 20 is a device that carries in, positions, and carries out the board 2. As an example, the board conveyor 20 of this embodiment has a pair of belt conveyors and a support device (not shown) that supports the board 2 from below.

[0041] The control device 22 is configured to be able to communicate with the head unit 15 and the board conveyor 20 in addition to the cameras 21 and 30 described above. As shown in FIG. 1 , the control device 22 includes a CPU 24 and a memory 26. The memory 26 is configured with a volatile memory and a non-volatile memory. The memory 26 stores a program 28 and a brightness threshold Th1. The program 28 may be, for example, a program that executes preparations for determining whether the component 4 is accurately mounted in the mounting area 40 of the board 2. For example, during the operation of mounting the component 4 on the board 2, the CPU 24 determines whether the mounting position of the component 4 is within a predetermined area based on an image of the component 4 mounted in the mounting area 40 of the board 2. At this time, the CPU 24 executes a scanning line setting process (see FIG. 5 ), which will be described later, and acquires the mounting position of the component 4 using the scanning line set by the scanning line setting process. Furthermore, in the scanning line setting process, the CPU 24 executes a shape data generation process (see FIG. 3 ), which will be described later, and sets scanning lines based on the shape data indicating the contour lines of the component 4 generated by the shape data generation process. The CPU 24 executes the shape data generation process and the scanning line setting process in accordance with the program 28. The brightness threshold Th1 is used to extract a first edge (see FIGS. 5 and 6 ) indicating the outline of the component 4. The program 28 and the brightness threshold Th1 are stored in advance in the memory 26 when the component mounter 10 is shipped. In a modified example, the program 28 and the brightness threshold Th1 may be installed in the memory 26 later, for example, from an external server.

[0042] The shape data generation process executed by the CPU 24 of the control device 22 will be described with reference to Figures 3 and 4. As described above, the shape data generation process is a process for generating shape data of the component 4. The CPU 24 executes the shape data generation process in response to the start of the program 28, for example. Figure 3 shows a flowchart of the shape data generation process, and Figure 4 shows an enlarged view of the area surrounded by the dashed line IV in Figure 2 in the component-free image I1, component-present image I2, and difference image I3 used in the shape data generation process.

[0043] In S2, the CPU 24 sets the illumination color to be used in generating the shape data. In this embodiment, the CPU 24 generates the shape data in the order of illumination colors R, G, and B. Therefore, the CPU 24 first sets the illumination color R. Hereinafter, the illumination color set in S2 among the illumination colors R, G, and B may be referred to as the "set illumination color."

[0044] In S4, the CPU 24 transmits an image capture instruction to the mark camera 30 and receives a component-free image (e.g., I1) from the mark camera 30. As a result, the CPU 24 acquires the component-free image. As shown in FIG. 4 , the component-free image I1 is an image of the mounting area 40 in a state where no components 4 are arranged. The component-free image I1 includes the surface 3 of the board 2, a plurality of terminals 42, and conductor portions 44 that electrically connect the terminals 42 to each other. When capturing the component-free image, the mark camera 30 irradiates the surface 3 of the board 2 with monochromatic light of a set illumination color (e.g., R) from the illumination light source 32. As a result, the monochromatic light of the set illumination color is irradiated onto the surface 3 of the board 2, and the reflected light is reflected from the surface 3 of the board 2. The mark camera 30 acquires the luminance of the reflected monochromatic light for each pixel P1 and captures the component-free image.

[0045] In S10, the CPU 24 causes the head unit 15 to mount the component 4 in the mounting area 40 of the board 2. As shown in the component-present image I2 in Fig. 4 , the component 4 is fixed to the mounting area 40 with solder 46. This electrically connects the component 4 and the terminal 42.

[0046] In S12, the CPU 24 sends an image capture instruction to the mark camera 30 and receives a component-present image (e.g., I2) from the mark camera 30. The component-present image is an image of the mounting area 40 in a state where the component 4 has been placed. As shown in Fig. 4, the component-present image I2 is an image in which the component 4 and solder 46 have been added to the component-free image I1. A plurality of bump electrodes 5 are placed on the surface of the component 4.

