Feeder control device and feeder control method

Abstract

This feeder control device is applied to a bulk feeder provided with a track member that is installed in a component mounting machine and forms a supply region where a plurality of components are supplied in a collectable manner, and is provided with a replenishment control unit that controls a replenishment operation for components to the track member on the basis of the supply state of the components in the supply region.

Description

Feeder control device and feeder control method 【0001】 The present invention relates to a feeder control device and a feeder control method. 【0002】 The feeder control device is applied to a bulk feeder that is set in a component mounting machine and supplies components. As shown in Patent Document 1, the bulk feeder is provided with a component case that houses a large number of components in a bulk state, and conveys the components discharged from the component case to a predetermined supply area, so that the component mounting machine can collect the components. 【0003】 International Publication No. 2021 / 095219 【0004】 The supply process of the components of the bulk feeder includes a component replenishment operation to a track member forming a component conveyance path and a conveyance operation to convey the components on the conveyance path to a supply area. For such a bulk feeder, in order to improve the efficiency of the component supply operation, it is required that the component replenishment operation be preferably executed. 【0005】 An object of this specification is to provide a feeder control device and a feeder control method capable of improving the efficiency of the component supply operation. 【0006】 This specification is applied to a bulk feeder provided with a track member forming a supply area that is set in a component mounting machine and can supply a plurality of components, and based on the supply state of the components in the supply area, a replenishment control unit that controls the replenishment operation of the components to the track member is provided. A feeder control device is disclosed. 【0007】 This specification is applied to a bulk feeder provided with a track member forming a supply area that is set in a component mounting machine and can supply a plurality of components, and based on the supply state of the components in the supply area, a feeder control method including a replenishment control step of controlling the replenishment operation of the components to the track member is disclosed. 【0008】This specification also discloses the technical idea of ​​changing "the feeder control device described in claim 2" to "the feeder control device described in claim 2 or 3" in claim 4 of the original application, the technical idea of ​​changing "the feeder control device described in any one of claims 4-7" to "the feeder control device described in any one of claims 4-8" in claim 9 of the original application, and the technical idea of ​​changing "the feeder control device described in any one of claims 1-7" to "the feeder control device described in any one of claims 1-9" in claim 10 of the original application. 【0009】 With this configuration, the supply operation of parts is controlled based on the supply status of parts in the supply area, thereby reducing the surplus or shortage of parts in the track members. This improves the efficiency of the parts supply operation. 【0010】 This is a schematic plan view of a parts mounting machine. This is a perspective view showing the external appearance of a bulk feeder. This is a schematic side view showing the main parts and parts case of a bulk feeder. This is a plan view seen from direction IV in Figure 3. This is a block diagram showing a bulk feeder to which a feeder control device has been applied. This is a flowchart of the parts supply process. This is a flowchart of the supply status recognition process. This is a diagram showing image data captured from the supply area. This is a diagram showing the result of the supply status recognition process. This is a flowchart of the process for determining whether replenishment processing is necessary. 【0011】 1. Overview of the Feeder Control Device 60 The feeder control device 60 is applied to a bulk feeder 20 that is set in the component mounting machine 10 and supplies components. In this embodiment, as shown in Figures 1 and 5, the feeder control device 60 is incorporated into the component mounting machine 10 and the bulk feeder 20 and performs control for various operations of the bulk feeder 20. The component mounting machine 10 performs the mounting process of mounting components onto a substrate as a predetermined substrate-to-substrate operation. Multiple substrate-to-substrate operation machines are installed, for example, in the direction of substrate transport to constitute a production line. 【0012】As shown in Figure 5, production system 1 consists of the production line, host computer 2, and a parts warehouse (not shown). The host computer 2 controls the production line. Each of the multiple board-to-board work machines is connected to the host computer 2 for communication. The production line includes multiple board-to-board work machines such as solder printing machines, multiple component mounting machines 10, a reflow oven, and an inspection machine. 【0013】 In this embodiment, the production facility for substrate products may consist of multiple production lines. The configuration of each of the multiple production lines may be appropriately added or changed depending on, for example, the type of substrate product to be produced. Specifically, the multiple production lines may be appropriately equipped with substrate handling equipment such as buffer devices for temporarily holding the substrates being transported, substrate supply devices, substrate inversion devices, various inspection devices, shielding devices, adhesive application devices, and ultraviolet irradiation devices. 【0014】 2. Configuration of the Component Mounting Machine 10 2-1. Substrate Transport Device 11 As shown in Figure 1, the component mounting machine 10 includes a substrate transport device 11. The substrate transport device 11 consists of two transport mechanisms 111, etc., which are installed side by side in the Y direction. The transport mechanism 111 has a pair of guide rails 112. The pair of guide rails 112 extend in the transport direction (X direction) of the substrate and support the periphery of the substrate 91 that is placed on the conveyor belt and transported. At least one of the pair of guide rails 112 is provided on a base so as to be movable in the Y direction. The substrate transport device 11 sequentially transports the substrate 91 in the transport direction and positions the substrate 91 at a predetermined position inside the machine. After the component mounting process is completed, the substrate transport device 11 transports the substrate 91 out of the component mounting machine 10. 【0015】2-2. Parts Supply Device 12 The parts supply device 12 supplies parts to be mounted on the circuit board 91. The parts supply device 12 has feeders 122 set in each of the multiple slots 121. For example, a tape feeder is used for the feeder 122 to feed and move a carrier tape containing a large number of parts so that the parts can be picked up. Alternatively, a bulk feeder 20 is used for the feeder 122 to supply parts stored in bulk so that they can be picked up. Details of the bulk feeder 20 will be described later. 【0016】 2-3. Part Transfer Device 13 The part mounting machine 10 includes a part transfer device 13. The part transfer device 13 transfers parts supplied by the part supply device 12 to predetermined mounting positions on the substrate 91. The part transfer device 13 includes a head drive device 131, a mobile table 132, a mounting head 133, and a suction nozzle 134. The head drive device 131 moves the mobile table 132 horizontally (X direction and Y direction) by a linear motion mechanism. The mounting head 133 is detachably fixed to the mobile table 132 by a clamping member (not shown) and is provided to move horizontally within the machine. 