CN112042285A - Automatic replacement system, management device, and automatic replacement method - Google Patents

Automatic replacement system, management device, and automatic replacement method Download PDF

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Publication number
CN112042285A
CN112042285A CN201980028913.5A CN201980028913A CN112042285A CN 112042285 A CN112042285 A CN 112042285A CN 201980028913 A CN201980028913 A CN 201980028913A CN 112042285 A CN112042285 A CN 112042285A
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CN
China
Prior art keywords
component
unit
component supply
recognition
end effector
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Granted
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CN201980028913.5A
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Chinese (zh)
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CN112042285B (en
Inventor
小林广纪
江口亮司
大堀哲史
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Panasonic Intellectual Property Management Co Ltd
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Panasonic Intellectual Property Management Co Ltd
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Priority to CN202311021685.3A priority Critical patent/CN117062427A/en
Publication of CN112042285A publication Critical patent/CN112042285A/en
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
    • B25J—MANIPULATORS; CHAMBERS PROVIDED WITH MANIPULATION DEVICES
    • B25J5/00—Manipulators mounted on wheels or on carriages
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K13/00—Apparatus or processes specially adapted for manufacturing or adjusting assemblages of electric components
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K13/00—Apparatus or processes specially adapted for manufacturing or adjusting assemblages of electric components
    • H05K13/02—Feeding of components

Abstract

A transfer device of an automatic exchange system includes an end effector, a moving mechanism, a recognition unit, a path setting unit, and a control unit. An end effector holding component supply device or a component container. The moving mechanism moves the end effector. The identification unit identifies a unit identifier provided in the component supply unit. The path setting unit sets a movement path for moving the end effector. The control unit controls the moving mechanism to move the end effector to at least one of the component supplying device and the component container based on the set moving path and the recognition result obtained by the recognition unit.

Description

Automatic replacement system, management device, and automatic replacement method
Technical Field
The present disclosure relates to an automatic replacement system and management device and an automatic replacement method for a component container and a component supply device of a replacement component supply unit.
Background
The component mounting apparatus includes a component container such as a reel for accommodating a plurality of components, and a component supply unit such as a carriage for holding the component container in parallel with a component supply device such as a feeder for moving the components accommodated in the component container to a component supply position, and mounts the components supplied to the component supply position on the substrate. An automatic exchange device for automatically exchanging a component supply device mounted on such a component mounting device is known (for example, see patent document 1). Patent document 1 discloses that a component cassette in which a component container and a component supply device are integrated is placed on a standby platform provided in a component mounting device, gripped by a robot provided in the component mounting device, transferred to a component supply unit, and replaced.
Prior art documents
Patent document
Patent document 1: japanese laid-open patent publication No. 4-283035
Disclosure of Invention
However, in the case where the component supply device and the component container separately assembled are replaced individually, or in the case where the component supply device and the component container are replaced by a robot independent of the component mounting device, or the like, the robot and the replacement object may be displaced from a predetermined position, and in such a case, there is room for improvement in not erroneously replacing the component supply device and the component container.
The present disclosure provides an automatic replacement system, a management device, and an automatic replacement method capable of accurately replacing a component container.
The automatic exchange system of the present disclosure exchanges at least one of the component container and the component supply device that moves the component accommodated in the component container to the component supply position. The component feeding device and the component container are included in the component feeding unit. The automatic exchange system includes a transfer device having an end effector, a moving mechanism, a recognition unit, a path setting unit, and a control unit. An end effector holding component supply device or a component container. The moving mechanism is configured to move the end effector. The identification unit identifies a unit identifier provided in the component supply unit and used for identifying the component supply unit. The path setting unit sets a movement path for moving the end effector. The control unit controls the moving mechanism. The control unit moves the end effector to at least one of the component supply device and the component container based on the set movement path and the recognition result obtained by the recognition unit.
The management device of the present disclosure generates a work instruction for the transfer device. The transfer device includes a movable end effector that replaces at least one of the component container and the component supply device that moves the component accommodated in the component container to the component supply position. The component container and the component feeding device are included in the component feeding unit. The management device includes: a storage unit for storing the outer dimension information of the component supply unit; and a work instruction generating unit that generates a work instruction including a movement target of the end effector, based on the outside dimension information of the component supply unit.
The automatic replacement method of the present disclosure replaces at least one of the component supply device and the component container with a transfer device having a movable end effector. The component feeding device and the component container are included in the component feeding unit. The component supplying device moves the components accommodated in the component container to the component supplying position. In the automatic replacement method, a unit identifier provided in the component supply unit and used for identifying the component supply unit is identified. On the other hand, a movement path for moving the end effector is set. Then, the end effector is moved to at least one of the component supplying device and the component container based on the set moving path and the recognition result of the unit recognition object.
According to the present disclosure, the component container can be accurately replaced.
Drawings
Fig. 1 is a structural explanatory diagram of a component mounting system according to an embodiment of the present disclosure.
Fig. 2 is a diagram illustrating a component mounting line included in the component mounting system according to the embodiment of the present disclosure.
Fig. 3 is an explanatory diagram of the configuration of a component mounting device to which a component supply cart provided in a component mounting system according to an embodiment of the present disclosure is attached.
Fig. 4 is a front view of a component supply carriage included in the component mounting system according to the embodiment of the present disclosure.
Fig. 5 is an explanatory diagram of a configuration of a component mounting device equipped with a tray feeder included in the component mounting system according to the embodiment of the present disclosure.
Fig. 6 is a perspective view of a tray feeder included in the component mounting system according to the embodiment of the present disclosure.
Fig. 7 is an explanatory diagram of the configuration of a transfer device provided in the component mounting system according to the embodiment of the present disclosure.
Fig. 8 is a block diagram showing a configuration of a control system of a component mounting system (automatic replacement system) according to an embodiment of the present disclosure.
Fig. 9 is an explanatory diagram of an example of unit information used in the component mounting system (automatic replacement system) according to the embodiment of the present disclosure.
Fig. 10 is an explanatory diagram of the outer dimensions of the component supply carriage included in the component mounting system according to the embodiment of the present disclosure.
Fig. 11 is an explanatory diagram of an example of the outer dimension information used in the component mounting system (automatic replacement system) according to the embodiment of the present disclosure.
Fig. 12 is an explanatory diagram of an example of supply device information used in the component mounting system (automatic replacement system) according to the embodiment of the present disclosure.
Fig. 13 is a diagram illustrating a flow of an automatic replacement method according to an embodiment of the present disclosure.
Fig. 14A is an explanatory view of a process of automatically replacing a component reel in a component mounting system (automatic replacement system) according to an embodiment of the present disclosure.
Fig. 14B is a process explanatory diagram following the automatic replacement of the component reel of fig. 14A.
Fig. 14C is a process explanatory diagram following the automatic replacement of the component reel of fig. 14B.
