Feeder storage system

Abstract

This feeder storage system comprises: a detection unit that detects an additional feeder, which is a feeder that is not a conveyance plan and is added as an object of conveyance during execution of a loading process in which feeders for supplying components are loaded, on the basis of a prescribed conveyance plan, onto a conveyance vehicle that conveys objects of conveyance to a production line configured to include a component mounting machine; and an adjustment unit that, when the additional feeder is detected, adjusts the conveyance plan such that the additional feeder is conveyed with priority.

Description

Feeder Storage System

[0001] The present invention relates to a feeder storage system.

[0002] The feeder storage system controls the storage of feeders that are installed in component mounting machines and supply components. Patent Document 1 discloses a configuration that provides setup guidance, including feeder setup, to a production line that produces product boards, depending on the production progress, etc. Patent Document 1 also discloses a configuration that edits the setup content in response to changes in the production plan.

[0003] International Publication No. 2018 / 092250

[0004] However, in actual production, even though production is progressing according to a production plan, the estimated remaining number of parts may actually be low, or more parts may be consumed than planned due to an unexpected event. In such cases, it may be necessary to transport additional feeders to make up for the shortage, separate from the original transport plan for transporting feeders to the production line. However, if it takes time to edit and update the transport plan, the transport of the additional feeders may be delayed, which may affect production.

[0005] The present specification aims to provide a feeder storage system that can simplify the task of adding a specified feeder to a transport target and maintain productivity.

[0006] This specification discloses a feeder storage system that includes a detection unit that detects an additional feeder that is not included in a predetermined transport plan and has been added to a transport object during a loading process that loads a feeder that supplies components onto a transport vehicle that transports the transport object to a production line that includes a component mounting machine based on the predetermined transport plan, and an adjustment unit that adjusts the transport plan when the additional feeder is detected so that the additional feeder is transported with priority.

[0007] This specification also discloses the technical idea of ​​changing "the feeder storage system according to claims 1-4" in claim 6 as originally filed to "the feeder storage system according to any one of claims 1-5," the technical idea of ​​changing "the feeder storage system according to claim 6" in claim 8 as originally filed to "the feeder storage system according to claim 6 or 7," the technical idea of ​​changing "the feeder storage system according to claim 6" in claim 9 as originally filed to "the feeder storage system according to any one of claims 6-8," and the technical idea of ​​changing "the feeder storage system according to claims 1-4" to "the feeder storage system according to any one of claims 1-10" in claim 11 as originally filed.

[0008] According to this configuration, if an additional feeder is detected during the execution of a mounting process based on a transport plan, the transport plan is adjusted so that the additional feeder is transported with priority, so that the additional feeder can be added to the transport targets without the need for an operator to edit or update the transport plan. This makes it possible to maintain productivity.

[0009] FIG. 1 is a schematic diagram showing a production system to which a feeder storage system is applied; FIG. 2 is a schematic top view showing a component mounting machine; FIG. 3 is a schematic side view showing a feeder; FIG. 4 is a schematic diagram showing the configuration of the feeder storage system; FIG. 5 is a front view of the feeder storage system; FIG. 6 is a diagram showing various information including a transport plan; FIG. 7 is a functional block diagram of the feeder storage system; FIG. 8 is a flowchart showing a transport plan adjustment process; and FIG. 9 is a diagram showing a transport plan adjusted by the transport plan adjustment process.

[0010] 1. Overview of Feeder Storage System 50 The feeder storage system 50 controls the storage of feeders 20 that are equipped to component mounting machines 10 and supply components. The component mounting machines 10 perform a predetermined substrate-related operation, which is a mounting process for mounting components on a board. As shown in FIG. 1 , a production line Ln is configured by arranging multiple substrate-related operation machines in a line in the transport direction of the board. Each of the multiple substrate-related operation machines is communicatively connected to a line management device 82 and a host computer 81, which provide overall control of the production line Ln. The line management device 82 manages the production line Ln on which it is installed. The production line Ln includes a buffer device 83, a loader 84, multiple solder printers as substrate-related operation machines, multiple component mounting machines 10, a reflow furnace, and an inspection machine.

[0011] The buffer device 83 temporarily holds the boards being transported. A magazine 71 capable of accommodating a feeder 20 is removably set in the buffer device 83. The feeders 20 mounted in the magazine 71 set in the buffer device 83 are capable of communicating with the line management device 82 via the control device of the buffer device 83. The feeders 20 are transported between the component mounting machines 10 and the buffer device 83 by a loader 84. The loader 84 is provided so as to be movable relative to the multiple component mounting machines 10 and the buffer device 83 along the direction in which the component mounting machines 10 are lined up. The loader 84 performs a feeder 20 replacement operation for a predetermined component mounting machine 10 or buffer device 83.

[0012] In this embodiment, the production system Sy for product substrates may be configured with multiple production lines Ln (Ln1, Ln2, ...). Note that the configuration of each of the multiple production lines Ln may be appropriately added to or modified depending on, for example, the type of product substrate to be produced. Specifically, the multiple production lines Ln may be appropriately equipped with substrate-related operating machines such as a substrate supply device, a substrate reversing device, various inspection devices, a shield mounting device, an adhesive application device, and an ultraviolet irradiation device.

[0013] The storage device of the host computer 81 stores a production plan M1, product information M2, production information M3, and a transfer plan M4. As shown in FIG. 6, the production plan M1 indicates the types of product boards to be produced (product types: U1, U2, U3, ...), the target production quantities (T1, T2, T3, ...), and the production sequence of these. The product information M2 indicates the types of components (Pa, Pb, Pc, ...) required for each type of product board (U1, U2, U3, ...). The product information M2 indicates the number of components consumed for each type of component when producing one product board of a predetermined type.

[0014] The production information M3 indicates the required times (RT1, RT2, RT3, ...) for the mounting processes (Job1, Job2, Job3, ...) executed by the component mounting machines 10. In particular, when a predetermined type of product board is produced on a predetermined production line Ln, the total required times (RT11+RT12+RT13+...) for the mounting processes assigned to each of the component mounting machines 10 constituting the production line Ln is set to be the required time for the mounting processes to produce the predetermined type of product board (RT1=RT11+RT12+RT13+...).