【0017】 The mounting head 133 supports a plurality of suction nozzles 134 so as to be rotatable and vertically movable. The suction nozzles 134 are holding members that pick up and hold parts supplied by the feeder 122. The suction nozzles 134 use supplied negative pressure air to pick up the parts supplied by the feeder 122. As the holding member attached to the mounting head 133, a chuck or the like that which holds the parts by gripping them may be used. 【0018】2-4. Component Camera 14, Substrate Camera 15 The component mounting machine 10 includes a component camera 14 and a substrate camera 15. The component camera 14 and the substrate camera 15 are digital imaging devices having an image sensor such as a CMOS. The component camera 14 and the substrate camera 15 perform imaging based on a control signal and transmit the image data acquired by the imaging. The component camera 14 is configured to be able to image a component held by the suction nozzle 134 from below. The substrate camera 15 is mounted on a movable table 132 so as to be able to move horizontally integrally with the mounting head 133. The substrate camera 15 is configured to be able to image the substrate 91 from above. 【0019】 Furthermore, in addition to imaging the surface of the substrate 91, the substrate camera 15 can also image various devices and other objects as long as they are within the movable range of the mobile stand 132. For example, in this embodiment, as shown in Figure 4, the substrate camera 15 can capture images of the supply area As where the bulk feeder 20 supplies components and the reference mark 49 provided on the upper part of the bulk feeder 20 within its camera field of view. In this way, the substrate camera 15 can be used to image different objects in order to acquire image data used for various image processing applications. 【0020】 2-5. Control device 16, feeder management unit 60A The component mounting machine 10 is equipped with a control device 16, as shown in Figure 1. The control device 16 is mainly composed of a CPU, various memories, and control circuits. The control device 16 is equipped with a feeder management unit 60A, as shown in Figure 5. The feeder management unit 60A, together with the feeder control unit 60B which will be described later, constitutes the feeder control device 60. Details of the feeder management unit 60A will be described later. 【0021】The control device 16 stores various data such as control programs, component data, and cavity information used to control the mounting process. The control program indicates the mounting position, mounting angle, and component type of the components to be mounted on the substrate 91 in the planned mounting order. The mounting process includes a process that repeats a PP cycle (pick and place cycle), which includes a picking cycle and a mounting cycle, multiple times. The "picking cycle" mentioned above is a process that repeats the picking operation, in which components supplied by the component supply device 12 are picked up by the suction nozzle 134, multiple times. 【0022】 Furthermore, the "mounting cycle" described above is a process that repeatedly performs a mounting operation in which the collected parts are mounted at a predetermined mounting position on the substrate 91 at a predetermined mounting angle. In this way, the control program has a preset execution order for PP cycles, which consist of multiple grouped sampling and mounting operations, taking into consideration the number of suction nozzles 134 supported by the mounting head 133 and the travel distance of the mounting head 133. 【0023】 The part data includes shape data for each type of part. The "shape data" mentioned above includes at least one of the part's outer edge shape, the shape of the part's characteristic parts, and the part's dimensions. The "outer edge shape" of a part refers to the shape of the outer edge when the inside of the part is separated from the background using the outer edge as the boundary. 【0024】 The "shape of the characteristic part" of a component refers to the boundary shape of the external characteristic part resulting from the shape, pattern, color, etc., of the component. Examples of characteristic parts of a component include corners, bumps, terminals, and leads. In addition to shape data, component data may also include, for example, the maximum allowable travel speed (acceleration) for each component and the sampling position (e.g., the position where it contacts the suction nozzle 134). 【0025】Cavity information is information about cavities 45 (see Figure 4) formed in the supply area As of the bulk feeder 20, which are capable of individually accommodating parts, and is associated with the identification information (feeder ID) of the bulk feeder 20. The cavity information may include the shape of the cavity 45 in the supply area As (including the length and depth of each side), its position, orientation, and the type of corresponding part. 【0026】 The control device 16 performs recognition processing of the holding state of the parts held by each of the multiple holding members (suction nozzles 134). Specifically, the control device 16 processes the image data acquired by the part camera 14 to recognize the position and angle of each part with respect to the reference position of the mounting head 133. In addition to the part camera 14, the control device 16 may also process image data acquired by, for example, a head camera unit integrally provided with the mounting head 133, which images the parts from the side, below, or above. 【0027】 During the mounting process, the control device 16 controls the mounting operation by the mounting head 133 so that the component is mounted on the substrate 91 in a predetermined orientation. At this time, the control device 16 controls the mounting operation based on the recognized holding state of the component. In other words, the control device 16 corrects the position of the mounting head 133 and the angle of the suction nozzle 134 around the Q-axis to correct any positional and angular deviations of the component held by the suction nozzle 134 with respect to the Q-axis (the rotation axis of the suction nozzle 134). As a result, the component held by the suction nozzle 134 is mounted at a predetermined mounting position and angle as instructed by the control program. 【0028】 3. Configuration of the Bulk Feeder 20 As shown in Figure 2, the bulk feeder 20 is mounted on the parts mounting machine 10 and functions as part of the parts supply device. The bulk feeder 20 supplies parts that are stored in a bulk state (a random state with irregular orientations) that is not aligned like a carrier tape. Therefore, unlike a tape feeder, the bulk feeder 20 does not use a carrier tape, which has the advantage of eliminating the need to load a carrier tape and collect used tapes. 【0029】Some bulk feeders 20 supply parts in irregular positions to a planar supply area. However, if the parts are so close together in the supply area that they are touching each other, or if they are piled up (overlapping vertically), or if they are in a horizontal position with their width oriented vertically, the parts mounting machine 10 cannot pick up these parts. Therefore, in order to increase the proportion of parts that can be picked up, some bulk feeders 20 supply parts in an aligned state within the supply area. In this embodiment, a bulk feeder 20 of the type that aligns parts will be described as an example. 【0030】 3-1. Feeder body 21, bracket 22, support base 23 The bulk feeder 20 includes a feeder body 21, as shown in Figure 3. The feeder body 21 is formed in a flat, box-like shape. A connector 211 and two pins 212 are provided at the front of the feeder body 21 (the right end in Figure 3). When the feeder body 21 is set in the slot 121 of the component supply device 12, it is powered via the connector 211 and becomes capable of communicating with the control device 16 of the component mounting machine 10. The two pins 212 are inserted into guide holes provided in the slot and are used for positioning when the feeder body 21 is set in the slot 121. 【0031】 As shown in Figure 3, the bulk feeder 20 includes a bracket 22. The bracket 22 is vibrably mounted relative to the feeder body 21. The bracket 22 is formed in a block shape that extends in the front-rear direction of the feeder body 21 and supports the track member 41 of the transport unit 30 which is attached to the upper surface. The bracket 22 is subjected to a predetermined vibration from the transport vibration device 50. The track member 41 supported by the bracket 22 is fixed by a locking member (not shown). 