JP7536168B2 - Component Mounting Machine - Google Patents

Description

This invention relates to a component mounter that enables the automation of feeder replacement work while the component mounter is in operation (during production).

Conventional component mounters, as shown in Patent Document 1 (JP Patent Publication No. 2009-266990), have a large number of tape feeders mounted on a collective exchange cart with casters, and the tape feeders are collectively attached and detached from the component mounter using this collective exchange cart, or, as shown in Patent Document 2 (JP Patent Publication No. 2012-169685), have a large number of tape feeders that can be detachably set on a feeder set table provided on the component mounter.

JP 2009-266990 A JP 2012-169685 A

In the conventional component mounting machines described above, when a tape feeder ran out of components while the component mounting machine was in operation (during production), the tape feeder needed to be replenished with components or replaced when the production board was changed, etc., and this required manual work by an operator, which could result in a human error setting the wrong tape feeder and stopping production. Moreover, manual tape feeder replacement is not only time-consuming, but also leads to a shortage of manpower when multiple tape feeder replacement periods overlap (during rush hour), which can cause the component mounting machine to stop.

The object of the present invention is to provide a component mounter that enables the automation of feeder replacement work while the component mounter is in operation.

In order to solve the above problems, the present invention provides a component mounter that mounts components on a circuit board, comprising: a suction work area in which a plurality of feeders that supply components to a component suction position of the component mounter are set in a line in the board transport direction; a feeder stock area that stores the next feeder to be replaced with a used feeder in the suction work area and collects the used feeder; and a replacement robot that replaces the used feeder in the suction work area with the feeder stored in the feeder stock area, and there is one feeder stock area that is located directly below the suction work area, the replacement robot has a clamp mechanism that clamps the feeder, and the replacement robot clamps the used feeder in the suction work area with the clamp mechanism and moves the feeder to the feeder stock area by lowering the clamp mechanism, and clamps the feeder stored in the feeder stock area with the clamp mechanism and moves the feeder to the suction work area by raising the clamp mechanism.

FIG. 1 is a perspective view showing a cassette-type feeder replacement system for a component mounter according to a first embodiment of the present invention. FIG. 2 is a perspective view showing a cassette type feeder. FIG. 3 is a perspective view showing a cassette-type feeder replacement system for a component mounter according to a second embodiment of the present invention. FIG. 4 is a perspective view showing a cassette-type feeder replacement system for a component mounter according to a third embodiment of the present invention. FIG. 5 is a perspective view showing a cassette-type feeder replacement system for a component mounter according to a fourth embodiment of the present invention as a reference example.

Below, we will explain how to implement the present invention using four examples 1 to 4.

A first embodiment of the present invention will be described with reference to FIGS.
First, the configuration of the cassette feeder 11 will be described with reference to FIG.
The cassette case 12 of the cassette type feeder 11 is formed of a transparent or opaque plastic plate or metal plate, etc., and has a side portion (cover) that can be opened and closed. A tape loading section 15 is provided inside the cassette case 12, into which a tape reel 14 around which a component supply tape 13 is wound is detachably (replaceably) loaded. A reel holding shaft 16 that rotatably holds the tape reel 14 is provided at the center of the tape loading section 15.

Inside the cassette case 12, there are provided a tape feed mechanism 18 that feeds the component supply tape 13 pulled out from the tape reel 14 to the component suction position, and a top film peeling mechanism 19 that peels off the top film 20 from the component supply tape 13 just before the component suction position to expose the components in the component supply tape 13. The component suction position is located near the end of the top surface of the cassette case 12 in the tape feed direction. Inside the cassette case 12, there is provided a tape guide 21 that guides the component supply tape 13 pulled out from the tape reel 14 to the component suction position.

The tape feed mechanism 18 is composed of a sprocket 22 located near the lower part of the component suction position, a motor 23 that rotates the sprocket 22, and other components. The teeth of the sprocket 22 engage with tape feed holes formed at a predetermined pitch on one side edge of the component supply tape 13 to rotate the sprocket 22, thereby feeding the component supply tape 13 to the component suction position.