[0015] The transfer plan M4 is generated in advance based on the production plan M1, product information M2, and production information M3, and indicates a transfer target Gt, which is the transfer destination of a specific feeder 20, and a transfer order for the specific feeder 20. Specifically, as shown in FIG. 6 , for each of multiple transfer targets Bt (FID011, FID012, FID013, ...), one of multiple production lines Ln is indicated as a transfer target Gt (Ln1, Ln2, Ln3, ...). In this embodiment, the feeder 20 that is the transfer target Bt is stored in a magazine 71 together with other feeders 20 that share the same transfer target Gt, and is transferred by the automated guided vehicle 70.

[0016] Therefore, the transport plan M4 also indicates magazines 71 (Mg01, Mg02, Mg03, ...) that store multiple feeders 20 (FID011, FID012, FID013, ...) that share the same transport target Gt. In this way, the transport plan M4 indicates the execution order of multiple transport processes that store multiple feeders 20 in the magazine 71, load the magazine 71 onto the automatic guided vehicle 70, and then transport the magazine 71 to the transport target Gt.

[0017] 2. Configuration of the component mounting machine 10 2-1. Board transport device 11 As shown in Fig. 2, the component mounting machine 10 includes a board transport device 11. The board transport device 11 sequentially transports the boards 91 in a transport direction and positions the boards 91 at predetermined positions within the machine.

[0018] 2-2. Component Supply Device 12 The component mounting machine 10 is equipped with a component supply device 12. The component supply device 12 supplies components to be mounted on the board 91. The component supply device 12 has feeders 20 set in multiple slots 121. The feeders 20 may be tape feeders, stick feeders, bulk feeders, or the like. The tape feeder feeds and moves the carrier tape 41 (see FIG. 3) to supply components so that they can be picked up. The component supply device 12 holds a reel 30 around which the carrier tape 41 is wound.

[0019] 2-3. Component Transfer Device 13 The component mounting machine 10 is equipped with a component transfer device 13. The component transfer device 13 transfers components supplied by the component supply device 12 to predetermined mounting positions on the board 91. The component transfer device 13 is equipped with a head drive device 131, a movable table 132, a mounting head 133, and a suction nozzle 134. The head drive device 131 moves the movable table 132 in horizontal directions (X and Y directions) using a linear motion mechanism. The mounting head 133 is detachably fixed to the movable table 132 by a clamp member (not shown) and is provided so as to be movable horizontally within the machine.

[0020] The mounting head 133 supports a plurality of suction nozzles 134 that are rotatable and movable up and down. The suction nozzles 134 are holding members that can pick up and hold components supplied by the feeder 20. The suction nozzles 134 use supplied negative pressure air to pick up the components supplied by the feeder 20. A chuck or the like that grips and holds components can be used as the holding member attached to the mounting head 133.

[0021] In this embodiment, the mounting head 133 includes eight holders (not shown) arranged at equal intervals on a ring centered on an R axis extending in the vertical direction. A suction nozzle 134 used for the mounting process is attached to each of the eight holders. The eight suction nozzles 134 are rotatable about the R axis and also about a Q axis passing through the center of each nozzle and extending in the vertical direction.

[0022] 2-4. Component camera 14, board camera 15 The component mounting machine 10 is equipped with a component camera 14 and a board camera 15. The component camera 14 and the board camera 15 are digital imaging devices having imaging elements such as CMOS. The component camera 14 and the board camera 15 capture images based on control signals and send image data acquired by the images. The component camera 14 is configured to be able to capture images of the components held by the suction nozzle 134 from below. The board camera 15 is mounted on a moving stage 132 so as to be movable horizontally integrally with the mounting head 133. The board camera 15 is configured to be able to capture images of the board 91 from above.

[0023] Furthermore, in addition to capturing an image of the surface of the circuit board 91, the circuit board camera 15 can also capture an image of various devices within the movable range of the movable table 132. For example, the circuit board camera 15 can capture an image of the supply area where the feeder 20 supplies components, as well as identification codes and reference marks provided on the feeder 20 and various components, within the camera's field of view. In this way, the circuit board camera 15 can be used to capture images of different devices in order to obtain image data to be used for various image processing.

[0024] 2-5. Control Device 16 The component mounting machine 10 is equipped with a control device 16. The control device 16 is mainly composed of a CPU, various memories, and a control circuit. The control device 16 acquires and stores various data, such as a control program used to control the mounting process and component data, from the host computer 81 or the line management device 82. The control program indicates the mounting position, mounting angle, and component type of components to be mounted on the board 91 in the mounting process in the planned mounting order. The component data indicates shape data for each type of component, the maximum allowable movement speed (acceleration), and the pickup position (for example, the position at which the component comes into contact with the suction nozzle 134).

[0025] The mounting process includes a process of repeating a PP cycle (pick-and-place cycle), which includes a pickup cycle and a mounting cycle, multiple times. The "pick-up cycle" refers to a process of repeating a pickup operation, in which the suction nozzle 134 picks up components supplied by the component supply device 12, multiple times.

[0026] The above-mentioned "mounting cycle" refers to the process of sequentially mounting picked components onto the board 91, and more specifically, to the process of repeating a mounting operation multiple times to mount components at a predetermined mounting position on the board 91 at a predetermined mounting angle. In this way, the control program may have a preset execution order for a PP cycle, which is made up of multiple picking and mounting operations grouped together, taking into consideration the number of suction nozzles 134 supported by the mounting head 133 (eight in this embodiment), the movement distance of the mounting head 133, etc.

[0027] The control device 16 executes a process for recognizing the holding state of the components held by each of the multiple holding members (suction nozzles 134). Specifically, the control device 16 processes image data acquired by image capture by the component camera 14, and recognizes the position and angle of each component relative to the reference position of the mounting head 133. Note that in addition to the component camera 14, the control device 16 may also process image data acquired by, for example, a head camera unit integrally provided on the mounting head 133 capturing an image of the component from the side, below, or above.

[0028] In the mounting process, the control device 16 controls the mounting operation by the mounting head 133 so that the component is mounted on the board 91 in a predetermined orientation. At this time, the control device 16 controls the mounting operation based on the recognized holding state of the component. In other words, the control device 16 corrects the position of the mounting head 133 and the angle of the suction nozzle 134 about the Q axis so as to correct any positional and angular deviations of the component held by the suction nozzle 134 relative to the Q axis (the axis of rotation of the suction nozzle 134). As a result, the component held by the suction nozzle 134 is mounted at a predetermined mounting position and angle instructed by the control program.

