Tape removal system

Abstract

A tape removal system disclosed herein comprises: a tape removal determination unit for determining whether a carrier tape needs to be removed from a feeder including a reel support part for detachably supporting a reel around which a carrier tape for storing a component is wound, a sprocket that engages a feed hole of the carrier tape, and a motor for generating a driving force for conveying the carrier tape by rotating the sprocket; and an operation control unit for returning a predetermined length of the carrier tape in a return direction, opposite to the component feeding direction, in the feeder when it is determined by the tape removal determination unit that the carrier tape needs to be removed from the feeder.

Description

Tape Removal System

[0001] The present disclosure relates to a tape removal system.

[0002] Currently, when a feeder runs out of components during board production using a component placement machine, an operator in the kitting area manually replaces the reel supported by the feeder. For example, the operator removes the feeder from the component placement machine, cuts off the waste tape portion of the carrier tape from which the components have been removed, sets the feeder on a kitting stand installed in the kitting area, and presses and holds the return button on the operation panel installed on the top surface of the kitting stand or feeder until the carrier tape is released from the feeder sprocket. Then, after the carrier tape is released from the sprocket, the operator opens the feeder reel cover and removes the reel from the feeder.

[0003] Meanwhile, a technology has been disclosed in which a feeder provides guidance to remove a reel from the feeder when a predetermined condition is met (see, for example, Patent Document 1). In the device described in Patent Document 1, a display unit displays guidance to remove a reel from the feeder when the current component type will not be used in the production of the next or subsequent board types. When the automatic rewind mode is selected, the carrier tape is automatically rewound onto the reel in the feeder. Thereafter, the operator removes the reel from the feeder during a setup change. With this configuration, the operator does not need to rewind the carrier tape, simplifying the operator's work when removing the reel from the feeder.

[0004] Also, a technology has been disclosed that rewinds the carrier tape when it is detected that a feeder is being removed from a component mounting machine (see, for example, Patent Document 2). In the device described in Patent Document 2, the carrier tape is rewound until the carrier tape is emptied of components due to the supply of components and the portion of the tape that protrudes from the feeder body is retracted within the feeder body. This configuration prevents the carrier tape from protruding from the feeder when the feeder is removed from the component mounting machine, thereby preventing the carrier tape from becoming entangled around the head of the component mounting machine.

[0005] JP 2022-063313 A JP 2013-254895 A

[0006] However, in the device described in Patent Document 2, although the rewinding process of the carrier tape can retract the protruding tape portion of the carrier tape into the feeder body, the carrier tape remains engaged with the sprocket inside the feeder, which may result in an insufficient rewind of the carrier tape. In other words, simply retracting the used tape portion into the feeder body requires additional work to remove the carrier tape and, ultimately, the reel from the feeder.

[0007] Furthermore, in the device described in Patent Document 1, if the current component type is not used in the production of the next or subsequent board types, the carrier tape is automatically rewound onto the reel. However, since there is no specific description of how to control the amount of rewinding during this automatic rewinding or the timing for stopping the rewinding, there is a risk that the sprocket may continue to rotate excessively, or conversely, the leading end of the carrier tape may remain engaged with the sprocket, which could result in the carrier tape not being automatically rewound properly.

[0008] An object of the present specification is to provide a tape removal system that can properly remove a carrier tape from a feeder in which a reel on which the carrier tape is wound is set.

[0009] This specification discloses a tape removal system comprising: a tape removal determination unit that determines whether or not it is necessary to remove a carrier tape from a feeder having a reel support unit that detachably supports a reel on which a carrier tape that contains components is wound, a sprocket that engages with a feed hole in the carrier tape, and a motor that rotates the sprocket to generate a driving force that transports the carrier tape; and an operation control unit that, when it is determined by the tape removal determination unit that it is necessary to remove the carrier tape from the feeder, transports the carrier tape in the feeder back by a predetermined length in a return direction that is opposite to the component feed direction.

[0010] According to the disclosed configuration, the carrier tape can be properly removed from the feeder in which the reel on which the carrier tape is wound is set.

[0011] This specification also discloses the technical idea of ​​changing "the tape removal system described in claim 1" to "the tape removal system described in claim 1 or 2" in claim 3 as originally filed, the technical idea of ​​changing "the tape removal system described in claim 1" to "the tape removal system described in any one of claims 1 to 10" in claim 11 as originally filed, and the technical idea of ​​changing "the tape removal system described in claim 1" to "the tape removal system described in any one of claims 1 to 11" in claim 12 as originally filed.

[0012] FIG. 1 is a plan view of a carrier tape. FIG. 2 is a side view of a feeder. FIG. 3 is a plan view of an operation panel provided on the feeder. FIG. 4 is a perspective view of a part of a component mounting machine on which a feeder is mounted. FIG. 5 is a system configuration diagram of a tape removal system. FIG. 6 is a perspective view of a kitting stand on which a feeder is set. FIG. 7 is an operation time chart of a first operation example of the tape removal system. FIG. 8 is an operation time chart of a second operation example of the tape removal system. FIG. 9 is an operation time chart of a component mounting machine and a feeder that are prerequisites for a modified operation example of the tape removal system. FIG. 10 is an operation time chart of a modified operation example of the tape removal system.

[0013] The configuration of the tape removal system 1 according to the embodiment will be described. In the embodiment, for convenience, the component feed direction in which the carrier tape is fed and transported is used as the reference direction to define the upstream and downstream directions, as well as the left and right directions perpendicular to the component feed direction.

[0014] 1. Overview of the Tape Removal System The tape removal system 1 is a system for removing a carrier tape T that has been set in a feeder 90 from the feeder 90. The tape removal system 1 is separated from a production line in which a component mounting machine 80 that mounts components P in the carrier tape T onto a board V is located, and is incorporated into a board production system as a complement. As will be described in detail later, the tape removal system 1 is realized using a kitting stand 10 provided in an off-site setup area, a host computer for board production, and the like.