【0032】As shown in Figure 3, the bulk feeder 20 includes a support base 23. The support base 23 is vibrably mounted relative to the feeder body 21 and supports the parts case 35 via the case holder 31 of the transport unit 30. The support base 23 is formed in a block shape that extends in the front-rear direction of the feeder body 21 and supports the case holder 31 attached to its upper surface. The support base 23 is subjected to a predetermined vibration by a discharge vibration device 56. In this embodiment, the case holder 31 supported by the support base 23 is fixed by a locking member (not shown). 【0033】 3-2. Conveying Unit 30 The bulk feeder 20 includes a conveying unit 30, as shown in Figure 3. The conveying unit 30 is detachably attached to the feeder body 21. In this embodiment, the conveying unit 30 supports the set parts case 35. The conveying unit 30 is a unit for conveying parts from the area that receives parts discharged from the parts case 35 (receiving section 311) to the supply area As. 【0034】 After being used for a predetermined loading process, the bulk feeder 20 undergoes a removal operation as a type of maintenance, in which all parts inside the feeder are removed in preparation for the next use. The transport unit 30 is designed to accommodate such removal operations and is modularized so that the part that functions as a flow path for the parts can be removed from the feeder body 21 in order to improve workability. In this embodiment, the transport unit 30 comprises a case holder 31, a track unit 32, and a connecting member 33. 【0035】3-2-1. Case Holder 31 The case holder 31 is vibrably mounted relative to the feeder body 21. The case holder 31 is attached to the feeder body 21 via a support base 23. As a result, the case holder 31 is vibrated by the discharge vibration device 56 via the support base 23. The case holder 31 supports the set parts case 35. The case holder 31 has a receiving portion 311 for receiving parts discharged from the parts case 35. In this embodiment, the part receiving portion of the case holder 31 has an inclined surface that is tilted forward with respect to the horizontal plane. The case holder 31 forms a flow path for parts that extends upward from the lower end of the inclined surface. 【0036】 The parts case 35 is an external device that houses multiple parts in bulk. The parts case 35 is detachably (replaceable) set in the case holder 31 of the transport unit 30 of the bulk feeder 20. The parts case 35 is formed in a flat, box-like shape, similar to the feeder body 21. The parts case 35 is set in the case holder 31 and is in a state where parts can be discharged from the discharge port 351 formed at the bottom. 【0037】 3-2-2. Track Unit 32 The track unit 32 includes a track member 41 that is detachably attached to the feeder body 21. The track member 41 is attached to the feeder body 21 via a bracket 22. As a result, the track member 41 is subjected to vibration by the transport vibration device 50 via the bracket 22. The track member 41 forms a transport path R through which multiple parts are transported, and a supply area As that is open upward and communicates with the transport path R, allowing multiple parts to be picked up. 【0038】 Here, "supply area As" refers to the area where parts are supplied in bulk and where parts can be picked up by the parts mounting machine 10. Also, "transport path R" refers to the path through which parts that have flowed from the case holder 31 side along the track member 41 are transported to supply area As. 【0039】The track member 41 is formed so as to extend in the front-to-back direction (left-to-right direction in Figure 3) of the feeder body 21. In this embodiment, an alignment member 42 is interchangeably attached to the track member 41. This alignment member 42 is, for example, one or more plate-shaped members. Thus, the track unit 32 is unitized by attaching one of several types of alignment members 42, selected according to the shape of several types of parts, to a common track member 41. 【0040】 As shown in Figure 4, the alignment member 42 constitutes a plurality of cavities 45 arranged in a predetermined pattern (staggered in this embodiment). Each of the plurality of cavities 45 is rectangular in shape, slightly larger than the outer shape of the parts supplied by the bulk feeder 20. In this way, the bulk feeder 20 has a plurality of cavities 45 that accommodate parts in a supply area As where parts are supplied in a collectible manner, with the thickness direction of the parts being in the vertical direction. A pair of side walls 46 projecting upward are formed on both edges of the track unit 32 in the width direction (vertical direction in Figure 4). The pair of side walls 46, together with the tip portion 47 of the track unit 32, surround the periphery of the transport path R, preventing leakage of parts being transported along the transport path R. 【0041】 The track unit 32 has a shutter 48 provided on the front end side of the track member 41. The shutter 48 is provided on the track member 41 so as to be openable and closable, and in the closed state closes the opening of the supply area As. When the track unit 32 is attached to the feeder body 21, the shutter 48 is connected to a shutter drive device 27. The opening and closing operation of the shutter 48 is controlled by the shutter drive device 27. The bulk feeder 20 can prevent parts from flying out and foreign matter from entering the supply area As by opening and closing the shutter 48. 【0042】3-2-3. Connecting Member 33 The connecting member 33 connects the case holder 31 and the track unit 32 so that a plurality of parts can flow through therebetween. The connecting member 33 forms a tubular shape through which a plurality of parts can flow inside. The connecting member 33 has flexibility and absorbs respective vibrations by deforming in response to the vibrations of the case holder 31 and the track unit 32. Thereby, the connecting member 33 reduces or blocks the vibrations transmitted between the case holder 31 and the track unit 32 that vibrate independently of each other. 【0043】 3-3. Air Supply Device 26 The bulk feeder 20 includes an air supply device 26 that supplies positive-pressure air to the conveying unit 30. When the conveying unit 30 is attached to the feeder main body 21, it is supplied with positive-pressure air by the air supply device 26, and a plurality of parts are circulated from the case holder 31 through the connecting member 33 to the track unit 32. In the present embodiment, the air supply device 26 supplies or blocks the positive-pressure air supplied from the outside based on the command of a feeder control device 60 described later from below the case holder 31. 【0044】 3-4. Shutter Driving Device 27 The shutter driving device 27 is a driving device that opens and closes the shutter 48 when the track unit 32 is attached to the feeder main body 21. The shutter driving device 27 switches between the closed state and the open state of the shutter 48 based on the command of the feeder control device 60. The closed state of the shutter 48 is a state in which the shutter 48 contacts the track member 41 and the opening of the supply area As is completely blocked. Further, the open state of the shutter 48 is a state in which the opening of the supply area As is not blocked and the main range of the supply area As (the range in which a plurality of cavities 45 are provided in the present embodiment) is exposed. 【0045】 3-5. Conveying Vibration Device 50 The bulk feeder 20 includes a conveying vibration device 50 provided on the feeder main body 21. The conveying vibration device 50 is a vibration device that conveys the parts on the conveying path R by applying vibration to the track member 41. In the present embodiment, the conveying vibration device 50 applies vibration to the bracket 22 to which the track member 41 is integrally fixed, and thereby applies vibration to the track member 41 that forms the conveying path R. 