Feeder storage system

Abstract

This feeder storage system comprises: a storage module in which a plurality of stages of storage shelves for storing a component feeder for supplying a component to be mounted on a substrate are provided in the vertical direction, the component feeder being detachably mounted on a component mounting machine; a departure / arrival station which is disposed side by side with the storage module and at which a transport device for transporting the component feeder toward the component mounting machine or a production line of a substrate product configured to include the component mounting machine departs / arrives; a setting unit which sets the storage shelf of a specific stage of at least one storage module as an access area to be accessed by an operator and sets the storage shelf not set as the access area as a non-access area not to be accessed by the operator; and a transfer device which transfers the component feeder between the storage module and the departure / arrival station and between the access area and the non-access area.

Description

Feeder Storage System

[0001] This specification relates to a feeder storage system for storing component feeders that are interchangeably equipped on a component mounter.

[0002] Technologies for mass-producing board products by performing on-board operations on a board with a circuit pattern formed thereon have become widespread. Furthermore, it has become common to arrange a plurality of types of on-board operation machines side by side to form a production line for board products. A representative example of an on-board operation machine is a component mounter that mounts components on a board. Many component mounters are equipped with component feeders that can be attached and detached. As a general-purpose component feeder, a tape feeder that uses a carrier tape containing a plurality of components is frequently used. It is common to configure multiple component feeders to be installed on a component mounter and collect them in a storage area or the like for temporary storage. One technical example regarding the storage of this type of component feeder is disclosed in Patent Document 1.

[0003] Patent Document 1 discloses a storage facility (storage shelf) having a plurality of storage sections in the vertical direction (Claim 2, Paragraph 0032, FIG. 5), and separately stores a tape feeder (component feeder) to be installed on a component mounter and a tape feeder recovered from the component mounter in different storage sections (Claim 14, Paragraph 0089), and further stores a plurality of tape feeders side by side in a plurality of storage positions in the storage section in the order of use (Paragraph 0090). According to this, when replacing a plurality of tape feeders with a component mounter, it is only necessary to convey the tape feeders grouped in one storage section, so that the setup replacement is made more efficient and conveyance errors are suppressed (Paragraph 0092).

[0004] International Publication No. 2024 / 157370

[0005] Incidentally, in the technical example of Patent Document 1, it is preferable that multiple parts feeders that transport parts to the parts mounting machine can be gathered into a single storage shelf. However, there is a risk that the operator may be confused about which storage shelf to insert the set-up parts feeders into, or from which storage shelf to remove the parts feeders that have been recovered from the parts mounting machine. In addition, if the storage shelves are crowded, it becomes difficult for the operator to insert and remove the parts feeders, reducing work efficiency.

[0006] Therefore, the problem to be solved in this specification is to provide a feeder storage system that allows an operator to easily identify the storage shelf to which the parts feeder insertion and removal operation will be performed, and that facilitates the operator's insertion and removal of the parts feeder.

[0007] This specification discloses a feeder storage system comprising: a storage module having multiple vertically arranged storage shelves for storing component feeders that are detachably mounted on a component mounting machine and supply components to be mounted on a circuit board; a departure / arrival station arranged alongside the storage module and for which a transport device that transports the component feeders to the component mounting machine or a production line for circuit board products comprising the component mounting machine departs and arrives; a setting unit that sets the storage shelves of a specific stage of at least one of the storage modules as an access area accessible to an operator, and sets the storage shelves that are not set as an access area as an inaccessible area not accessible to an operator; and a transport device that transports the component feeders between the storage module and the departure / arrival station, and between the access area and the inaccessible area.

[0008] Furthermore, this specification discloses the technical idea of ​​changing "the feeder storage system described in claim 1" to "the feeder storage system described in any one of claims 1-3" in claim 4 of the original application; the technical idea of ​​changing "the feeder storage system described in claim 5" to "the feeder storage system described in any one of claims 5-8" in claim 9 of the original application; the technical idea of ​​changing "the feeder storage system described in claim 5" to "the feeder storage system described in any one of claims 5-9" in claim 10 of the original application; the technical idea of ​​changing "the feeder storage system described in any one of claims 1-4" to "the feeder storage system described in any one of claims 1-10" in claim 11 of the original application; and the technical idea of ​​changing "the feeder storage system described in any one of claims 1-4" to "the feeder storage system described in any one of claims 1-11" in claim 12 of the original application.

[0009] In the disclosed feeder storage system, storage shelves at specific levels are designated as access areas, and other storage shelves are designated as non-access areas. This allows workers to easily identify the storage shelves in the access areas that are the target of parts feeder insertion and removal operations. Furthermore, the transfer device moves parts feeders from the access areas to the non-access areas, creating more space in the storage shelves of the access areas, thereby facilitating the insertion and removal of parts feeders by workers.

[0010] This is a schematic plan view showing an example configuration of a component mounting machine equipped with a tape feeder, a form of component feeder, which can be detachably attached. This is a side view of the tape feeder. This is an explanatory diagram schematically showing an example configuration of a feeder storage system and related configurations in an embodiment for storing tape feeders. This is a schematic front view showing a storage module. This is a front view showing an example of areas set in multiple storage modules. This is a diagram of a list showing multiple types of tasks performed by a transfer device and their corresponding execution priorities. This is a diagram of an operation flow explaining the operations related to the transport preparation task and inter-area transfer task of the feeder storage system. This is a diagram of an operation flow explaining the operations related to the recovery processing task of the feeder storage system. This is an explanatory diagram schematically showing an example configuration of a modified form of a production line for substrate products. This is a diagram of an operation flow explaining the operations related to the transport preparation task and inter-area transfer task in the modified form.

[0011] 1. Example Configuration of Component Mounting Machine 9 The feeder storage system 1 of this embodiment stores tape feeders (8A, 8B) that are detachably mounted on the component mounting machine 9. First, an example configuration of the component mounting machine 9 will be explained with reference to Figure 1. The component mounting machine 9 performs mounting work to produce circuit board products by mounting components onto a circuit board K. In Figure 1, the horizontal direction from the left to the right of the paper is the X-axis direction for transporting the circuit board K, the horizontal direction from the bottom (front) to the top (rear) of the paper is the Y-axis direction, and the vertical direction is the Z-axis direction. The component mounting machine 9 is configured by assembling a circuit board transport device 92, a component supply device 93, a component transfer device 94, and a control device (not shown) on a base 91.

[0012] The substrate transport device 92 consists of a pair of guide rails 921, a pair of transport conveyors (not shown), and a clamping mechanism 922. The pair of guide rails 921 extend in the X-axis direction across the center of the upper surface of the base 91 and are assembled to the base 91 parallel to each other. The pair of transport conveyors rotate along the guide rails 921 with two parallel sides of the substrate K placed on them, transporting the substrate K to a stopping position near the center of the base 91. The clamping mechanism 922 is located below the stopping position and pushes up the substrate K and clamps it between itself and the guide rails 921 to position it. After the component mounting work by the component transfer device 94 is completed, the clamping mechanism 922 releases the substrate K, and the transport conveyors carry the substrate K out of the machine.

[0013] The parts supply device 93 is positioned at the front of the upper surface of the base 91 in the Y-axis direction. The parts supply device 93 consists of a pallet stand 931 and a plurality of tape feeders (8A, 8B), etc. The pallet stand 931 is formed in a roughly rectangular shape in plan view. The pallet stand 931 may be formed in a trolley shape with casters for movement and be detachable from the base 91. The pallet stand 931 has a plurality of slots 932 that are spaced apart from each other and extend parallel to each other in the Y-axis direction. The plurality of tape feeders (8A, 8B) are each detachably inserted into the slots 932 and installed. Each of the tape feeders (8A, 8B) supplies parts using a carrier tape CT containing a plurality of parts.