Fig. 15A is a process explanatory diagram following the automatic replacement of the component reel in fig. 14C.
Fig. 15B is a process explanatory diagram following the automatic replacement of the component reel of fig. 15A.
Fig. 15C is a process explanatory diagram following the automatic replacement of the component reel in fig. 15B.
Fig. 16 is a front view of a 2 nd component supply cart provided in the component mounting system according to the embodiment of the present disclosure.
Fig. 17A is a partially enlarged view of an example of a carriage recognition target formed on the 2 nd component supply carriage according to the embodiment of the present disclosure.
Fig. 17B is a partially enlarged view of an example of the mounting portion recognition target formed on the 2 nd component supply cart according to the embodiment of the present disclosure.
Fig. 18 is an explanatory view of the configuration of the 2 nd transfer device included in the component mounting system according to the embodiment of the present disclosure.
Fig. 19A is a process explanatory diagram of a contact detection operation for identifying the position of the cart identification target by the 2 nd transfer device according to the embodiment of the present disclosure.
Fig. 19B is a process explanatory diagram following the contact detection operation of fig. 19A.
Fig. 19C is a process explanatory diagram following the contact detection operation of fig. 19B.
Fig. 20 is an explanatory view for identifying the position of the 2 nd component supply carriage by the 2 nd transfer device according to the embodiment of the present disclosure.
Detailed Description
Hereinafter, an embodiment of the present disclosure will be described in detail with reference to the drawings. The configurations, shapes, and the like described below are examples for explanation, and can be appropriately changed according to the specifications of the component mounting system, the component mounting line, the component mounting device, the component feeding carriage, and the tray feeder. In the following, corresponding elements in all the drawings are denoted by the same reference numerals, and redundant description thereof is omitted. In fig. 1 and a part described later, an X direction (a left-right direction in fig. 4) in a substrate transfer direction and a Y direction (a left-right direction in fig. 3) in a substrate transfer direction are shown as 2-axis directions orthogonal to each other in a horizontal plane. In fig. 2, the Z direction (vertical direction in fig. 3) is shown as a height direction perpendicular to the horizontal plane.
First, the structure of the component mounting system 1 will be described with reference to fig. 1. The component mounting system 1 is configured such that 3 component mounting lines L1 to L3 arranged on the floor F are connected via a wired or wireless communication network 2 and managed by a management computer 3. Each of the component mounting lines L1 to L3 is configured by connecting a plurality of devices including a component mounting device as described below, and has a function of manufacturing a mounting board on which components are mounted on a board. The number of the component mounting lines L1 included in the component mounting system 1 does not need to be 3, and may be 1, 2, or 4 or more.
A material storage W is provided on the ground F. It is assumed that the components to be supplied to the component mounting apparatuses constituting the component mounting lines L1 to L3 are stored in the material storage W so as to be stored in component reels, trays, rod-shaped housings, and the like. The component reel, the tray, and the rod-like housing are component containers that accommodate a plurality of components.
The floor F is provided with a plurality of transfer devices V as automated guided vehicles. The transfer device V incorporates a wireless communication unit T, and transmits and receives signals and information to and from the management computer 3 via a wireless management communication unit 3a of the management computer 3. The transfer device V autonomously moves on the travel path set on the floor surface F based on the work instruction transmitted from the management computer 3, using information collected by itself such as a travel path belt provided on the floor surface F, a beacon, various sensors (such as a GPS and an obstacle sensor) built in the transfer device V, and a camera.
Next, the detailed structure of the component mounting lines L1 to L3 will be described with reference to fig. 2. The component mounting lines L1 to L3 have the same configuration, and the component mounting line L1 will be described below. The component mounting line L1 includes a printer M1, a component mounting device M2, a component mounting device M3, a component mounting device M4, and a reflow apparatus M5 in this order from the upstream side (left side in fig. 2) in the substrate conveyance direction. Each apparatus has a substrate transport mechanism such as a belt conveyor, and the substrate transport mechanism of each apparatus transports the substrate from upstream to downstream to manufacture a mounted substrate. Each device is connected to the management computer 3 via the wired or wireless communication network 2, and can transmit and receive data to and from the management computer 3.
In fig. 2, a printer M1 has a function of printing cream-like solder on a substrate via a screen mask. The 3-stage component mounting devices M2 to M4 have the following functions: the component supplied to the component supply unit 4 is picked up by a component suction nozzle mounted on the mounting head, and is transferred to and mounted on the mounting point of the board on which the cream solder is printed. The component supply carriage 5 described later is mounted on the component supply unit 4 of the component mounting devices M2 and M3. The component feeder 6 described later is mounted on the component supply section 4 of the component mounting device M4.
The reflow apparatus M5 has a function of heating a substrate on which a component is mounted, melting the cream solder, and then solidifying the solder to solder the component to the substrate. The management computer 3 executes processes for assisting the replenishment work of the components to the component mounting apparatuses M2 to M4, in addition to the production management of the mounting boards manufactured in the component mounting lines L1 to L3, the downloading of programs and data necessary for the manufacture of the mounting boards with respect to the respective apparatuses for component mounting, and the like.
Next, the structure of the component mounting apparatuses M2 and M3 will be described with reference to fig. 3 and 4. In fig. 3, a substrate transport mechanism 8 provided on the upper surface of a base 7 transports, positions, and holds a substrate 9 in the X direction. Above the substrate transfer mechanism 8, a mounting head 10 is provided which is moved in the horizontal direction (X direction, Y direction) by a head moving mechanism (not shown). A suction nozzle 10a is provided at the lower end of the mounting head 10. The suction nozzle 10a holds the component D by vacuum suction. The component supply carriage 5 is mounted on the component supply unit 4 provided on the side of the substrate transport mechanism 8.
In fig. 4, a feeder fitting portion 12 is provided at an upper portion of the component feeding carriage 5. On the upper surface of the feeder mounting part 12, a plurality of slots S for mounting the tape feeders 13 or the rod feeders 14 are formed in the substrate conveying direction (X direction). When the component feeding carriage 5 is mounted to the component feeding section 4, the feeder mounting section 12 is separated from the lower portion 5a of the component feeding carriage 5 and joined to the base 7. A plurality of upper reel holding portions 5U aligned in the X direction and a plurality of lower reel holding portions 5B aligned in the X direction are provided vertically on a lower portion 5a of the component supply carriage 5. The upper reel holding portion 5U and the lower reel holding portion 5B rotatably hold the component reel 16, respectively, and the component reel 16 winds the component storage tape 15 in which the component D is stored.
