Production system and conveyance preparation method

Abstract

This production system comprises: one or more mounting lines having a mounting device that mounts components by using a component supply unit; one or more warehouses that store the component supply unit outside the mounting line; and a transfer device that transfers the component supply unit inside the warehouse. The production system comprises a control unit that: when the warehouse is for a plurality of mounting lines, executes conveyance preparation control for a plurality of lines, which is for controlling the transfer device so as to gather, at a prescribed location inside the warehouse, the component supply unit that needs to be conveyed after confirming the state of the plurality of mounting lines and determining, as a conveyance destination, a mounting line that satisfies a prescribed condition; and when the warehouse is for a single mounting line, executes conveyance preparation control for a single line, which is for controlling the transfer device so as to gather, at a prescribed location, the component supply unit that needs to be conveyed using the mounting line as a conveyance destination without confirming the state of the mounting line.

Description

Production System and Conveyance Preparation Method

[0001] This specification discloses a production system and a conveyance preparation method.

[0002] Conventionally, a production system has been proposed that includes a mounting line equipped with a mounting device for mounting components, a warehouse for storing component supply units, and a transfer device for transferring component supply units within the warehouse (see, for example, Patent Document 1). In this system, after confirming that the mounting line is in an acceptable state where it can receive a component supply unit, conveyance preparation control is executed to control the transfer device to collect the component supply units that need to be conveyed to the mounting line at a predetermined location in the warehouse.

[0003] International Application No. 2023 / 38912

[0004] In the above-mentioned Patent Document 1, the conveyance preparation control is executed in the same manner regardless of whether the warehouse is for multiple mounting lines or for a single mounting line. However, in a warehouse for a single mounting line, if the mounting line is not in an acceptable state, the conveyance preparation control may be started after waiting for the mounting line to become acceptable, resulting in a long waiting time. Therefore, there is room for improvement in order to promptly convey the component supply units.

[0005] The main object of the present disclosure is to efficiently perform the conveyance preparation of component supply units in the warehouse regardless of whether the warehouse is for multiple mounting lines or for a single mounting line.

[0006] The present disclosure has adopted the following means to achieve the above main object.

[0007] The present disclosure provides a production system comprising: one or more mounting lines having mounting devices for mounting components using component supply units; one or more warehouses for storing the component supply units outside the mounting lines; and a transfer device for transferring the component supply units within the warehouses, wherein, when the warehouses are for multiple mounting lines, the system performs transport preparation control for multiple lines, which involves checking the status of the multiple mounting lines, determining a mounting line that satisfies predetermined conditions as the transport destination, and then controlling the transfer device to gather the component supply units that need to be transported at a predetermined location within the warehouse; and when the warehouses are for a single mounting line, the system performs transport preparation control for a single line, which involves controlling the transfer device to gather the component supply units that need to be transported at a predetermined location with the mounting line as the transport destination without checking the status of the mounting line.

[0008] In the production system disclosed herein, different transport preparation control is performed depending on whether the automated warehouse is for multiple assembly lines or a single assembly line. Furthermore, when the warehouse is for a single assembly line, unlike when it is for multiple assembly lines, the parts supply units are collected without checking the status of the assembly line, so the transport preparation control can be started quickly. In other words, when the warehouse is for a single assembly line, different transport preparation control can be appropriately performed compared to when it is for multiple assembly lines. Therefore, regardless of whether the warehouse is for multiple assembly lines or a single assembly line, the transport preparation of parts supply units within the warehouse can be performed efficiently.

[0009] A schematic diagram of the production system 10 (10A). A schematic diagram of the production system 10 (10B). A schematic diagram of the assembly line 20, automated warehouse 50, and automated guided vehicle 70. A schematic diagram of the assembly device 30. A block diagram showing the configuration related to the control of the production system 10. An explanatory diagram showing an example of feeder information 82a. A flowchart showing an example of feeder transport-related processing. A flowchart showing an example of transport preparation control for multiple lines. A flowchart showing an example of transport preparation control for a single line.

[0010] Embodiments of the present disclosure will be described with reference to the drawings. Figure 1 is a schematic diagram of the production system 10 (10A). Figure 2 is a schematic diagram of the production system 10 (10B). Figure 3 is a schematic diagram of the mounting line 20, the automated warehouse 50, and the automated guided vehicle 70. Figure 4 is a schematic diagram of the mounting device 30. Figure 5 is a block diagram showing the configuration related to the control of the production system 10. In this embodiment, the left-right direction (X-axis), front-back direction (Y-axis), and up-down direction (Z-axis) are as shown in Figures 3 and 4.

[0011] The production system 10 includes one or more mounting lines 20 for mounting parts using feeders 32, an automated warehouse 50 for storing the feeders 32 outside the mounting lines 20, an automated guided vehicle 70 for transporting the feeders 32 between the mounting lines 20 and the automated warehouse 50, and a management device 80 for managing the entire system.