[0047] In S14, the CPU 24 generates a difference image (e.g., I3) and displays it on the touch screen 11. The CPU 24 generates the difference image by subtracting the luminance of the component-absent image from the luminance of the component-present image for each pixel P1. Thus, for example, as shown in FIG. 4 , the luminance of pixel P1 representing the surface 3 of the board 2 in the difference image I3 is zero because the corresponding pixels in both images I1 and I2 have the same luminance. As a result, in the difference image I3, the luminance of pixel P1 representing the same object included in each of images I1 and I2 is displayed lower than the luminance of pixel P1 representing the object included only in the component-present image I2. Similarly, pixel P1 representing terminal 42 is displayed with a lower luminance in the difference image I3. In contrast, the luminance of pixel P1 representing component 4 and solder 46 included only in the component-present image I2 is different from the luminance of the corresponding pixel P1 in the component-absent image I1.

[0048] In S20, the CPU 24 determines whether the difference image generated in S14 includes a negative area. A negative area is an area where the difference between the luminance of the component-present image and the luminance of the component-absent image is a negative value. That is, the negative area includes pixels where the luminance of the component-absent image is greater than the luminance of the component-present image. For example, in the example shown in FIG. 4 , the luminance of pixel P1 representing component 4 in component-present image I2 is greater than the luminance of the corresponding pixel P1 in component-absent image I1, and the luminance of pixel P1 representing solder 46 in component-present image I2 is less than the luminance of the corresponding pixel P1 in component-absent image I1. Therefore, the difference between the luminance of component-present image I2 and the luminance of component-absent image I1 is a positive value for pixel P1 representing component 4 and a negative value for pixel P1 representing solder 46. If the differential image I3 contains a negative area (e.g., pixel P1 indicating solder 46) (YES in S20), the CPU 24 proceeds to S22, and if the differential image I3 does not contain a negative area (NO in S20), the CPU 24 skips S22 and proceeds to S30.

[0049] In S22, the CPU 24 sets the negative area determined to be included in the differential image in S20 as an exclusion area. The exclusion area is an area that is excluded when generating the shape data described below. That is, when generating the shape data, the CPU 24 does not use the brightness of pixels included in the exclusion area in the differential image. As described above, the brightness of the component 4 is greater than, for example, the brightness of the surface 3 and the conductor portion 44 of the board 2. Therefore, it is presumed that negative areas in which the component-absent image has a higher brightness than the component-present image are caused by factors other than the component 4 (e.g., solder 46). If factors other than the component 4 were used to generate the shape data, accurate shape data for the component 4 would not be generated. Because the CPU 24 generates the shape data by excluding the negative area, accurate shape data can be generated without being affected by factors other than the component 4.

[0050] In S30, the CPU 24 determines whether to accept the selection of a specific region from the user. Here, the specific region is the region of the difference image displayed on the touch screen 11 for which the user's selection was accepted in S14. The difference image I3 shown in FIG. 4 includes the bump electrodes 5 disposed on the surface of the component 4. Because the bump electrodes 5 are circular electrodes disposed on the surface of the component 4, accurate shape data cannot be generated when the bump electrodes 5 are used to generate shape data representing the outline of the component 4. In this case, the user selects, for example, a specific region including the bump electrodes 5 in the difference image. If the CPU 24 accepts the selection of a specific region (YES in S30), the process proceeds to S32. If the CPU 24 does not accept the selection (NO in S30), the process skips S32 and proceeds to S40.

[0051] In S32, similar to S22 described above, the CPU 24 sets an exclusion range for the specific region selected in S30. This allows the CPU 24 to exclude specific regions (e.g., bump electrodes 5) that should not be used in generating shape data for the component 4 based on a user instruction, thereby generating accurate shape data.