【0046】 Specifically, the conveying vibration device 50 includes a plurality of support members 51, a plurality of piezoelectric elements 52, and a power supply device 53. The plurality of support members 51 directly or indirectly connect the feeder main body 21 and the bracket 22 to support the bracket 22. In the present embodiment, the plurality of support members 51 include a forward support member 51A used for forward conveyance of parts and a backward support member 51B used for backward conveyance. The forward support member 51A and the backward support member 51B have different inclination directions with respect to the vertical direction. 【0047】 The plurality of piezoelectric elements 52 are vibrators that vibrate at a frequency corresponding to the power supplied by the power supply device 53. The plurality of piezoelectric elements 52 are attached to each of the plurality of support members 51. When at least a part of the plurality of piezoelectric elements 52 vibrates, vibration is applied to the track member 41 via the bracket 22. Also, the amplitude of the track member 41 varies according to the voltage applied to the piezoelectric element 52. 【0048】 The vibration sensor 55 is provided in the conveying vibration device 50 and detects a vibration value indicating the vibration state of the vibrating track member 41. As the vibration value indicating the above vibration state, an amplitude, a frequency, a decay time, a vibration locus (the movement locus of a specific part accompanying vibration), etc. can be applied. In the present embodiment, the vibration sensor 55 detects the actual vibration amplitude of the track member 41 when the piezoelectric element 52 is powered and vibrates. 【0049】 Further, the vibration sensor 55 is provided in each of the plurality of support members 51 that support the bracket 22 that vibrates integrally with the track member 41. More specifically, the piezoelectric element 52 and the vibration sensor 55 are provided in each of the forward support member 51A and the backward support member 51B. The forward vibration sensor 55A provided in the forward support member 51A detects the actual amplitude as a vibration value when the piezoelectric element 52 provided in the forward support member 51A is powered and applies vibration to the track member 41 via the bracket 22. 【0050】Furthermore, the retraction vibration sensor 55B, provided on the retraction support member 51B, detects the actual amplitude as a vibration value when the piezoelectric element 52 provided on the retraction support member 51B is powered and vibration is applied to the track member 41 via the bracket 22. When the transport vibration device 50 applies vibration to the track member 41, the track member 41 moves in an elliptical motion when viewed from the side. As a result, multiple parts on the transport path R are subjected to an external force either forward and upward, or backward and upward, depending on the rotational direction of the elliptical motion of the track member 41. As a result, multiple parts are transported to the front side or to the rear side of the track member 41. 【0051】 The power supply device 53 varies the frequency and voltage of the power supplied to the piezoelectric element 52 based on commands from the feeder control device 60, which will be described later. This adjusts the frequency and amplitude of the vibrations applied to the track member 41, and determines the rotational direction of the elliptical motion of the track member 41. When the frequency and amplitude of the vibrations of the track member 41, and the rotational direction of the elliptical motion caused by the vibrations, change, the transport speed of the transported parts, the degree of dispersion of the parts, and the transport direction also change. 【0052】 Therefore, in order to improve transport efficiency, the transport vibration device 50 pre-sets the power supply (drive voltage, drive frequency) to correspond to the vibration characteristics that vary from unit to unit. For example, the bulk feeder 20 performs a preparatory process to set the initial drive voltage and drive frequency when the track member 41 to be used in the planned supply operation is attached, that is, when the track member 41 is locked to the bracket 22 by the locking device. Details of the above preparatory process will be described later. 【0053】 3-6. Discharge Vibration Device 56 The bulk feeder 20 is equipped with a discharge vibration device 56 provided on the feeder body 21. The discharge vibration device 56 is a vibration device that discharges parts from the parts case 35 by applying vibration to the case holder 31 that supports the parts case 35. In this embodiment, the discharge vibration device 56 applies vibration to the support base 23 to which the case holder 31 is integrally fixed, thereby applying vibration to the parts case 35 via the case holder 31. 【0054】The discharge vibration device 56 has an oscillator that applies vibration to the case holder 31 in accordance with the supplied power. The discharge vibration device 56 may employ a configuration in which a solenoid 57, which is excited by the power supply, is used as the oscillator. The solenoid 57 is excited only during the period when it is supplied with power by the power supply device 58, thereby generating a magnetic field. As a result, the part to be vibrated (not shown) provided on the support base 23 is attracted to the solenoid 57 and moves from its initial position. 【0055】 Furthermore, when the power supply to the solenoid 57 by the power supply device 58 is interrupted, the magnetic force disappears, and the support base 23 moves back to its initial position. In this configuration, the discharge vibration device 56 vibrates the support base 23, the case holder 31, and the component case 35 by supplying pulsed power to the solenoid 57 via the power supply device 58, causing them to reciprocate horizontally. 【0056】 3-7. Feeder Control Unit 60B The bulk feeder 20 is equipped with a feeder control unit 60B. The feeder control unit 60B mainly consists of a CPU, various memories, and control circuits. When the bulk feeder 20 is set in the slot of the component mounting machine 10, the feeder control unit 60B is powered via the connector 211 and becomes capable of communicating with the control device of the component mounting machine 10. As shown in Figure 5, the feeder control unit 60B includes a storage unit 61, a transport control unit 62, and a replenishment control unit 67. 【0057】 The memory unit 61 of the feeder control unit 60B stores various data such as programs and transport parameters used to control the parts supply process. The transport control unit 62 controls the operation of the air supply device 26, the transport vibration device 50, the discharge vibration device 56, etc. The above-mentioned "transport parameters" are parameters used to control the operation of the transport vibration device 50 so that the vibration applied to the track unit 32 is appropriate when transporting parts in the parts supply process, and are set in advance, for example, associated with each type of part. The replenishment control unit 67 controls the replenishment operation of parts 36 to the track member 41. 【0058】In the bulk feeder 20 having the above configuration, the transport unit 30 and the transport vibration device 50 constitute a transport device that supports the parts 36 supplied by the replenishment operation and transports the parts 36 between the transport path R, which communicates with the supply area As, and the supply area As. As a transport device, in addition to the vibration method that applies vibration to the track member 41, an air transport method that blows positive pressure air upward from the top surface of the transport path R or the supply area As, or forward and backward from the side, may be adopted. The transport control unit 62 executes transport processing according to the type of transport device applied to the bulk feeder 20. 【0059】 4. Parts supply process of the bulk feeder 20 The parts supply process by the bulk feeder 20, which has the above configuration, will be explained with reference to Figure 6. The feeder control unit 60B first performs preparation processing (S10). Preparation processing includes initialization processing, which is performed for the first time after power is supplied to the bulk feeder 20, calibration processing of the transport vibration device 50, and processing to set the initial drive voltage and drive frequency. 