[0012] In this embodiment, the production system 10A in Figure 1 comprises one assembly line 20A and one automated warehouse 50A. The production system 10B in Figure 2 comprises two assembly lines 20B and 20C and one automated warehouse 50B. The production systems 10A and 10B are configured similarly except for the difference in the number of assembly lines 20. For example, let's assume that production system 10A is installed at company A, and production system 10B is installed at company B. Alternatively, production systems 10A and 10B may be installed at the same company, for example, in different factories (buildings), and the feeders 32 used in the assembly line 20 are stored in the automated warehouse 50 within each production system 10. Furthermore, production systems 10A and 10B are provided with an assembly area 12 where the assembly lines 20 are located, a warehouse area 14 where the automated warehouse 50 is located, and a work area 16 where workers M perform various tasks such as assembling the feeders 32 and reels R.

[0013] The mounting line 20 comprises a printing device 22, a printing inspection device 24, a buffer station 26, a plurality of mounting devices 30, and a mounting inspection device 28. These are arranged in a line along the transport direction (X-axis direction) of the substrate S. The mounting line 20 also includes a loader 45 that can move between the buffer station 26 and each mounting device 30 along the X-axis direction, and a line control device 40 that controls the entire mounting line 20. The mounting line 20 may also include a reflow device for reflow processing of the substrate S with components mounted. In this embodiment, each mounting line 20A, 20B, and 20C has the same configuration, but in this embodiment, they may have different configurations as long as they include at least a buffer station 26, one or more mounting devices 30, and a loader 45.

[0014] The printing device 22 prints onto the substrate S by pushing solder into pattern holes formed in the screen mask. The printing inspection device 24 inspects the condition of the solder printed on the substrate S. The mounting device 30 mounts components supplied by the feeder 32 onto the substrate S. The mounting inspection device 28 inspects the mounting condition of the components mounted on the substrate S.

[0015] The mounting device 30 includes a substrate transport device 31 for transporting substrates S, a plurality of feeders 32 for supplying components, a head 33 for picking up components and mounting them onto substrates S by raising and lowering a picking member such as a nozzle in the Z-axis direction, a moving mechanism 34 for moving the head 33 in the XY direction, and a control unit (not shown) composed of a CPU, ROM, RAM, etc. The feeders 32 are configured as tape feeders, each fitted with a reel R around which tape that holds components at a predetermined pitch is wound, and components are supplied by feeding out the tape by rotating the reel R. The feeders 32 are detachable from a plurality of slots formed on the front of the mounting device 30 and are held in a row in the X-axis direction. The mounting device 30 has two areas, one above the other, where a plurality of slots are formed. The upper area is where the feeders 32 can supply components to the head 33. The lower area is where the feeders 32 are temporarily stored.

[0016] The loader 45, although not shown in detail, comprises a loader body that can accommodate one or more feeders 32 and is movable, a moving mechanism for moving the loader body, a transfer mechanism for transferring feeders 32 between the buffer station 26 and each mounting device 30 and the loader body, and a control unit composed of a CPU, ROM, RAM, etc. The loader 45 retrieves used feeders 32 from the mounting device 30 and collects them in the buffer station 26, and retrieves feeders 32 to be used from the buffer station 26 and supplies them to the mounting device 30.

[0017] The buffer station 26 is provided as an in-line storage facility for storing the feeder 32 within the implementation line 20, and is also called the feeder 32 receiving section or temporary storage facility. At the buffer station 26, the loader 45 and the automated guided vehicle 70 can automatically load and unload the feeder 32. The buffer station 26 is also divided into two buffer sections, for example, a first buffer section 26a and a second buffer section 26b, which are arranged side by side.

[0018] The line control device 40 comprises a control unit 41 composed of a CPU, ROM, RAM, etc., a storage unit 42 such as an HDD or SSD for storing various information, and a communication unit 43 for communicating with each device in the mounting line 20 and the management device 80. The storage unit 42 stores feeder information 42a related to the feeders 32 in the mounting line 20, and production information 42b related to the production of the substrate S. The feeder information 42a, as will be described in detail later, is information that indicates the usage status and placement location of the feeders 32, and includes, for example, the placement location of each feeder 32, the feeder ID which is identification information, the type of component and the number of remaining components of the components stored in the feeder 32 (reel R). The production information 42b includes the type of substrate to be produced, the number of substrates S to be produced, the solder printing position on the substrate S, the type of components to be mounted on the substrate S, the required number of components, mounting position, and mounting order, and stores, for example, information transmitted from the management device 80.

[0019] Furthermore, the line control device 40 outputs various command signals to each device in the mounting line 20 based on production information 42b to perform production, and inputs information regarding the production status from each device. Based on feeder information 42a and production information 42b, the line control device 40 controls the loader 45 to take feeder 32 from the buffer station 26 and supply it to each mounting device 30, or to take feeder 32 from each mounting device 30 and collect it back at the buffer station 26. The line control device 40 also inputs the operating status of the loader 45 and the status of the buffer station 26 (each buffer unit 26a, 26b). The line control device 40 transmits information such as the production status of the mounting line 20, the operating status of the loader 45, the status of the buffer station 26, and feeder information 42a to the management device 80. Furthermore, based on the feeder information 42a and production information 42b, the line control device 40 identifies feeder 32 that need to be supplied (replaced) due to parts shortages and feeder 32 that need to be supplied due to changes in substrate type. The line control device 40 creates a preparation list requesting the preparation (transportation) of the feeders 32 and transmits it to the management device 80. The preparation list includes information such as the type of part and the start time of use due to part shortages or changes in board type. The management device 80 may also create the preparation list based on information received from the assembly line 20. Alternatively, the line control device 40 may transmit the preparation list to the automated warehouse 50.