[0015] Furthermore, setting the carrier tape T on the feeder 90 may include a process of engaging the carrier tape T pulled out from the reel R with a sprocket of the feeder 90 so that it can be fed and moved. Furthermore, setting the carrier tape T on the feeder 90 may be an automated process of enabling the carrier tape T to be fed and moved, or may include a process of automatically attaching and detaching the reel R itself to and from the reel support portion of the feeder 90.

[0016] 2. Carrier Tape Structure The carrier tape T is a tape that houses components P. The components P are electronic components such as transistors, diodes, capacitors, and resistors that are mounted on a substrate. The components P vary in size, from tiny components measuring, for example, 0.2 mm x 0.1 mm, to large components such as capacitors. The carrier tape T is an embossed tape or paper tape that is made of a flexible material and extends in the longitudinal direction. The tape width of the carrier tape T is generally determined in advance as a standard, and is, for example, 4 mm to 24 mm. The carrier tape T holds multiple components P aligned in a row in the longitudinal direction of the tape.

[0017] As shown in Fig. 1, the carrier tape T has a base tape TB having cavities CV for accommodating components P, and a cover tape TC that covers the cavities CV of the base tape TB. The cavities CV are provided at a first predetermined pitch in the tape longitudinal direction. The base tape TB also has sprocket holes SH. The sprocket holes SH are provided at a second predetermined pitch in the tape longitudinal direction along one side edge of the base tape TB.

[0018] The cover tape TC is normally adhered to the upper surface of the base tape TB and is peeled off from the base tape TB before the component P is removed from the cavity portion CV. After the component P is removed from the cavity portion CV, the cover tape TC may be returned to contact the base tape TB and discharged together with the base tape TB, or may be discharged independently via a route separate from the base tape TB after the component P is removed from the cavity portion CV.

[0019] The carrier tape T is wound around a reel R. The carrier tape T is transported wound on the reel R (see FIG. 2 ), set in a feeder 90, and used via the reel R in the feeder 90. The reel R is formed in a disk shape. An identification code for identifying each individual reel R is attached to the side or the like of the reel R. A plurality of types of reels R are provided corresponding to the material, tape width, and width of the carrier tape T, respectively. The identification code of the reel R may include information such as the material, tape width, and width of the carrier tape T, respectively. The identification code of the reel R may also include information such as the size, type, mass, and shape of the components P to be accommodated in the cavity portion CV of the carrier tape T.

[0020] 3. Feeder Configuration The feeder 90 is a device that is detachably mounted on the component mounting machine 80 that mounts the components P on the board, and is a device that feeds and transports the carrier tape T that houses the components P. As shown in FIG. 2 , the feeder 90 has a reel housing section 91, a reel support section 92, and a reel cover section 93.

[0021] The reel housing 91 is a section that forms a space for housing the reel R. The reel support section 92 is a section that rotatably and detachably supports the reel R within the reel housing 91. The reel cover section 93 is an opening / closing plate section that closes the reel entrance of the reel housing 91 and opens the reel entrance more open, enabling or facilitating the installation and removal of the reel R from the reel housing 91. The reel housing 91, reel support section 92, and reel cover section 93 are located on the right side of the feeder 90. With the reel R supported by the reel support section 92 within the reel housing 91, the feeder 90 feeds and transports the carrier tape T to supply the components P to a predetermined supply position S.

[0022] The feeder 90 is formed to be thin and have a small width. A plurality of types of feeders 90 are provided corresponding to the types of reels R and the types of carrier tapes T. The plurality of types of feeders 90 may have different mechanisms for feeding and moving the carrier tapes T. An identification label (not shown) bearing an identification code for identifying each individual feeder 90 is affixed to the side of the feeder 90.

[0023] There are various types of feeders 90, for example, a full-peel type in which the cover tape TC is completely peeled from the base tape TB in the tape width direction, and after the components are removed from the cavity portion CV, the cover tape TC is discharged independently via a route separate from the base tape TB or wound onto a take-up reel, and a half-peel type in which, as shown in Figure 2, the cover tape TC is peeled from the base tape TB on only one side in the tape width direction, and after the components are removed from the cavity portion CV, the cover tape TC is returned to contact the base tape TB and discharged integrally with the base tape TB.

[0024] As shown in FIG. 2, the feeder 90 also has a motor 94, a sprocket 95, a tape guide 96, a carrier tape outlet 97, an operation panel 98, and a feeder control unit 99.

[0025] The motor 94 is a drive unit that generates a driving force for feeding the carrier tape T. The motor 94 is electrically connected to the feeder control unit 99, and rotates in accordance with commands from the feeder control unit 99. The motor 94 is connected to a sprocket 95.

[0026] The sprocket 95 is a rotating body that transports the carrier tape T. The sprocket 95 is located on the upper front downstream side of the main body of the feeder 90. The sprocket 95 is rotatably supported on the side wall of the main body of the feeder 90. The sprocket 95 has a plurality of teeth that engage with the feed holes SH of the carrier tape T. The teeth at the upper end of the sprocket 95 protrude above the tape transport path. The sprocket 95 rotates when the driving force of the motor 94 is transmitted, and can transport the carrier tape T from the upstream side to the downstream side at a constant pitch by intermittently driving the motor 94 in the forward direction. The sprocket 95 may also be capable of transporting the carrier tape T from the downstream side to the upstream side by driving the motor 94 in the reverse direction.

[0027] The tape guide 96 peels the cover tape TC from the base tape TB of the carrier tape T to expose the components P in the cavity portion CV to the outside at a predetermined supply position S, and guides the carrier tape T as it is transported. The tape guide 96 is located near the upper end of the downstream side of the feeder 90 main body. The tape guide 96 is supported by the feeder 90 main body so that it can swing. The tape guide 96 has a U-shaped cross section and includes a ceiling wall and a pair of side walls. The tape guide 96 guides the carrier tape T on the lower surface of the upper wall and the inner surface of the side wall. The tape guide 96 may be formed in a different shape depending on the type of carrier tape T and the type of feeder 90.