In fig. 3, a reel mark Mb is attached to a side surface of the component reel 16. The reel mark Mb includes a bar code or a two-dimensional code in which information for specifying the component reel 16 is recorded. The component storage tape 15 pulled out from the component reel 16 held in the upper reel holding part 5U or the lower reel holding part 5B is inserted into the tape insertion port 13a of the tape feeder 13. The tape feeder 13 conveys the component storage tape 15 inserted from the tape insertion port 13a in a tape feeding direction, and supplies the component D to the component supply position E. That is, the tape feeder 13 is a component supply device that moves the components D accommodated on the component reel 16 (component container) to the component supply position E.
In fig. 4, the rod feeder 14 supplies a plurality of components D housed in a serial state in an elongated and hollow rod case 17 to a component supply position E. As a method of moving the component D in the bar feeder 14 to the component supply position E, vibration, pushing out of a wire, or the like is used. The rod case 17 is housed in a stacked state in a loading portion 14a provided at an upper portion of the rod feeder 14. That is, the lever feeder 14 is a component supply device that moves the components D accommodated in the lever housing 17 (component container) to the component supply position E. In this way, the component supply carriage 5 includes the component container (the component reel 16, the rod case 17) and the component supply device (the tape feeder 13, the rod feeder 14), and constitutes a component supply unit that supplies the components D to the component mounting devices M2, M3.
In fig. 3, the component mounting devices M2, M3 include a substrate conveyance mechanism 8, a mounting head 10, and a mounting control unit 18 that controls a head movement mechanism. The mounting control portion 18 sends a supply instruction of the component D to the tape feeder 13 or the lever feeder 14, causing the component D to be supplied to the component supply position E. The mounting control unit 18 controls the mounting head 10 and the head moving mechanism, and the mounting head 10 takes out the component D supplied to the component supply position E by the component supply device, and performs a component mounting operation of transferring the mounted component to the mounting position of the substrate 9 held by the substrate transport mechanism 8.
In fig. 4, a carriage mark Mc is marked on the outer appearance of the lower portion 5a of the component supply carriage 5. The feeder fitting portion 12 is marked with a fitting portion mark Ma in its outer appearance. The carriage mark Mc and the mounting portion mark Ma include a barcode, a two-dimensional code, a unique mark, and the like, in which information for specifying the component supply carriage 5 is recorded. When a plurality of marks are marked on the component supply carriage 5 (here, the carriage mark Mc is 2 and the mounting portion mark Ma is 2), information for specifying the position to be added to each mark is also recorded.
As described above, the carriage mark Mc and the mounting portion mark Ma are unit identifiers added (formed) to the appearance of the component supply unit (component supply carriage 5). The carriage mark Mc and the mounting portion mark Ma may be marked on any one of the front surface, the side surface, the upper surface, the rear surface, and the lower surface when viewed from the side where the marks are recognized, as long as the marks are visually recognizable from the outside.
In the tape feeder 13, a tape feeder mark Mt is marked on the side where the tape insertion port 13a is formed. The tape feeder mark Mt includes a barcode, a two-dimensional code, a unique mark, and the like, in which information for determining the tape feeder 13 is recorded. In the lever feeder 14, a lever feeder mark Ms is marked on one side of the supply lever housing 17. Included in the lever feeder mark Ms are a bar code, a two-dimensional code, a unique mark, and the like, on which information for determining the lever feeder 14 is recorded.
In this way, the tape feeder marks Mt and the lever feeder marks Ms are supply device identification bodies that mark (form) the appearance of the component supply devices (tape feeders 13, lever feeders 14). The supply device identifier is provided for identifying the component supply device.
Note that, the tape feeder mark Mt and the lever feeder mark Ms may be marked on any one of the front surface, the side surface, the upper surface, the rear surface, and the lower surface, as viewed from the side where the marks are recognized, as long as the marks are visually recognizable from the external appearance.
Next, the structure of the component mounting apparatus M4 will be described with reference to fig. 5 and 6. The component mounting device M4 is similar to the component mounting devices M2 and M3 except that the tray feeder 6 is mounted on the component supply section 4 instead of the component supply carriage 5, and the configuration of the tray feeder 6 will be described below. In fig. 5, a rack portion 21 is provided on the front side of the tray feeder 6 mounted on the component feeding portion 4 and a pallet moving portion 22 is provided on the rear side of the upper surface of the feeder mounting portion 20 included in the tray feeder 6.
In the rack portion 21, a plurality of (2 in this case) cartridge holding portions 26 are arranged in the vertical direction, the cartridges 25 are stored in the cartridge holding portions 26, and the pallets 24 to which the trays 23 stored in the members D are attached are stored in the cartridges 25 in a stacked manner. A rack door 26a that is freely openable forward is provided on the operation surface of the rack portion 21. The magazine 25 is inserted into and removed from the magazine holding portion 26 in a state where the rack door 26a is opened (lower side in fig. 6). A pallet placing portion 27 is provided above the uppermost cartridge holding portion 26. An opening/closing cover 27a which is openable upward (arrow a) is provided on the operation surface of the rack portion 21. When the opening/closing cover 27a is opened, 1 pallet 24 with the pallet 23 mounted thereon can be placed on the pallet placing section 27 into the pallet feeder 6.
In fig. 5, pallet moving unit 22 includes a pallet table 28, a lifting mechanism 29, and a take-out mechanism 28 a. The elevation mechanism 29 elevates the pallet table 28 (arrow b) and moves the pallet table 28 to a height position at which the pallet 24 stored in the magazine 25 or the pallet 24 placed on the pallet placement portion 27 is placed, or a component supply position E at which the mounting head 10 takes out the component D. The removing mechanism 28a pulls out and holds the pallet 24 from the magazine 25 or the pallet placement unit 27, and stores the held pallet 24 in the magazine 25 or the pallet placement unit 27.
Thus, the tray 23 and the magazine 25 storing the plurality of trays 23 are component containers storing the plurality of components D. The pallet moving unit 22 having the pallet table 28, the lifting mechanism 29, and the pickup mechanism 28a is a component supply device that moves the component D accommodated in the pallet 23 (component container) to the component supply position E. The tray feeder 6 includes a component container (tray 23) and a component feeding device, and is a component feeding unit that feeds the component D to the component mounting device M4.
In fig. 6, a rack mark Ml is marked on the appearance of each rack door 26 a. The rack mark Ml includes a barcode, a two-dimensional code, a unique mark, and the like, which are used to specify information of the tray feeder 6 and information on the position (upper layer and lower layer) of the rack door 26a (cartridge holder 26) recorded thereon. An opening/closing mark Mo is provided on the front surface of the opening/closing cover 27 a. The opening/closing mark Mo includes a barcode or a two-dimensional code in which information for specifying the tray feeder 6 is recorded. In this way, the rack mark Ml and the opening/closing mark Mo are unit identifiers marked (formed) on the appearance of the component feeding unit (tray feeder 6). The unit identifier is provided to identify the component supply unit. Note that, the rack mark Ml and the opening/closing mark Mo may be marked on any one of the front surface, the side surface, the upper surface, the rear surface, and the lower surface as viewed from the side where each mark is recognized, as long as the mark is visually recognizable from the external appearance.