The top film peeling mechanism 19 is composed of a tape holder 25 for holding down the component supply tape 13 just before the component suction position and peeling off the top film 20 from the upper surface of the component supply tape 13, a top film feed gear mechanism 27 for pulling the top film 20 peeled off by the tape holder 25 in the direction opposite to the tape feed direction and feeding it into the top film recovery section 26 provided at the top of the cassette case 12, and a motor 28 for driving the top film feed gear mechanism 27.

A waste tape discharge passage 30 is provided extending downward at the edge of the cassette case 12 in the tape feed direction, which guides downward and discharges the waste tape 13a (in this embodiment 1, only the carrier tape from which the top film 20 has been peeled off) that has passed the component suction position and from which the components have been removed, and the outlet 30a of the waste tape discharge passage 30 is provided at a position below the center of the end face of the cassette case 12 in the tape feed direction. An air inlet (not shown) is provided at the top of the waste tape discharge passage 30 so as to open into the end face of the cassette case 12 in the tape feed direction, and air is introduced into the waste tape discharge passage 30 from the air inlet to generate a downward air flow in the waste tape discharge passage 30.

A control device 32 is provided inside the cassette case 12, which controls the motor 23 of the tape feed mechanism 18 and the motor 28 of the top film peeling mechanism 19. In addition, although not shown, the cassette case 12 is provided with a communication and power connector that is connected to a communication and power connector on the cassette type feeder replacement system 34 side, which will be described later.

In addition, an identification information recording section (not shown) that records or stores feeder identification information (hereinafter referred to as "feeder ID") is provided at a predetermined position of the cassette case 12. As this identification information recording section, for example, a code label that records the feeder ID as a barcode, two-dimensional code, etc., may be used, or an electronic tag (also called an RF tag, IC tag, radio wave tag, or wireless tag) that stores feeder ID data may be used.

Next, the configuration of a cassette feeder replacement system 34 (multi-feeder unit) using the cassette feeder 11 configured as above will be described with reference to FIG. 1. A component mounter 35 is mounted on a base stand 36. The component mounter 35 is provided with two conveyors 37 for transporting circuit boards, a mounting head 38 that holds a suction nozzle (not shown) that picks up components supplied from the cassette feeder 11 and mounts them on the circuit board, an XY movement mechanism 39 that moves the mounting head 38 in the XY directions (left-right, front-back directions), and an imaging device (not shown) that takes an image of the components picked up by the suction nozzle.

The cassette feeder replacement system 34 is detachably installed in front of the component mounter 35 (in a direction perpendicular to the conveying direction of the conveyor 37). The cassette feeder replacement system 34 has three upper and lower levels: a suction work area 41, a replacement area 42, and a feeder stock area 43. The suction work area 41, located at the top level, is an area where multiple cassette feeders 11 that supply components to the component suction position of the component mounter 35 are lined up and set. This suction work area 41 is provided with a positioning mechanism (not shown) such as a positioning pin that positions the cassette feeder 11, and a holding mechanism (not shown) that holds the cassette feeder 11 by a spring mechanism or the like. Furthermore, the suction work area 41 is provided with a connector for communication and power (not shown) that is connected to a connector for communication and power (not shown) on the cassette feeder 11 side, and by connecting the two connectors, control signals and the like are sent and received between the control device 32 in the cassette case 12 and the control device of the component mounter 35, and electricity is supplied to the control device 32 in the cassette case 12, etc.

The feeder stock area 43, located at the bottom, is an area for storing the next cassette feeder 11 to replace the used cassette feeder 11 in the suction work area 41 and for collecting the used cassette feeder 11. This feeder stock area 43 has slots for setting the cassette feeders 11 one by one, the number of which corresponds to the number of feeders that can be accommodated in the feeder stock area 43, and is provided with an identification information reading unit (not shown) that reads the feeder ID from the identification information recording unit of the cassette feeder 11 set in each slot. The feeder ID read by the identification information reading unit is transmitted to the control device (control means) of the cassette feeder replacement system 34, so that the part type, etc. of the cassette feeder 11 set in each slot is automatically recognized.