[0014] There are several types of tape feeders (8A, 8B). In this embodiment, at least the standard type and wide-width type described below are used in combination. The standard type tape feeder 8A has a standard width dimension in the X-axis direction and is installed in one slot 932. The wide-width type tape feeder 8B has a larger width dimension in the X-axis direction than the standard type tape feeder 8A and is installed across two slots 932. In practice, it is possible to use three or more types of tape feeders in combination based on width dimensions alone, and it is also possible to use multiple types of tape feeders with different internal structures in combination.

[0015] The component transfer device 94 consists of a Y-axis moving body 941, an X-axis moving body 942, a mounting head 943, a nozzle tool 944, a plurality of suction nozzles 95, a substrate camera 946, and a component camera 947. The Y-axis moving body 941 and the X-axis moving body 942 constitute an X-Y drive mechanism that moves the mounting head 943 in two horizontal directions. A rotationally symmetric nozzle tool 944 is provided below the mounting head 943. The nozzle tool 944 is equipped with a plurality of suction nozzles 95 (20 in the example in Figure 1) that can be automatically replaced. The suction nozzles 95 perform the mounting operation by picking up components supplied from tape feeders (8A, 8B) and mounting them on the substrate K at the stopping position. The mounting head 943 may be equipped with a plurality of suction nozzles 95 arranged in a line or in a grid pattern. In addition, component mounting devices other than the suction nozzles 95, such as chucks for gripping components, may be automatically replaced on the mounting head 943.

[0016] The substrate camera 946 is mounted facing downwards on the X-axis moving body 942, alongside the mounting head 943. The substrate camera 946 captures position marks on the substrate K from above to accurately determine the stopping position of the substrate K. The component camera 947 is mounted facing upwards between the substrate transport device 92 and the component supply device 93. The component camera 947 captures and recognizes components held by the suction nozzle 95 from below while the mounting head 943 is moving from the component supply device 93 to the substrate K. This allows for the determination of whether the component is correct or incorrect, and also detects the position and orientation of the component relative to the suction nozzle 95, which is then reflected in the mounting operation. Examples of substrate cameras 946 and component cameras 947 include digital imaging devices having image sensors such as CCD (Charge Coupled Device) and CMOS (Complementary Metal Oxide Semiconductor).

[0017] The control device, not shown in the figure, is mounted on the base 91, and its position is not particularly limited. The control device is configured using a computer. The control device may also be configured with multiple CPUs distributed within the machine and connected via communication. Based on mounting work data created for each type of substrate product (substrate K), the control device controls the substrate transport device 92, the component supply device 93, and the component transfer device 94 to proceed with the component mounting work. The mounting work data includes material information such as the type and shape of the substrate K and components, coordinate information indicating the suction position and mounting position of the components, and correspondence information that associates the type of component with the type of tape feeder (8A, 8B) used.

[0018] 2. Example of Tape Feeder 8A Configuration Next, an example of the configuration of tape feeder 8A will be explained with reference to Figure 2. Tape feeders (8A, 8B) are a form of parts feeder that detachably holds a reel RL on which a carrier tape CT is wound. The configurations of the two types of tape feeders (8A, 8B) are similar to each other except for the difference in width dimensions, so here we will explain using the standard type tape feeder 8A as an example. Tape feeder 8A pulls the carrier tape CT from the reel RL and feeds it in a predetermined feeding direction, supplying parts at a predetermined supply position 816. In Figure 2, the direction from left to right is the feeding direction of the carrier tape CT, with the left side being the upstream side and the right side being the downstream side. Tape feeder 8A is constructed to be thin in the width direction by assembling various components onto a feeder body 81 including side plates. The tape feeder 8A consists of the feeder body 81, a feeding mechanism 83, a tape peeling mechanism 84, a tape guide 85, a feeder control unit 86, and an indicator lamp 87, among other components.

[0019] The feeder body 81 includes a detachable rail 811, a reel holding section 812, an opening / closing plate 813, a tape transport path 815, and a locking mechanism 818. The detachable rail 811 is provided on the bottom surface of the feeder body 81 and is inserted into a slot 932 when attached to the component mounting machine 9. An upper positioning pin 821, a connector 822, and a lower positioning pin 823 are provided sequentially from the upper to the lower side of the downstream end face of the feeder body 81. The upper positioning pin 821 and the lower positioning pin 823 engage with positioning holes provided in the pallet base 931 to position the tape feeder 8A. When the tape feeder 8A is positioned, the connector 822 automatically engages with the receiving connector provided in the pallet base 931. As a result, power is supplied to the tape feeder 8A, and the feeder control unit 86 is connected to the control device of the component mounting machine 9.

[0020] The reel holding section 812 is composed of multiple frame members that form a large circular internal space approximately in the center of the feeder body 81. The reel holding section 812 rotatably holds the reel RL in the internal space. The opening / closing plate 813, which covers the majority of the lower part of the internal space, is pivotably supported by a support section 914 provided near the attachment / detachment rail 811. The opening / closing plate 813 swings downward around the support section 914 and opens, allowing the reel RL to be attached and detached.

[0021] The tape transport path 815 corresponds to a passage that transports the carrier tape CT in a predetermined feeding direction. The tape transport path 815 is formed in a rectangular cylindrical shape using, for example, a bottom plate, two side plates, and a top plate, and a part of the cylindrical shape may be omitted. The tape transport path 815 starts at a position close to the reel RL, extends diagonally upward in the downstream direction, extends generally horizontally in the downstream direction from a certain point, and ends at the upper part of the downstream end of the feeder body 81. A predetermined supply position 816 that opens upward is defined near the end of the tape transport path 815.

[0022] A tape peeling mechanism 84 is provided upstream of the supply position 816 of the tape transport path 815. The tape peeling mechanism 84 is part of a detachable tape guide 85. The tape guide 85 constitutes part of the tape transport path 815, and the supply position 816 is provided therein. The tape guide 85 is biased downward by a biasing member (not shown), which presses the carrier tape CT against the bottom plate of the tape transport path 815. This ensures that the teeth of the sprocket 831 (described later) engage securely with the feed holes of the carrier tape CT, and stabilizes the relative height of the carrier tape CT with respect to the tape peeling mechanism 84.

[0023] The tape transport path 815 guides the carrier tape CT, which has been pulled out from the reel RL, to the tape peeling mechanism 84. The tape peeling mechanism 84 puts the carrier tape CT in a partially peeled state, enabling the removal of parts. The tape transport path 815 guides the partially peeled carrier tape CT to the supply position 816. At the supply position 816, the carrier tape CT from which the parts have been removed is bent downwards in the feeding direction and discharged downwards.

[0024] The locking mechanism 818 is located at the upper upstream side of the feeder body 81. The locking mechanism 818 consists of a locking pin 81A, a locking operating member 81B, and a locking sensor 81C. The locking pin 81A is a cylindrical member that is held by the feeder body 81 so as to be able to move up and down. The locking pin 81A is normally pushed up by a biasing spring (not shown in numerals) to enter a locked state, restricting the removal operation of the tape feeder 8A. The locking operating member 81B is a Y-shaped member with a pivot point in the center. When the locking operating member 81B is driven to swing automatically or manually, it drives the locking pin 81A downward to release the locked state and allow the removal operation of the tape feeder 8A. The locking sensor 81C detects the position of the locking pin 81A, i.e., whether it is in a locked state or not, and outputs it to the feeder control unit 86.

[0025] The feeding mechanism 83 feeds the carrier tape CT at a constant pitch and supplies components sequentially at the supply position 816. The feeding mechanism 83 consists of a sprocket 831, a servo motor (not shown), and a gear mechanism. The sprocket 831 is positioned below the tape transport path 815 and approximately directly below the tape guide 85, and is rotatably supported by the feeder body 81. The teeth of the sprocket 831 protrude from grooves formed in the bottom plate of the tape transport path 815 and engage with the feed holes of the carrier tape CT. The sprocket 831 is rotationally driven by the servo motor via the gear mechanism to feed the carrier tape CT in the feeding direction. Furthermore, the sprocket 831 is driven to rotate in the reverse direction when the servo motor reverses, returning the carrier tape CT in the reverse direction.