【0060】 Next, the supply control unit 67 performs a supply process for parts to the transport path R formed on the track member 41, based on, for example, an external supply command or the result of a determination of whether or not a supply process is necessary (S20). This "supply process" is the process of supplying parts discharged from the parts case 35 to the components that support the parts (case holder 31, track member 41). In detail, in the supply process (S20), the supply control unit 67 performs a discharge operation of parts from the parts case 35 (S21). 【0061】 The supply control unit 67 controls the operation of the discharge vibration device 56 so that vibration is applied to the parts case 35 via the case holder 31 and support base 23. When the parts case 35 vibrates, parts are discharged from the discharge port 351. The discharged parts fall onto the inclined portion of the case holder 31 located below the discharge port 351 and slide forward along the inclined surface of the inclined portion. As a result, the parts accumulate in the receiving portion 311 in front of the inclined portion. 【0062】In this state, the supply control unit 67 performs a blow-up operation for the parts (S22). Specifically, the supply control unit 67 commands the air supply device 26 to supply positive-pressure air. The positive-pressure air supplied by the air supply device 26 blows up the multiple parts that had been accumulating and flows through the passage formed in the case holder 31 together with the parts. As a result, the positive-pressure air and the multiple parts flow from the case holder 31 through the connecting member 33 to the track unit 32 and reach the transport path R of the track unit 32. Here, the positive-pressure air is exhausted to the outside through an exhaust port formed in the cover of the track unit 32. 【0063】 The feeder control unit 60B determines whether or not there is an external supply command after the supply process of parts to the transport path R as described above (S31). If there is no supply command (S31: No), the transport control unit 62 suspends the execution of the parts transport process. As a result, the current supply status of parts in the supply area As is maintained, and the system remains in a state of waiting for a supply command. 【0064】 When a supply command is received (S31: Yes), the transport control unit 62 executes the transport process for the parts (S32). In the transport process for the parts, the transport vibration device 50 performs a transport operation (an operation to move the parts forward and backward) to transport the parts on the transport path R. Specifically, the transport control unit 62 causes the transport vibration device 50 to apply vibration to the track member 41 via the bracket 22. As a result, multiple parts are transported forward to the supply area As side. The transport control unit 62 also applies vibration to the track member 41 to move the parts forward or backward depending on the amount of parts to be supplied in the supply area As. 【0065】 Some of the multiple parts transported to the supply area As are housed in the cavity 45. Parts not housed in the cavity 45 are retracted into the transport path R by vibrations applied by the transport vibration device 50 and removed from the supply area As. When the shutter 48 is opened, the parts housed in the multiple cavities 45 become ready for pickup by the parts mounting machine 10. The opening and closing operation of the shutter 48 is performed based on commands from an external source. 【0066】Next, the feeder control unit 60B performs an adjustment process (S33) to set and adjust the frequency of vibration to be applied to the track member 41 in subsequent parts transport processes. This adjustment process (S33) adjusts the drive voltage as needed based on the actual amplitude of the track member 41 detected by the vibration sensor 55 as a result of the parts transport process (S32), and further adjusts the drive frequency according to the adjusted drive voltage. 【0067】 The feeder control device 60 determines whether a parts replenishment process (S20) is necessary (S34) after the parts transport process (S32) and adjustment process (S33). The necessity of the replenishment process is determined, for example, by the presence or absence of an external command from the feeder command unit 82 of the parts mounting machine 10, or based on the remaining amount (including estimated value) of parts supported by the track members 41. Details of the determination of whether a replenishment process is necessary will be described later. If a parts replenishment process is necessary (S34: Yes), the parts replenishment process is executed again (S20), and parts are replenished in the transport path R. On the other hand, if a parts replenishment process is not necessary (S34: No), the parts replenishment process is omitted, and the device enters a state of waiting for a supply command (S31). 【0068】 5. Detailed Configuration of the Feeder Control Device 60 In the parts supply process using the bulk feeder 20, it is necessary to stabilize the transport of parts and improve the efficiency of the supply operation. To this end, appropriate control of the vibration device (transport vibration device 50, discharge vibration device 56) and the air supply device 26 is required. More specifically, in a configuration as in this embodiment in which vibrators (piezoelectric elements 52, solenoids 57) apply vibration to the components (track members 41, case holders 31) according to the supplied power, it is preferable that the voltage (driving voltage) and frequency (driving frequency) of the power supplied to the vibration device are appropriately set. 【0069】For example, the drive voltage contributes to the amplitude of vibration, and in principle, the higher the setting, the larger the amplitude of vibration of the track member 41. Here, the vibrating body including the track member 41 has a predetermined natural frequency. The above-mentioned "vibrating body" is an assembly of members that vibrate integrally with the track member 41 due to excitation by the transport vibration device 50. In this embodiment, the vibrating body excited by the transport vibration device 50 consists of the track member 41, the bracket 22, a locking device connecting them, and a cover attached to the track member 41. 【0070】 The vibrating body, including the track member 41, is assembled in contact with other members such as the connecting member 33 within the bulk feeder 20, and also supports multiple parts being transported. Therefore, the vibrating body is subjected to reaction forces from other members and multiple parts during vibration, and the reaction forces also fluctuate depending on the number of parts it supports, resulting in a vibration environment. In such a vibration environment, the vibrating body resonates when it is subjected to vibrations at a frequency corresponding to its own natural frequency. The frequency at which the vibrating body resonates in accordance with this vibration environment will be referred to as the "resonance frequency" below. 【0071】 The vibrating body, including the track member 41, resonates when vibration is applied by a transport vibration exciter 50 supplied with power whose drive frequency is the resonant frequency, and vibrates stably with an expected amplitude corresponding to the drive voltage. In other words, if the drive frequency deviates from the resonant frequency, it may become impossible to obtain the expected amplitude for the drive voltage, or the vibration may become unstable, such as the amplitude periodically increasing or decreasing. If the vibration becomes unstable, the distance traveled by the component per unit time may decrease, or the component may be subjected to shock due to the amplitude suddenly increasing. 【0072】Therefore, in the preparation process (S10), the initial drive voltage and drive frequency are set so that the power supplied to the transport vibration device 50 during the parts supply process is appropriate. However, since the resonance frequency may fluctuate with changes in the vibration environment, adjustment of the drive frequency (S33) during production is necessary to maintain a good parts supply process. In addition, if the amount of parts supported by the track member 41 is insufficient or excessive, it may affect the efficiency of the parts supply process. Therefore, the feeder control device 60 of this embodiment employs a configuration that can improve the efficiency of the parts supply operation. 