[0028] The ceiling wall of the tape guide 96 is provided with a tape peeling section that peels the cover tape TC from the base tape TB of the carrier tape T, and an extraction hole for removing upward the cover tape TC itself that has been peeled from the base tape TB and the components P in the cavity portion CV of the base tape TB from which the cover tape TC has been peeled. When the carrier tape T is transported with the sprocket 95 engaged with the feed holes SH of the carrier tape T, the tape guide 96 inserts the tape peeling section between the base tape TB and the cover tape TC, thereby peeling the cover tape TC from the base tape TB. The components P in the cavity portion CV of the base tape TB are exposed from the cavity portion CV by peeling the cover tape TC, and are extracted toward the board from the extraction hole located at a predetermined supply position S downstream of the tape peeling section.

[0029] The carrier tape outlet 97 is an outlet through which the carrier tape T, from which the components P have been removed from the cavity portion CV, is discharged from inside the feeder 90 to the outside. The carrier tape outlet 97 is provided at the lower downstream portion of the main body of the feeder 90. After the cover tape TC has been peeled from the base tape TB and the components P have been removed from the cavity portion CV, the carrier tape T is discharged to the outside from the carrier tape outlet 97 via a discharge path within the feeder 90.

[0030] The feeder 90 can be set in the slot 82 of the component mounting machine 80 or in the kitting stand 10. In this set state, the feeder 90 is connected for communication with the control unit of the component mounting machine 80 or the control unit of the kitting stand 10 via a connector terminal (not shown). It is preferable that the kitting stand 10 has a structure compatible with multiple types of feeders 90, and a kitting stand 10 may be provided for each type of feeder 90.

[0031] The feeder control unit 99 is a control device that mainly controls the drive of the sprocket 95. When the feeder 90 is installed in the component mounting machine 80, the feeder control unit 99 is supplied with power from the component mounting machine 80 and is communicatively connected to the main body control unit 86 of the component mounting machine 80 and to a host computer (i.e., management device 20) that is communicatively connected to the main body control unit 86. When the feeder 90 is set in the kitting stand 10, the feeder control unit 99 is supplied with power from the kitting stand 10 and is communicatively connected to the control device of the kitting stand 10 and to the host computer that is communicatively connected to the control device.

[0032] The operation panel 98 is a section having an input section that can be operated by an operator and an output section that outputs to the operator. The operation panel 98 is located at the upper upstream side of the feeder 90 main body. As shown in FIG. 3, the operation panel 98 has a feed button 98a, an origin button 98b, a return button 98c, and an indicator lamp 98d. Each of the buttons 98a to 98c and the indicator lamp 98d are connected to the feeder control unit 99. Each of the buttons 98a to 98c is a push button switch that is operated by pressing it, and the operation state thereof is detected by the feeder control unit 99. The operation state of each of the buttons 98a to 98c may distinguish between a normal press operation and a long press operation. The indicator lamp 98d can be selected to be off, lit in green, lit in yellow, or lit in red, and lights up in the color according to a command from the feeder control unit 99.

[0033] 4. Configuration of the Component Mounting Machine The component mounting machine 80 is a device that picks up components P in cavities CV of carrier tape T supplied to a predetermined supply position S by feeder 90 by suction, gripping, etc., and transfers and mounts them on a board. In the component mounting machine 80, the direction in which the board is transported is defined as the X direction, the direction in which the carrier tape T is transported in feeder 90 that is perpendicular to the X direction is defined as the Y direction, and the vertical direction perpendicular to both the X direction and the Y direction is defined as the Z direction.

[0034] As shown in Fig. 4, the component mounting machine 80 has a feeder setting table 81. The feeder setting table 81 is a table on which a plurality of feeders 90 are set. The feeder setting table 81 also has slots 82 as shown in Fig. 4. The slots 82 are gaps into which the feeders 90 are detachably inserted. The slots 82 are shaped to support the feeders 90 in a vertical position. A plurality of slots 82 are arranged side by side in the left-right direction on the feeder setting table 81. The number of slots 82 on the feeder setting table 81 is, for example, 20.

[0035] The feeder set table 81 has clamp grooves 83 for fitting the feeders 90 and connector terminals 84 for connecting the power lines and signal lines of the feeders 90, corresponding to the slots 82. The feeder set table 81 also has a tape outlet 85 for discharging a waste tape portion of the carrier tape T (see FIG. 1) that stores the components P.

[0036] The component mounting machine 80 also has a board transport device that transports the board in the left-right direction, a component supply device that supplies components P to a predetermined supply position S using a feeder 90 set on the feeder set table 81, and a component transfer device that transfers components P from the predetermined supply position S of the feeder 90 to the board (all of which are not shown). When the feeder 90 is set on the feeder set table 81 and the feeder 90 is installed in the component mounting machine 80, a feeder control unit 99 of the feeder 90 is connected to the main body control unit 86 of the component mounting machine 80 for communication.

[0037] The main body control unit 86 is a part that receives detection result information from the board camera and component camera, etc., and controls the operation of each device in the component mounting machine 80. The main body control unit 86 is mainly composed of a microcomputer, and sends operation commands to each device to perform its operation based on mounting operation data corresponding to the type of board, etc.

[0038] 5. Configuration of the Tape Removal System The tape removal system 1 performs a process of removing the carrier tape T that was set in the feeder 90 from that feeder 90. The feeder 90 from which the tape removal system 1 removes the carrier tape T is the feeder in which the carrier tape T that has run out of components P has been set.

[0039] Note that "out of components" may be limited to when the number of components P remaining on the carrier tape T is zero, or may indicate that the number is below a predetermined number and the tape is half-used. Furthermore, whether or not components are out of components may be determined by the component mounting machine 80. For example, it may be determined that components are out of components when a predetermined number of consecutive pickup errors occur during the component mounting process on a board in the component mounting machine 80, meaning that the component cannot be picked up and the stored number of remaining components is below a predetermined number.