The replacement area 42 located in the middle is an area for moving the cassette feeder 11 left and right (X direction) to match the empty slots (empty spaces) in the suction work area 41 and the feeder stock area 43 when replacing the cassette feeder 11 between the suction work area 41 and the feeder stock area 43.

An exchange robot 45 is provided in front of the cassette feeder exchange system 34. This exchange robot 45 is composed of a clamp mechanism 46 that clamps the cassette feeder 11, a lifting mechanism 47 that raises and lowers the clamp mechanism 46 between the suction work area 41 and the feeder stock area 43, and a horizontal movement mechanism 48 that moves the clamp mechanism 46 in the arrangement direction of the cassette feeders 11 in the exchange area 42. Although only one exchange robot 45 is shown in FIG. 1, a configuration with two exchange robots 45 may also be provided. The following explanation will be given of an example of operation with two exchange robots 45.

Next, the operation of the cassette-type feeder replacement system 34 having the above configuration will be described.
During production (when the component mounting machine 35 is operating), the number of cassette feeders 11 required for production are set in the top suction work area 41 of the cassette feeder replacement system 34, and the next cassette feeder 11 to replace the out-of-parts (used) cassette feeder 11 in the suction work area 41 is stored in the bottom feeder stock area 43.

If any of the cassette feeders 11 in the suction work area 41 runs out of parts during production, the clamping mechanism 46 of one of the replacement robots 45 is raised to a position in the suction work area 41 by the lifting mechanism 47, and then the clamping mechanism 46 is moved in the X direction (the arrangement direction of the cassette feeders 11) by the horizontal movement mechanism 48 to align the position of the clamping mechanism 46 with the position of the out-of-part cassette feeder 11, and the out-of-part cassette feeder 11 is clamped and removed from the holding mechanism of the suction work area 41. After this, the clamp mechanism 46 is lowered to the middle replacement area 42, and the out-of-part cassette feeder 11 clamped by the clamp mechanism 46 is lowered to the middle replacement area 42, and then the clamp mechanism 46 is moved in the X direction by the horizontal movement mechanism 48 to align the X direction position of the out-of-part cassette feeder 11 with the position of an empty slot in the bottom feeder stock area 43, and then the out-of-part cassette feeder 11 is lowered and collected in an empty slot in the feeder stock area 43. If there is no empty slot in the feeder stock area 43, the out-of-part cassette feeder 11 is made to wait in the replacement area 42. Then, the out-of-part cassette feeder 11 is manually or automatically discharged from the feeder stock area 43, and the wait is released.

Simultaneously with, or before or after, the operation of removing the out-of-part cassette feeder 11 from the top-level suction work area 41 and recovering it in the bottom-level feeder stock area 43 as described above, the clamping mechanism 46 of the other replacement robot 45 is lowered to the position of the bottom-level feeder stock area 43 by the lifting mechanism 47, and then the clamping mechanism 46 is moved in the X direction by the horizontal movement mechanism 48 to align the clamping mechanism 46 with the position of the next cassette feeder 11 to replace the out-of-part cassette feeder 11, and clamps the next cassette feeder 11. Thereafter, the clamp mechanism 46 is raised to the middle replacement area 42, and the next cassette feeder 11 clamped to the clamp mechanism 46 is raised to the middle replacement area 42. The clamp mechanism 46 is then moved in the X direction by the horizontal movement mechanism 48 to align the X direction position of the next cassette feeder 11 with the position of the slot in the top suction work area 41 from which the out-of-part cassette feeder 11 was removed. The next cassette feeder 11 is then raised and set in the slot in the suction work area 41. During this setting, the next cassette feeder 11 is positioned by the positioning mechanism and held by the holding mechanism.

The cassette feeder 11 may be set in the suction work area 41 manually by an operator before the start of production, or the cassette feeder 11 may be transferred from the feeder stock area 43 to the suction work area 41 by a replacement robot 45.

In the present embodiment 1 described above, the cassette feeder 11 can be freely replaced between the suction work area 41 and the feeder stock area 43 during production by the replacement robot 45, and the replacement work of the cassette feeder 11 can be automated.