The front surface of cartridge 25 in the state of being inserted into cartridge holder 26 marks cartridge mark Mm. The cartridge mark Mm includes a barcode, a two-dimensional code, a unique mark, and the like, in which information for specifying the cartridge 25 is recorded. A tray mark Mp (not shown) is provided on the front surface of the tray 23 in a state of being accommodated in the tray feeder 6. The tray mark Mp includes a barcode, a two-dimensional code, a unique mark, and the like, in which information for specifying the tray 23 is recorded. Note that, if the cartridge mark Mm and the tray mark Mp are visually recognizable from a side other than the front surface from which the respective marks are recognized, they may be marked on any one of the front surface, the side surface, the upper surface, the rear surface, and the lower surface as viewed from the side from which the respective marks are recognized.
Next, the structure of the transfer device V will be described with reference to fig. 7. The transfer device V includes a robot mechanism 31 and a storage unit 32 above the carriage unit 30. The carriage unit 30 includes wheels 30a, a motor for driving the wheels 30a, a direction changing mechanism for changing the direction of the wheels 30a, and a traveling mechanism 33 (see fig. 8) including a sensor for detecting the position and posture of the transfer device V.
The robot mechanism 31 is an articulated robot having an end effector 34 disposed at the distal end thereof, and the end effector 34 is moved in the X direction, the Y direction, and the Z direction by a plurality of servomotors, and is rotated in the direction of θ while changing the direction. The control method of the robot mechanism 31 is not particularly limited, and for example, an impedance control method, a compliance control method, and the like can be cited, but other control methods, a control method combining a plurality of control methods, control using AI, and the like can be used.
The end effector 34 has a function of gripping (holding) the component supply device (tape feeder 13, lever feeder 14) or the component container (component reel 16, lever housing 17, tray 23, magazine 25). The end effector 34 may have a function of holding, sucking, or the like, in addition to gripping, as long as it can hold the component supplying device or the component container. Further, a moving camera 35 (imaging section) that images the unit identifiers (the carriage mark Mc, the mounting portion mark Ma, the rack mark Ml, the opening/closing mark Mo), the feeding device identifiers (the tape feeder mark Mt, the lever feeder mark Ms), the magazine mark Mm, the tray mark Mp, and the like is arranged in the end effector 34.
The information and the position recorded in each mark are recognized by performing recognition processing on each mark captured by the moving camera 35 by a recognition processing unit 36 (see fig. 8) included in the transfer device V. In this way, the moving camera 35 (imaging unit) is a recognition unit that recognizes (images) the unit recognition object (the mark formed on the component supply unit) and the supply apparatus recognition object (the mark formed on the component supply apparatus). The robot mechanism 31 is a moving mechanism that moves the end effector 34 and the moving camera 35, and matches the imaging axis of the moving camera 35 with various markers.
In fig. 7, a plurality of (4 in this case) storage shelves 32a open to the side facing the robot mechanism 31 are arranged in the storage unit 32. The storage rack 32a can mount replacement component supply devices (the tape feeders 13 and the rod feeders 14), component containers (the component reels 16, the rod housings 17, the trays 23, and the magazines 25), and the like. The transfer device V places the component supply device for replenishment and the component container taken out of the material storage W on the storage rack 32a, and conveys the components to the component mounting devices M2 to M4 to be replenished.
The storage unit 32 is provided with a head camera 37 having an imaging axis directed downward, between the robot mechanism 31 and the storage unit. The head camera 37 photographs a reel mark Mb marked on the side surface of the component reel 16 held by the end effector 34 from above. The information recorded on the reel mark Mb is recognized by the recognition processing unit 36 by performing recognition processing on the reel mark Mb imaged by the head camera 37.
The moving camera 35 may have the function of the head camera 37. In this case, the moving camera 35 is attached at a position where the end effector 34 can photograph the reel mark Mb marked on the side surface of the component reel 16 in a state where the component reel 16 is gripped. Alternatively, the moving camera 35 may take an image of the reel mark Mb marked on the upper surface of the component reel 16 in a state where the component reel 16 is pulled out from the storage 32 by the end effector 34.
Next, the configuration of the control system of the component mounting system 1 will be described with reference to fig. 8. Here, in the component mounting system 1, the description will be given of the configuration relating to the functions of the component supply devices and the component containers of the component mounting devices M2 to M4 replaced by the transfer device V. The management computer 3 includes a wireless management communication unit 3a, a management storage unit 40, a work instruction generation unit 41, a management input unit 42, and a management display unit 43. The management input unit 42 is an input device such as a keyboard, a touch panel, or a mouse, and is used for inputting an operation command or data. The management display unit 43 is a display device such as a liquid crystal panel, and displays various information such as an operation screen for managing the operation of the input unit 42.
The management storage unit 40 is a storage device, and stores component information 40a, unit information 40b, outer dimension information 40c, supply device information 40d, replacement work information 40e, and the like. The parts information 40a includes, for each part number for specifying the part D, information (such as a size) relating to a part name (type) and a part container in which the part D is stored, information relating to a mark attached to the part container such as a reel mark Mb and a pallet mark Mp, and the like. That is, the component information 40a includes the diameter and thickness of the component reel 16 as the component container, and the outer dimensions (vertical, horizontal, and depth) of the rod-like case 17, the tray 23, and the magazine 25. The unit information 40b includes unit unique information, which is information unique to the component feeding unit, for each component feeding unit (the component feeding carriage 5, the tray feeder 6).
Here, details of the unit information 40b will be described with reference to fig. 9. The unit information 40b includes a unit number 50, a unit type 51, an identification method 52, a reel correction value 53, and a slot correction value 54. The unit number 50 is information for determining the component supply unit. The unit type 51 is information for specifying the type of the component supply unit. In the unit type 51, "carriage (17)" and "carriage (30)" are component supply carriages 5 having 17 rows and 30 rows of slots S, upper reel holding portions 5U, and lower reel holding portions 5B, respectively, and "tray (20)" is a tray supplier 6 capable of storing 20 pallets 24.
The recognition method 52 is information (unit recognition information) for specifying whether the unit recognition object (carriage mark Mc, mounting part mark Ma, rack mark Ml, opening/closing mark Mo) is imaged by the moving camera 35 (imaging part, recognition part) of the transfer device V or the outer shape of the component supply unit is recognized when determining the work position in the component supply unit. In the recognition method 52, the "mark" is an imaging target of the unit recognition object, and the "outline" is an outline of the whole or a part of the component supply unit. As described above, by specifying the recognition method by the recognition method 52, even if the component supply units are different in structure, such as the presence or absence of the unit recognition object, the same automatic replacement method described later can be applied.