[0020] The automated guided vehicle (AGV) 70 automatically moves between the implementation area 12 and the warehouse area 14, transporting feeders 32 intended for use and used feeders 32. While detailed illustrations are omitted, the AGV 70 comprises a vehicle body, a battery, motors for driving the vehicle's wheels, a transfer device, detection sensors for detecting obstacles, speed sensors for detecting movement speed, position sensors for detecting its own position, and a control unit consisting of a CPU, ROM, RAM, etc. The AGV 70 is configured, for example, as an AMR (Autonomous Mobile Robot) that moves along a predetermined path based on the surrounding conditions, and runs by driving motors with battery power. Alternatively, the AGV 70 could be an AGV (Automatic Guided Vehicle) that moves along a predetermined path. Furthermore, the AGV 70 transports multiple feeders 32 (for example, 20 or 30) stored in a magazine 35, which serves as a predetermined storage component. The first buffer section 26a and the second buffer section 26b of the buffer station 26 described above each house one magazine 35. For this reason, multiple rollers are provided in each buffer section of the automated guided vehicle 70 and the buffer station 26 for inserting and removing the magazine 35.

[0021] The loader 45 of the mounting line 20 inserts and removes feeders 32 into the magazine 35 of one of the buffer sections, the first buffer section 26a and the second buffer section 26b, and collects used feeders 32 into the magazine 35 of the buffer section. The other buffer section is left empty. When the automated guided vehicle 70 transports feeders 32 from the automated warehouse 50 to the mounting line 20, it transports multiple feeders 32 together with the magazine 35 and loads them into the other empty buffer section. The automated guided vehicle 70 then unloads the multiple feeders 32 collected in the one buffer section, along with the magazine 35, and transports them to the automated warehouse 50. Thus, in this embodiment, the transport of feeders 32 between the warehouse area 14 (automated warehouse 50) and the mounting area 12 (each mounting line 20) is performed using the magazine 35, but it is not limited to this, and the feeders 32 may be transported without using the magazine 35.

[0022] The automated warehouse 50 comprises a plurality of storage units 51 and a buffer station 53. These are arranged in a line along a predetermined direction (for example, the X-axis direction in Figure 3). The automated warehouse 50 also includes a loader 55 that can move between each storage unit 51 and the buffer station 53 along the predetermined direction, and a warehouse control device 60 that controls the entire automated warehouse 50. The feeders 32 are detachable from a plurality of slots formed on the front of the storage units 51 and are held in a line along the X-axis direction. The storage unit 51 has two areas, one above the other, where a plurality of slots for attaching and detaching the feeders 32 are formed.

[0023] Furthermore, each storage unit 51 is equipped with one status bar 52a above the area where the feeders 32 are stored, and multiple slot LEDs 52b below each slot. The status bar 52a is a bar-shaped LED lamp that is long in the X-axis direction, and indicates by the difference in the color of its illumination whether the storage unit 51 is mainly storing feeders 32 that are scheduled to be used or feeders 32 that have been used and are not scheduled to be used. Note that the storage unit 51 may store feeders 32 whose status bar 52a illumination color does not indicate whether they are scheduled to be used or not. The slot LEDs 52b are rectangular LED lamps that are the same width as the feeder 32, and indicate by the difference in the color of their illumination whether the feeder 32 in each slot is scheduled to be used or not. Note that the slot LEDs 52b are turned off when no feeder 32 is installed in the slot. The status bar 52a and slot LED 52b indicate when a feeder is scheduled for use by lighting up in a first color (e.g., green) and when it is not scheduled for use by lighting up in a second color (e.g., blue). By checking the color of the status bar 52a and slot LED 52b, the worker M can install the feeder 32 scheduled for use into the slot of the storage unit 51 or remove the used feeder 32 from the slot of the storage unit 51. Note that an LED that lights up similarly to the slot LED 52b may be provided on the feeder 32 instead of the slot.

[0024] The buffer station 53 is configured similarly to the buffer station 26 on the implementation line 20, and is divided into two sections: a first buffer section 53a and a second buffer section 53b, each capable of accommodating one magazine 35. Above the first buffer section 53a and the second buffer section 53b, corresponding status bars 54 are provided. The status bars 54, like the status bar 52a, are bar-shaped LEDs that indicate whether or not they are scheduled for use by the difference in their illuminated color.

[0025] Loader 55 is configured similarly to loader 45 on the mounting line 20, and takes feeders 32 from the storage 51 and collects them at the buffer station 53, and takes feeders 32 from the buffer station 53 and returns them to the storage 51. Loader 55, for example, takes feeders 32 in and out of the magazine 35 of one of the buffer sections, either the first buffer section 53a or the second buffer section 53b, and collects the feeders 32 to be transported into the magazine 35 of one of the buffer sections. Automated guided vehicles 70 transport the multiple feeders 32 collected in one of the buffer sections, along with the magazine 35, to the mounting line 20 and into the buffer station 26. Also, automated guided vehicles 70 transport multiple feeders 32, along with the magazine 35, from the mounting line 20 to the automated warehouse 50 and into an empty buffer section. At the buffer station 53, for example, the status bar 54 of one buffer section where the feeders 32 to be transported are collected lights up in a first color, and the status bar 54 of the buffer section into which the collected magazines 35 are brought lights up in a second color. Normally, worker M inserts and removes the feeders 32 into and out of the storage unit 51, but by checking the color of the status bar 54, it is possible to insert and remove the feeders 32 into and out of the buffer station 53.