Furthermore, an exchange area 42 is provided between the suction work area 41 and the feeder stock area 43, and when the cassette feeder 11 is exchanged between the suction work area 41 and the feeder stock area 43, the cassette feeder 11 is moved in the X direction to match an empty slot in the suction work area 41 and the feeder stock area 43, and if there is no empty slot in the area to receive the cassette feeder 11, the cassette feeder 11 is made to wait in the exchange area 42 until the empty slot becomes available, so that the cassette feeder 11 can be smoothly exchanged between the suction work area 41 and the feeder stock area 43.

In addition, in this embodiment 1, the cassette feeder 11 is provided with an identification information recording unit that records or stores the feeder ID, and the feeder stock area 43 is provided with an identification information reading unit that reads the feeder ID from the identification information recording unit of the cassette feeder 11 stored in the feeder stock area 43. The control device of the cassette feeder replacement system 34 identifies the cassette feeder 11 based on the feeder ID transmitted from the identification information reading unit of the feeder stock area 43. Therefore, when storing the cassette feeder 11 in the feeder stock area 43, it is possible to freely store it in any available slot, and storing the cassette feeder 11 in the feeder stock area 43 can be easily performed.

In addition, the present invention may be configured so that only one replacement robot 45 is used to replace the cassette feeder 11 between the suction work area 41 and the feeder stock area 43. In this case, when replacing the cassette feeder 11 between the suction work area 41 and the feeder stock area 43, an empty slot can be provided in the area into which the feeder is to be inserted.

In addition, the present invention is not limited to a configuration in which only one component mounter 35 is mounted on the base stand 36 as shown in FIG. 1, but multiple component mounters 35 may be mounted side by side on the base stand 36. When a cassette-type feeder replacement system 34 is provided for multiple component mounters 35, each component mounter 35 may be provided with one cassette-type feeder replacement system 34, or one cassette-type feeder replacement system 34 may be used to replace the cassette feeders 11 for two or more component mounters 35.

Next, a second embodiment of the present invention will be described with reference to FIG. 3. However, parts that are substantially the same as those in the first embodiment will be given the same reference numerals and descriptions thereof will be omitted or simplified, and mainly the parts that differ from the first embodiment will be described.

In this second embodiment, the supply of cassette-type feeders 11 to the feeder stock area 43 is automated. Specifically, a feeder transport conveyor 51 is provided inside the base table 36 for carrying in cassette-type feeders 11 to be supplied to the feeder stock area 43 and carrying out used (out-of-parts) cassette-type feeders 11, and a transfer robot 52 is provided for transferring cassette-type feeders 11 between the feeder transport conveyor 51 and the feeder stock area 43.

The feeder transport conveyor 51 is set up to transport the cassette feeder 11 in a horizontal position in the same direction (X direction) as the circuit board transport conveyor 37. The feeder transport conveyor 51 is provided with a stopper 53 that can be raised and lowered to stop the cassette feeder 11 that has been brought in at a position behind the feeder stock area 43.

The loading robot 52 is composed of a clamping mechanism 54 that clamps the cassette feeder 11, a rotation mechanism 55 that rotates the clamping mechanism 54 around a horizontal axis, and a movement mechanism 56 that moves the clamping mechanism 54 in the vertical direction and the XY direction (horizontal direction).

In the present embodiment 2 configured as described above, the feeder transport conveyor 51 and the transfer robot 52 are used to transfer the cassette-type feeder 11 between the feeder transport conveyor 51 and the feeder stock area 43 as follows:

When a cassette-type feeder 11 to be replenished in the feeder stock area 43 is carried in on the conveyor 51, the stopper 53 is protruded upward to stop the cassette-type feeder 11 at the rear position of the feeder stock area 43. After this, the loading and unloading robot 52 is operated to clamp the cassette-type feeder 11 lying on its side on the feeder transport conveyor 51 with the clamp mechanism 54, and the moving mechanism 56 raises the clamp mechanism 54 to lift the cassette-type feeder 11 from the feeder transport conveyor 51, ensuring a rotation space for the cassette-type feeder 11. After this, the clamp mechanism 54 is rotated 90° by the rotation mechanism 55 to rotate the cassette feeder 11 90° to an upright position, and then the movement mechanism 56 moves the clamp mechanism 54 in a direction parallel to the feeder transport conveyor 51 (X direction) to align the cassette feeder 11 with the position of an empty slot in the feeder stock area 43, and the cassette feeder 11 is stored in the empty slot in the feeder stock area 43.