[0029] 3. Feeder 20 The configuration of the feeder 20 will be described with reference to Fig. 3. The left-right direction in Fig. 3 is the transport direction of the carrier tape 31, with the left side of Fig. 3 being the upstream side in the transport direction and the right side of Fig. 3 being the downstream side in the transport direction. In this embodiment, the feeder 20 is a tape feeder that performs a supply operation to supply components by feeding and moving the carrier tape 31.

[0030] 3-1. Feeder Body 21 The feeder 20 includes a feeder body 21. The feeder body 21 is formed in a flat box shape. The feeder body 21 is formed so that it can supply components at a supply position 216 located at the upper part on the downstream side in the transport direction of the carrier tape 31. The feeder body 21 is formed with a tape transport path 215 that guides the carrier tape 31 pulled out from the reel 30 to the supply position 216. The tape transport path 215 is formed in a rectangular cylindrical shape using, for example, a bottom plate, two side plates, and a ceiling plate.

[0031] The tape transport path 215 may also have a tape presser that presses the carrier tape 31 against the bottom plate. The tape transport path 215 may also have a portion of its cylindrical shape omitted. The tape transport path 215 starts at a position close to the reel 30, extends diagonally upward in the downstream direction, extends roughly horizontally in the downstream direction from the middle, and ends at the top of the downstream end of the feeder main body 21. The position close to the end of the tape transport path 215 is the supply position 216.

[0032] The feeder body 21 is mounted in the slot 121 of the component mounting machine 10. An upper positioning pin 221, a connector 222, and a lower positioning pin 223 are provided on the downstream end face of the feeder body 21. The upper positioning pin 221 and the lower positioning pin 223 are fitted into positioning holes provided on the slot 121 side to position the feeder 20. When the feeder 20 is positioned, the connector 222 automatically fits into a receiving connector provided on the slot 121 side. When the feeder 20 is set in the slot 121, it is supplied with power and is connected to the control device 16 of the component mounting machine 10 so as to be able to communicate with it.

[0033] 3-2. Feeding Mechanism 23 The feeder 20 includes a feeding mechanism 23 that feeds and moves the carrier tape 31 during component supply operations. The feeding mechanism 23 has a sprocket 231 rotatably supported on the feeder body 21. Teeth of the sprocket 231 protrude from grooves formed in the bottom plate of the tape transport path 215 and engage with feed holes formed at predetermined intervals in the carrier tape 31. The feeding mechanism 23 has an electric motor 232 that generates driving force that is transmitted to the sprocket 231 via a speed reducer (not shown). The motor 232 is capable of intermittent and continuous operation, and can be switched between forward and reverse rotation. The feeding mechanism 23 rotates the sprocket 231 using the motor 232 to feed and move the carrier tape 31.

[0034] 3-3. Tape guide 24 The feeder 20 includes a tape guide 24. The tape guide 24 is detachably mounted on the top of the feeder body 21. The tape guide 24 peels one widthwise end of the cover tape from the base tape that constitutes the carrier tape 31, opening cavities that individually house components. The opened cavities are transported to the supply position 216, exposing the housed components so that they can be picked up. The base tape is then discharged below the feeder 20 together with the cover tape that has passed above the tape guide 24.

[0035] 3-4. Reel Holding Unit 25 The feeder 20 includes a reel holding unit 25. The reel holding unit 25 replaceably holds a reel 30 around which a carrier tape 31 is wound. The reel holding unit 25 rotatably holds the outer periphery or the center of the reel 30. In this embodiment, the reel holding unit 25 prevents the reel 30 from slipping out of position by using an openable and closable holding cover.

[0036] 4. Feeder Storage System 50 A feeder storage system 50 according to an embodiment will be described with reference to FIGS. 4 and 5. In addition to storing feeders 20, the feeder storage system 50 automates or reduces the labor required for transport within the system, transport to and from the outside of the system, and the installation and removal of reels 30. The feeder storage system 50 is composed of a plurality of storage modules 51, a station 53, a feeder setup device 54, a transfer device 55, and a management control device 60. In this embodiment, as shown in FIGS. 4 and 5, the feeder storage system 50 includes a station 53, six storage modules 51, and a feeder setup device 54 arranged in a row.

[0037] 4-1. Storage Module 51 Each of the storage modules 51 is formed in a box shape that opens to the front, and has an upper first storage shelf 511 and a lower second storage shelf 512. Each of the first storage shelf 511 and the second storage shelf 512 has a plurality of slots aligned in the left-right direction. Each of the plurality of slots is formed in the same shape as the slot 121 of the component mounting machine 10, and is configured to be able to accommodate and store a feeder 20.

[0038] Each feeder 20 is stored occupying a number of slots according to its size. The first storage shelf 511 and the second storage shelf 512 have positioning holes into which the upper positioning pins 221 and the lower positioning pins 223 are fitted, and a receiving connector into which the connector 222 is automatically fitted. As a result, the feeders 20 stored in the first storage shelf 511 and the second storage shelf 512 are supplied with power and are connected to the management control device 60 so as to be able to communicate with them.

[0039] It should be noted that the number and arrangement of the storage modules 51 can be changed even after the feeder storage system 50 has begun operation, and multiple storage modules 51 may be arranged vertically. The size of the storage module 51 is not limited to the above description. In other words, only one large storage module having multiple storage shelves in the left-right and up-down directions may be used. Conversely, multiple small storage modules each having one storage shelf may be used.

[0040] 4-2. Station 53 As shown in FIGS. 4 and 5, the station 53 is arranged next to a series of storage modules 51. The front of the station 53 is aligned with the front of the storage module 51. An automated guided vehicle 70 arrives and departs from the station 53. The automated guided vehicle 70 transports a magazine 71 loaded thereon. The magazine 71 is used to improve the efficiency of the transport operation of the feeders 20 between the station 53 and the component mounting machine 10. The magazine 71 is formed in a box shape with at least one of the front and rear faces omitted. The magazine 71 has multiple storage positions lined up in the width direction, and stores multiple feeders 20 in a removable and retractable manner.