[0026] The warehouse control device 60 comprises a control unit 61 composed of a CPU, ROM, RAM, etc., a storage unit 62 such as an HDD or SSD for storing various information, and a communication unit 63 for communicating with each device in the automated warehouse 50 and the management device 80. The storage unit 62 stores feeder information 62a related to the feeders 32 in the automated warehouse 50, and line number information 62b related to the number of implementation lines 20 to which the automated warehouse 50 is associated. The control unit 61 lights up the status bar 52a of each storage unit 51 based on setting instructions from the worker M via the management device 80. In addition, when a feeder 32 is installed in a slot, the control unit 61 obtains whether it is scheduled for use by communicating with the management device 80, etc., and lights up the slot LED 52b.

[0027] The line number information 62b stored in the memory unit 62 includes information on the number of implementation lines 20 to which the automated warehouse 50 is associated, that is, the number of implementation lines 20 that the production system 10 has. For example, production system 10A has one implementation line 20A, and automated warehouse 50A is associated with one implementation line 20A. Therefore, the line number information 62b in the memory unit 62 of automated warehouse 50A is a value of 1. Automated warehouse 50A is also referred to as a warehouse for a single implementation line 20. On the other hand, production system 10B has two implementation lines 20B and 20C, and automated warehouse 50B is associated with two implementation lines 20B and 20C. Therefore, the line number information 62b in the memory unit 62 of automated warehouse 50B is a value of 2. Automated warehouse 50B is also referred to as a warehouse for multiple implementation lines 20.

[0028] In the work area 16, worker M performs various tasks related to the feeder 32. For example, to prepare the feeder 32 to be used in the mounting device 30, worker M retrieves reels R containing the necessary parts from a reel warehouse (not shown), transports them to the work area 16, and assembles them onto the feeder 32. At this time, worker M uses a mobile terminal P to read the feeder ID (code) of the feeder 32 and the reel ID of the reel R. This transmits information about the combination of feeder 32 and reel R to the management device 80. Worker M also transports the prepared feeder 32 to the warehouse area 14 and installs it in the storage compartment 51 of the automated warehouse 50. Worker M also retrieves used feeders 32 collected in the automated warehouse 50 from the storage compartment 51, transports them to the work area 16, and removes the reels R from the feeder 32. Worker M returns any reels R with remaining parts to the reel warehouse.

[0029] The management device 80 comprises a control unit 81 composed of a CPU, ROM, RAM, etc., a storage unit 82 such as an HDD or SSD for storing various information, and a communication unit 83 for communicating with line control devices 40 of each mounting line 20, a warehouse control device 60 of the automated warehouse 50, an automated guided vehicle 70, a mobile terminal P, etc. The management device 80 also comprises an input unit 86 such as a keyboard or mouse, and a display unit 88 such as a display. The storage unit 82 stores feeder information 82a, production information 82b similar to production information 42b, line number information 83b similar to line number information 62b, etc. The control unit 61 outputs production instructions to the line control devices 40 of each mounting line 20 based on the production information 82b.

[0030] Figure 6 is an explanatory diagram showing an example of feeder information 82a. In Figure 6, the feeder information 82a stored in the storage unit 82 of the management device 80 in the production system 10A is shown. The feeder information 82a includes information about the placement location of the feeder 32, including which location and which position (slot) the feeder 32 is located in among the automated warehouse 50 and each mounting line 20. The feeder information 82a also includes the feeder ID, the type of parts and the number of remaining parts of the parts stored in the feeder 32 (reel R), and may also include the reel ID. The control unit 81 updates the feeder information 82a as needed through communication with the line control device 40 and the warehouse control device 60. The feeder information 42a of each mounting line 20 includes the information from the feeder information 82a that corresponds to its own mounting line 20. The feeder information 62a of the automated warehouse 50 includes the information from the feeder information 82a that corresponds to the automated warehouse 50.

[0031] Furthermore, the control device 80 outputs an instruction to the automated warehouse 50 to collect the necessary feeders 32 for the assembly line 20 based on the preparation list of feeders 32 received from the assembly line 20. Upon receiving the instruction, the automated warehouse 50 controls the loader 55 to collect the feeders 32 into the magazine 35 of one of the buffer sections of the buffer station 53, and transmits a message to the control device 80 when it has finished collecting. The control device 80 checks the status of the assembly line 20, the automated warehouse 50, and the automated guided vehicle 70, and outputs an instruction to the automated guided vehicle 70 to automatically transport feeders 32 from the automated warehouse 50 to the assembly line 20, or to automatically transport feeders 32 from the assembly line 20 to the automated warehouse 50.

[0032] Next, we will explain the operation of the production system 10 of this embodiment, as configured in this way, and in particular, the process of automatically transporting the feeder 32 required for the destination assembly line 20. Figure 7 is a flowchart showing an example of feeder transport-related processing. This flowchart is executed by the management device 80 (control unit 81) of the production system 10A or the management device 80 (control unit 81) of the production system 10B, but it may also be executed by the warehouse control device 60 of the automated warehouse 50. That is, it may be executed by the warehouse control device 60 (control unit 61) of the automated warehouse 50A or the warehouse control device 60 (control unit 61) of the automated warehouse 50B. In the following explanation, we will assume that the control unit 81 is executing the process.