In fig. 9, the reel correction value 53 is an offset amount from the ideal position P0 where the carriage mark Mc is marked to the actually marked position P1, and is represented by an offset amount 53X (Δ X) in the X direction and an offset amount 53Z (Δ Z) in the Z direction (see fig. 10). The groove correction value 54 is a deviation amount from the ideal position of the mark mounting portion mark Ma to the actually marked position, and is represented by a deviation amount 54X (Δ X) in the X direction and a deviation amount 54Z (Δ Z) in the Z direction. In this way, the unit type 51, the identification method 52, the reel correction value 53, and the slot correction value 54 of each component supply unit including the unit number 50 constitute unit unique information 55 that specifies the component supply unit. That is, the cell identification information (identification method 52) is included in the cell unique information 55.
The reel correction value 53 may include an offset amount of the transfer device V from the component supply unit in the Y direction. The offset amount in the Y direction is a difference between an ideal distance between the transfer device V and the component supply unit and a distance between the transfer device V and the component supply unit which are actually stopped, and can be calculated based on the size of the entire or a part of the carriage mark Mc imaged by the moving camera 35. Further, by imaging the plurality of carriage marks Mc, the offset amount of the transfer device V from the component supply unit in the Y direction can be approximately grasped. Further, by taking the offset amount in the Y direction into consideration, the offset amount 53X (Δ X) in the X direction and the offset amount 53Z (Δ Z) in the Z direction can be calculated with higher accuracy. Similarly, slot correction value 54 may also include an offset in the Y-direction.
In fig. 8, in the outer shape dimension information 40c, information on the outer shape used in the automatic replacement work of the component feeding device and the component container is included for each kind of the component feeding unit (the component feeding carriage 5, the tray feeder 6) and each kind of the component feeding device (the tape feeder 13, the lever feeder 14).
Here, details of the outer shape size information 40c will be described with reference to fig. 11. Fig. 11 shows information on the positions of the lower reel holding unit 5B and the upper reel holding unit 5U in the outside dimension information 40c of the component supply carriage 5 whose unit type 51 is "carriage (17)". The outer dimension information 40c includes a holding portion number 56 and a holding portion position 57. The holding section number 56 is information for specifying the lower reel holding section 5B and the upper reel holding section 5U, "B01" to "B17" indicate the lower reel holding section 5B, and "U01" to "U17" indicate the upper reel holding section 5U. The holding portion position 57 is shown at an X position 57X and a Z position 57Z from an ideal position P0 of a carriage mark Mc marked on the component supply carriage 5 (see fig. 10).
The outside dimension information 40c in which the unit type 51 is the "carriage (17)" includes information on the position of the groove S, information on the outside dimensions (vertical, horizontal, depth) of the component supply carriage 5, and the like, in addition to the holding portion position 57 shown in fig. 11. The outside dimension information 40c of the "carriage (30)" as the cell type 51 includes the same information as the outside dimension information 40c of the "carriage (17)" as the cell type 51. The outside dimension information 40c in which the unit type 51 is the "tray (20)" includes information on the position of the rack door 26a, information on the position of the opening/closing cover 27a, information on the outside diameter dimension of the tray feeder 6, and the like.
Further, information relating to the position of the tape insertion port 13a, information of the outer shape size of the tape feeder 13, and the like are included in the outer shape size information 40c of the tape feeder 13. Information relating to the position of the loading portion 14a, information of the outer shape size of the rod feeder 14, and the like are included in the outer shape size information 40c of the rod feeder 14.
In fig. 8, the supply device information 40d includes supply device unique information as information unique to the component supply device for each component supply device (tape feeder 13, lever feeder 14).
Here, details of the supply device information 40d will be described with reference to fig. 12. The feeder information 40d includes a feeder number 60, a feeder type 61, an identification method 62, and a feeder correction value 63. The feeder number 60 is information for specifying the component feeding device. The feeder type 61 is information for specifying the type of the component feeding device. In the feeder type 61, "tape (8 mm)" and "tape (16 mm)" are tape feeders 13 that carry component storage tapes 15 having widths of 8mm and 16mm, respectively, and "lever (10)" is a lever feeder 14 that can store 10 lever-shaped housings 17.
The recognition method 62 is information (supply device recognition information) for specifying whether the supply device recognition object (tape feeder mark Mt, lever feeder mark Ms) is photographed by the moving camera 35 (image pickup portion, recognition portion) of the transfer device V or the outer shape of the component supply device is recognized when determining the work position in the component supply device. In the recognition method 62, "mark" is an imaging target as the supply device recognition object, and "outline" is an outline of the imaging target as the component supply device. As described above, by specifying the identification method by the identification method 62, the same automatic replacement method can be applied even to component supply apparatuses having different configurations such as the presence or absence of a supply apparatus identifier.
In fig. 12, the feeder correction value 63 is a shift amount from an ideal position where the tape feeder mark Mt or the rod feeder mark Ms is marked to an actually marked position, and is represented by a shift amount 63X (Δ X) in the X direction and a shift amount 63Z (Δ Z) in the Z direction. In this way, the feeder type 61, the identification method 62, and the feeder correction value 63 for each component feeder including the feeder number 60 constitute feeder unique information 64 for identifying the component feeder. That is, the supply device identification information (identification method 62) is included in the supply device unique information 64.
In fig. 8, the replacement work information 40e includes information (such as a component number) specifying the component container to be replenished or replaced, a feeder number 60 of the component feeder to be replenished or replaced, a position, a replacement order, and the like. The position of the replenishment object or the replacement object is information for specifying the position of the component container or the component supply device to be supplied, using the corresponding component mounting lines L1 to L3, the component mounting devices M2 to M4, the unit number 50 of the component supply carriage 5, the holding part number 56, the unit number 50 of the tray supplier 6, or the like. The replacement work information 40e is created in advance based on a production plan, production data, material/equipment information, and the like.
In fig. 8, the work instruction generating unit 41 generates a work instruction including a destination of the transfer device V based on the replacement work information 40 e. Further, the work instruction generating unit 41 generates a work instruction for identifying which of the unit identifiers marked (formed) on the component supply unit or a work instruction for identifying the external shape of the component supply unit, based on the replacement work information 40e and the unit identification information (identification method 52). The work instruction generating unit 41 generates a work instruction for identifying which of the feeding device identifiers marked (formed) on the component feeding devices or a work instruction for identifying the external shape of the component feeding devices, based on the replacement work information 40e and the feeding device identification information (identification method 62). Further, a work instruction is generated for each step of the work, and the movement coordinates of the end effector 34 are calculated for each generated step.
The work instruction generating unit 41 generates a work instruction including a moving target of the end effector 34 included in the transfer device V based on the replacement work information 40e, the unit unique information 55, the supply device unique information 64, and the outer dimension information 40c of the component supply unit and the component supply device. When the carriage mark Mc is recognized at the time of replacing the component reel 16, for example, the moving target of the end effector 34 is indicated by the XZ coordinate with the recognized carriage mark Mc as a base point. At this time, the deviation of the position marked with the carriage mark Mc is corrected based on the reel correction value 53. For example, when the lower reel holding unit 5B of the component supply carriage 5 having the left lower end holding unit number 56 of "B01" in fig. 10 is at the working position, the instruction movement target is corrected to (X1+ Δ X, Z1+ Δ Z).