[0041] The magazine 71 is preferably formed to be approximately half the size of the X-direction width of the component supply device 12. In this way, by using two magazines 71, all of the feeders 20 equipped in the component supply device 12 can be completely replaced. To make the complete replacement efficient, the station 53 is provided with two departure and arrival positions for the automatic guided vehicle 70 to depart and arrive, and two placement positions for the magazines 71, which are arranged side by side on the left and right. The magazine 71 may also be formed to be approximately the full size, which is approximately the same as the width dimension of the component supply device 12, so that complete replacement can be achieved by using one magazine.

[0042] The magazine 71 is automatically transferred between the station 53 and the automated guided vehicle 70. A roller conveyor is provided on the automated guided vehicle 70 side as a loading / unloading device for transferring the magazine 71. However, the loading / unloading device may be provided on the station 53 side. The automated guided vehicle 70 travels, for example, along a travel path indicated by a path indicator tape (not shown), and transports the magazine 71 to a plurality of component mounting machines 10 or a buffer device 83 that constitutes the production line Ln. The automated guided vehicle 70 is one form of a transport device that transports the feeder 20 toward a transport target (a specified production line Ln, component mounting machine 10, or buffer device 83).

[0043] The automated guided vehicle 70 may employ a different travel method, such as detecting the surrounding conditions or predetermined signs to determine its current position and determine its travel route. The automated guided vehicle 70 may also be loaded with a plurality of individual feeders 20 without using the magazine 71. As an alternative form of the transport device, a belt conveyor may be used when the component mounting machine 10 is located away from the station 53, or an arm-type robot may be used when the component mounting machine 10 is located close to the station 53.

[0044] 4-3. Feeder Setup Device 54 As shown in FIGS. 4 and 5, the feeder setup device 54 is arranged alongside the series of storage modules 51. The feeder setup device 54 performs setup work for at least some models of feeders 20. In this embodiment, the feeder setup device 54 automatically performs the operation of attaching and detaching the reel 30 to and from a standard feeder 20. The operation of attaching and detaching the reel 30 to and from a large feeder 20 is performed by an operator, for example, in the setup area Rt. The feeder setup device 54 has a box-shaped housing 541 that is larger than the storage module 51. A right front face 542 on the front side of the housing 541 protrudes further forward than a left front face 543. The feeder setup device 54 is arranged so that the left front face 543 of the housing 541 is aligned in a straight line with the front face of the storage module 51.

[0045] A reel carry-in entrance 544 is provided on the right front surface 542 of the housing 541, and a feeder insertion opening 545 is provided on the left front surface 543. A reel carry-out exit (not shown) is provided on the rear surface of the housing 541. The operator inserts the reel 30 to be attached to the feeder 20 into the feeder setup device 54 through the reel carry-in entrance 544. The operator also removes the reel 30 removed from the feeder 20 from the reel carry-out exit.

[0046] 4-4. Transfer Device 55 The transfer device 55 inserts the feeder 20 into the magazine 71 placed on the station 53 and removes it in the opposite direction. The transfer device 55 also inserts the feeder 20, which is the target of the reel 30 attachment or detachment operation, into the feeder setup device 54 through the feeder insertion port 545. The transfer device 55 also removes the feeder 20, for which the attachment or detachment operation has been performed, from the feeder insertion port 545 to the outside.

[0047] The transfer device 55 moves left and right in front of the plurality of storage modules 51, stations 53, and the left front surface 543 of the feeder setup device 54 to transfer the feeders 20. The transfer device 55 is composed of a device main body 551, a pair of left and right intrusion monitoring sensors 552, a control unit (not shown), etc. The transfer device 55 has a movement mechanism, an elevator unit, a feeder operation unit, etc. (not shown).

[0048] The movement mechanism is composed of, for example, running wheels and a drive source. The running wheels run along running rails (not shown) or run on the floor surface. A servo motor or a pulse motor with good controllability is used as a drive source for rotating the running wheels. The lifting unit is provided inside the device main body 551 so that it can be raised and lowered. A ball screw feed mechanism or a linear motor mechanism is used as an elevation drive mechanism for driving the lifting unit. The feeder operation unit is provided in the lifting unit, holds the feeder 20 inside, and operates the feeder 20 in the forward and backward directions. A battery or a contactless power supply mechanism is used as a power source for the electrical components inside the device main body 551.

[0049] When the lifting unit is in the raised position, the feeder operation unit is located at the height of the upper first storage shelf 511 of the storage module 51 and operates to insert and remove feeders 20 into and from the first storage shelf 511. Furthermore, the feeder operation unit is located at the height of the magazine 71 placed on the station 53 and operates to insert and remove feeders 20 into and from the magazine 71. Furthermore, the feeder operation unit is located at the height of the feeder insertion opening 545 of the feeder setup device 54 and operates to insert and remove feeders 20 into and from the feeder insertion opening 545. Meanwhile, when the lifting unit is in the lowered position, the feeder operation unit is located at the height of the lower second storage shelf 512 of the storage module 51 and operates to insert and remove feeders 20 into and from the second storage shelf 512.

[0050] A pair of left and right intrusion monitoring sensors 552 are provided on the left and right sides of the lower front portion of the device main body 551. The intrusion monitoring sensors 552 detect an intruder that has entered the movement range of the transfer device 55 and output a detection signal to the control unit. Specifically, the intruder may be an operator or equipment such as a transport cart brought in by the operator. The intrusion monitoring sensors 552 may be a non-contact sensor that uses, for example, infrared rays or ultrasonic waves. The intrusion monitoring sensors 552 may also be arranged outside the transfer device 55, for example, on the front surface of the storage module 51.

[0051] The control unit (not shown) is configured using a computer device, and its location is not particularly limited. In response to commands from the management control device 60, the control unit controls the movement mechanism to move the transfer device 55, and controls the lifting drive mechanism and the feeder operation unit to insert and remove the feeder 20. Furthermore, the control unit suspends the movement of the transfer device 55 when an intrusion monitoring sensor 552 detects an intrusion, and resumes the movement of the transfer device 55 after the intrusion has left the movement range of the transfer device 55. The work of transporting the feeders 20, reels 30, and the like between the setup area Rt and the storage module 51 is performed by an operator using a transport cart or the like.