[0033] In the feeder transport-related processing shown in Figure 7, the control unit 81 determines whether the automated warehouse 50 provided by the production system 10 corresponds to multiple mounting lines 20 based on the line number information 83b stored in the memory unit 82 (S100). If the control unit 81 determines that it corresponds to multiple mounting lines 20, it executes transport preparation control for multiple lines (S110) and returns to S100. If the control unit 81 determines that it corresponds to one mounting line 20, i.e., a single mounting line 20, it executes transport preparation control for a single line (S120) and returns to S100. Therefore, in this embodiment, if the control unit 81 is the control unit 81 of the management device 80 in production system 10A, it will execute transport preparation control for a single line, and if the control unit 81 is the control unit 81 of the management device 80 in production system 10B, it will execute transport preparation control for multiple lines. Below, the transport preparation control for multiple lines will be explained first.

[0034] In the transport preparation control for multiple lines shown in Figure 8 (S110), the control unit 81 acquires information regarding the status of each mounting line 20 at predetermined intervals (S200), and determines, based on the acquired information, whether or not there is a mounting line 20 that is in an acceptable state and can be received by the feeder 32 (S210). The control unit 81 determines that, among the multiple mounting lines 20, a mounting line 20 in which, for example, one buffer section of the buffer station 26 is free and no abnormal stoppage of the loader 45 has occurred is in an acceptable state. If the control unit 81 determines that there is no mounting line 20 in an acceptable state, it returns to S200.

[0035] On the other hand, when the control unit 81 determines that there is an assembly line 20 that is ready to accept, it obtains a preparation list of the feeders 32 for the assembly line 20 that is ready to accept (S220). Although not shown in the diagram, the preparation list includes information on the type and number of parts required for each assembly line 20, as well as information on the start time when the feeder 32 will be put into use. Next, the control unit 81 determines the destination assembly line 20 from the assembly lines 20 that are ready to accept (S230). For example, the control unit 81 determines the destination assembly line 20 from the assembly lines 20 that are ready to accept, based on the preparation list, to be the assembly line 20 with the feeder 32 that will be put into use earliest. Alternatively, the control unit 81 may determine the destination assembly line 20 with the largest number of required feeders based on the preparation list.

[0036] In S230, the control unit 81 determines the destination and, based on the preparation list for the destination assembly line 20, instructs the automated warehouse 50 to collect the feeders 32 to be transported (S240), and waits for the loader 55 of the automated warehouse 50 to finish collecting the feeders 32 (S250). In S240, the control unit 81 transmits the preparation list for the destination assembly line 20 to the automated warehouse 50. Upon receiving the preparation list, the warehouse control device 60 (control unit 61) controls the loader 55 to collect the feeders 32.

[0037] When the control unit 81 determines in S250 that it has finished collecting the feeders 32, it reconfirms the status of the destination assembly line 20 (S260) and determines whether or not it is in a state where it can be accepted (S270). Since it has already been determined in S110 that it is in a state where it can be accepted, in S270 it determines whether or not the destination assembly line 20 has become unacceptable while the feeders 32 are being collected in the automated warehouse 50. When the control unit 81 determines that the destination assembly line 20 is in a state where it can be accepted, it instructs the automated guided vehicle 70 to transport the feeders 32 from the buffer station 53 of the automated warehouse 50 to the buffer station 26 of the destination assembly line 20 (S280), and ends this process.

[0038] On the other hand, if the control unit 81 determines in S270 that the product is not in an acceptable state, it further checks the state of another mounting line 20 (S290) and determines whether there is another mounting line 20 that is in an acceptable state (S300). If the control unit 81 determines that mounting line 20B is the destination in S230, it checks the state of mounting line 20C in S290, and if it determines that mounting line 20C is the destination in S230, it checks the state of mounting line 20B in S290. If the control unit 81 determines that there is no other mounting line 20 that is in an acceptable state, it returns to S260 and repeats the process.

[0039] Furthermore, if the control unit 81 determines that there is another assembly line 20 that is in a receivable state, it instructs the automated warehouse 50 to return the feeders 32 collected at the buffer station 53 to the storage unit 51 (S310), and waits for the feeders 32 to be returned (S320). When the control unit 81 determines that the loader 55 of the automated warehouse 50 has finished returning the feeders 32, it returns to S200. That is, the control unit 81 ensures that there are no feeders 32 to be transported collected at the buffer station 53 of the automated warehouse 50 before executing the processing from S200 onward. When it returns to S200, it usually determines the other assembly line 20 that was deemed receivable in S300 as the transport destination, and the transport preparation control in S240 is executed. However, if there are other assembly lines 20 that were determined to be receivable in S210, it is sufficient to determine any of the assembly lines 20 as the transport destination in S230.

[0040] Next, the transport preparation control for a single line will be described. In the transport preparation control for a single line shown in Figure 9 (S120), the control unit 81 obtains a preparation list for the corresponding single mounting line 20 (mounting line 20A in the example of Figure 1) from the automated warehouse 50 (S400). The preparation list is the same as that in S220. Next, the control unit 81 instructs the automated warehouse 50 to collect the feeders 32 to be transported based on the preparation list for the destination mounting line 20 (single mounting line 20) (S410), and waits for the loader 55 of the automated warehouse 50 to finish collecting the feeders 32 (S420). S410 and S420 are executed in the same way as S240 and S250.