[0040] When a component P is picked up at a predetermined supply position S of the feeder 90 in the component mounting machine 80, the portion of the carrier tape T from which the component was picked up is discharged as a waste tape portion through a discharge path within the feeder 90, out of the feeder through a carrier tape discharge port 97, and also through a tape discharge port 85 of the feeder set table 81. If the carrier tape T set in the feeder 90 runs out of components, the feeder 90 is subsequently removed from the slot 82 of the feeder set table 81 by an operator or the like, and the waste tape portion hanging down from the feeder 90 is cut near the carrier tape discharge port 97. The waste tape portion may be cut by a cutting mechanism provided in the component mounting machine 80 or the feeder 90 before the operator removes the feeder 90.

[0041] After the waste tape portion has been cut off as described above, the feeder 90 is transported to the kitting stand 10. The transport of the feeder 90 to the kitting stand 10 may be performed manually by an operator, or may be performed automatically using a robot, a transport vehicle, or the like.

[0042] As shown in FIG. 5, the tape removal system 1 includes a kitting stand 10, a management device 20, and an operation control unit 30.

[0043] The kitting stand 10 is an off-site setup device in which the setting work of setting the reel R and therefore the carrier tape T on the feeder 90 is performed, and the removal work of removing the reel R and therefore the carrier tape T from the feeder 90 is performed.

[0044] The kitting stand 10 may be configured to automatically set the reel R on the feeder 90 set on the kitting stand 10. The kitting stand 10 may also be configured to automatically perform cueing of the component P by feeding the leading end of the carrier tape T to a sprocket 95 after the reel R is set on the feeder 90, thereby feeding the leading component P on the carrier tape T to a predetermined supply position S.

[0045] The kitting stand 10 may also be configured to automatically rewind the waste tape portion from the feeder 90 onto the reel R when the feeder 90 runs out of components, etc. Furthermore, the kitting stand 10 may also be configured to automatically remove the reel R from the feeder 90 after the waste tape portion has been rewound onto the reel R in the feeder 90.

[0046] The kitting stand 10 holds the feeders 90 in a detachable manner. The kitting stand 10 is installed in a work space in an off-site setup area away from the component mounting machine 80. The kitting stand 10 allows an operator to perform operations such as attaching and detaching the feeders 90. The kitting stand 10 may be movable within a production factory. The kitting stand 10 may be configured to allow only one detachable feeder 90 to be attached, or may be configured to allow two or more detachable feeders 90 to be attached. FIG. 6 shows a kitting stand 10 to which two detachable feeders 90 can be attached.

[0047] 6, the kitting stand 10 has a base body 11, a fitting portion 12, a connector terminal 13, a kitting control portion 15, and a code reader 16. The base body 11 is, for example, an L-shaped workbench so that the lower portion of the feeder 90 body and the downstream end of the body are in contact with each other. The fitting portion 12 is a portion for attaching and fixing the feeder 90 to the base body 11. The fitting portion 12 has a recessed rail 12a into which a detachable rail at the lower portion of the feeder 90 body is inserted, and a positioning hole 12b into which a pin at the downstream end of the feeder 90 body is inserted.

[0048] Connector terminal 13 is a connection part to which the connector terminal of feeder 90 is connected, and which distributes power to be supplied to feeder 90 and transmits signals to and from feeder 90. Kitting control unit 15 is capable of supplying power to feeder 90 connected to connector terminal 13 and transmitting and receiving signals to and from feeder 90. Kitting control unit 15 is activated when a power switch provided on, for example, the outer surface of base body 11 is turned on, and is deactivated when the power switch is turned off.

[0049] When the detachable rail of feeder 90 is inserted into recessed rail 12a and the pin of feeder 90 is inserted into positioning hole 12b, the connector terminal of feeder 90 and the connector terminal 13 of kitting stand 10 are connected to each other, and power is supplied from kitting stand 10 to feeder 90 via connector terminal 13. Once feeder 90 is held in kitting stand 10 and power can be supplied, operation of operation panel 98 and operation of feeder control unit 99 and sprocket 95 become possible.

[0050] The code reader 16 is a reader that reads various identification codes, including the identification code of the reel R and the identification code of the feeder 90. The code reader 16 is a handheld reader that can be operated by an operator, such as a barcode reader or a QR code (registered trademark) reader. The code reader 16 is connected to the kitting control unit 15 and can be operated by power supplied from the kitting control unit 15. The code reader 16 can supply the read identification codes to the kitting control unit 15.

[0051] The management device 20 is a device that performs overall management of the components P, carrier tape T, and feeder 90. Note that the management device 20 may also manage the reel R on which the carrier tape T is wound. The management device 20 is positioned higher than the main body control unit 86 mounted on the component mounting machine 80, the feeder control unit 99 mounted on the feeder 90, and the kitting control unit 15 mounted on the kitting stand 10, and is capable of communicating with these control units 15, 86, and 99. The management device 20 performs overall management of the entire production factory or for each production line. The management device 20 is a host computer mainly composed of a microcomputer.

[0052] As shown in FIG. 5, the management device 20 has a database unit 21, a set determination unit 22, a component out-of-stock information acquisition unit 23, an identification information acquisition unit 24, a tape removal determination unit 25, and a component out-of-stock notification unit 26.

[0053] The database unit 21 is a storage unit that stores the reels R that are set or will be set in the feeder 90, as well as the carrier tape T and components P, in association with one another. The database unit 21 associates the identification information of the reel R with the identification information of the feeder 90, thereby making it possible to store information about the reel R, information about the carrier tape T wound on the reel R, information about the components P accommodated on the carrier tape T, and information about the feeder 90 in association with one another.

[0054] The database unit 21 may store operational parameters of the feeder 90. The operational parameters are determined according to the size, mass, or shape of the components P, the type, tape width, or component storage pitch of the carrier tape T that stores the components P, or the type of feeder 90 in which the carrier tape T is set.