[0052] 4-5. Display Unit 56 A plurality of display units 56 are provided in the plurality of storage modules 51 and stations 53. In this embodiment, the plurality of display units 56 are an upper shelf display unit 561, a lower shelf display unit 562, a first departure / arrival display unit 563, and a second departure / arrival display unit 564. The upper shelf display unit 561 is located in the upper left corner of the front surface of the storage module 51. The lower shelf display unit 562 is located in the upper right corner of the front surface of the storage module 51. The first departure / arrival display unit 563 is located in the upper left corner of the front surface of the station 53. The second departure / arrival display unit 564 is located in the upper right corner of the front surface of the station 53.

[0053] The display unit 56 has a rectangular shape that is elongated in the horizontal direction, but may have other shapes. The upper shelf display unit 561 displays the first storage shelf 511 on the upper level, and the lower shelf display unit 562 displays the second storage shelf 512 on the lower level. The first departure / arrival display unit 563 displays the magazine 71 placed at the first departure / arrival position (left side of Figure 5) of the station 53 as the display unit, and the second departure / arrival display unit 564 displays the magazine 71 placed at the second departure / arrival position (right side of Figure 5). The upper shelf display unit 561, the lower shelf display unit 562, the first departure / arrival display unit 563, and the second departure / arrival display unit 564 are forms of display units that can distinguish between multiple display units.

[0054] In this embodiment, the display unit 56 uses an indicator lamp whose display color and display state (on, blinking, off) can be switched. Furthermore, the display unit 56 can display the storage module 51 as a display unit by displaying the same display color and the same display state. The display unit 56 is not limited to the indicator lamp described above, and may display any of graphic symbols, letters, and combinations thereof.

[0055] The display unit 56 displays the storage purpose of the feeder 20 accommodated for each display unit. Specifically, these displays assist the operator by guiding the range and position of the slots into which the feeder 20 is inserted or removed. The specific storage purpose indicated by the display on the display unit 56 is determined by the display request set by the operator. For example, when a specific storage module 51 is being used to temporarily store a feeder 20 to be used in a specific production, or when the feeder 20 is waiting to be transported by the automated guided vehicle 70 at the departure and arrival position of the station 53, the display unit 56 may display the production line Ln to which the feeder 20 will be subsequently transported as the transport target.

[0056] 4-6. Management Control Device 60 The management control device 60 is configured using a computer device, and its location is not particularly limited. The management control device 60 is equipped with an input device that accepts input operations from an operator. The management control device 60 is communicatively connected to a line management device 82 that manages the production line Ln. The line management device 82 transmits various data used in production (such as control programs and component data) to multiple substrate-related performing machines to instruct them to perform their work, and also manages the operating status of the substrate-related performing machines. The production line Ln can be configured in a variety of ways, and may include multiple lines.

[0057] The management control device 60 controls each component of the feeder storage system 50. More specifically, the management control device 60 communicates with the feeders 20 stored in the storage module 51 to acquire identification information (feeder ID). As a result, the management control device 60 manages the identification information of the feeders 20 by associating it with the slot in the storage module 51 that corresponds to the storage position of the feeder 20 or the slot in the magazine 71 placed on the station 53.

[0058] The management control device 60 also controls the reel attachment / detachment operation of the feeder setup device 54 using wired communication, and controls the transfer operation of the transfer device 55 using wireless communication. Furthermore, the management control device 60 cooperates with a transfer control unit (not shown) that controls the automated guided vehicle 70 to manage the transfer operation, loading and unloading operation, etc. of the automated guided vehicle 70. The management control device 60 also controls the display processing executed by the display unit 56.

[0059] The management control device 60 executes the transport process based on the transport plan M4. Specifically, the management control device 60 cooperates with the host computer 81 and the multiple production lines Ln to grasp the progress of production of various product boards according to the production plan M1, the remaining number of necessary parts, whether any errors have occurred, etc. The management control device 60 recognizes the status of the feeders 20 stored in the multiple storage modules 51 and stations 53, and executes the loading process. The management control device 60 then instructs the automated guided vehicle 70 to load and depart the magazine 71 at a predetermined timing so that a specific production line Ln does not run out of parts.

[0060] The above-described loading process is a process of loading feeders 20 onto automatic guided vehicle 70 based on transportation plan M4. In this embodiment, the loading process is executed in storage area Rs, which stores feeders 20 that are to be loaded with components and installed in component mounting machine 10. Storage area Rs includes feeders 20 that are to be loaded with components and installed in component mounting machine 10 as storage targets. The loading process also includes a process in which transfer device 55 transfers multiple feeders 20 from storage module 51 or feeder setup device 54 to magazine 71 placed on station 53, and a process in which magazine 71 containing multiple feeders 20 is loaded onto automatic guided vehicle 70.

[0061] By carrying out such a transport process, a magazine 71 containing a plurality of feeders 20 to be used in a mounting process scheduled to be executed is transported to a buffer device 83 on a predetermined production line Ln. Thereafter, the feeders 20 to be used are exchanged for used feeders 20 between the buffer device 83 and the plurality of component mounting machines 10. In this way, production continues by supplying feeders 20 to the component mounting machines 10 at appropriate times, and unnecessary feeders 20 are collected in the magazine 71 and returned to the setup area Rt or storage area Rs by the automatic guided vehicle 70.

[0062] 5. Detailed Configuration of Feeder Storage System 50 As described above, production of product boards proceeds according to production plan M1, and feeders 20 loaded with components are transported so that they are replenished to multiple component mounting machines 10 based on the production progress, product information M2, production information M3, and transport plan M4. However, in actual production, even though production is proceeding according to production plan M1, there are cases where components need to be replenished earlier than planned. Possible causes for this include the actual number of remaining components being lower than estimated, or the consumption of more components than planned due to an unforeseen event.

[0063] Furthermore, if there is a request to change the production sequence in the production plan M1 or if there is a request to interrupt the production of a type of product board that is not included in the production plan M1, it may be necessary to replenish the necessary parts to the target production line Ln. In such cases, it becomes necessary to carry out additional transport of feeders 20 to make up for the shortage, separate from the original transport plan M4 that transports feeders 20 to the target production line Ln. However, if it takes time to edit and reflect the transport plan M4, there is a risk that the transport of the necessary feeders 20 will be delayed, which will affect production.