[0041] When the control unit 81 determines in S420 that it has finished collecting feeders 32, it checks the status of the mounting line 20 (S430) and determines whether or not it is in a ready state for acceptance (S440). If the control unit 81 determines that it is not in a ready state for acceptance, it waits for it to become ready for acceptance. If the control unit 81 determines in S440 that it is ready for acceptance, it instructs the automated guided vehicle 70 to transport the feeders 32 from the buffer station 53 of the automated warehouse 50 to the buffer station 26 of the mounting line 20 (S450), and ends this process.

[0042] In this single-line transport preparation control, the feeder 32 starts collecting materials in S410 without confirming that the line is in a receivable state. Therefore, compared to the transport preparation control for multiple lines, it is more likely that the system will determine in S430 and S440 that the line is not in a receivable state. However, since the feeder 32 has already finished collecting materials, once the mounting line 20 changes to a receivable state, a transport instruction can be immediately output to the automated guided vehicle 70, allowing the feeder 32 to be transported automatically. In other words, by quickly starting to collect materials with the feeder 32 without confirming the state of the single mounting line 20, the transport preparation of the feeder 32 can be performed efficiently, and automatic transport can be performed quickly.

[0043] Here, the correspondence between the components of this embodiment and the components of the present disclosure will be clarified. The mounting line 20 of this embodiment corresponds to the mounting line of the present disclosure, the automated warehouse 50 corresponds to the warehouse, the loader 55 corresponds to the transfer device, and the control unit 81 of the management device 80 that performs feeder transport-related processing corresponds to the control unit. The automated guided vehicle 70 corresponds to the automated guided vehicle. In this embodiment, an example of the transport preparation method of the present disclosure is also clarified by describing the operation of the production system 10.

[0044] In the production system 10 of the embodiment described above, the automated warehouse 50 executes different conveyance preparation controls depending on whether it is for a plurality of mounting lines 20 or for a single mounting line 20. Further, when the automated warehouse 50 is for a single mounting line 20, unlike the case of a plurality of mounting lines 20, the feeders 32 are collected without checking the state of the mounting line 20, so that the conveyance preparation can be started promptly. Therefore, regardless of whether the automated warehouse 50 is for a plurality of mounting lines 20 or for a single mounting line 20, the conveyance preparation of the feeders 32 in the automated warehouse 50 can be efficiently performed.

[0045] Also, in the conveyance preparation control for multiple lines, the control unit 81 determines one mounting line 20 in the receivable state as the conveyance destination. For this reason, when the automated warehouse 50 is for a plurality of mounting lines 20, even though the feeders 32 are collected at the buffer station 53 (predetermined location), it is possible to suppress the situation of waiting for conveyance because the mounting line 20 is not in the receivable state. On the other hand, when the automated warehouse 50 is for a single mounting line 20, since the state of the mounting line 20 is not checked, the conveyance preparation of the feeders 32 can be started promptly without waiting for the mounting line 20 to become in the receivable state.

[0046] Also, in the conveyance preparation control for multiple lines and the conveyance preparation control for a single line, when the collection of the feeders 32 at the buffer station 53 is completed, the control unit 81 outputs a conveyance instruction for the feeders 32 to the automated guided vehicle 70. By efficiently performing the conveyance preparation of the feeders 32, the conveyance instruction to the automated guided vehicle 70 can also be output promptly, and the feeders 32 can be automatically conveyed promptly.

[0047] Further, when the control unit 81 has finished collecting the feeders 32 at the buffer station 53, before outputting a conveyance instruction to the automated guided vehicle 70, it checks that the mounting line 20 at the destination is in an acceptable state and then outputs the conveyance instruction. Therefore, when the automated warehouse 50 is for a plurality of mounting lines 20, if the mounting line 20 changes to a non-acceptable state while the feeders 32 are being collected, appropriate countermeasures can be taken. Also, whether the automated warehouse 50 is for a plurality of mounting lines 20 or for a single mounting line, it is possible to prevent the automated guided vehicle 70 from waiting for a long time while transporting the feeders 32 toward the mounting line 20 at the destination or returning to the automated warehouse 50 without being able to transport them.

[0048] Further, in the conveyance preparation control for multiple lines, when the control unit 81 checks that the mounting line 20 at the destination is not in an acceptable state and another mounting line 20 is in an acceptable state before outputting a conveyance instruction, it returns the feeders 32 collected at the buffer station 53 to the storage 51 (another storage location) in the automated warehouse 50 (50B), and controls the loader 55 to collect the feeders 32 with another mounting line 20 as the destination. On the other hand, in the conveyance preparation control for a single line, when the control unit 81 checks that the mounting line 20 at the destination is not in an acceptable state before outputting a conveyance instruction, it waits for the mounting line 20 to become in an acceptable state and then outputs the conveyance instruction. Therefore, when the mounting line 20 at the destination is not in an acceptable state when the collection of the feeders 32 at the buffer station 53 is completed, appropriate countermeasures can be taken according to whether the automated warehouse 50 is for a plurality of mounting lines 20 or for a single mounting line 20. In particular, when the automated warehouse 50 is for a plurality of mounting lines 20, there is no need to keep waiting for the non-acceptable mounting line 20 to become acceptable again, so the conveyance preparation of the feeders 32 can be efficiently performed. Also, when the automated warehouse 50 is for a single mounting line 20, it will wait for the state to change to an acceptable state, but since the feeders 32 have already been collected, if the mounting line 20 changes to an acceptable state, the conveyance instruction can be immediately output to the automated guided vehicle 70 and automatic conveyance can be performed promptly.