[0026] The feeder control unit 86 is located at the lower upstream side of the feeder body 81, and its position is not limited. The feeder control unit 86 communicates with the control device of the component mounting machine 9 via the connector 822. The feeder control unit 86 controls the feeding mechanism 83 to carry out the component supply operation according to commands from the control device. The feeder control unit 86 also monitors the status of the lock mechanism 818. The feeder control unit 86 stores identification information to identify individual tape feeders 8A and transmits the identification information in response to requests from other control units.

[0027] The indicator lamp 87 is located near the bottom of the upstream end face of the feeder body 81. The indicator lamp 87 can display three or more states by combining illumination, blinking, and being off. Furthermore, the indicator lamp 87 can display four or more states by variably switching the blinking interval or changing the illumination color. Multiple indicator lamps 87 may also be provided. The feeder control unit 86 controls the illumination of the indicator lamp 87 to display various states such as operating status, adjustment status, and error status.

[0028] 3. Configuration of the Feeder Storage System 1 of the Embodiment Next, the configuration of the feeder storage system 1 of the embodiment will be described with reference to Figures 3-6. The feeder storage system 1 is provided in common to multiple production lines 9A that produce circuit board products. The feeder storage system 1 not only stores the tape feeders (8A, 8B) equipped on the component mounting machines 9 of the production line 9A, but also automates or reduces the labor involved in transporting them within the system, transporting them to and from the outside of the system, and attaching and detaching the reels RL. As shown in Figure 3, the feeder storage system 1 consists of six storage modules (21-26), a departure / arrival station 3, a reel attachment / detachment device 4, a transport device 5, and a control device 6, etc.

[0029] Of the six storage modules (21-26), the leftmost one is referred to as the first storage module 21, and the subsequent modules to the right are referred to as the second storage module 22 through the fifth storage module 25, with the rightmost one being referred to as the sixth storage module 26. As shown in Figure 4, each of the six storage modules (21-26) is formed in a box shape that opens to the front. Furthermore, each of the storage modules (21-26) has multiple rows of storage shelves (27, 28) arranged vertically. In the illustrated example, the storage modules (21-26) are provided with an upper storage shelf 27 and a lower storage shelf 28. Each of the storage shelves (27, 28) has multiple storage slots 29 arranged horizontally. In the illustrated example, there are 14 storage slots 29, but there may be many more.

[0030] Each of the multiple storage slots 29 is capable of storing tape feeders (8A, 8B) by inserting a detachable rail 811 into it. Each tape feeder (8A, 8B) is stored in such a way that it occupies a number of storage slots 29 corresponding to its width. Each storage slot 29 has a positioning hole into which an upper positioning pin 821 and a lower positioning pin 823 engage, and a receiving connector into which a connector 822 automatically mates. Therefore, when tape feeders (8A, 8B) are stored in the storage slots 29, power is supplied to them, and the feeder control unit 86 is connected to the control device 6 via communication.

[0031] Each of the storage modules (21-26) has a shelf indicator lamp 2A positioned above each of the storage shelves (27, 28). The shelf indicator lamp 2A distinguishes and displays items set for each storage shelf (27, 28) by using the illuminated and unilluminated states with changing display colors. The storage modules (21-26) also have a slot indicator lamp 2B positioned above each of the storage slots 29. The slot indicator lamp 2B distinguishes and displays items set for each storage slot 29 or for each tape feeder (8A, 8B) by using the illuminated and unilluminated states. For example, the slot indicator lamp 2B is illuminated when it points to a storage slot 29 that is the target of the tape feeder (8A, 8B) insertion and removal operation performed by the operator. Alternatively, instead of the slot indicator lamp 2B, the indicator lamps 87 of the tape feeders (8A, 8B) stored in the storage slots 29 may be used for display.

[0032] The size of the storage modules (21-26) is not limited to the above description. In other words, the number of storage modules (21-26) is not limited to six. Also, the storage modules (21-26) may have three or more storage shelves in the vertical direction. Depending on the height of the storage shelves (27-28), the workability of inserting and removing tape feeders (8A-8B) by an operator accessing the storage shelves (27-28) changes.

[0033] More specifically, the upper storage shelf 27 is close to the height of the worker's hands, resulting in good workability and high work reliability for insertion and removal operations. The upper storage shelf 27 can be rephrased as the second storage shelf 27 from the bottom. On the other hand, the lower storage shelf 28 requires the worker to bend or crouch to perform insertion and removal operations, resulting in poor workability and reduced work reliability. Furthermore, if there are three or more storage shelves, the storage shelves from the third shelf from the bottom require the worker to reach upwards or stretch to perform insertion and removal operations, resulting in poor workability and reduced work reliability. The optimal height for a storage shelf 27 with good workability may vary depending on the height dimensions of the tape feeders (8A, 8B) and the structure of the storage modules (21-26). For example, if the height dimensions of the tape feeders (8A, 8B) are reduced through a design change, the third storage shelf from the bottom may become the most workable. The height and workability of the storage shelves (27, 28) are taken into consideration when the setting unit 61, described later, performs its settings.

[0034] As shown in Figure 3, the arrival / departure station 3 is located to the left of the first storage module 21. The front of the arrival / departure station 3 is in line with the front of the storage modules (21-26). The arrival / departure station 3 is the station where the automated guided vehicle 7 arrives and departs. The automated guided vehicle 7 carries the feeder magazine 71. The feeder magazine 71 is used to improve the efficiency of the transport operation of the tape feeders (8A, 8B) between the arrival / departure station 3 and the parts mounting machine 9. The feeder magazine 71 is formed in a box shape with at least one of its front and rear sides omitted. The feeder magazine 71 has multiple storage positions arranged in the width direction inside to accommodate multiple tape feeders (8A, 8B).

[0035] It is preferable that the feeder magazine 71 be formed to approximately half the width dimension of the pallet base 931 in the X-axis direction. This allows for the complete replacement of all tape feeders (8A, 8B) equipped on the pallet base 931 by using two feeder magazines 71. Alternatively, the feeder magazine 71 may be formed to the full size, approximately equal to the width dimension of the pallet base 931, allowing for complete replacement with the use of a single magazine. To streamline the transport and loading / unloading of the feeder magazines 71, the arrival / departure station 3 is provided with two arrival / departure positions for the automated guided vehicle 7 and two placement positions for the feeder magazines 71, arranged side by side.

[0036] The operation of inserting tape feeders (8A, 8B) into the feeder magazine 71 placed on the arrival / departure station 3, and the operation of removing them in the reverse direction, are performed by the transfer device 5. The feeder magazine 71 is automatically transferred between the arrival / departure station 3 and the automated guided vehicle 7. A roller conveyor device is provided on the side of the automated guided vehicle 7 as a loading and unloading device for the transfer. However, it is not limited to this, and the loading and unloading device may be provided on the side of the arrival / departure station 3.

[0037] The automated guided vehicle (AGV) 7 travels, for example, along a route indicated on a route indicator tape 75, and transports the feeder magazine 71 to a buffer station 96 located on the production line 9A. The AGV 7 may also travel according to a different travel method, for example, a method that determines its current position and travel route by detecting the surrounding conditions and predetermined signs. Alternatively, the AGV 7 may transport multiple individual tape feeders (8A, 8B) instead of using the feeder magazine 71. The AGV 7 is one form of transport device that transports parts feeders toward the parts mounting machine 9 or the production line 9A. As an alternative form of transport device, a belt conveyor device can be used when the transport distance is relatively long, and an arm-type robot can be used when the transport distance is short.