[0064] Therefore, the feeder storage system 50 employs a configuration that can detect a specific feeder 20 that has been added to the feeder storage system 50 and simplify the process of adding the specific feeder 20 to the list of transport targets. Specifically, the feeder storage system 50 includes a detection unit 61 and an adjustment unit 63. This allows the feeder storage system 50 to maintain productivity in the production system Sy. The feeder storage system 50 may further include an acquisition unit 62. In this embodiment, the detection unit 61, the acquisition unit 62, and the adjustment unit 63 are incorporated into the management control device 60.

[0065] The detection unit 61 detects an additional feeder 20A that is a feeder 20 not included in the transfer plan M4 and that has been added to the transfer target Bt during execution of the mounting process based on the transfer plan M4. The additional feeder 20A is a feeder 20 that is not recorded as a feeder 20 to be transferred in the transfer plan M4 and is not scheduled for use in the initial transfer plan M4, but is a feeder 20 that has been added as a transfer target to one of the devices that make up the feeder storage system 50.

[0066] Various detection methods can be employed for the detection unit 61. In this embodiment, when a feeder 20 is placed in the storage module 51 or the station 53 in the storage area Rs by an operation other than the operation of the automated guided vehicle 70 and the transfer device 55, the detection unit 61 detects the feeder 20 as an additional feeder 20A. In other words, when a feeder 20 is set in the storage module 51 or the station 53 from outside, the detection unit 61 detects the feeder 20 as an additional feeder 20A.

[0067] Specifically, when a feeder 20 is manually placed in the storage area Rs by a worker (including an operator of the feeder management system), the detection unit 61 detects the feeder 20 as an additional feeder 20A. In addition, it is assumed that a feeder 20 that is not included in the transport plan M4 is set in a magazine 71 placed in the storage module 51 or station 53 by an AMR (autonomous mobile transport robot), and in such a case, the detection unit 61 detects the feeder 20 as an additional feeder 20.

[0068] It should be noted that a large feeder 20 that cannot be used by the feeder setup device 54 for the attachment / detachment operation of the reel 30 may be prepared by an operator in the off-site setup area Rt, and the large feeder 20 may be set in one of the storage modules 51. In such a case, the detection unit 61 recognizes that the large feeder 20 has been set, but determines that the feeder 20 is not an additional feeder 20A because it is recorded as a transport target in the transport plan M4. The detection unit 61 may also determine that a feeder 20 set in a specific area among the multiple storage modules 51 or a feeder 20 whose transport target Gt is unknown by the acquisition unit 62 (described later) is not an additional feeder 20A.

[0069] Furthermore, the detection unit 61 may have a detection target area preset. Specifically, in addition to detecting feeders 20 set in multiple storage modules 51 or stations 53, the detection target area may also include, for example, one or multiple magazines 71 placed in station 53. In the above case, when a feeder 20 is manually set in a magazine 71 placed in station 53 by an operator, the detection unit 61 detects the feeder 20 as an additional feeder 20A. On the other hand, even if a feeder 20 is manually set in the first storage shelf 511 or the second storage shelf 512 of multiple storage modules 51 by an operator, the detection unit 61 does not treat the feeder 20 as an additional feeder 20A so that the feeder 20 is not subject to priority transport. The detection target area by the detection unit 61 can be adjusted as appropriate by an operator, etc.

[0070] The detection unit 61 may also be configured to preset the setting method of the feeder 20 to be detected. Specifically, when a feeder 20 is set externally in the magazine 71 placed on the station 53, the detection unit 61 may determine whether the setting method was performed manually by an operator or by some other method (for example, an AMR operated outside the storage area Rs), and detect the feeder 20 as an additional feeder 20A only if the setting method was performed manually. On the other hand, if the setting method was not performed manually by an operator, the detection unit 61 moves the feeder 20 set in this manner to a predetermined position in the storage module 51 and does not treat the feeder 20 as an additional feeder 20A so that the feeder 20 is not subject to priority transport. The setting method of the feeder 20 to be detected by the detection unit 61 can be appropriately adjusted by an operator, etc.

[0071] 5-2. Acquisition Unit 62 The acquisition unit 62 acquires the transport target Gt of the additional feeder 20A. The acquisition unit 62 can employ various acquisition methods. In this embodiment, the acquisition unit 62 acquires the transport target Gt displayed on the display unit 56 corresponding to the storage area As in which the additional feeder 20A was detected as the transport target Gt of the additional feeder 20A. Here, the storage area As corresponds to the area capable of accommodating the feeder 20 in the first storage shelf 511, the second storage shelf 512 of the storage module 51, and the station 53 in a state in which the magazine 71 is placed at the departure and arrival position.

[0072] Furthermore, the display units 56 corresponding to the storage area As correspond to an upper shelf display unit 561, a lower shelf display unit 562, a first departure / arrival display unit 563, and a second departure / arrival display unit 564. For example, when predetermined feeders 20 are being collected from the storage module 51 by the transfer device 55 into the magazine 71 placed at the first departure / arrival position on the left side of the station 53, the first departure / arrival display unit 563 displays the production line Ln (for example, "Ln1") as the transfer target Gt.

[0073] If an operator manually sets a predetermined feeder 20 in such a magazine 71, the feeder 20 is detected as an additional feeder 20A by the detection unit 61, and the transfer target Gt (Ln1) of the additional feeder 20A is acquired by the acquisition unit 62. In other words, the operator can specify the transfer target Gt by setting the additional feeder 20A in the storage region As corresponding to the display unit 56 that displays the transfer target Gt of the additional feeder 20A brought into the storage area Rs.

[0074] In addition to the above, when the additional feeder 20A is detected, the acquisition unit 62 may accept input of the transfer target Gt of the additional feeder 20A and acquire the input result as the transfer target Gt. For example, the display unit 56 displays the storage purpose using the storage area As as a display unit, and therefore does not necessarily display the transfer target Gt. In such a case, the acquisition unit 62 may accept input of the transfer target Gt of the recognized additional feeder 20A, for example, from an input device installed in the storage area Rs or a terminal device carried by the worker. This allows the worker to specify the transfer target Gt of the additional feeder 20A.