[0049] It goes without saying that this disclosure is not limited in any way to the embodiments described above, and can be implemented in various forms as long as they fall within the technical scope of this disclosure.

[0050] In this embodiment, the production system 10A, which performs transport preparation control for a single line, is exemplified as having one assembly line 20 and one automated warehouse 50, but it is not limited to this configuration. For example, there may be two or more equal numbers of assembly lines 20 and automated warehouses 50, and one automated warehouse 50 may correspond to one assembly line 20 (a one-to-one configuration). If one automated warehouse 50 corresponds to one assembly line 20, there may be more automated warehouses 50 than assembly lines 20. Also, the production system 10 is equipped with one automated guided vehicle 70, but it is not limited to this, and may be equipped with multiple automated guided vehicles 70.

[0051] In this embodiment, in the transport preparation control for multiple lines, the transport destination was determined from among the mounting lines 20 that meet the conditions for being in an acceptable state, such as the mounting line 20 with the feeder 32 that will be used first, or the mounting line 20 with the largest number of required feeders. However, it is not limited to this. For example, even if a mounting line 20 is not in an acceptable state, it may be included if it is in a state close to an acceptable state, such as if it will become acceptable by replacing the remaining few feeders 32. That is, mounting lines 20 that are in an acceptable state and mounting lines 20 that are close to an acceptable state may be considered as mounting lines 20 that meet the predetermined conditions, and the transport destination may be determined from among them. Thus, in the transport preparation control for multiple lines, it is sufficient to check the status of multiple mounting lines 20 and determine the mounting line 20 that meets the predetermined conditions as the transport destination.

[0052] In this embodiment, in the transport preparation control for multiple lines, if it is confirmed that the destination mounting line 20 is not in a receivable state but another mounting line 20 is in a receivable state before the output of the transport instruction, i.e., when the feeders 32 have finished being collected at the buffer station 53, the feeders 32 collected at the buffer station 53 are returned to the storage unit 51, but this is not limited to this. For example, the control unit 81 may wait for the destination mounting line 20 to become receivable again. However, if it does not become receivable even after a predetermined time has elapsed, the feeders 32 may be returned to the storage unit 51 as in this embodiment.

[0053] In this embodiment, the control unit 81 confirmed that the destination mounting line 20 was in a receivable state before outputting the transport instruction, i.e., when it had finished collecting the feeders 32 at the buffer station 53, but it is not limited to this. For example, the control unit 81 may confirm whether the destination mounting line 20 is in a receivable state before outputting the transport instruction, such as when a predetermined number (e.g., half) of the feeders 32 to be transported have been collected, or it may confirm both during and after collecting the feeders 32. Alternatively, the control unit 81 may have the automated guided vehicle 70 transport the feeders 32 after it has finished collecting the feeders 32 at the buffer station 53 without confirming whether the destination mounting line 20 is in a receivable state. In this case, if the destination mounting line 20 is not in a receivable state, the automated guided vehicle 70 can be made to wait near the mounting line 20. Furthermore, the confirmation of whether the destination mounting line 20 is in a receivable state before outputting the transport instruction may differ between transport preparation control for multiple lines and transport preparation control for a single line. For example, in the transport preparation control for multiple lines, as in the embodiment, it is checked whether the mounting line 20 is in a receivable state before outputting the transport instruction, while in the transport preparation control for a single line, it is not checked whether the mounting line 20 is in a receivable state before outputting the transport instruction. In this way, in the transport preparation control for a single line, the automated guided vehicle 70 is quickly launched, and when the mounting line 20 changes to a receivable state, the automated guided vehicle 70 has already moved to the vicinity of the mounting line 20, so the feeder 32 can be quickly transported to the mounting line 20 (buffer station 26).

[0054] In this embodiment, in the feeder transport-related processing shown in Figure 7, the process returns to S100 after executing the transport preparation control for multiple lines in S110, and after executing the transport preparation control for a single line in S120. Therefore, even if the number of installation lines 20 or the number of automated warehouses 50 in the production system 10 increases or decreases, the appropriate transport preparation control can be selected and executed. Alternatively, in the feeder transport-related processing shown in Figure 7, whether or not it is for multiple lines may be determined only at the first execution, and the determination may be omitted thereafter. That is, after executing the transport preparation control for multiple lines in S110, the process may return to S110 again, and after executing the transport preparation control for a single line in S120, the process may return to S120 again.

[0055] In this embodiment, the mounting line 20 includes a buffer station 26, and the automated guided vehicle 70 transports the feeder 32 to the buffer station 26, but it is not limited to this. For example, the automated guided vehicle 70 may transport the feeder 32 to the mounting device 30. Alternatively, the production system 10 is not limited to one that includes an automated guided vehicle 70, and may not include one. In such a case, the worker M would transport the feeder 32, but as in the embodiment, the effect of performing different transport preparation controls for a single mounting line 20 and for multiple mounting lines 20 would still be achieved.