[0055] The set determination unit 22 is a part that determines whether or not the feeder 90 is set on the kitting stand 10. Specifically, the set determination unit 22 determines that the feeder 90 is set on the kitting stand 10 when the feeder 90 is attached to the base body 11 of the kitting stand 10 and the detachable rails or pins of the feeder 90 are inserted into the recessed rails 12a or the positioning holes 12b, or when the connector terminals are connected to each other.

[0056] The set determination unit 22 may make the above determination based on information sent from the kitting control unit 15 of the kitting stand 10. In this case, the kitting control unit 15 may detect whether the feeder 90 is set in the kitting stand 10 by using an output signal from a sensor installed in, for example, the fitting unit 12 of the kitting stand 10 or a communication signal from the connector terminal 13, and may output a set signal to the management device 20 when it detects that the feeder 90 is set.

[0057] The out-of-component information acquisition unit 23 is a component that acquires information about a component shortage in a feeder 90, in association with the identification information of the feeder 90. During board production by a component mounting machine 80 equipped with a feeder 90, if the main body control unit 86 of the component mounting machine 80 detects that the feeder 90 is out of components, the main body control unit 86 can notify the management device 20 of the out-of-component information in association with the identification information of the feeder 90. The out-of-component information acquisition unit 23 receives information notified from the component mounting machine 80, and acquires information about a component shortage in the feeder 90, in association with the identification information of the feeder 90. This out-of-component information about the feeder 90 is stored in the database unit 21 in association with the identification information of the feeder 90.

[0058] The identification information acquisition unit 24 is a component that acquires the identification information of the feeder 90 set on the kitting stand 10. The kitting control unit 15 can notify the management device 20 of the identification information of the feeder 90 on the kitting stand 10. The kitting control unit 15 may request the feeder control unit 99 of the feeder 90 to notify it of the identification information for each request from the management device 20, and notify the management device 20 of the identification information sent from the feeder control unit 99 in accordance with the request, or may notify the management device 20 of the identification information of the feeder 90 that has been read in advance by the code reader 16 and stored. The identification information acquisition unit 24 acquires the identification information of the feeder 90 on the kitting stand 10 based on the information from the kitting control unit 15.

[0059] The tape removal determination unit 25 is a part that determines whether or not it is necessary to remove the carrier tape T from the feeder 90. The tape removal determination unit 25 determines whether or not it is necessary to remove the carrier tape T, using the feeder 90 set in the kitting stand 10 as the target feeder. When the identification information acquisition unit 24 acquires the identification information of the feeder 90 on the kitting stand 10, the tape removal determination unit 25 first accesses the database unit 21 to check whether or not there is out-of-stock information based on the identification information of the feeder 90, and when the out-of-stock information acquisition unit 23 acquires information that the feeder 90 is out of stock, the tape removal determination unit 25 determines that it is necessary to remove the carrier tape T from the feeder 90.

[0060] The out-of-component notification unit 26 is a unit that notifies the feeder 90 of the out-of-component situation from the management device 20 via the kitting stand 10 when the tape removal determination unit 25 determines that the carrier tape T needs to be removed from the feeder 90. When the carrier tape T needs to be removed from the feeder 90 on the kitting stand 10 due to the feeder 90 being out of components, the out-of-component notification unit 26 notifies the feeder control unit 99 of the feeder 90 via the kitting control unit 15 of the kitting stand 10 of the out-of-component situation.

[0061] The operation control unit 30 is a part that returns the carrier tape T in a return direction opposite to the component feed direction in a feeder 90 where the carrier tape T needs to be removed. The operation control unit 30 is provided in the feeder control unit 99 of the feeder 90 and is a part of the feeder control unit 99. When the feeder control unit 99 receives a component out-of-component notification for a feeder 90 from the component out-of-component notification unit 26 of the management device 20 via the kitting control unit 15, the operation control unit 30 causes the carrier tape T of that feeder 90 to be returned in the return direction.

[0062] This return transport is performed for a predetermined length required for the leading end of the carrier tape T, specifically, the leading end of the waste tape portion of the carrier tape T that hangs down and is discharged from the carrier tape discharge outlet 97 of the feeder 90 to return to a position where it disengages from the sprocket 95. The carrier tape T is cut near the carrier tape discharge outlet 97 when the feeder 90 is removed from the component mounting machine 80. Furthermore, the discharge path of the carrier tape T from the sprocket 95 to the carrier tape discharge outlet 97 in the feeder 90 is predetermined for each feeder 90, and the length of the discharge path is constant for each feeder 90.

[0063] Therefore, the above-mentioned predetermined length is set to roughly the path length from the sprocket 95 to the carrier tape outlet 97, and more specifically, it is set to the path length plus the length (more specifically, the longest length) from the carrier tape outlet 97 to the cut point of the carrier tape T that is predicted to be cut when the feeder 90 is removed. In response to a component shortage notification from the management device 20, the operation control unit 30 drives the motor 94 to rotate in the return direction of the carrier tape T by the above-mentioned predetermined length.

[0064] As shown in FIG. 5, the feeder control unit 99 of the feeder 90 has an operation control unit 30, a notification determination unit 31, a nonvolatile memory 32, and a memory clear unit 33.

[0065] The notification determination unit 31 is a component that determines whether or not a notification of out-of-component of the carrier tape T transmitted from the out-of-component notification unit 26 of the management device 20 has been received. The feeder control unit 99 is capable of receiving the notification of out-of-component of the carrier tape T transmitted from the out-of-component notification unit 26 via the kitting control unit 15. The notification determination unit 31 makes a positive determination when the notification has been received by the feeder control unit 99. When the notification determination unit 31 determines that a notification of out-of-component has been received, the operation control unit 30 drives the motor 94 to rotate in the reverse direction by the above-mentioned predetermined length.