On the other hand, when removing a used (out of parts) cassette-type feeder 11 from the feeder stock area 43 and transporting it, the stopper 53 is retracted downward, and the used cassette-type feeder 11 from the feeder stock area 43 is clamped by the clamp mechanism 54 and pulled out, and the clamp mechanism 54 is rotated 90 degrees by the rotation mechanism 55 to turn the cassette-type feeder 11 from an upright position to a lying position, and then placed on the feeder transport conveyor 51 for transport.

In the present embodiment 2 described above, a feeder transport conveyor 51 is provided to bring in cassette-type feeders 11 to be replenished in the feeder stock area 43 and to transport used cassette-type feeders 11 out, and a transfer robot 52 is provided to transfer the cassette-type feeders 11 between the feeder transport conveyor 51 and the feeder stock area 43, so that the supply of cassette-type feeders 11 to the feeder stock area 43 can also be automated.

In this embodiment 2, a single feeder transport conveyor 51 is used to bring in cassette feeders 11 to be replenished in the feeder stock area 43 and to transport used cassette feeders 11, but a separate conveyor dedicated to bringing in cassette feeders 11 and a separate conveyor dedicated to transporting used cassette feeders 11 may also be provided.

Next, a third embodiment of the present invention will be described with reference to FIG. 4. However, parts that are substantially the same as those in the first embodiment will be given the same reference numerals and descriptions thereof will be omitted or simplified, and the following mainly describes parts that are different from the first embodiment.

In this embodiment 3, the cassette feeder 11 is supplied to the feeder stock area 43 by an operator. Specifically, the cassette feeder replacement system 34 is provided with a front door 61 that can be opened and closed to open the feeder stock area 43, and the replacement robot 45 is provided inside the front door 61. In FIG. 4, the front door 61 is a large door that opens and closes the three areas of the suction work area 41, the replacement area 42, and the feeder stock area 43 all at once, but it may be a small door that opens and closes only the feeder stock area 43. In this case, the large door can automatically replace the cassette feeder 11 in the suction work area 41, but it is necessary to stop the operation of the component mounter 35 to ensure the safety of the operator. On the other hand, it is desirable that the small door only stops the operation of the replacement robot 45, the clamp mechanism 46, the lift mechanism 47, and the horizontal movement mechanism 48 when opening and closing.

In this embodiment 3, a feeder set table 62 on which the cassette feeders 11 are set is provided in the feeder stock area 43 so that it can be tilted forward, and by tilting the feeder set table 62 forward when the front door 61 is open, the cassette feeders 11 can be easily replenished manually onto the feeder set table 62. After the cassette feeders 11 have been replenished onto the feeder set table 62, the feeder set table 62 can be returned to its original upright position and the front door 61 closed, allowing the cassette feeder replacement system 34 to become operable.

In the above-described embodiment 3, the cassette feeders 11 are replenished to the feeder stock area 43 by an operator, but the cassette feeders 11 can be freely replaced between the suction work area 41 and the feeder stock area 43 during production by the replacement robot 45, so that the replacement work of the cassette feeders 11 can be automated.

In addition, because the timing of replenishing the component supply tape 13 can be determined according to the convenience of the worker, not the convenience of the component mounter 35, in a production line equipped with multiple component mounters 35, it is possible to replenish the cassette feeders 11 in the feeder stock area 43 for the multiple component mounters 35 in sequence, eliminating the need for a worker to remain in front of the component mounter 35 to continue production, and reducing the number of workers required for production management.