Similarly, when the groove S of the component supply carriage 5 is the working position, the movement target is corrected based on the groove correction value 54. When the tape insertion port 13a of the tape feeder 13 or the loading portion 14a of the rod feeder 14 is at the working position, the movement destination is corrected based on the feeder correction value 63. That is, the work instruction generating unit 41 generates a work instruction in which the movement target of the end effector 34 is corrected based on at least one of the unit position correction value (the reel correction value 5, the slot correction value 54) and the feeder position correction value (the feeder correction value 63). The unit position correction value (reel correction value 53, slot correction value 54) is a value for correcting the movement target of the end effector 34 based on the positional deviation of the unit identifier, and the feeder position correction value (feeder correction value 63) is a value for correcting the movement target of the end effector 34 based on the positional deviation of the feeder identifier.
As described above, by correcting the moving target by the correction value stored in advance, even if the position to which the various marks are applied is shifted for each component supply unit or each component supply device, the end effector 34 can be accurately moved. The work instruction generated by the work instruction generating unit 41 is transmitted to the transfer device V that performs the replacement work via the wireless management communication unit 3 a. The work instruction generating unit 41 may generate a work instruction for a moving target that is not corrected by the correction value, transmit the unit position correction value and the supply device position correction value together with the work instruction, and correct the moving target when a path setting unit 47, which will be described later, sets a moving path in the transfer device V.
As described above, the management computer 3 includes the storage unit (management storage unit 40), the unit unique information 55, and the work instruction generating unit 41. The management storage unit 40 stores the outside dimension information 40c of the component supply unit in association with the unit unique information 55 specifying the component supply unit. The work instruction generating unit 41 generates a work instruction including a moving target of the end effector 34 based on the outside dimension information 40c of the component supply unit. The management computer 3 is a management device that generates a work instruction for the transfer device V having the movable end effector 34. The management computer 3 need not be constituted by 1 computer, and may be constituted by a plurality of devices. For example, a part or all of the management storage unit 40 may be provided in the cloud via a server.
In fig. 8, the transfer device V includes a travel mechanism 33, a robot mechanism 31, an end effector 34, a motion camera 35, a recognition processing unit 36, a head camera 37, a transfer storage unit 44, a travel control unit 45, a replacement control unit 46, a route setting unit 47, and a wireless communication unit T. The transfer storage unit 44 is a storage device that stores the work instruction information 44a, the recognition result information 44b, and the like. The job instruction information 44a stores a job instruction transmitted from the management computer 3 (management apparatus) and received by the wireless communication unit T.
The recognition result information 44b stores: the recognition processing unit 36 recognizes information recorded in each mark obtained by performing recognition processing on the imaging result of the moving camera 35 (imaging unit, recognition unit), information relating to the position of each mark, and component information recorded in the reel mark Mb obtained by performing recognition processing on the imaging result of the head camera 37 by the recognition processing unit 36. Further, the recognition result information 44b also stores: the recognition processing section 36 recognizes the external shape of the component supply unit and the component supply device captured by the moving camera 35, and obtains information such as the slot S of the component supply carriage 5, the positions of the upper reel holding section 5U and the lower reel holding section 5B, the rack door 26a of the tray feeder 6, the position of the opening/closing cover 27a, the position of the tape insertion port 13a of the tape feeder 13, and the position of the loading section 14a of the lever feeder 14.
The travel control unit 45 controls the travel mechanism 33 based on the destination of the transfer device V included in the operation instruction, and moves the transfer device V to the designated destination. The replacement control unit 46 controls the robot mechanism 31 based on the identification destination included in the work instruction, and causes the moving camera 35 to capture an image of the identification destination. The path setting unit 47 sets a movement path (for example, arrows C2 to C6 in fig. 14B to 15C) for moving the end effector 34 based on the movement target of the end effector 34 included in the work instruction.
At this time, the path setting unit 47 sets the movement path so that the end effector 34 does not interfere with the main body of the component supply unit, based on the external dimensions (vertical, horizontal, and depth) of the component supply unit included in the external dimension information 40c of the component supply unit. That is, the movement path is set so that the end effector 34 moves along a different trajectory by an object that is not gripped or gripped by the end effector 34.
The replacement control unit 46 (control unit) controls the robot mechanism 31 (moving mechanism) based on the moving path set by the path setting unit 47 and the recognition result (recognition result information 44b) obtained by the moving camera 35 (imaging unit, recognition unit), and moves the end effector 34 to at least one of the component supply device and the component container. Thus, even if the stop position of the transfer device V is deviated from the predetermined destination or the positions of the component supply device and the component container in the component supply unit are deviated from the predetermined positions, the component supply device and the component container can be accurately gripped by the end effector 34.
As described above, the transfer device V includes the end effector 34, the moving mechanism (the robot mechanism 31) for moving the end effector 34, the recognition unit (the moving camera 35), the path setting unit 47, and the control unit (the replacement control unit 46) for controlling the moving mechanism. The transfer device V and the management device (management computer 3) having the work instruction generating unit 41 for generating the work instruction constitute an automatic replacement system for replacing at least one of the component supply device and the component container of the component supply unit.
Next, an automatic replacement method for replacing at least one of the component supply device and the component container of the component supply unit by the transfer device V having the movable end effector 34 will be described with reference to fig. 14A to 15C along the flow of fig. 13. Hereinafter, an example will be described in which the component reel 16 as the component container is taken out from the component supply carriage 5 (component supply unit) mounted in the component mounting device M2 and replaced. In fig. 14A to 15C, the robot mechanism 31 of the transfer device V is not depicted for convenience.
In fig. 13, first, the management computer 3 (management device) generates an operation instruction designating a transfer destination before the component reel 16 to which the replacement target is attached is supplied to the carriage 5, and transmits the operation instruction to the transfer device V on which the component reel 16 to be replenished is mounted. In the transfer device V that has received the work instruction, the travel control unit 45 moves the transfer device V to the designated transfer destination in accordance with the work instruction (ST 1: transfer device moving step). When the movement is completed, the transfer device V transmits the result to the management computer 3. In addition, even when the transfer device V moves to a predetermined transfer destination, a stop error of several centimeters or several millimeters occurs.
Next, in the management computer 3, the work instruction generating unit 41 removes the component reel 16 to be replaced from the component supply carriage 5, and generates a work instruction for mounting the component reel 16 to be replenished (ST 2: work instruction generating step). In the work instruction generating step (ST2), the carriage mark Mc (unit identifier) is recognized, and a work instruction including the moving target of the end effector 34 with the recognized carriage mark Mc as the base point is generated. Then, the management computer 3 transmits the generated job instruction to the transfer device V (ST 3: job instruction transmission step).