[0066] The non-volatile memory 32 is a component that stores information that the feeder 90 is out of carrier tape T when the main body control unit 86 of the component mounting machine 80 equipped with the feeder 90 notifies the feeder 90 that the carrier tape T is out of components during board production in the component mounting machine 80. The non-volatile memory 32 can continue to store the stored content even after the feeder 90 is powered off. When the main body control unit 86 detects that the feeder 90 is out of components, it notifies the management device 20 of the information about the out-of-components, and also notifies the feeder control unit 99 of the feeder 90. When the feeder control unit 99 receives the information about the out-of-components from the main body control unit 86, it stores the information about the out-of-components in the non-volatile memory 32.

[0067] The memory clearing unit 33 is a part that clears the out-of-parts information stored in the non-volatile memory 32 when the operation control unit 30 has completed the return transport of the carrier tape T by the above-mentioned predetermined length.

[0068] 6. Operation and Effects of the Tape Removal System When a feeder 90 equipped to a component mounting machine 80 runs out of components and is removed from the component mounting machine 80, and the waste tape portion of the carrier tape T is cut, the feeder 90 is set on the kitting stand 10 for removal of the carrier tape T and, by extension, the reel R. When the feeder 90 is set on the kitting stand 10, the tape removal system 1 begins operation as shown in Figure 7. A first operation example and a second operation example will be described below.

[0069] [First Operation Example] This first operation example is executed according to the operation time chart shown in FIG. 7 . After the tape removal system 1 starts operating, the kitting control unit 15 of the kitting stand 10 first notifies the management device 20 of the feeder set information. When the set determination unit 22 of the management device 20 receives the feeder set information from the kitting control unit 15, it determines that the feeder 90 has been set on the kitting stand 10. Upon such determination, the identification information acquisition unit 24 of the management device 20 requests the kitting control unit 15 to notify it of the identification information of the feeder 90 on the kitting stand 10. In accordance with the notification request from the management device 20, the kitting control unit 15 requests the feeder control unit 99 of the feeder 90 to notify it of the identification information, and then notifies the management device 20 of the identification information sent from the feeder control unit 99. As a result, the identification information acquisition unit 24 acquires the identification information of the feeder 90 set on the kitting stand 10.

[0070] Based on information sent from the main body control unit 86 of the component mounting machine 80 during board production, the out-of-component information acquisition unit 23 of the management device 20 acquires information about out-of-component conditions in the feeder 90 in association with the identification information of the feeder 90. The out-of-component condition information in the feeder 90 acquired by the out-of-component information acquisition unit 23 is stored in the database unit 21 in association with the identification information of the feeder 90.

[0071] When the identification information acquisition unit 24 acquires the identification information of the feeder 90 on the kitting stand 10, the tape removal determination unit 25 of the management device 20 first accesses the database unit 21 to check whether there is any out-of-component information based on the identification information of the feeder 90. If the result of the check indicates that the out-of-component information acquisition unit 23 has acquired information that the feeder 90 is out of components, the tape removal determination unit 25 determines that the carrier tape T needs to be removed from the feeder 90 on the kitting stand 10.

[0072] When the tape removal determination unit 25 determines that the carrier tape T needs to be removed from the feeder 90, the out-of-components notification unit 26 of the management device 20 notifies the feeder 90 that it is out of components via the kitting stand 10. When the feeder control unit 99 is notified of the out-of-components situation in the feeder 90 via the kitting control unit 15, the operation control unit 30 drives the motor 94 to rotate in the reverse direction to feed the carrier tape T of the feeder 90 back a predetermined length in the return direction. When this return feeding is performed, the leading end of the waste tape portion of the carrier tape T hanging down from the carrier tape discharge port 97 of the feeder 90 is returned to a position where it disengages from the sprocket 95.

[0073] In this way, in the tape removal system 1 of the first operation example, when a feeder 90 removed from a component mounting machine 80 that produces circuit boards runs out of components, the carrier tape T set in that feeder 90 can be automatically disengaged from the sprocket 95. Then, the carrier tape T can be conveyed back by just the length that is appropriate for disengaging the carrier tape T from the sprocket 95, and is neither too long nor too short.

[0074] This prevents the carrier tape T from remaining engaged with the sprocket 95 in a feeder 90 that has run out of components on the kitting stand 10, and eliminates the need for an operator to perform additional work until the carrier tape T and the sprocket 95 are disengaged, thereby reducing the amount of work required by the operator to remove the carrier tape T and, ultimately, the reel R from the feeder 90. Conversely, this also prevents the motor 94 and sprocket 95 from continuing to rotate excessively even when the carrier tape T and the sprocket 95 are disengaged, thereby preventing unnecessary operation of the motor 94, etc.

[0075] Therefore, according to the tape removal system 1, unnecessary carrier tape T and thus reel R can be properly and efficiently removed from a feeder 90 on a kitting stand 10 in which a reel R wound with carrier tape T is set.

[0076] [Second operation example] In the first operation example described above, when the feeder 90 receives a component out-of-stock notification from the management device 20 via the kitting stand 10, the operation control unit 30 immediately (automatically) drives the motor 94 in reverse rotation to transport the carrier tape T back in the return direction by a predetermined length.

[0077] In contrast, in a second operation example, when the feeder 90 receives a component out-of-stock notification from the management device 20 via the kitting stand 10, the operation control unit 30 drives the motor 94 to rotate in the reverse direction, thereby feeding the carrier tape T back by a predetermined length, on the condition that the operator then operates a switch on the feeder 90 on the kitting stand 10. This second operation example is executed in accordance with the operation time chart shown in FIG.

[0078] Specifically, after the tape removal determination unit 25 determines that the carrier tape T needs to be removed from the feeder 90, the out-of-components notification unit 26 notifies the feeder control unit 99 via the kitting control unit 15 that the feeder 90 is out of components, and then out-of-components information is set and stored in the feeder control unit 99. When such out-of-components information is set, for example, the indicator lamp 98d on the operation panel 98 of the feeder 90 lights up or flashes in red or other color, thereby visually notifying a worker near the kitting stand 10 that the feeder 90 is out of components. This notification may also be accompanied by the output of a voice or a buzzer sound.