[0052] In S40, the CPU 24 generates shape data based on the difference image. The CPU 24 calculates the shape data by, for example, applying various known edge filters to the difference image. As shown in the difference image I3 in FIG. 4, the shape data D1 indicates the contour of the component 4. If an exclusion range (e.g., bump electrode 5) was set in S22 or S32, the CPU 24 applies the edge filter while excluding the exclusion range. As a result, shape data excluding the exclusion range is generated.

[0053] In S42, the CPU 24 determines whether shape data for three illumination colors (e.g., R, G, and B) have been generated. If the three shape data are not stored in the memory 26 (NO in S42), the CPU 24 returns to S2, sets monochromatic light for another illumination color (e.g., G), and again executes the processes of S4 to S40 to generate shape data for the other illumination color. If the three shape data are stored in the memory 26 (YES in S42), the CPU 24 proceeds to S50. As described above, in this embodiment, accurate shape data for the component 4 can be generated even if, for example, terminals 42 are included around the component 4 on the surface 3 of the substrate 2 by using a differential image between a component-free image, which is an image of a state in which the component 4 is not mounted in the mounting area 40 of the substrate 2, and a component-present image, which is an image of a state in which the component 4 is mounted in the mounting area 40.

[0054] In S50, the CPU 24 accepts from the user a selection of one of the three shape data generated by the above-described process as the shape data to be used. The shape data to be used is used in the scanning line setting process described later with reference to FIGS. 5 and 6 . The user selects, as the shape data to be used, the shape data that is considered to most accurately represent the contour of the component 4 among the three shape data. The user may determine which shape data is most accurate by, for example, rotating and moving each of the three shape data. As described above, the mark camera 30 is capable of emitting three monochromatic lights. For example, different types of component 4 may be more easily reflected by different irradiated colors. The CPU 24 generates three shape data using the three monochromatic lights of the mark camera 30 and identifies one of the shape data selected by the user as the shape data to be used. That is, the user selects, from the three shape data displayed on the touch screen 11, the shape data that most accurately represents the contour of the component 4, thereby enabling the CPU 24 to identify the shape data to be used. In this embodiment, by using the mark camera 30, it is possible to generate shape data with a simpler configuration than a configuration that includes a dedicated camera for generating shape data. Furthermore, since the mark camera 30 can capture an image of the component 4 from above, the shape data generated by utilizing the difference between the image without the component and the image with the component captured by the mark camera 30 can be used to determine the mounting position of the component 4.

[0055] The scanning line setting process will be described with reference to Figures 5 and 6. The CPU 24 executes the scanning line setting process upon completion of the shape data generation process of Figure 3. Figure 5 shows a flowchart of the scanning line setting process, and Figure 6 shows a setting image I4 in which scanning lines are set for a component-present image using the used shape data (e.g., D2) generated in the shape data generation process. For ease of understanding, Figure 6 shows the used shape data D2 with a dashed line, and the outline of the component 4 inside the used shape data D2 with a solid line.

[0056] In S60, the CPU 24 sets scanning lines based on the usage shape data. For example, the CPU 24 sets a predetermined number of scanning lines at equal intervals along each side of the usage shape data. In the example shown in FIG. 6, the CPU 24 sets three scanning lines C1 to C3 and C6 to C8 along each of a pair of opposing long sides of the usage shape data D2, and two scanning lines C4 to C5 and C9 to C10 along each of a pair of short sides. As a result, scanning lines C1 to C10 are set along the usage shape data D2. The scanning lines C1 to C10 indicate the range in which changes in luminance are measured along a direction perpendicular to the usage shape data D2. In a modified example, the CPU 24 may set scanning lines at positions a predetermined distance from the end of each side of the usage shape data, or at positions at a predetermined ratio to the length of each side.