【0073】 The feeder control device 60 includes a replenishment control unit 67. The replenishment control unit 67 controls the replenishment operation of parts to the track member 41 based on the supply status of parts in the supply area As. The feeder control device 60 may also further include a state recognition unit 81. In this embodiment, as shown in Figure 5, the feeder control device 60 is composed of a feeder management unit 60A provided on the control device 16 of the parts mounting machine 10 and a feeder control unit 60B provided on the bulk feeder 20. The feeder control device 60 also employs a feeder control method applied to the bulk feeder 20. The feeder control method includes a replenishment control step executed by the replenishment control unit 67. The feeder control method may also further include a state recognition step executed by the state recognition unit 81. 【0074】 5-1. State Recognition Unit 81 The feeder management unit 60A has a state recognition unit 81. The state recognition unit 81 processes image data D1 (see Figure 8A) acquired by imaging the supply area As in which a plurality of cavities 45 are formed, to recognize the supply status of the parts 36 in the supply area As. The supply status of the parts 36 includes the determination result of whether the parts 36 supplied to the supply area As of the bulk feeder 20 are suitable for the part picking operation by the part mounting machine 10. 【0075】More specifically, as shown in Figure 7, the state recognition unit 81 acquires image data D1 by imaging with a camera (in this embodiment, a substrate camera 15) (S41). The supply area As contains a large number of bulk components 36, some of which may be housed in the cavity 45 in a normal orientation, some outside the cavity 45, some in contact with or piled up with others, and some in a horizontal orientation. Next, the state recognition unit 81 processes the image data D1 to perform recognition processing of the components 36 in the image data D1 (S42). 【0076】 More specifically, the state recognition unit 81 recognizes the component 36 included in the image data D1, for example, by blob analysis. The state recognition unit 81 binarizes the image data D1 according to a predetermined threshold and generates a blob. The state recognition unit 81 recognizes the component 36 based on the size and shape of the generated blob and the component data. Subsequently, the state recognition unit 81 performs a determination process to determine whether the recognized component 36 can be collected (S43). Even if a component 36 is located in the supply area As, if it is not housed in the cavity 45 or is in contact with other components 36, it is determined that it cannot be collected (unsuitable as a target for collection). 【0077】 The state recognition unit 81 records the recognition result of the supply state (S44). In this embodiment, the state recognition unit 81 determines the state for each of the multiple cavities 45. As a result, the multiple cavities 45 are classified into: accommodation cavities Cs (shown with diagonal lines in Figure 8B, "OK") that can accommodate the component 36 for collection; unsuitable cavities Cu (shown with an X mark connecting diagonals in Figure 8B, "NG") that contain at least a portion of the component 36 that is unsuitable for collection; and empty cavities Ce (shown with a dashed line in Figure 8B, "EMP") that do not contain the component 36. The state recognition unit 81 calculates the number (V1, V2, V3) of each state (OK, NG, EMP) of the multiple cavities 45. 【0078】Furthermore, in addition to determining the housing state for each of the multiple cavities 45 as described above, the state recognition unit 81 may also recognize the position and angle of the component 36 to be housed in the housing cavity Cs within the cavity 45. Note that the above-mentioned supply state recognition process (S40) is performed after the supply operation of the component 36 by the bulk feeder 20 is performed. The state recognition unit 81 can perform the supply state recognition process in parallel with, for example, the substrate loading process or the PP cycle. In this embodiment, the state recognition unit 81 performs the supply state recognition process (S40) each time a transport operation is performed in which multiple components 36 are transported between the transport path R and the supply area As and an attempt is made to house the components 36 in the multiple cavities 45. The result of the recognition process is updated according to the picking operation when a component 36 is picked from the bulk feeder 20, and is discarded when the supply operation of the component 36 by the bulk feeder 20 is performed. 【0079】 Furthermore, the control device 16 sets the movement path of the mounting head 133 in the sampling cycle based on the result of the recognition process (S40) by the state recognition unit 81. The above-mentioned "movement path" is the path taken when the mounting head 133 moves in the XY direction to pick up parts 36 from a plurality of cavities 45 in the sampling cycle of the PP cycle, and indicates the position and order of the plurality of cavities 45 in which the mounting head 133 is positioned. In this way, the control device 16 controls the system to efficiently pick up the required number of parts 36 from the supply area As of the bulk feeder 20 in the PP cycle. 【0080】 5-2. Feeder Command Unit 82 The feeder command unit 82 sends various commands, including a command to supply parts 36, to a plurality of feeders 122. In this embodiment, the feeder command unit 82 sends a command to supply parts 36 to the bulk feeder 20 and a command to replenish parts 36 to the transport unit 30, based on the progress of the mounting process and the results of the state recognition unit 81. As a result, the feeder control unit 60B of the bulk feeder 20 controls the replenishment and transport operations of the transport vibration device 50, the discharge vibration device 56, and the air supply device 26 in accordance with the command, and executes the replenishment and supply processes of parts 36. 【0081】5-3. Resupply Control Unit 67, Determination of Necessity of Resupply Processing Here, in order to suitably perform the transport processing (S32) and adjustment processing (S33) of the parts 36 as described above, it is desirable that the quantity of parts 36 supported by the case holder 31 and track members 41 (hereinafter also referred to as "remaining quantity") be within an appropriate range. This is because if the remaining quantity of parts 36 is insufficient, the probability of them being able to be collected and accommodated in the cavity 45 decreases, and if the remaining quantity of parts 36 is excessive, the excess parts 36 tend to remain in the supply area As without being removed. 【0082】 Therefore, the feeder command unit 82 sends a replenishment command to the bulk feeder 20 after it has performed a specified number of sampling cycles, causing it to discharge parts 36 from the parts case 35 or to operate the air supply device 26 to blow the parts 36 up onto the transport path R of the track member 41. However, in the above-described control, if there is a large error between the expected remaining amount of parts 36 based on the operation of the discharge vibrator 56 and the air supply device 26 for a predetermined time and the actual remaining amount, the remaining amount may be insufficient or excessive. 【0083】 Therefore, in this embodiment, the supply control unit 67 controls the supply operation of parts to the track member 41 based on the supply status of parts in the supply area As. Various modes can be adopted for controlling the supply operation. An example of a control mode for the supply operation is described below. Here, the determination of whether or not the supply process for part 36 is necessary (S34) is performed in the part supply process. 【0084】 As shown in Figure 9, the feeder management unit 60A determines whether the number of parts 36 collected since the previous replenishment process has reached a specified number (S51). The specified number corresponds, for example, to the number of parts 36 that are expected to be replenished to the track member 41 by the blowing operation of the air supply device 26 in one replenishment process. If the number of collected parts has reached the specified number (S51: Yes), the feeder management unit 60A determines that a replenishment process for parts 36 is required (S54). 