[0079] After setting the out-of-component information in the feeder control unit 99, when the operator presses the return button 98c on the operation panel 98, the operation control unit 30 drives the motor 94 to rotate in the reverse direction, thereby feeding the carrier tape T of the feeder 90 back a predetermined length in the return direction. When this return feeding is performed, the leading end of the waste tape portion of the carrier tape T hanging down from the carrier tape discharge port 97 of the feeder 90 is returned to a position where it disengages from the sprocket 95.

[0080] In this way, in the tape removal system 1 of the second operation example, when a feeder 90 removed from a component mounting machine 80 that is producing circuit boards runs out of components, the carrier tape T set in that feeder 90 can be automatically disengaged from the sprocket 95 on the condition that an operator operates a switch. Then, the carrier tape T can be conveyed back by just the length that is appropriate for disengaging the carrier tape T from the sprocket 95, and is neither too long nor too short. Therefore, the same effects as those of the first operation example can be obtained.

[0081] Furthermore, according to this second operation example, the operator's will can be involved in the reverse rotation drive of the motor 94 to carry out the return transport of the carrier tape T, thereby preventing the carrier tape T from being automatically returned immediately after a feeder 90 that is out of parts is set on the kitting stand 10.

[0082] 7. Modified Embodiments In the above embodiment, the tape removal determination unit 25 is provided in the management device 20. After the feeder 90 is set on the kitting stand 10, if the tape removal determination unit 25 determines that the carrier tape T needs to be removed from the feeder 90, the out-of-component notification unit 26 of the management device 20 notifies the feeder control unit 99 of the feeder 90 that the carrier tape T is out of components, and after the out-of-component notification, the operation control unit 30 of the feeder 90 carries out return transport of the carrier tape T.

[0083] However, the present disclosure is not limited to this, and a tape removal determination unit that determines whether or not the carrier tape T needs to be removed may be provided in the feeder 90 instead of the management device 20. In this modified embodiment, during board production by the component mounting machine 80 before the feeder 90 is set on the kitting stand 10, the component mounting machine 80 may notify the feeder 90 that the feeder 90 is out of components and store the information, and then, when the feeder 90 is removed from the component mounting machine 80 and set on the kitting stand 10, the tape removal determination unit of the feeder 90 may determine whether or not the carrier tape T needs to be removed based on the stored information, and if it is determined that the carrier tape T needs to be removed, the operation control unit 30 of the feeder 90 may perform return transport of the carrier tape T.

[0084] The operation example of the above-described modified embodiment is executed in accordance with the operation time charts shown in Figures 9 and 10. Specifically, first, during component production by the component mounting machine 80, the main body control unit 86 determines whether or not the feeders 90 installed in each slot 82 are out of components. Then, when the main body control unit 86 detects that any of the feeders 90 is out of components, it notifies the feeder control unit 99 of that feeder 90 of information that the feeder 90 is out of components. When the feeder control unit 99 receives the notification of out-of-components from the main body control unit 86, it stores in the non-volatile memory 32 that the feeder 90 is out of components.

[0085] Then, when the feeder 90 is removed from the component mounting machine 80, the carrier tape T is cut near the carrier tape outlet 97, and the feeder 90 is set in the kitting stand 10, the kitting control unit 15 of the kitting stand 10 first notifies the management device 20 of the feeder set information.

[0086] When the set determination unit 22 of the management device 20 receives the feeder set information from the kitting control unit 15, it determines that the feeder 90 has been set on the kitting stand 10. When this determination is made, the identification information acquisition unit 24 of the management device 20 requests the kitting control unit 15 to notify it of the identification information of the feeder 90 on that kitting stand 10. In accordance with the notification request from the management device 20, the kitting control unit 15 requests the feeder control unit 99 of the feeder 90 to notify it of the identification information, and then notifies the management device 20 of the identification information sent from the feeder control unit 99. As a result, the identification information acquisition unit 24 acquires the identification information of the feeder 90 set on the kitting stand 10.

[0087] Furthermore, when the feeder control unit 99 of the feeder 90 receives an identification information notification from the identification information acquisition unit 24 of the management device 20 via the kitting control unit 15, it can know that its own feeder 90 is set on the kitting stand 10. After receiving this identification information, a tape removal determination unit provided in the feeder control unit 99 determines whether or not the carrier tape T needs to be removed based on the presence or absence of out-of-component information stored in the non-volatile memory 32. If it is determined that removal is necessary, the operation control unit 30 of the feeder 90 performs a return transport of the carrier tape T. When this return transport is performed, the leading end of the waste tape portion of the carrier tape T hanging down from the carrier tape discharge port 97 of the feeder 90 is returned to a position where it disengages from the sprocket 95.

[0088] In this way, even in the tape removal system 1 of the modified operational example, when a feeder 90 removed from a component mounting machine 80 that produces circuit boards runs out of components, the carrier tape T set in that feeder 90 can be automatically disengaged from the sprocket 95. Then, the carrier tape T can be conveyed back by just the right length to disengage the carrier tape T from the sprocket 95. Therefore, the same effects as those of the first operational example can be obtained.

[0089] Furthermore, according to this operation example, after the feeder 90 is set on the kitting stand 10, it is not necessary for the management device 20 to determine whether or not it is necessary to remove the carrier tape T from the feeder 90, and after determining whether or not this is necessary, it is not necessary for the management device 20 to notify the feeder 90 that the part is out of stock.Therefore, it is possible to realize return transport of the carrier tape T in the feeder 90 immediately after the feeder 90 is set on the kitting stand 10.

[0090] Furthermore, in the above-described modified embodiment, when the operation control unit 30 has completed the return transport of the carrier tape T by a predetermined length, the memory clear unit 33 clears the out-of-components information stored in the nonvolatile memory 32. Therefore, when the feeder 90 is once removed from the kitting stand 10 and then set on the kitting stand 10 again, it is possible to prevent the carrier tape T from being erroneously returned and transported based on the out-of-components information in the nonvolatile memory 32.