[0038] The reel attachment / detachment device 4 is positioned to the right of the sixth storage module 26, as shown in Figure 3. The reel attachment / detachment device 4 is designed for a standard type tape feeder 8A and automatically performs the attachment and detachment operations (loading and removal) of reels RL. The reel attachment / detachment device 4 has a box-shaped housing 41 that is larger than the storage modules (21-26). The front right front 411 of the housing 41 protrudes further forward than the left front 412. The reel attachment / detachment device 4 is positioned so that the left front 412 of the housing 41 is in a straight line with the front of the storage modules (21-26).

[0039] A reel loading port 413 is provided on the right front 411 of the housing 41, and a feeder insertion port 414 is provided on the left front 412. A reel discharge port (not shown) is provided on the rear of the housing 41. The operator loads the reel RL to be loaded into the tape feeder 8A into the reel loading / unloading device 4 through the reel loading port 413. The operator also removes the reel RL removed from the tape feeder 8A from the reel discharge port at the rear. Meanwhile, the transfer device 5 inserts the tape feeder 8A, which is the target of the loading and unloading operations, into the reel loading / unloading device 4 through the feeder insertion port 414. The transfer device 5 also removes the tape feeder 8A, which has undergone at least one of the loading and unloading operations, from the feeder insertion port 414 to the outside.

[0040] For reference, the applicant has disclosed a detailed configuration example of the reel attachment / detachment device 4 in International Publication No. 2023 / 286209. Note that the attachment / detachment of reels RL for tape feeders other than the standard type (such as the wide-type tape feeder 8B) is performed by an operator in the setup area 9M. The setup area 9M is provided in common for multiple production lines 9A.

[0041] As shown by arrow T1 in Figure 3, the transfer device 5 moves left and right in front of the left front 412 of the loading / unloading station 3, the storage modules (21-26), and the reel attachment / detachment device 4, to transfer the tape feeders (8A, 8B) between them. The transfer device 5 also transfers the tape feeders (8A, 8B) between the upper storage shelf 27 and the lower storage shelf 28. When not performing a transfer operation, the transfer device 5 remains stationary in front of the loading / unloading station 3 to avoid interfering with workers accessing the storage modules (21-26). The transfer device 5 consists of a device body 51, a pair of left and right intrusion monitoring sensors 52, and a control unit (not shown). The device body 51 has a moving mechanism (not shown), a lifting unit, and a feeder operation unit.

[0042] The moving mechanism of the main body 51 of the device consists of, for example, wheels and a drive source. The wheels travel along a rail (not shown) or on the floor. A servo motor or pulse motor with good controllability is used as the drive source for rotating the wheels. The lifting section is provided inside the main body 51 so as to be able to move up and down. A ball screw feed mechanism or a linear motor mechanism is used as the lifting drive mechanism for the lifting section. The feeder operation section is provided in the lifting section. The feeder operation section holds the tape feeders (8A, 8B) inside and also performs insertion and removal operations for the tape feeders (8A, 8B). The feeder operation section may be a multi-type that can operate multiple tape feeders (8A, 8B) simultaneously, or a single-type that operates the tape feeders (8A, 8B) one by one. A battery or a contactless power supply mechanism is used as the power source for the electrical components inside the main body 51 of the device.

[0043] When the lifting / lowering unit is at the raised position, the feeder operation unit is positioned at the height of the upper storage shelf 27 of the storage modules (21 - 26), and performs the insertion / extraction operation of the tape feeders (8A, 8B) to / from the storage shelf 27. Further, the feeder operation unit is positioned at the height of the feeder magazine 71 placed on the loading / unloading station 3 and the feeder insertion port 414 of the reel attachment / detachment device 4, and performs the putting-in / taking-out operation of the tape feeders (8A, 8B) to / from these. On the other hand, when the lifting / lowering unit is at the lowered position, the feeder operation unit is positioned at the height of the lower storage shelf 28 of the storage modules (21 - 26), and performs the insertion / extraction operation of the tape feeders (8A, 8B) to / from the storage shelf 28.

[0044] A pair of left and right intrusion monitoring sensors 52 are respectively provided on the left and right of the lower front part of the apparatus main body 51. The intrusion monitoring sensor 52 detects an intruding object that has entered the moving range of the transfer device 5, and outputs a detection signal to the control unit. The control unit stops the moving mechanism of the apparatus main body 51 based on the detection signal, and ensures safety while avoiding a collision with the intruding object. Specifically, the intruding object corresponds to an operator or equipment such as a cart brought in by the operator. The intrusion monitoring sensor 52 is, for example, a non-contact type sensor using infrared rays or ultrasonic waves. Note that the intrusion monitoring sensor 52 may be arranged outside the transfer device 5, for example, on the front surface of the storage modules (21 - 26).

[0045] When the transfer device 5 performs transfer between the upper storage shelf 27, the loading / unloading station 3, and the reel attachment / detachment device 4, the operation of the lifting / lowering unit is unnecessary, and when using the lower storage shelf 28, the operation of the lifting / lowering unit is required. For this reason, the transfer device 5 can improve the transfer efficiency by preferentially using the upper storage shelf 27 rather than the lower storage shelf 28. For reference, the applicant of the present application has disclosed a detailed configuration example of the transfer device 5 in International Publication No. 2022 / 118380.

[0046] The control device 6 shown in FIG. 3 is configured using a computer device, and its installation location is not particularly limited. The control device 6 is communicatively connected to a line management device 9B that manages the production line 9A of substrate products. The production line 9A is configured by arranging, in addition to three component mounting machines 9, a buffer station 96, a solder printer (not shown), a printing inspection machine, a substrate appearance inspection machine, and a reflow machine. The line configuration and the number of lines of the production line 9A can be changed.

[0047] The buffer station 96 is a part that relays tape feeders (8A, 8B) between the storage modules (21 - 26) and the three component mounting machines 9, and can temporarily store the tape feeders (8A, 8B). The transfer of the tape feeders (8A, 8B) between the buffer station 96 and the three component mounting machines 9 is performed by a line-side transfer device 97. The line-side transfer device 97 has the same configuration as the transfer device 5 and is controlled by the line management device 9B.

[0048] The line management device 9B stores in a memory and appropriately updates the production plan 9C for substrate products of multiple varieties. The line management device 9B manages the production progress status of the production line 9A based on the production plan 9C. The line management device 9B creates a usage schedule list LU that summarizes the types of components required by the three component mounting machines 9, the types of tape feeders (8A, 8B), and their conveyance plans based on the production plan 9C and the production progress status. The conveyance plan includes identification information of a plurality of tape feeders (8A, 8B) for which the automatic transport vehicle 7 plans to perform conveyance, information identifying the buffer station 96 as the conveyance destination (line identification information of the production line 9A), and information on the conveyance time. The usage schedule list LU also includes a collection schedule list that summarizes the tape feeders (8A, 8B) for which usage at the component mounting machine 9 is scheduled to end.

[0049] The line management device 9B presents the planned usage list LU to the worker and transmits the planned usage list LU to the control device 6. Based on the planned usage list LU, the worker retrieves the tape feeder 8A from the equipment warehouse 9N, transports it to the storage module (21-26), and inserts it into the storage shelf 27 in the insertion area AA1 (details described later). The worker also transports the reel RL to be loaded into the tape feeder 8A to the reel loading port 413 of the reel loading / unloading device 4. Furthermore, based on the planned usage list LU, the worker loads the reel RL into the tape feeder 8B in the setup area 9M and sets it up. The worker then transports the set up tape feeder 8B to the storage module (21-26) and inserts it into the storage shelf 27 in the insertion area AA1. Meanwhile, the control device 6 controls the loading operation of reels RL onto tape feeder 8A by the reel attachment / detachment device 4, and the transport operation of tape feeders (8A, 8B) by the transport device 5, based on the received usage list LU.