[0057] In S62, the CPU 24 extracts a first edge from the component-present image I2 using the scanning lines set in S60. As shown in the setting image I4, the CPU 24 measures luminance at predetermined intervals along the scanning line C1, for example, and extracts an edge E1 at the position where the change in luminance exceeds the luminance threshold Th1 stored in the memory 26. Similarly, the CPU 24 extracts an edge E2 along the scanning line C2 and an edge E3 along the scanning line C3. The CPU 24 similarly extracts edges E4 to E10 along the scanning lines C4 to C10. In this way, the CPU 24 can set multiple scanning lines (e.g., C1 to C10) and extract multiple edges E1 to E10 using the used shape data D2 generated by the shape data generation process of FIG. 4. As described above, the used shape data indicates the contour of the component 4, generated using the difference between the component-absent image and the component-present image. Setting the scanning lines using the used shape data allows the change in luminance around the contour of the component 4 to be measured, thereby reducing the measurement range. This allows the image processing time to be reduced compared to, for example, a configuration in which scanning lines are set along the entire range of the setting image I4.

[0058] In S70, the CPU 24 determines whether a second edge is extracted from the component-free image I1 using the scanning line set in S60. If a second edge is not extracted (NO in S70), the CPU 24 skips S80 and S82 and ends the processing in Fig. 5. If a second edge is extracted (YES in S70), the CPU 24 proceeds to S80.

[0059] In S80, the CPU 24 determines whether the second edge extracted in S70 is included in the first edges (e.g., E1 to E10) extracted in S62. If the second edge is not included in the first edges (NO in S80), the CPU 24 skips S82 and ends the processing in Fig. 5. If the second edge is included in the first edges (YES in S80), the CPU 24 proceeds to S82.

[0060] In S82, the CPU 24 deletes the scanning lines from among the multiple scanning lines (e.g., C1 to C10) set in S60 that extracted the first edge determined to be identical to the second edge. Here, the component-free image I1 does not include a component 4. Therefore, the scanning lines from which the second edge was extracted in the component-free image I1 extract the second edge based on a change in brightness that is not the outline of the component 4. Therefore, if the first edge is extracted using these scanning lines, it is likely that an edge different from the actual outline of the component 4 will be extracted. Because the CPU 24 deletes the scanning lines from which the second edge identical to the first edge was extracted, it is possible to prevent erroneous extraction of the first edge the next time the first edge is extracted. After completing the process of S82, the CPU 24 ends the process of FIG. 5. When mounting of the component 4 begins, the CPU 24 uses the scanning lines set by the process of FIG. 5 to detect the outline position of the component 4 mounted in the mounting area 40 of the board 2 and determines whether the mounted position of the component 4 is appropriate.

[0061] (Effects of this embodiment) In the component mounting system 100, the difference (e.g., difference image I3) between an image without a component (e.g., I1) and an image with a component (e.g., I2) is used to generate shape data (e.g., D1) of the component. Therefore, accurate shape data of the component can be generated without being affected by objects (e.g., terminals 42) included in both images.

[0062] The correspondence in this embodiment is as follows: The control device 22 is an example of a "generation device."

[0063] The process of S4 in FIG. 3 is an example of a process executed by a "first acquisition unit," and the process of S12 is an example of a process executed by a "second acquisition unit." The process of S40 is an example of a process executed by a "data generation unit." The process of S14 is an example of a process executed by an "image generation unit." The region to which solder 46 is applied is an example of a "region where the first luminance is greater than the second luminance." The process of S30 is an example of a process executed by a "selection unit." The process of S50 is an example of a process executed by a "identification unit." The process of S60 in FIG. 5 is an example of a process executed by a "setting unit." The process of S62 is an example of a process executed by a "first extraction unit," and the process of S70 is an example of a process executed by a "second extraction unit." The process of S80 is an example of a process executed by a "determination unit." The process of S82 is an example of a process executed by a "deletion unit."

[0064] Here are some points to note about the component mounting system 100 described in the embodiment. In the above-described embodiment, the CPU 24 of the control device 22 executes the shape data generation process and the scanning line setting process shown in FIG. 3 . However, in a modified example, for example, a management device configured to be able to communicate with the component mounter may execute these processes. In this modified example, the management device is an example of a "generation device."