[0091] In the above embodiment, the tape removal determination unit 25 is provided in the management device 20, and the operation control unit 30 is provided in the feeder 90. However, the present disclosure is not limited to this, and the tape removal determination unit may be provided in the kitting control unit 15, or the operation control unit 30 may be provided in the kitting control unit 15. In accordance with the configuration of this modified embodiment, the out-of-stock information acquisition unit, the identification information acquisition unit, and the out-of-stock notification unit may also be mounted in the kitting control unit 15.

[0092] Furthermore, in the above embodiment, the tape removal determination unit 25 determines that it is necessary to remove the carrier tape T from the feeder 90 when the feeder 90 is out of components. However, the present disclosure is not limited to this, and the tape removal determination unit 25 may determine that it is necessary to remove the carrier tape T from the feeder when it is determined that the carrier tape T will not be used even before the feeder 90 is out of components. This is to deal with, for example, a situation where a production change occurs and a component P is no longer in use, and a different component is replaced for the next production run.

[0093] In the above embodiment, in order to feed the carrier tape T back when the feeder 90 is set on the kitting stand 10, a return button 98c on the operation panel 98 of the feeder 90 is pressed. However, the present disclosure is not limited to this, and the kitting stand 10 may be provided with a button for feeding the carrier tape T back, and when the button is pressed when the feeder 90 is set on the kitting stand 10, the carrier tape T may be fed back in accordance with a command from the kitting control unit 15 to the feeder control unit 99.

[0094] The present disclosure is not limited to the above-described embodiments and modifications, and various modifications can be made without departing from the spirit of the present disclosure.

[0095] 1: Tape removal system, 10: Kitting stand, 15: Kitting control unit, 20: Management device, 21: Database unit, 22: Set determination unit, 23: Out-of-component information acquisition unit, 24: Identification information acquisition unit, 25: Tape removal determination unit, 26: Out-of-component notification unit, 30: Operation control unit, 31: Notification determination unit, 32: Non-volatile memory, 33: Memory clear unit, 80: Component mounting machine, 86: Main body control unit, 90: Feeder, 99: Feeder control unit, T: Carrier tape, R: Reel, S: Predetermined supply position.

Claims

1. A tape removal system comprising: a tape removal determination unit that determines whether or not it is necessary to remove a carrier tape from a feeder having a reel support unit that detachably supports a reel on which a carrier tape that contains components is wound, a sprocket that engages with a feed hole in the carrier tape, and a motor that rotates the sprocket to generate a driving force to transport the carrier tape; and an operation control unit that, when it is determined by the tape removal determination unit that it is necessary to remove the carrier tape from the feeder, transports the carrier tape in the feeder by a predetermined length in a return direction that is opposite to the component feed direction.

2. A tape removal system as described in claim 1, wherein the predetermined length is the length required for the leading edge of the waste tape portion of the carrier tape pulled out from the reel supported by the reel support portion and discharged outward from the feeder to return to a position where it disengages from the sprocket.

3. A tape removal system as described in claim 1, wherein the tape removal determination unit determines that the carrier tape needs to be removed from the feeder when the carrier tape wound on the reel supported by the reel support unit in the feeder is out of components.

4. A tape removal system as described in claim 3, comprising: a component out-of-stock information acquisition unit that acquires information about the component outage in the feeder in association with identification information of the feeder; and an identification information acquisition unit that acquires identification information of the feeder set on a kitting stand to which the feeder can be detached; wherein the tape removal determination unit determines that the carrier tape needs to be removed from the feeder when the component out-of-stock information acquisition unit has acquired that the component outage has occurred in the feeder whose identification information has been acquired by the identification information acquisition unit.

5. A tape removal system as described in claim 4, wherein the component out-of-stock information acquisition unit, the identification information acquisition unit, and the tape removal determination unit are provided in a management device that manages the components, the carrier tape, and the feeder in an integrated manner.

6. A tape removal system as described in claim 5, wherein the management device has a component shortage notification unit that notifies the feeder via the kitting stand that the component has run out when the tape removal determination unit determines that the carrier tape needs to be removed from the feeder.

7. A tape removal system as described in claim 6, wherein the operation control unit is provided in the feeder, the feeder has a notification determination unit that determines whether or not the notification of out-of-component is received from the out-of-component notification unit, and the operation control unit drives the motor so that the carrier tape is transported back in the return direction by the specified length when it is determined by the notification determination unit that the notification has been received.

8. A tape removal system as described in claim 3, further comprising a set determination unit that determines whether the feeder is set on a kitting stand, wherein the feeder has a non-volatile memory that stores information indicating that the feeder is out of components when the component mounting machine equipped with the feeder notifies the feeder of the out-of-component status during board production by the component mounting machine, and wherein the tape removal determination unit determines that the carrier tape needs to be removed from the feeder when the non-volatile memory stores information indicating that the feeder is out of components when the set determination unit determines that the feeder is set on the kitting stand.

9. A tape removal system as described in claim 8, wherein the feeder has a memory clearing unit that clears the out-of-part information stored in the non-volatile memory when the operation control unit has completed the return transport of the carrier tape by the specified length.

10. A tape removal system as described in any one of claims 3 to 9, wherein the tape removal determination unit determines that the carrier tape needs to be removed from the feeder if it is determined that the carrier tape will not be used even before the feeder runs out of components.

11. A tape removal system as described in claim 1, wherein the tape removal determination unit determines whether or not the carrier tape needs to be removed from the feeder when the feeder is set on a kitting stand to which the feeder can be detached.

12. A tape removal system as described in claim 1, wherein the operation control unit drives the motor so that the carrier tape is transported back in the return direction by the specified length when a specified switch provided on the feeder is operated after the tape removal determination unit determines that the carrier tape needs to be removed from the feeder.

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