[0050] The control device 6 controls each component of the feeder storage system 1. More specifically, the control device 6 acquires identification information from the feeder control unit 86 of the tape feeders (8A, 8B) stored in the storage modules (21-26). Based on this, the control device 6 associates the identification information of the tape feeders (8A, 8B) with the position of the storage slot 29 to manage the storage status. The control device 6 also controls the illumination of the shelf indicator lamp 2A and slot indicator lamp 2B of the storage modules (21-26). Furthermore, the control device 6 controls the attachment and detachment operation of the reel attachment / detachment device 4 using wired communication, and controls the transport operation of the transport device 5 and the execution of tasks described later using wireless communication. The control device 6 also works in conjunction with the transport control unit (not shown) that controls the automated guided vehicle 7 to manage the transport operation and loading / unloading operation of the automated guided vehicle 7.

[0051] The control device 6 has two functional units, namely a setting unit 61 and a transport control unit 62, which are mainly configured using software. The setting unit 61 sets and modifies the settings for the six storage modules (21-26). The transport control unit 62 controls the execution of multiple types of tasks performed by the transport device 5. The detailed functions of the two functional units will be explained in separate chapters.

[0052] 4. Setting of Areas by the Setting Unit 61 The setting unit 61 sets a storage shelf 27 in a specific row of at least one storage module (21-26) as an access area AA, which is accessed by the worker. The setting unit 61 also sets storage shelves (27, 28) that are not set as access area AA as a non-access area AN, which is not accessed by the worker. In this embodiment, the setting unit 61 sets a storage shelf 27 in a specific row where the workability of inserting and removing tape feeders (8A, 8B) performed by the worker by accessing the storage shelf (27, 28) is good as an access area AA. Specifically, as described above, the setting unit 61 sets some or all of the multiple storage shelves 27 in the upper row (second row from the bottom) where the workability is good as an access area AA. The access area AA is substantially determined by the worker's selection operation, and the setting unit 61 makes the setting based on the selection operation.

[0053] In the example shown in Figure 5, as indicated by the dashed line, the upper storage shelves 27 of the fifth storage module 25 and the upper storage shelves 27 of the sixth storage module 26 are set to access area AA. On the other hand, the lower storage shelves 28 of the fifth storage module 25 and the lower storage shelves 28 of the sixth storage module 26 are set to non-access area AN. Furthermore, the upper storage shelves 27 and lower storage shelves 28 of the first storage module 21, the second storage module 22, the third storage module 23, and the fourth storage module 24 are each set to non-access area AN.

[0054] Furthermore, the setting unit 61 can be configured to change the access area AA. For example, consider a case where the two storage shelves 27 within the aforementioned access area AA are nearing full capacity. In this case, the setting unit 61 can change, for example, the upper storage shelf 27 of the third storage module 23 and the upper storage shelf 27 of the fourth storage module 24 from the non-access area AN to the access area AA.

[0055] Furthermore, the setting unit 61 can set a portion of the multiple storage shelves 27 within the access area AA as an insertion area AA1 where an operator inserts tape feeders (8A, 8B). In this case, the setting unit 61 sets the remaining portion of the multiple storage shelves 27 within the access area AA as an extraction area AA2 where an operator removes tape feeders (8A, 8B). In the example shown in Figure 5, the upper storage shelf 27 of the sixth storage module 26 is set as an insertion area AA1, and the upper storage shelf 27 of the fifth storage module 25 is set as an extraction area AA2. The operation of removing the tape feeders (8A, 8B) from the insertion area AA1 is not performed by an operator, but by the transfer device 5. The operation of inserting the tape feeders (8A, 8B) into the extraction area AA2 is not performed by an operator, but by the transfer device 5.

[0056] The storage rack 27 in access area AA is permitted to change settings between insertion area AA1 and extraction area AA2 only if there are no tape feeders (8A, 8B) stored in it. Conversely, when changing settings between insertion area AA1 and extraction area AA2 in storage rack 27, all tape feeders (8A, 8B) must be removed from that storage rack 27. This prevents confusion between insertion and extraction operations caused by setting changes.

[0057] The setting unit 61 controls the illumination of the shelf indicator lamps 2A to indicate the set area to the operator. In the example shown in Figure 5, the shelf indicator lamp 2A of the storage shelf 27 set in the insertion area AA1 is illuminated in blue, and the shelf indicator lamp 2A of the storage shelf 27 set in the extraction area AA2 is illuminated in green. In addition, the shelf indicator lamps 2A of the ten storage shelves (27, 28) set in the non-access area AN are turned off. The shelf indicator lamps 2A may also be used for purposes other than indicating an area. For example, the shelf indicator lamps 2A may illuminate in red to indicate an abnormal state of the storage shelves (27, 28).

[0058] The aforementioned area settings and displays allow the operator to easily distinguish between the storage shelves 27 in the insertion area AA1, the storage shelves 27 in the extraction area AA2, and the storage shelves (27, 28) in the non-accessible area AN. The non-accessible area AN corresponds to a storage area where, under normal circumstances, the insertion and removal of tape feeders (8A, 8B) is not performed by the operator, but rather by the transfer device 5.

[0059] As shown by the dashed arrow M1 in Figure 3, the worker transports the tape feeder 8A, which has been taken out of the equipment warehouse 9N, and the tape feeder 8B, which has been set up in the setup area 9M, to the sixth storage module 26 and inserts them into the storage shelf 27 in the insertion area AA1. Also, as shown by the dashed arrow M2, the worker retrieves the tape feeder 8A, which has had its reel RL removed by the reel attachment / detachment device 4 and is stored in the storage shelf 27 in the extraction area AA2 of the fifth storage module 25, and returns it to the equipment warehouse 9N. The worker also retrieves the tape feeder 8B, which is stored in the storage shelf 27 in the extraction area AA2, transports it to the setup area 9M, and removes its reel RL.

[0060] Furthermore, the control device 6 can illuminate one of the slot indicator lamps 2B in the insertion area AA1 to instruct the operator to insert the tape feeders (8A, 8B) into the storage slot 29. In addition, the control device 6 can illuminate the slot indicator lamps 2B in the extraction area AA2 to selectively display tape feeders (8A, 8B) that have been stored for an extended period and request their extraction.

[0061] 5. Task Execution Control of the Transport Device 5 by the Transport Control Unit 62 The Transport Control Unit 62 controls the Transport Device 5 according to execution requests directly or indirectly indicated in the Usage List LU, execution requests input from the Transport Control Unit of the Automated Guided Vehicle 7 and the worker, and other execution requests. As shown in Figure 6, the Transport Control Unit 62 sets execution priorities for several types of tasks performed by the Transport Device 5. The retreat task with execution priority 1 (highest) is the task in which the Transport Device 5 retreats from the Automated Guided Vehicle 7. In other words, from just before the Automated Guided Vehicle 7 arrives at the departure / arrival station 3 until it departs, the Transport Control Unit 62 controls the Transport Device 5 to retreat from the front position of the departure / arrival station 3, including the waiting position. The waiting task with execution priority 2 is the task in which the Transport Device 5 waits at the waiting position. In other words, when a worker accesses the access area AA, the Transport Control Unit 62 controls the Transport Device 5 to return to the waiting position even if it is in the middle of a transport operation to avoid interfering with the worker. Evacuation tasks and standby tasks are executed immediately upon receiving an execution request via interrupt control, even if a task with an execution priority of 3 or lower is in the middle of execution.

[0062] The reel loading / unloading support task with an execution priority of 3 consists of the task of loading the tape feeder 8A into the reel loading / unloading device 4 and the task of unloading the tape feeder 8A from the reel loading / unloading device 4. There are three types of tasks with an execution priority of 4: the startup task, the transport preparation task, and the retrieval processing task. The startup task is the task of checking the storage status of the tape feeders (8A, 8B) when the control device 6 is started up and transporting the tape feeders (8A, 8B) as needed. The transport preparation task is the task of transporting the prepared tape feeders (8A, 8B) to the feeder magazine 71 of the arrival / departure station 3 to prepare for transport. As a preprocessing step for the transport preparation task, the reel loading / unloading support task is executed as needed, and the reel RL is loaded onto the tape feeder 8A in the reel loading / unloading device 4.