[0065] In the above-described embodiment, the CPU 24 executes the processes S2 to S40 of FIG. 3 for each of the illumination colors R, G, and B. Alternatively, in this modified example, the CPU 24 may acquire a component-free image for each of the illumination colors R, G, and B (see S4 of FIG. 3), then mount the component 4 in the mounting area 40 (see S10), and then acquire a component-present image for each of the illumination colors R, G, and B (see S12). In this case, the CPU 24 may generate three pieces of shape data using the component-free image and the component-present image for each of the illumination colors R, G, and B (see S14 to S40), and then accept selection of the shape data to be used (see S50). According to this modified example, three pieces of shape data can be generated using one component 4.

[0066] The CPU 24 does not need to execute S14 in Fig. 3. For example, the CPU 24 may generate shape data of the component-absent image and shape data of the component-present image, and then generate shape data of the component 4 by deleting the same portion of the shape data of the component-present image that is the same as the shape data of the component-absent image. In this modification, the "image generation unit" can be omitted.

[0067] The mark camera 30 may capture an image without a component containing multiple colors and an image with a component containing multiple colors.

[0068] The CPU 24 does not have to execute the processes of S20 and S22 in Fig. 3. In this modification, the CPU 24 does not have to generate shape data by excluding negative areas in S40.

[0069] The CPU 24 does not have to execute the processes of S30 and S32 in Fig. 3. In this modification, the CPU 24 does not have to generate shape data by excluding the specific region in S40.

[0070] The mark camera 30 may be capable of emitting, for example, only white monochromatic light. In this modification, the CPU 24 may generate one piece of shape data. In a further modification, the mark camera 30 may be capable of emitting four monochromatic colors of light: cyan, magenta, yellow, and green, instead of the above-described three colors (R, G, and B). In this case, the CPU 24 may generate four pieces of shape data.

[0071] 3, the CPU 24 may, for example, identify, of the three shape data, the shape data that is closest to the predetermined data previously stored in the memory 26, and set the identified shape data as the shape data to be used. That is, in this modified example, the CPU 24 does not need to accept selection of shape data from the user.

[0072] The component-free image and the component-present image do not need to include the mounting area 40 of the board 2. In this modification, for example, the component-free image and the component-present image may be images of the component 4 picked up by the nozzle 6 taken from below. In this modification, the downward camera 21 is an example of an "imaging device." In a further modification, the component-free image and the component-present image may be images of the component 4 picked up by the nozzle 6 taken from the side. In this modification, the side camera is an example of an "imaging device."

[0073] 5. In this case, the CPU 24 may compare the external shape of the component 4 mounted on the board 2 with the use shape data, and if the two are identical by more than a predetermined percentage, determine that the component 4 is accurately mounted on the board 2. In this modification, the "setting unit" and the "first extraction unit" can be omitted.

[0074] The CPU 24 does not have to execute the processes of S70 to S80 in Fig. 5. In this modification, the "second extraction unit" and the "determination unit" can be omitted.

[0075] The CPU 24 may not execute the process of S82 in Fig. 5. In this modification, the "deletion unit" may be omitted. In this modification, for example, if the determination in S80 is YES, the scanning line from which the first edge that has become identical to the second edge has been extracted may be moved by a predetermined distance.

[0076] The technical elements described in this specification or drawings exhibit technical utility either alone or in various combinations, and are not limited to the combinations described in the claims at the time of filing. Furthermore, the technologies illustrated in this specification or drawings simultaneously achieve multiple objectives, and achieving one of those objectives is itself technically useful.

[0077] For example, this specification also discloses a technical idea in which "the component mounting system according to claim 3" is changed to "the component mounting system according to claim 3 or 4" in claim 5. Similarly, a technical idea in which "the component mounting system according to claim 3" is changed to "the component mounting system according to any one of claims 3 to 5" in claim 6, a technical idea in which "the component mounting system according to claim 1" is changed to "the component mounting system according to any one of claims 1 to 7" in claim 8, and a technical idea in which "the component mounting system according to claim 1" is changed to "the component mounting system according to any one of claims 1 to 9" in claim 10 are also disclosed.