【0085】In contrast, if the number of samples taken has not reached the specified number (S51: No), the replenishment control unit 67 obtains the result of the supply status recognition process (the result of determining whether or not it is suitable to be the target of the sampling operation by the parts mounting machine 10) (S52). In this embodiment, the replenishment control unit 67 obtains the results of the recognition process for a specified number of times from the most recent. The above "specified number of times" is a value that can be set arbitrarily and is set taking into account the actual supply processing of parts 36, etc. 【0086】 The supply control unit 67 determines, in the supply state recognition process performed a predetermined number of times, whether the ratio of empty cavities Ce to multiple cavities 45 is above a preset threshold (S53). Specifically, the supply control unit 67 calculates the ratio (V3 / (V1+V2+V3)) of the number of empty cavities Ce (V3) to the total number of cavities 45 (V1+V2+V3 in Figure 8) in the acquired supply state recognition process results. The supply control unit 67 then determines whether the state in which this ratio of empty cavities Ce is above the threshold has continued for a predetermined number of times. 【0087】 The replenishment control unit 67 determines that replenishment of component 36 is required if the proportion of empty cavity Ce remains high for a specified number of consecutive times (S53: Yes) (S54). As a result, as a response to a shortage of component 36, replenishment processing (S20) is executed, as shown in Figure 6. On the other hand, if the proportion of empty cavity Ce is below the threshold, or if the proportion does not remain high for a specified number of consecutive times (S53: No), the replenishment control unit 67 determines that replenishment of component 36 is not required (S55). As a result, the execution of replenishment processing (S20) is omitted. 【0088】 According to the above determination (S53), it can be inferred that the number of remaining parts 36 has decreased to a predetermined number due to an increase in the proportion of empty cavities Ce. Furthermore, the above determination (S53) includes a determination of whether the state of having a high proportion of empty cavities Ce has continued for a predetermined number of times. This prevents immediate replenishment processing in the event that a part 36 is accidentally removed from the supply area As to the transport path R side without being accommodated in the cavity 45. 【0089】In this way, the replenishment control unit 67 controls the replenishment operation based on the ratio of empty cavities Ce to the multiple cavities 45. This makes it possible to maintain the remaining amount of parts 36 supported by the track members 41 within an appropriate range. As a result, it is possible to control whether or not parts need to be replenished and to transport them efficiently, thereby improving the efficiency of the parts supply operation. 【0090】 Furthermore, if the bulk feeder 20 is set up externally and installed on the parts mounting machine 10 but has not yet started operation, even if the replenishment operation is performed a predetermined number of times from the first time, the proportion of empty cavity Ce may remain high for a continuous period. This is because, in the initial state of the bulk feeder 20 as described above, the parts 36 have been removed from the track member 41, and even if the replenishment operation is performed a predetermined number of times, the parts have not reached the supply area As, resulting in a high proportion of empty cavity Ce. 【0091】 However, if a replenishment operation is performed in the bulk feeder 20 in this state simply because the proportion of empty cavities Ce remains high for an extended period, it is possible that many parts 36 may have already reached the transport path R, resulting in excessive replenishment. Therefore, the replenishment control unit 67 may, after performing the replenishment operation a predetermined number of times from the initial operation, restrict the execution of the replenishment operation until the ratio of the number of accommodating cavities Cs to the number of cavities 45 exceeds a preset value. By adding such a determination, it is possible to prevent excessive replenishment of parts 36. 【0092】 Alternatively, without adding the above-mentioned determination, the supply control unit 67 may perform the example determination of whether or not to supply parts (S34), and, for example, if the proportion of unsuitable cavity Cu in the supply state of parts 36 is above a preset second threshold, it may take action by performing a predetermined removal process, assuming that there is an excess of parts 36 in the supply area As. The above removal process may include, for example, control in the transport process of parts 36 in which vibrations that cause parts 36 to move backward are applied for a longer period of time than vibrations that cause parts 36 to move forward. 【0093】6. Modifications of the Embodiment 6-1. Determination of the Necessity of Replenishment Processing In this embodiment, the replenishment control unit 67 controls the replenishment operation of parts based on the supply status of parts determined by the state recognition unit 81. As an example of this control of replenishment operation, blowing up parts 36 by the air supply device 26 is given as an example. In contrast, the replenishment control unit 67 may, in addition to or instead of blowing up parts 36, control the discharge operation of parts based on the supply status of parts. For example, if it is estimated that the number of remaining parts is small, the period for applying vibration to the parts case 35 may be extended or the amplitude of the vibration may be increased. 【0094】 Furthermore, the supply control unit 67 is configured to use the supply status recognized by the state recognition unit 81 through image processing. In contrast, the supply status of the parts may be determined based on the results of a sensor or vibration sensor 55 that detects the presence or absence of parts and is provided in the supply area, in addition to or instead of the results of image processing. 【0095】 Furthermore, in the embodiment, since the transport unit 30 had a cavity 45, the proportion of empty cavity Ce was used to determine whether replenishment processing was necessary. In contrast, if the transport unit 30 does not have a cavity 45, for example, the ratio of the number of parts that can be collected or the number of parts unsuitable for collection to the total number of parts in the supply area As may be used to determine whether replenishment processing is necessary. 【0096】 6-2. Feeder Control Device 60 In this embodiment, the feeder control device 60 is configured such that the replenishment control unit 67 is incorporated into the feeder control unit 60B of the bulk feeder 20, and the state recognition unit 81 is incorporated into the feeder management unit 60A of the component mounting machine 10. Alternatively, the replenishment control unit 67 and the state recognition unit 81 of the feeder control device 60 may be incorporated into the component mounting machine 10, the bulk feeder 20, and external devices. For example, the replenishment control unit 67 and the state recognition unit 81 may be incorporated into the control device of the component mounting machine 10 or the host computer 2. 【0097】1: Production system, 2: Host computer, 10: Parts mounting machine, 16: Control device, 20: Bulk feeder, 30: Conveying unit (conveying device), 31: Case holder, 32: Track unit, 41: Track member, 42: Alignment member, 45: Cavity, 33: Connecting member, 35: Parts case, 351: Discharge port, 36: Parts, 50: Vibration device for conveying (conveying device), 60: Feeder control device, 60A: Feeder management unit, 81: State recognition unit, 82: Feeder command unit, 60B: Feeder control unit, 61: Memory unit, 62: Conveying control unit, 62: Supply control unit, 91: Substrate, As: Supply area, R: Conveying path