[0063] The retrieval processing task is for processing tape feeders (8A, 8B) that have been retrieved from the parts mounting machine 9 to the arrival / departure station 3 by the automated guided vehicle 7. The retrieval processing task is performed when the feeder magazine 71 is transported from the buffer station 96 to the arrival / departure station 3. Tasks with execution priorities of 3 and 4 do not undergo interrupt processing; the next task starts only after the task currently being executed has finished. In addition, if multiple execution requests for tasks with execution priorities of 3 and 4 overlap, they are executed in order of highest execution priority and earliest execution request.

[0064] When the transfer control unit 62 controls the execution of the transfer preparation task and the retrieval processing task, it controls the destination of the tape feeders (8A, 8B) based on the usage schedule list LU received from the line management device 9B. In other words, the transfer control unit 62 controls the destination of the tape feeders (8A, 8B) based on at least one of the production plan and the production progress status of the substrate products. Furthermore, the transfer control unit 62 performs control that takes into account the type of tape feeder (8A, 8B).

[0065] To elaborate on the transport preparation task, the transport control unit 62 first controls the transport device 5 to transport a standard type tape feeder 8A, which is scheduled for use but does not have a reel RL loaded, from the insertion area AA1 to the reel loading / unloading device 4 in the pre-processing reel loading / unloading support task. Next, the control device 6 controls the reel loading / unloading device 4 to load a reel RL into the tape feeder 8A. The transport control unit 62 also controls the transport device 5 to transport the tape feeder 8A, which has been loaded with a reel RL and set up, to the non-access area AN for temporary storage. Then, when it is time to transport, the transport control unit 62 controls the transport device 5 to transport the tape feeder 8A, which has been set up by the reel loading / unloading device 4, as well as the tape feeder 8B, which has been set up by the operator and brought into the insertion area AA1, to the feeder magazine 71 of the arrival / departure station 3.

[0066] To elaborate on the retrieval process, the transfer control unit 62 controls the transfer device 5 to transfer any tape feeders 8A that have been retrieved at the arrival / departure station 3 and are scheduled for use in their current state to the non-access area AN. The transfer control unit 62 also controls the transfer device 5 to transfer any tape feeders 8A that are not scheduled for use in their current state to the reel attachment / detachment device 4. Next, the control device 6 controls the reel attachment / detachment device 4 to replace the old used reel RL with a new reel RL if the tape feeder 8A is scheduled for use with a reel change, or to remove the used reel RL if the tape feeder 8A is not scheduled for use. Then, the transfer control unit 62 controls the transfer device 5 to transfer any tape feeders 8A with a new reel RL loaded to the non-access area AN, and transfer any tape feeders 8A that do not have a new reel RL loaded to the removal area AA2. Furthermore, the transfer control unit 62 controls the transfer device 5 to transfer the tape feeder 8B, which has been collected at the arrival / departure station 3, to the non-access area AN if it is scheduled for use, and to the extraction area AA2 if it is not scheduled for use.

[0067] An inter-area transfer task with an execution priority of 5 (the lowest) is a task in which the worker transfers tape feeders (8A, 8B) inserted into storage shelf 27 in insertion area AA1 to storage shelf (27, 28) in non-access area AN. For example, in the inter-area transfer task shown by the dashed arrow M3 in Figure 5, the tape feeders (8A, 8B) inserted into the upper storage shelf 27 (insertion area AA1) of the sixth storage module 26 are transferred to the lower storage shelf 28 (non-access area AN). The inter-area transfer task is not essential, as it allows for more space in the storage shelf 27 of insertion area AA1, facilitating subsequent insertion of tape feeders (8A, 8B) by the worker. Therefore, the execution priority of the inter-area transfer task can be set lower compared to essential transport preparation tasks and retrieval processing tasks.

[0068] The transfer control unit 62 determines whether or not to have the transfer device 5 perform an inter-area transfer task based on the usage schedule list LU. Specifically, the transfer control unit 62 controls the transfer device 5 to perform an inter-area transfer task for tape feeders (8A, 8B) that are scheduled for use in the parts mounting machine 9 but are not scheduled for the next transport by the automated guided vehicle 7. In other words, if tape feeders (8A, 8B) inserted into insertion area AA1 are scheduled for use but are not scheduled for the next transport, they may be stored in insertion area AA1 for a long time, potentially making it difficult to insert other tape feeders (8A, 8B). For this reason, the transfer control unit 62 controls the transfer device 5 to move the tape feeders (8A, 8B) to an inaccessible area AN (for example, the lower storage shelf 28).

[0069] Furthermore, the transport control unit 62 controls the tape feeders (8A, 8B) that are scheduled for use and are scheduled for the next transport by the automated guided vehicle 7 to remain in the insertion area AA1. In other words, tape feeders (8A, 8B) inserted in the insertion area AA1 are unlikely to overlap with the insertion work of other tape feeders (8A, 8B) if they are to be transported to the departure / arrival station 3 in the near future, so they are left in the insertion area AA1 to avoid the hassle of transporting them twice. The transport control unit 62 also controls the tape feeders (8A, 8B) that are not scheduled for use to remain in the removal area AA2.

[0070] The transfer control unit 62 prefers to have the transfer device 5 perform inter-area transfer tasks during downtime when the automated guided vehicle 7 is not transporting tape feeders (8A, 8B). In other words, the transfer control unit 62 does not need to carry out transfer preparation tasks during downtime when the automated guided vehicle 7 is not operating, so it can use the resulting downtime to have the transfer device 5 perform inter-area transfer tasks, thereby improving the overall execution efficiency of multiple types of tasks. There are two types of downtime. The first type of downtime is the time when the buffer station 96 is unable to receive tape feeders (8A, 8B) from the automated guided vehicle 7. For example, the time when the line-side transfer device 97 or an operator is accessing the buffer station 96 is the first type of downtime.

[0071] The second type of downtime is the period during which the quantity requirement for tape feeders (8A, 8B) transported by the automated guided vehicle (AGV) 7 is not met. In other words, the second type of downtime is the period during which the quantity of tape feeders (8A, 8B) stored in the storage modules (21-26) is excessively insufficient compared to the quantity of tape feeders (8A, 8B) that the AGV 7 is scheduled to transport. To clarify, if the AGV 7 transports only a small number of tape feeders (8A, 8B, etc.) (one or two, for example), the transport operations become frequent, and the feeder magazine 71 cannot be effectively utilized, resulting in reduced transport efficiency. As a countermeasure, the quantity requirement is set so that, in each transport operation, the AGV transports more than the specified quantity of tape feeders (8A, 8B), while allowing for a slight shortage from the quantity to be transported. The quantity requirement is defined using the absolute number or ratio of tape feeders (8A, 8B).

[0072] To illustrate with a specific example, let's assume that the capacity of the feeder magazine 71 is equivalent to 29 standard tape feeders 8A. In this case, the absolute quantity requirement is defined as, for example, 20 or more tape feeders 8A. Naturally, tape feeder 8B will be counted as two tape feeders 8A. The ratio quantity requirement is defined as, for example, 80% or more of the number of tape feeders (8A, 8B) to be transported. To give a specific numerical example, if the number of tape feeders (8A, 8B) to be transported this time is 26 (it is rare to use up the capacity), the quantity requirement will be 21 (≒ 26 x 80%) or more. The quantity requirement can be met when the reel attachment / detachment device 4 loads reel RL onto tape feeder 8A, or when the operator inserts the prepared tape feeder 8B into the insertion area AA1, thereby eliminating the second type of downtime.

[0073] 6. Operation of the Feeder Storage System 1 Next, the operation of the feeder storage system 1 will be explained with reference to the operation flows in Figures 7 and 8. Figure 7 mainly explains the operations related to the transport preparation task and the inter-area transfer task. As a prerequisite, we assume a system configuration in which the number of automated guided vehicles 7 and feeder magazines 71 is constrained by the number of lines in the production line 9A, for example, a system configuration in which automated guided vehicles 7 and feeder magazines 71 are reused in multiple production lines 9A. In addition, we assume that the setting unit 61 has already set the area and that empty feeder magazines 71 are prepared at the departure / arrival station 3.