[0056] The transport preparation method of the present disclosure is a transport preparation method for preparing for the transport of a component supply unit in a production system comprising: one or more mounting lines having mounting devices for mounting components using component supply units; one or more warehouses for storing the component supply units outside the mounting lines; and a transfer device for transferring the component supply units within the warehouses, the method comprising: (a) when the warehouse is for multiple mounting lines, performing transport preparation control for multiple lines, which involves checking the status of the multiple mounting lines, determining a mounting line that satisfies predetermined conditions as the transport destination, and then controlling the transfer device to gather the component supply units that need to be transported at a predetermined location within the warehouse; and (b) when the warehouse is for a single mounting line, performing transport preparation control for a single line, which involves controlling the transfer device to gather the component supply units that need to be transported at a predetermined location with the mounting line as the transport destination without checking the status of the mounting line.

[0057] The transport preparation method of this disclosure, similar to the production system of this disclosure described above, enables efficient preparation of parts supply units for transport within a warehouse, regardless of whether the warehouse is for multiple assembly lines or a single assembly line. Various embodiments of the production system of this disclosure may be adopted in this transport preparation method, or steps may be added to realize the functions of the production system of this disclosure.

[0058] This disclosure is applicable to the technical field of production systems in which component supply units to be transported to the assembly line are gathered at a predetermined location in a warehouse using a transfer device.

[0059] 10, 10A, 10B Production system, 12 Assembly area, 14 Warehouse area, 16 Work area, 20, 20A, 20B, 20C Assembly line, 22 Printing device, 24 Printing inspection device, 26, 53 Buffer station, 26a, 53a First buffer section, 26b, 53b Second buffer section, 28 Assembly inspection device, 30 Assembly device, 31 Substrate transport device, 32 Feeder (component supply unit), 33 Head, 34 Moving mechanism, 35 Magazine, 40 Line control device, 41, 61, 81 Control unit, 42, 62, 82 Storage unit, 42a, 62a, 82a Feeder information, 42b, 82b Production information, 43, 63, 83 Communication unit, 45, 55 Loader, 50 Automated warehouse, 51 Storage unit, 52a, 54 Status bar, 52b Slot LED, 60 Warehouse control device, 62b Line count information, 70 Automated guided vehicle, 80 Management device, 86 Input unit, 88 Display unit, M Worker, P Mobile terminal, R Reel, S Circuit board.

Claims

1. A production system comprising: one or more mounting lines having mounting devices for mounting components using component supply units; one or more warehouses for storing the component supply units outside the mounting lines; and a transfer device for transferring the component supply units within the warehouses, wherein, when the warehouses are for multiple mounting lines, the system performs transport preparation control for multiple lines, which involves checking the status of the multiple mounting lines, determining a mounting line that satisfies predetermined conditions as the transport destination, and then controlling the transfer device to gather the component supply units that need to be transported at a predetermined location within the warehouse; and when the warehouses are for a single mounting line, the system performs transport preparation control for a single line, which involves controlling the transfer device to gather the component supply units that need to be transported at a predetermined location with the mounting line as the transport destination without checking the status of the mounting line.

2. The production system according to claim 1, wherein the control unit, in the transport preparation control for the multiple lines, determines one of the mounting lines that satisfies the predetermined condition of being in an acceptable state in which the component supply unit can be received as the transport destination.

3. The production system according to claim 1 or 2, comprising an automated guided vehicle for transporting the parts supply units between the assembly line and the predetermined location in the warehouse, wherein the control unit, in the transport preparation control for the multiple lines and the transport preparation control for the single line, outputs a transport instruction for the parts supply units to the automated guided vehicle when it has finished collecting the parts supply units at the predetermined location.

4. The production system according to claim 3, wherein, after the control unit has finished collecting the component supply units at the predetermined location, it confirms that the mounting line at the destination is in an acceptable state capable of receiving the component supply units before outputting the transport instruction.

5. The production system according to claim 4, wherein, in the transport preparation control for multiple lines, before outputting the transport instruction, the control unit confirms that the destination mounting line is not in the acceptable state but another mounting line is in the acceptable state, and controls the transfer device to return the parts supply units collected at the predetermined location to another location in the warehouse and collect the parts supply units that need to be transported to the other mounting line at the predetermined location; and in the transport preparation control for a single line, before outputting the transport instruction, the control unit confirms that the destination mounting line is not in the acceptable state, and waits for the mounting line to become acceptable before outputting the transport instruction.

6. A production system comprising one or more mounting lines having mounting devices for mounting components using component supply units, one or more warehouses for storing the component supply units outside the mounting lines, and a transfer device for transferring the component supply units within the warehouses, comprising: a step of performing transport preparation control for multiple lines, in which, when the warehouse is for multiple mounting lines, the transfer device is controlled to gather the component supply units that need to be transported at a predetermined location within the warehouse after checking the status of the multiple mounting lines and determining a mounting line that satisfies predetermined conditions as the transport destination; and a step of performing transport preparation control for a single line, in which, when the warehouse is for a single mounting line, the transfer device is controlled to gather the component supply units that need to be transported at a predetermined location with the mounting line as the transport destination without checking the status of the mounting line.

Images