In fig. 13, when the transfer device V receives the work instruction, the replacement work is executed in accordance with the work instruction. First, when the recognition of the various markers is instructed in the operation instruction (yes in ST 4), the replacement control unit 46 controls the robot mechanism 31 to move the moving camera 35 (image pickup unit, recognition unit) to a position before the carriage marker Mc (arrow c1 in fig. 14A) and recognizes the carriage marker Mc (ST 5: unit recognition step). That is, the unit identifier (carriage mark Mc) that is marked (formed) on the appearance of the component supply unit (component supply carriage 5) is identified.
When the identification of the various marks is instructed, the transfer device V may determine whether or not the marks match the various marks instructed by the operation instruction. Whether or not the various marks are correct is judged, and if not, the operation is stopped. In this way, it is possible to prevent in advance a working error caused by the component supply unit being wiped off or the like due to an erroneous operation by the operator.
Next, the moving camera 35 (image pickup portion, recognition portion) recognizes the feeding device recognition body (tape feeder mark Mt, lever feeder mark Ms) before moving to the feeding device recognition body (ST 6: feeding device recognition process). Here, since the identification of the supply device identifier is not included in the job instruction, the supply device identifying step (ST6) is skipped. When the recognition of the external shape is instructed by the work instruction (no in ST 4), the replacement control unit 46 controls the robot mechanism 31 to recognize the external shape of the component supply unit or the component supply device instructed by the moving camera 35 (ST 7: external shape recognition step).
When the recognition of the mark (ST5, ST6) or the recognition of the outer shape (ST7) is completed, the path setting unit 47 then sets the movement path for moving the end effector 34 based on the work instruction and the recognition result (ST 8: path setting step). Thus, a movement path is set in which a stop error of the transfer device V, a deviation of the component supply device and the component container in the component supply unit, and the like are corrected. Then, the replacement control unit 46 controls the robot mechanism 31 based on the set movement path, moves the end effector 34 to the component reel 16 to be replaced (arrow c2 in fig. 14B), and grips the component reel 16 by the end effector 34.
In fig. 13, the replacement control unit 46 then moves the end effector 34 that grips the component reel 16 to remove the component reel 16 from the upper reel holding unit 5U (ST9), rotates the component reel 16 by 90 degrees to move to the storage unit 32 (arrow C3 in fig. 14C), and stores the component reel in the empty storage rack 32a (ST 10). Next, the replacement control unit 46 causes the end effector 34 to grip and take out the component reel 16 to be supplied in the storage rack 32a (ST11) (arrow c4 in fig. 15A). At this time, the reel mark Mb marked on the component reel 16 is photographed by the head camera 37, and whether or not the component reel 16 is the instructed replenishment target is checked.
Next, the replacement control unit 46 rotates the end effector 34 holding the component reel 16 by 90 degrees to move to the front of the component supply carriage 5 (arrow C5 in fig. 15B), and attaches the end effector to the upper reel holding unit 5U of the component reel 16 instructed to be supplied (ST12) (arrow C6 in fig. 15C). Next, when the replacement operation is not completed with the component reel 16 (component container) to be replaced remaining (no in ST 13), the process returns to the operation instruction generation step (ST2), and the replacement operation of the next component reel 16 is executed. When the replacement operation of all the component reels 16 is completed (yes in ST 13), the automatic replacement is completed.
When the job instruction (ST2, ST3 of the 1 ST time) generated and transmitted by the management computer 3 includes all the strokes of the replacement job, the process returns to ST4 without returning to the job instruction generation step (ST2) to execute the next replacement job. When the necessary information can be acquired at the 1 ST time, the recognition of the mark (ST5, ST6) or the recognition of the outline (ST7) at the 2 nd and subsequent times is skipped.
As described above, ST9 to ST12 are moving steps for moving the end effector 34 to at least one of the component supply device and the component container based on the recognition result in the moving path and cell recognition step (ST5), the supply device recognition step (ST6), or the outline recognition step (ST7) set in the path setting step (ST 8). That is, the automatic exchange method of the present embodiment includes a cell recognition step (ST5), a route setting step (ST8), and a movement step (ST9 to ST 12). This enables accurate replacement of the component reel 16 (component container).
In addition, in the automatic replacement method shown in fig. 13, in the case of replacing the component feeding devices (tape feeders 13, lever feeders 14), the mounting portion mark Ma is recognized in the unit recognizing process (ST 5). When the tray 23 (component container) of the tray feeder 6 (component supply unit) is replaced, the opening/closing mark Mo is recognized in the unit recognizing step (ST5), and the opening/closing of the opening/closing cover 27a and the recognition by the moving camera 35 (image pickup portion, image pickup means) of the tray mark Mp of the tray 23 on the tray placing portion 27 are performed in the moving step.
In addition, when the magazine 25 (component container) of the tray feeder 6 (component supply unit) is replaced, the rack mark Ml is recognized in the unit recognition step (ST5), and the opening and closing of the rack door 26a and the recognition by the moving camera 35 of the magazine mark Mm of the magazine 25 in the rack portion 21 are performed in the moving step. Further, after the replacement of the component reel 16, in the case where the component storage tape 15 is inserted into the tape insertion port 13a of the tape feeder 13, the tape feeder mark Mt is recognized in the feeding device recognizing process (ST 6). Further, in the case of replacing the lever housing 17 (component container) of the lever feeder 14, the lever feeder mark Ms is recognized in the feeding device recognizing process (ST 6).
As described above, the component mounting system 1 of the present embodiment replaces at least one of the component supply device (the tape feeder 13, the lever feeder 14, the pallet moving portion 22) and the component container (the component reel 16, the lever housing 17, the tray 23, the magazine 25). The component container accommodates a plurality of components D. The component supplying device moves the component D accommodated in the component container to the component supplying position E. The component feeding device and the component container are included in a component feeding unit (component feeding carriage 5, tray feeder 6).
The automatic exchange system has a transfer device V. The transfer device V includes an end effector 34, a moving mechanism (robot mechanism 31), a recognition unit (moving camera 35), a path setting unit 47, and a control unit (replacement control unit 46). The end effector 34 grips the component supply device or the component container. The robot mechanism 31 moves the end effector. The moving camera 35 recognizes unit recognition bodies (formed in the component supply unit) marked on the appearance of the component supply unit (a carriage mark Mc, an assembly portion mark Ma, a rack mark Ml, an opening/closing mark Mo). The path setting unit 47 sets a movement path for moving the end effector 34. The replacement control unit 46 controls the moving mechanism.
Then, the control unit moves the end effector 34 to at least one of the component supply device and the component container based on the set moving path and the recognition result by the recognition unit. This enables the component container to be accurately replaced.