Claims

1. A component mounting system comprising: an imaging device that is equipped in a component mounter that mounts components on a board and that captures an image of a predetermined area within the component mounter; and a generation device that generates shape data of the component based on the image captured by the imaging device, wherein the generation device comprises: a first acquisition unit that acquires from the imaging device a component-free image that is an image of the predetermined area when the component is not placed; a second acquisition unit that acquires from the imaging device a component-present image that is an image of the predetermined area when the component is placed; and a data generation unit that generates the shape data of the component by using the difference between the component-free image acquired by the first acquisition unit and the component-present image acquired by the second acquisition unit.

2. The component mounting system according to claim 1, wherein the generation device further comprises an image generation unit that generates a difference image showing the difference, and the data generation unit generates the shape data based on the difference image generated by the image generation unit.

3. The component mounting system according to claim 2, wherein the imaging device captures an image of the specified area by irradiating the specified area with at least one monochromatic light and acquiring the luminance of the monochromatic light reflected from the specified area for each pixel, and the image generation unit generates the differential image for each corresponding pixel by utilizing the difference between a first luminance, which is the luminance of the image without components, and a second luminance, which is the luminance of the image with components.

4. The component mounting system according to claim 3, wherein the data generating unit generates the shape data of the component by excluding the brightness of an area where the first brightness is greater than the second brightness.

5. The component mounting system of claim 3, wherein the generation device further comprises: a display unit that displays the difference image; and a selection unit that accepts a user's selection of a specific area from the difference image displayed on the display unit; and when the selection unit accepts the selection of the specific area, the data generation unit generates the shape data of the component by excluding the brightness of the specific area.

6. The component mounting system according to claim 3, wherein the at least one monochromatic light includes monochromatic light of three colors; the imaging device captures three images of the specified area by irradiating the specified area with each of the three monochromatic lights and acquiring for each pixel the brightness of each of the three monochromatic lights reflected from the specified area; the image generation unit generates three difference images for each corresponding pixel in each of the images of the three specified areas by utilizing the difference between the first brightness and the second brightness; the data generation unit generates three pieces of shape data based on the three difference images generated by the image generation unit; and the generation device further comprises an identification unit that identifies one piece of shape data from the three pieces of shape data generated by the data generation unit.

7. The component mounting system according to claim 6, wherein the specifying unit specifies one of the three pieces of shape data selected by a user.

8. The component mounting system according to claim 1, wherein the predetermined area includes a mounting area on the board where the component is to be mounted, the component-free image is an image of the mounting area before the component is mounted, and the component-present image is an image of the mounting area after the component has been mounted.

9. The component mounting system according to claim 8, wherein the imaging device includes a mark camera that images the board from above.

10. The component mounting system of claim 1, wherein the shape data generated by the data generation unit indicates a contour line of the component, and the generation device further comprises: a setting unit that sets a plurality of scanning lines that are perpendicular to the contour line; and a first extraction unit that extracts at least one first edge that is a boundary between the component and a background, for each of the plurality of scanning lines set in the component-present image by the setting unit, based on a change in luminance of a group of pixels along the scanning line.

11. The component mounting system of claim 10, wherein the generating device further comprises: a second extraction unit that extracts, in the component-free image, a second edge that causes a predetermined brightness difference on the plurality of scanning lines set by the setting unit; and a determination unit that, when the second edge is extracted from the component-free image by the second extraction unit, determines whether the second edge is identical to the first edge.

12. The component mounting system of claim 11, wherein the generation device further includes a deletion unit that deletes the scanning line from which the first edge was extracted when the determination unit determines that the second edge extracted by the second extraction unit is identical to the first edge.

13. A generation device that generates shape data of a component to be mounted on a board by a component mounter, wherein the component mounter has an imaging device that images a predetermined area within the component mounter, and the generation device comprises: a first acquisition unit that acquires from the imaging device a component-free image that is an image of the predetermined area in a state where the component is not placed; a second acquisition unit that acquires from the imaging device a component-present image that is an image of the predetermined area in a state where the component is placed; and a data generation unit that generates the shape data of the component by utilizing the difference between the component-free image acquired by the first acquisition unit and the component-present image acquired by the second acquisition unit.

Images