[0075] Here, there are reasons why an operator may set a feeder 20 not included in the transport plan M4 in one of the devices of the feeder storage system 50 as an additional transport target. For example, as described above, there may be cases where the urgency of additional transport of the additional feeder 20A is relatively high because it is estimated that parts consumption is higher than expected and that parts will run out earlier than expected. There may also be cases where the urgency of additional transport of the additional feeder 20A is relatively low, such as when a spare feeder 20 is transported in advance to increase the margin of remaining parts on a specific production line Ln, taking into account past performance, etc.

[0076] Therefore, when accepting input of the transport target Gt, the acquisition unit 62 may also accept input of additional information Fd (see the upper part of FIG. 9 ) including the transport urgency Lr of the additional feeder 20A. Furthermore, when the display unit 56 simply displays a specific production line Ln, the operator can further input the detailed position Tc of the transport target Gt, such as which component mounting machine 10 on the production line Ln the transport should be made to and which slot 121 of the component mounting machine 10 the transport should be made to. In this way, the acquisition unit 62 may also accept input of the additional information Fd including the detailed position Tc of the transport target Gt.

[0077] 5-3. Adjustment Unit 63 When an additional feeder 20A is detected, the adjustment unit 63 adjusts the transport plan M4 so that the additional feeder 20A is given priority for transport. Here, when a feeder 20 loaded with a specified component needs to be replenished on a specified production line Ln or component mounting machine 10, it was necessary for an operator to transport the feeder 20 directly to the production line Ln, etc., or to edit the transport plan M4 so that the feeder 20 would be the target for transport by the automatic guided vehicle 70. In contrast, the adjustment unit 63 automatically adjusts the transport plan M4 when an additional feeder 20A is set while specifying a transport target Gt in the feeder storage system 50.

[0078] 6, the transport plan M4 indicates a transport target Gt (Ln1, Ln2, ...) for each of a plurality of transport objects Bt (FID011, FID012, ...), and indicates the execution order of a plurality of transport processes in which a plurality of feeders 20 having a common transport target Gt are stored in a magazine 71 (MG01, MG02, ...), the magazine 71 is loaded onto the automatic guided vehicle 70, and then the feeders 20 are transported to the transport target Gt. The adjustment unit 63 adjusts the transport plan M4 as described above, so that the additional feeder 20A is preferentially transported.

[0079] When the additional feeder 20A is detected, the adjustment unit 63 may execute an adjustment process in which a transport process including the transport of the additional feeder 20A is inserted and the execution order of subsequent transport processes is delayed, with the transport of the additional feeder 20A being treated as a process that should uniformly be given the highest priority. On the other hand, taking into consideration the progress of the ongoing mounting process, the current position of the automated guided vehicle 70, the urgency of the additional feeder 20A, and the like, it may not always be best to give the transport of the additional feeder 20A the highest priority.

[0080] Therefore, when preparation for a first transfer process, which is a transfer process for a transfer target Gt different from the transfer target Gt of the additional feeder 20A, is underway, the adjustment unit 63 may set whether to interrupt the transfer process including the transfer of the additional feeder 20A before or after the first transfer process based on the progress of the preparation for the first transfer process. Additionally, the adjustment unit 63 determines the appropriate timing for transferring the additional feeder 20A based on the urgency of the additional feeder 20A determined by the operator and the grace period until the automated guided vehicle 70 can depart from the station 53, and executes adjustment processing of the transfer plan M4 based on this.

[0081] 6. Adjustment Processing of Transfer Plan M4 The adjustment processing of the transfer plan M4 by the feeder storage system 50 will be described with reference to Figures 8 and 9. The adjustment processing of the transfer plan M4 is executed when the detection unit 61 detects the additional feeder 20A. The acquisition unit 62 acquires the transfer target Gt of the additional feeder 20A (S11). In the acquisition processing of the transfer target Gt, for example, the transfer target Gt displayed on the display unit 56 corresponding to the storage area As in which the additional feeder 20A is set is acquired as the transfer target Gt of the additional feeder 20A. Furthermore, when the transfer target Gt or the like is input by the operator, the urgency of the additional transfer, etc. can also be acquired from this.

[0082] Specifically, it is assumed that the additional feeder 20A (FIDx01) is detected and its transport target Gt (Ln3) is acquired, as shown in the upper part of Fig. 9. At this time, if the urgency Lr and detailed position Tc of the additional feeder 20A are input as additional information Fd, they are recorded in association with the additional feeder 20A.

[0083] The adjustment unit 63 determines whether preparation for another transport process (first transport process) is in progress (S12). The above-mentioned "other transport process" refers to a transport process with a transport target Gt different from the transport target Gt of the additional feeder 20A, and is referred to here as the "first transport process." Furthermore, the "preparation" for the transport process includes the process of loading the feeder 20 into the magazine 71. If preparation for the first transport process is not in progress (S12: No), or even if preparation for the first transport process is in progress (S12: Yes), if the progress level is lower than a preset threshold value or the urgency Lr of the additional feeder 20A is "high" (S13: Yes), the adjustment unit 63 recognizes that transport by the additional feeder 20A should be performed with the highest priority.

[0084] 9, even if preparation for the first transfer process (n10) is underway, priority is given to the transfer of the additional feeder 20A (FIDx01). As a result, the additional feeder 20A is stored in the current magazine 71 (Mg10) placed in the station 53 (S15). Furthermore, in order to improve the efficiency of the transfer process including the additional feeder 20A, the adjustment unit 63 stores in the magazine 71 (Mg10) the feeders 20 having the same transfer target Gt as the additional feeder 20A, and if the magazine 71 contains any unnecessary feeders 20, removes those feeders 20 and transfers them to the storage module 51 (S16).

[0085] After preparation for the additional transport process (n12) is complete, transport including the additional feeder 20A is started (S17). As a result, as shown in the lower right of Figure 9, the transport plan M4 is adjusted so that the transport process (n12) that has the same transport target Gt (Ln3) as the additional feeder 20A and was scheduled to be executed is executed with the highest priority. The first transport process (n10) and the like are moved down in order so that they are executed sequentially after the transport process (n12) including the additional feeder 20A.

[0086] On the other hand, if preparation for the first conveying process (n10) is underway (S12: Yes), the progress of the preparation is higher than the threshold, and the urgency Lr of the additional feeder 20A is not "high" (S13: No), the adjustment unit 63 recognizes that the first conveying process (n10) should be prioritized over conveying the additional feeder 20A, and that conveying the additional feeder 20A should be executed thereafter. Therefore, the adjustment unit 63 waits until preparation for the first conveying process (n10) is complete (S14).