[0074] In step S1 of Figure 7, the control device 6 acquires the usage schedule list LU for each of the multiple production lines 9A. In the next step S2, the transfer control unit 62 checks the status of the buffer stations 96 of each production line 9A and determines whether or not it falls within the first type of downtime period. If all buffer stations 96 are in the first type of downtime period ("NG"), the operation flow proceeds to step S10; otherwise, the operation flow proceeds to step S3 ("OK"). In step S3, the transfer control unit 62 determines whether the storage status of the storage modules (21-26) meets the quantity requirements for the transport plans included in the usage schedule list LU of each production line 9A. If none of the quantity requirements for each of the multiple production lines 9A are met, the operation flow proceeds to step S10; otherwise, the operation flow proceeds to step S4.

[0075] In step S4, the transport control unit 62 determines the buffer station 96 of the production line 9A to which the automated guided vehicle 7 will be transported, and the tape feeders (8A, 8B) to be transported to the buffer station 96. If, as determined in steps S2 and S3, multiple buffer stations 96 remain as candidates for the transport destination, the transport control unit 62 compares the transport plans of each production line 9A and selects the buffer station 96 with the earliest transport time as the transport destination.

[0076] In the next step S5, the transport control unit 62 controls the execution of a transport preparation task targeting the buffer station 96 determined as the transport destination. As a result, the transport device 5 transports the set up tape feeders (8A, 8B) from the storage module (21-26) to the feeder magazine 71 of the departure / arrival station 3 to prepare for transport. In the next step S6, the transport control unit 62 reconfirms whether the buffer station 96 determined as the transport destination has entered a first type of downtime period.

[0077] In step S7, if the status is "OK" and has not changed, the control device 6 causes the automated guided vehicle 7 to perform a transport operation. When the transport operation is completed and the feeder magazine 71 arrives at the buffer station 96, the usage list LU for the production line 9A is updated. After this, the operation flow is executed again from step S1. Also, in step S6, if the status is "NG" and it has changed to a first type of downtime period, the operation flow branches to step S8. In step S8, the transport control unit 62 checks the status of buffer stations 96 other than those determined to be transport destinations. If there are buffer stations 96 that do not fall within a first type of downtime period, the operation flow proceeds to step S9.

[0078] In step S9, the transport control unit 62 cancels the initial buffer station 96 that was determined as the destination in step S4, and determines a buffer station 96 that does not fall within the first type of downtime period in step S8 as a new destination candidate. Furthermore, the transport control unit 62 cancels the transport preparations made in step S5. In other words, the transport control unit 62 controls the transport device 5 to return the tape feeders (8A, 8B) that were temporarily stored in the feeder magazine 71 of the arrival / departure station 3 to the storage module (21-26) and store them again. After this, the operation flow is executed again from step S3. In this way, if the transport operation to the initially determined buffer station 96 becomes impossible, the transport control unit 62 can prioritize the transport operation to another buffer station 96, thereby efficiently using the limited number of automated guided vehicles 7 and feeder magazine 71.

[0079] Furthermore, if step S8 indicates "NG" (no buffer stations 96 that are not in the first type of downtime period), the operation flow proceeds to step S6. In this case, the automated guided vehicle 7 cannot perform a transport operation to any buffer station 96 at this time. The transport control unit 62 determines the buffer station 96 whose first type of downtime period is resolved the earliest as the transport destination and executes step S7, or steps S9 and S3 onward.

[0080] Furthermore, if the automated guided vehicle 7 cannot perform transport operations due to a Type 1 or Type 2 downtime, the operation flow proceeds to step S10. In step S10, the transport control unit 62 determines whether or not there are tape feeders (8A, 8B) that are the target of the inter-area transport task. If there are, in step S11, the transport control unit 62 controls the execution of the inter-area transport task. As a result, the transport device 5 transports the tape feeders (8A, 8B) in the insertion area AA1 that are the target of the transport to the non-access area AN (for example, the lower storage shelf 28). If there are multiple tape feeders (8A, 8B) that are the target of the inter-area transport task, the transport device 5 transports the multiple tape feeders (8A, 8B) simultaneously or in multiple separate transports. If there are no tape feeders (8A, 8B) that are the target of the inter-area transport task in step S10, and after the execution of step S11, the operation flow returns to step S1. In the returned step S1, the control device 6 considers the possibility that the usage list LU may have been updated over time, and as a precaution, retrieves the usage list LU again.

[0081] Next, Figure 8 illustrates the operations related to the retrieval process task. In step S21 of Figure 8, the automated guided vehicle 7 transports a feeder magazine 71 containing multiple tape feeders (8A, 8B) from one of the buffer stations 96 to the arrival / departure station 3. This corresponds to the retrieval of tape feeders (8A, 8B) that have finished being used in the component mounting machine 9 to the arrival / departure station 3. In the next step, S22, the transport control unit 62 focuses on one of the tape feeders (8A, 8B) in the feeder magazine 71 placed on the arrival / departure station 3.

[0082] In the next step S23, the transfer control unit 62 proceeds to step S27 if the tape feeder of interest (8A, 8B) is of the standard type, and proceeds to step S24 if it is not of the standard type. In step S24, the transfer control unit 62 determines whether or not there is a plan to use the tape feeder other than the standard type (for example, the wide-type tape feeder 8B). If there is a plan to use it, in step S25, the transfer control unit 62 controls the transfer device 5 to transfer the tape feeder to the non-access area AN for temporary storage. If there is no plan to use it, in step S26, the transfer control unit 62 controls the transfer device 5 to transfer the tape feeder to the extraction area AA2.

[0083] Steps S27 to S30 are operations applicable to a standard type tape feeder 8A. In step S27, the transfer control unit 62 determines whether or not there is a plan to use the tape feeder 8A in its current state. If there is a plan to use it, the operation flow proceeds to step S25. For example, the tape feeder 8A may have carrier tape CTs remaining at the end of production of the first type of substrate product, and may not be used in the production of the second type, but may be planned to be used in its current state in the production of the third type or later. In this case, the operation flow proceeds to step S25.

[0084] Furthermore, in step S28, if there are no plans to use the tape feeder 8A in its current state, the transfer control unit 62 determines whether or not there are plans to replace the reel RL of the tape feeder 8A. If there are plans to use it, in step S29, the transfer control unit 62 controls the transfer of the tape feeder 8A to the reel attachment / detachment device 4. The control device 6 then causes the reel attachment / detachment device 4 to replace the old and new reel RL. For example, the reel attachment / detachment device 4 removes the old reel RL, which has used up the carrier tape CT, from the tape feeder 8A and loads a new reel RL. After this, the operation flow proceeds to step S25. Also, in step S30, if there are no plans to replace the reel RL, the transfer control unit 62 controls the transfer of the tape feeder 8A to the reel attachment / detachment device 4. The control device 6 then causes the reel attachment / detachment device 4 to remove the reel RL. After this, the operation flow proceeds to step S26.

[0085] Ultimately, if the standard type tape feeder 8A is scheduled for use, in step S25 it is transported to the non-access area AN in a prepared state and temporarily stored. If the tape feeder 8A is not scheduled for use, in step S26 it is transported to the extraction area AA2 with the reel RL removed. After step S25 or step S26 is executed, the operation flow returns to step S22. The transport control unit 62 focuses on the next tape feeders (8A, 8B) and executes steps S23 onwards again. The operation flow ends when there are no more tape feeders (8A, 8B) left in the feeder magazine 71.