Next, a fourth embodiment of the present invention will be described with reference to FIG.
The cassette-type feeder replacement system 71 of the fourth embodiment is configured to include a suction work area 72 in which a plurality of cassette-type feeders 11 that supply components to component suction positions of the component mounter 35 are arranged and set, a used feeder recovery area 73 in which used (out of components) cassette-type feeders 11 are removed from the suction work area 72 and recovered, a feeder stock area 74 in which the next cassette-type feeder 11 to replace the used cassette-type feeder 11 in the suction work area 72 is stored, a recovery robot (not shown) that removes the used cassette-type feeder 11 from the suction work area 72 and recovers it in the used feeder recovery area 73, and a supply robot (not shown) that removes the next cassette-type feeder 11 from the feeder stock area 74 and supplies it to the suction work area 72. In this case, the feeder stock area 74 is arranged on the front side of the suction work area 72, and the used feeder recovery area 73 is arranged below the feeder stock area 74.

In this embodiment 4, the worker sets the necessary cassette feeders 11 in the feeder stock area 74 in advance. When any of the cassette feeders 11 in the suction work area 72 becomes used (out of parts) during production, a recovery robot removes the used cassette feeder 11 from the suction work area 72 and recovers it in the used feeder recovery area 73, and a supply robot removes the next cassette feeder 11 from the feeder stock area 74 and replenishes it in the suction work area 72. The used feeder recovery area 73 may be located for each component mounter 35, or multiple component mounters 35 may share a conductor and be collected in one place.

In the fourth embodiment described above, the replacement work of the cassette feeder 11 while the component mounter 35 is in operation can also be automated.

The cassette feeder used in the cassette feeder replacement system of the present invention is not limited to the configuration shown in FIG. 2. For example, a take-up section for taking up the component supply tape may be provided in the cassette case, and the component supply tape introduced into the cassette case from the outside may be wound up on the take-up section, so that the tape loading section loads the component supply tape into the cassette case.

It goes without saying that the present invention is not limited to the above examples, and can be modified in various ways without departing from the spirit and scope of the invention.

11... cassette type feeder, 12... cassette case, 13... component supply tape, 13a... waste tape, 14... tape reel, 15... tape loading section, 16... reel holding shaft, 18... tape feed mechanism, 19... top film peeling mechanism, 21... tape guide, 22... sprocket, 25... tape holder, 26... top film recovery section, 27... top film feed gear mechanism, 28... motor, 30... waste tape discharge passage, 32... control device, 34... cassette type feeder replacement system, 35... component mounting machine, 36... base stand, 37... conveyor, 38...Placement head, 39...XY movement mechanism, 41...Suction work area, 42...Replacement area, 43...Feeder stock area, 45...Replacement robot, 46...Clamp mechanism, 47...Lifting mechanism, 48...Horizontal movement mechanism, 51...Feeder transport conveyor, 52...Replacement robot, 53...Stopper, 54...Clamp mechanism, 55...Rotation mechanism, 56...Movement mechanism, 61...Front door, 62...Feeder set table, 71...Cassette type feeder replacement system, 72...Suction work area, 73...Used feeder collection area, 74...Feeder stock area

Claims (2)

A component mounter that mounts components on a circuit board,
a pickup work area in which a plurality of feeders for supplying the components to component pickup positions of the component mounter are arranged in a board transport direction;
a feeder stock area for storing a next feeder to replace the used feeder in the suction work area and for collecting the used feeder;
a replacement robot that replaces a used feeder in the suction work area with a feeder stored in the feeder stock area;
Equipped with
The feeder stock area is one, and is disposed directly below the suction operation area;
The replacement robot includes a clamping mechanism that clamps a feeder,
The replacement robot is a component mounter that clamps a used feeder in the suction work area with the clamp mechanism and lowers the clamp mechanism, thereby moving the feeder to the feeder stock area, and clamps a feeder stored in the feeder stock area with the clamp mechanism and raises the clamp mechanism, thereby moving the feeder to the suction work area. the replacement robot includes a lifting mechanism for lifting and lowering the clamping mechanism between the suction work area and the feeder stock area, and a horizontal movement mechanism for moving the clamping mechanism along an arrangement direction of the feeders in the suction work area,
2. The component mounter of claim 1, wherein, when removing a used feeder from the suction work area during production, the replacement robot raises the clamp mechanism to a position in the suction work area by the lifting mechanism, then moves the clamp mechanism along the arrangement direction of the feeders in the suction work area by the horizontal movement mechanism to align the position of the clamp mechanism with the position of the used feeder, clamps the used feeder, and removes it from the suction work area.

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