[0087] Thereafter, when another magazine 71 (Mg11) is placed on station 53, it becomes the current magazine 71 and accommodates additional feeder 20A (FIDx01), as shown by the bold frame on the lower left side of Figure 9 (S15). At this time, the adjustment unit 63 adjusts the order of the transport process based on the transport target Gt in order to improve the efficiency of the transport process, as described above. As a result, feeders 20 with the same transport target Gt as additional feeder 20A are accommodated in magazine 71 (Mg11), and if that magazine 71 contains any unnecessary feeders 20, those feeders 20 are removed and moved to storage module 51 (S16).

[0088] After preparation for the additional transport process (n12) is complete, transport including the additional feeder 20A is started (S17). As a result, as shown in the lower left of Figure 9, the transport plan M4 is adjusted so that the transport process (n12) that has the same transport target Gt (Ln3) as the additional feeder 20A and was scheduled to be executed is executed after the first transport process (n10). The other transport processes (n11) are moved down in order so that they are executed after the transport process (n12) including the additional feeder 20A.

[0089] With this configuration, if an additional feeder 20A is detected during execution of a mounting process based on the transport plan M4, the transport plan M4 is adjusted so that the additional feeder 20A is transported with priority. This makes it possible to add the additional feeder 20A to the transport targets without requiring an operator to edit or reflect the transport plan M4. This makes it possible to maintain productivity.

[0090] 7. Modifications of the Embodiment In the embodiment, the detection unit 61, acquisition unit 62, and adjustment unit 63 are configured to be incorporated into the management control device 60. However, some or all of the detection unit 61, acquisition unit 62, and adjustment unit 63 may be incorporated into an external device (such as a host computer 81) of the management control device 60.

[0091] 10: component mounting machine, 20: feeder (transport object), 20A: additional feeder, 30: reel, 50: feeder storage system, 51: storage module, 511: first storage shelf (storage area), 512: second storage shelf (storage area), 53: station (storage area), 54: feeder setup device, 55: transfer device, 56: display unit, 561: upper shelf display unit, 562: lower shelf display unit, 563: first departure / arrival display unit, 564: second departure / arrival display unit, 60: management control device, 61: detection unit, 62: acquisition unit, 63: adjustment unit, 70: automatic guided vehicle (guideline vehicle), 71: magazine, 81: host computer, 82: line management device, 83: buffer device, 84: loader, 91: board, M1: production plan, M2: product information, M3: Production information, M4: Transportation plan, Bt: Transportation object, Gt: Transportation target, Fd: Additional information, Lr: Urgency, Tc: Detailed location, Sy: Production system, Ln: Production line, Rt: Setup area, Rs: Storage area

Claims

1. A feeder storage system comprising: a detection unit that detects an additional feeder that is not included in a predetermined transport plan and has been added to a transport object during a loading process in which a feeder that supplies components is loaded onto a transport vehicle that transports the transport object to a production line that includes a component mounting machine based on the predetermined transport plan; and an adjustment unit that, when the additional feeder is detected, adjusts the transport plan so that the additional feeder is given priority for transport.

2. A feeder storage system according to claim 1, wherein the mounting process is performed in a storage area for storing the feeders that are loaded with components and are to be installed in the component mounting machine.

3. The feeder storage system of claim 2, further comprising: storage modules arranged in the storage area and each holding a plurality of the feeders; a station arranged in the storage area and transferring the feeders to and from the transport vehicle; and a transfer device that transfers the feeders between the storage modules and the station.

4. A feeder storage system as described in claim 3, wherein the detection unit detects the feeder as the additional feeder when the feeder is placed at the station in the storage area by an operation other than the operation of the transport vehicle and the transfer device.

5. A feeder storage system according to any one of claims 2 to 4, wherein the detection unit detects the feeder as the additional feeder when the feeder is manually placed in the station by an operator.

6. A feeder storage system as described in any one of claims 1 to 4, wherein the transport plan indicates a transport target for each of the multiple transport objects, and further comprises an acquisition unit that acquires the transport target of the additional feeder, and the adjustment unit adjusts the transport plan so that the additional feeder is transported with priority to the transport target.

7. A feeder storage system as described in claim 6, wherein a plurality of said production lines are provided in a production area for producing product substrates, and said transport plan indicates one of said plurality of said production lines as the transport target for each of said plurality of transport objects.

8. A feeder storage system as described in claim 6, further comprising a plurality of display units that display the transport target for each storage area of ​​the plurality of feeders stored, and the acquisition unit acquires the transport target displayed on the display unit corresponding to the storage area in which the additional feeder is detected as the transport target of the additional feeder.

9. The feeder storage system of claim 6, wherein the acquisition unit, when the additional feeder is detected, accepts input of the transport target of the additional feeder and acquires the input result as the transport target.

10. A feeder storage system as described in claim 9, wherein when accepting input of the transport target, the acquisition unit also accepts input of additional information including at least one of the urgency of transporting the additional feeder and the detailed location of the transport target.

11. A feeder storage system as described in any one of claims 1 to 4, wherein the transport plan is generated in advance based on a production plan indicating the type, number to be produced, and production sequence of the product boards to be produced by a production line composed of a plurality of the component mounting machines that produces product boards, product information indicating the type and quantity of the components required to produce the product boards, and production information indicating the required time for the mounting process performed by the component mounting machines.

12. The feeder storage system described in claim 11, wherein the transport plan indicates a transport target for each of the multiple transport objects, and indicates the execution order of multiple transport processes in which multiple feeders having the same transport target are stored in a magazine, the magazine is loaded onto the transport vehicle, and then the feeders are transported to the transport target, and the adjustment unit interrupts the transport process including the transport of the additional feeder and executes an adjustment process to delay the execution order of the subsequent transport processes.

13. The feeder storage system of claim 12, wherein when preparations for a first conveying process, which is a conveying process for a conveying target different from the conveying target of the additional feeder, are in progress, the adjustment unit sets whether the conveying process including the conveying of the additional feeder will be inserted before or after the first conveying process based on the degree of progress of preparations for the first conveying process.

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