Claims

1. A feeder control device applicable to a bulk feeder equipped with a track member having a supply area formed therein for supplying multiple parts in a manner that can be picked up, the feeder control device comprising a supply control unit that controls the operation of supplying parts to the track member based on the supply status of the parts in the supply area.

2. The feeder control device according to claim 1, further comprising a state recognition unit that performs image processing on image data acquired by imaging the supply area and performs recognition processing of the supply state in the supply area.

3. The feeder control device according to claim 2, wherein the state recognition unit recognizes the result of determining whether or not a plurality of components in the supply area are suitable for being picked up by the component mounting machine as the supply state.

4. The feeder control device according to claim 2, wherein the bulk feeder includes a transport device that transports the parts supplied by the replenishment operation between a transport path communicating with the supply area and the supply area, wherein the supply area has a plurality of cavities capable of accommodating the parts, and the state recognition unit recognizes the supply state by determining which of the plurality of cavities is an accommodation cavity that can accommodate the parts, an unsuitable cavity that contains at least a portion of the parts unsuitable for the sampling operation by the parts mounting machine, and an empty cavity that does not contain any parts.

5. The feeder control device according to claim 4, wherein the replenishment control unit controls the replenishment operation based on the ratio of the empty cavity to the plurality of cavities.

6. The feeder control device according to claim 4, wherein the state recognition unit performs the supply state recognition process each time a transport operation is performed in which a plurality of parts are transported by the transport device between the transport path and the supply area and an attempt is made to accommodate the parts in a plurality of cavities.

7. The feeder control device according to claim 6, wherein the supply control unit causes the supply operation to be executed when, in the supply state recognition process performed over a predetermined number of times, the ratio of the empty cavity to the plurality of cavities is equal to or greater than a preset threshold.

8. The feeder control device according to claim 6 or 7, wherein the replenishment control unit allows the replenishment operation to be performed a predetermined number of times from the first time, and then restricts the execution of the replenishment operation until the ratio of the storage cavity to the plurality of cavities exceeds a predetermined value set in advance.

9. The feeder control device according to any one of claims 4-7, wherein the conveying device has a vibration device that conveys the parts supported by the track member by applying vibration to the track member.

10. The feeder control device according to any one of claims 1 to 7, wherein the bulk feeder comprises a case holder that supports a parts case containing the parts and receives the parts discharged from the parts case below the track member, a connecting member that connects a plurality of the parts so that they can flow between the case holder and the track member, and an air supply device that supplies positive-pressure air to the case holder to allow the plurality of parts to flow to the track member, and the replenishment control unit controls the replenishment operation by controlling the operation of the air supply device.

11. A feeder control method applicable to a bulk feeder equipped with a track member having a supply area formed therein for supplying multiple parts in a manner that can be picked up, the method comprising a supply control step that controls the operation of supplying parts to the track member based on the supply state of the parts in the supply area.

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