[0086] In the feeder storage system 1 of the embodiment described above, a portion of the storage shelves 27 at a specific level is set as the access area AA, and the remaining storage shelves (27, 28) are set as the non-access area AN. Furthermore, the access area AA is divided into the insertion area AA1 and the extraction area AA2. Therefore, the operator can easily identify the storage shelves 27 in the access area AA that are the target of the tape feeder (8A, 8B) insertion and extraction work. In addition, the transfer device 5 performs an inter-area transfer task to transfer the tape feeders (8A, 8B) in the insertion area AA1 to the non-access area AN, thereby allowing for more storage space in the storage shelves 27 of the insertion area AA1. Therefore, the tape feeder (8A, 8B) insertion work by the operator is made easier.

[0087] 7. Modified Configuration Next, a modified configuration of the substrate product production line 9E will be described with reference to Figures 9 and 10. In the modified configuration shown in Figure 9, the hardware configuration of the feeder storage system 1 remains unchanged. On the other hand, the production line 9E is modified to a configuration without a buffer station 96 and a line-side transfer device 97. The automated guided vehicle 7 transports the feeder magazine 71 between the departure / arrival station 3 and multiple component mounting machines 9 (transport destinations), and the number of transport destinations increases compared to the embodiment. In addition, the usage schedule list LU created by the line management device 9B is created individually for each of the multiple component mounting machines 9. Furthermore, the transport plan in the usage schedule list LU includes information that identifies the component mounting machine 9 that will be the transport destination, instead of information that identifies the buffer station 96.

[0088] In the modified configuration, a portion of the software of the transfer control unit 62 is changed, and the operation flow shown in Figure 7 is transformed as shown in Figure 10. Specifically, steps S1, S2, S4, S6, and S8 are transformed into steps S1A, S2A, S4A, S6A, and S8A, respectively. In short, several operations targeting the production line 9A or buffer station 96 in the embodiment are transformed into operations targeting each of the multiple component mounting machines 9 in the modified configuration. The operation and effects in the modified configuration are the same as in the embodiment, so a description is omitted.

[0089] 8. Application and Modification of the Embodiment The reel attachment / detachment device 4 may be omitted, and the attachment / detachment of the reel RL for the standard type tape feeder 8A may be performed by an operator in the setup area 9M. Conversely, the function of the reel attachment / detachment device 4 may be improved, and the attachment / detachment of the reel RL for all types of tape feeders may be performed automatically. In either form, the configuration and function of the embodiment can be applied. The reel attachment / detachment device 4 may also be replaced with a feeder support device. The feeder support device supports the tape feeders (8A, 8B) inserted by the transfer device 5 and opens the opening / closing plate 813 to assist the operator in attaching and detaching the reel RL.

[0090] Furthermore, the insertion area AA1 and the extraction area AA2 may be operated simply as the access area AA without distinction, allowing the operator to perform both insertion and extraction operations on the storage shelves 27 in the access area AA. In addition, the non-access area AN can be divided into multiple types of lower-level areas, and the shelf indicator lamps 2A can be modified to display these divisions. For example, multiple storage shelves (27, 28) in the non-access area AN may be divided into units corresponding to the production line 9A, allowing the operator to visually check the quantity of stored tape feeders (8A, 8B) (progress of preparation for transport) for each production line 9A.

[0091] Furthermore, in the operation flow of Figure 7, there may be cases where there is a surplus of automated guided vehicles 7 and feeder magazines 71. For example, it is possible that one or more automated guided vehicles 7 and a considerable number of feeder magazines 71 are exclusively allocated to each of the multiple production lines 9A. In this case, even if the first type of downtime period occurs in step S6, the automated guided vehicle 7 can wait with the feeder magazines 71 ready for transport loaded, and then perform the transport operation after the first type of downtime period has ended. Also, the parts feeder is not limited to tape feeders (8A, 8B), but may also be a stick feeder using a cylindrical stick containing multiple parts, or a bulk feeder that does not use a specific parts storage member. Various other applications and modifications are possible for the embodiment and its variations.

[0092] 1: Feeder storage system 21-26: Storage module 27, 28: Storage shelf 29: Storage slot 2A: Shelf indicator lamp 2B: Slot indicator lamp 3: Departure / arrival station 4: Reel attachment / detachment device 5: Transfer device 6: Control device 61: Setting unit 62: Transfer control unit 7: Automated guided vehicle 71: Feeder magazine 8A, 8B: Tape feeder 9: Parts mounting machine 96: Buffer station 97: Line-side transfer device 9A, 9E: Production line 9B: Line management device 9C: Production plan 9M: Setup area 9N: Equipment warehouse AA: Access area AA1: Insertion area AA2: Extraction area AN: Non-access area LU: Usage list CT: Carrier tape RL: Reel

Claims

1. A feeder storage system comprising: a storage module having multiple vertically arranged storage shelves for storing component feeders that are detachably mounted on a component mounting machine and supply components to be mounted on a circuit board; a station arranged alongside the storage module where a transport device that transports the component feeders to the component mounting machine or a production line for circuit board products comprising the component mounting machine arrives and departs; a setting unit that sets the storage shelves of a specific level of at least one of the storage modules as an access area accessible by an operator, and sets the storage shelves that are not set as an access area as an access area not accessible by an operator; and a transport device that transports the component feeders between the storage module and the station, and between the access area and the access area.

2. The feeder storage system according to claim 1, wherein the setting unit sets the storage shelf at a specific level in the access area to ensure good workability for the insertion and removal of the parts feeder performed by the worker accessing the storage shelf.

3. The feeder storage system according to claim 2, wherein the setting unit sets the second storage shelf from the bottom to the access area.

4. The feeder storage system according to claim 1, wherein the setting unit is configured to allow the access area to be changed, and the storage module has a display unit that indicates whether each of the multiple storage shelves is set to the access area or the non-access area.

5. The feeder storage system according to any one of claims 1-4, further comprising a control unit that determines whether or not to cause the transfer device to perform an inter-area transfer task, which involves transferring the component feeder inserted by the worker into the storage shelf in the access area to the storage shelf in the non-access area, based on at least one of the production plan and the production progress status of the substrate product.

6. The feeder storage system according to claim 5, wherein the control unit controls the transfer device to perform the inter-area transfer task of the parts feeders that are scheduled to be used by the parts mounting machine and are not scheduled to be transported by the transfer device in the next transport, and controls the parts feeders that are scheduled to be used and are scheduled to be transported by the transfer device, and the parts feeders that are not scheduled to be used, to remain in the access area.

7. The feeder storage system according to claim 6, wherein the control unit causes the transport device to perform the inter-area transport task during periods when the transport device is not transporting the parts feeder.

8. The feeder storage system according to claim 7, wherein the downtime is at least one of the time period during which the parts mounting machine or the production line is unable to receive the parts feeders, and the time period during which the quantity of parts feeders stored in the storage module is insufficient to meet the quantity requirements for the parts feeders to be transported by the transport device.

9. The feeder storage system according to claim 5, wherein the control unit sets execution priorities for multiple types of tasks performed by the transfer device, and sets the execution priority of the inter-area transfer task to the lowest.

10. The feeder storage system according to claim 5, wherein the control unit controls the transfer device to move the parts feeder, which has been recovered from the parts mounting machine to the departure / arrival station by the transfer device, to the non-access area if it is scheduled to be used in the parts mounting machine, and to move it to the access area if it is not scheduled to be used.

11. The feeder storage system according to any one of claims 1 to 4, wherein the setting unit sets a portion of the plurality of storage shelves in the access area as an insertion area for the worker to insert the parts feeder, and sets the remaining portion of the plurality of storage shelves as an extraction area for the worker to remove the parts feeder.

12. The feeder storage system according to any one of claims 1 to 4, wherein the parts feeder is a tape feeder that uses a carrier tape containing a plurality of parts, the feeder storage system comprises a reel attachment / detachment device arranged alongside the storage module or the departure / arrival station for attaching and detaching a reel on which the carrier tape is wound to the tape feeder, and the transfer device transfers the tape feeder between the storage module and the reel attachment / detachment device.

Images