In addition, although the above description has been given of an example in which the component supply units (the component supply carriage 5 and the tray supplier 6) mounted in the component mounting devices M2 to M4 are so-called internally installed components of the component supply device or the component container, the present disclosure is not limited to the internally installed components. For example, the component supply units (the component supply carriage 5 and the tray supplier 6) detached from the component mounting devices M2 to M4 can be applied to so-called external installation in which the component supply devices or the component containers are replaced. In this case, the replacement work information 40e specifies a preparation area to be externally provided as the location of the replenishment object or the replacement object. In the external setting, the component supply unit may be moved to the transfer device V fixed to the floor surface F, and the component supply device or the component container may be replaced at the replacement position.
Further, each mark may not be constituted by 1 pattern, and for example, it may be constituted by a plurality of patterns as a surrounding character, and the entire mark constituted by the plurality of patterns may be recognized, and a specific pattern may be used as coordinates for correction.
Next, with reference to fig. 16, 17A, and 17B, embodiment 2 of the component supply carriage (hereinafter referred to as "2 nd component supply carriage 70") will be described. The 2 nd component supply carriage 70 includes a component container and a component supply device as in the component supply carriage 5 described above, and is a component supply unit that supplies the component D to the component mounting devices M2 and M3. The 2 nd component supply cart 70 is different from the component supply cart 5 in that it has cart recognition targets G1 and G2 instead of the cart mark Mc and has assembly portion recognition targets G3 and G4 instead of the assembly portion mark Ma. Hereinafter, the same components as those of the component supply carriage 5 are denoted by the same reference numerals, and detailed description thereof is omitted.
In fig. 16, a lower plate 71 extending the XY plane (horizontal plane) in the substrate conveyance direction (X direction) is provided on the front surface of the lower portion 5a of the 2 nd component supply carriage 70. Left and right side plates 72, 73 extending to YZ plane are provided on both ends of the lower plate 71 in the X direction to extend upward. A left side plate 72 and a left back plate 74 (see also fig. 17A) perpendicular to the lower plate 71 and extending in the ZX plane are provided on the left side of the lower plate 71. The lower plate 71, the left side plate 72, and the left back plate 74 constitute a left cart recognition target G1. The angle at which the lower plate 71, the left side plate 72, and the left back plate 74 intersect is the position Q1 of the left bogie identification target G1.
A right side plate 73 and a right back plate 75 are provided on the right side of the lower plate 71, perpendicular to the lower plate 71, and extending in the ZX plane. The lower plate 71, the right side plate 73, and the right back plate 75 constitute a right cart recognition target G2. The corner where the lower plate 71, the right side plate 73, and the right back plate 75 intersect is the position Q2 of the right dolly recognition target G2.
In fig. 16, left and right support plates 76 and 77 extending to YZ planes are provided to extend upward at both ends in the X direction of the feeder fitting portion 12. Between the upper portion of the left support plate 76 and the upper portion of the right support plate 77, an upper plate 78 is provided which extends the XY plane in the X direction. A left support plate 76 and a left back plate 79 (see also fig. 17B) that is orthogonal to the upper plate 78 and extends in the ZX plane are provided on the left side of the upper plate 78. The upper plate 78, the left support plate 76, and the left back plate 79 constitute a left attachment recognition target G3. The angle at which the upper plate 78, the left support plate 76, and the left back plate 79 intersect is the position Q3 of the left attachment recognition target G3.
A right support plate 77 and a right back plate 80 are provided on the right side of the upper plate 78, the right back plate being orthogonal to the upper plate 78 and extending in the ZX plane. The upper plate 78, the right support plate 77, and the right back plate 80 constitute a right attachment portion recognition target G4. The corner where the upper plate 78, the right support plate 77, and the right back plate 80 intersect is the position Q4 of the right attachment recognition target G4.
The carriage recognition targets G1, G2 and the mounting portion recognition targets G3, G4 are unit recognition objects for recognizing the position of the 2 nd component feeding carriage 70 and the position of the feeder mounting portion 12. In the 2 nd component supply cart 70, the identification method 52 of the unit information 40b stored in the management storage unit 40 of the management computer 3 is stored as a "target". In addition, in the unit information 40b, the position information of the carriage recognition targets G1, G2 and the assembly portion recognition targets G3, G4 in the 2 nd component supply carriage 70 is stored.
Next, referring to fig. 18, embodiment 2 of the transfer device (hereinafter, referred to as "2 nd transfer device V1") will be described. The 2 nd transfer device V1 has a robot mechanism 31 and a storage unit 32 above the carriage unit 30, and an end effector 34 is disposed at the tip of the robot mechanism 31, similarly to the transfer device V described above. The 2 nd transfer device V1 is different from the transfer device V in that a contact sensor 81 is provided at the tip of the end effector 34. Hereinafter, the same components as those of the transfer device V are denoted by the same reference numerals, and detailed description thereof is omitted.
In fig. 18, the contact sensor 81 has an elongated cylindrical shape protruding from the front surface of the end effector 34, and when the robot mechanism 31 moves the end effector 34 in the X direction, the Y direction, and the Z direction, the contact sensor moves in the X direction, the Y direction, and the Z direction integrally with the end effector 34. When the contact sensor 81 moves and the front end surface or the side surface of the cylindrical shape comes into contact with any object, it is possible to detect which direction the contact is made. The detection result of the contact sensor 81 is sent to the recognition processing unit 36. The recognition processing unit 36 recognizes (calculates) the position where the contact sensor 81 has made contact with the object, based on the position of the end effector 34 (the operation of the robot mechanism 31).
Next, a unit identifying process (ST5) performed when the 2 nd transfer device V1 automatically replaces the tape feeder 13 as the component supply device and the component reel 16 as the component container mounted on the 2 nd component supply carriage 70 (component supply unit) will be described with reference to fig. 19A to 19C. Here, it is assumed that the transfer device moving step (ST1) of moving the 2 nd transfer device V1 to the 2 nd component supply carriage 70 in response to the operation instruction is completed. That is, the 2 nd transfer device V1 and the 2 nd component supply carriage 70 are in the same positional relationship as the transfer device V and the component supply carriage 5 shown in fig. 14A to 15C.
An example of recognizing the left cart recognition target G1 will be described below. That is, in the work instruction generating step (ST2), the work instruction generating unit 41 generates a work instruction including information specifying the cell identifier of the left carriage recognition target G1 as the recognition target recognized by the contact sensor 81 (recognition unit). Then, in the cell recognition step (ST5), the replacement control unit 46 controls the robot mechanism 31 to execute a contact detection operation, which will be described later, before the contact sensor 81 moves to the left carriage recognition target G1, and recognizes the position Q1 of the left carriage recognition target G1.
In fig. 19A, in the contact detection operation, first, the replacement control unit 46 moves the contact sensor 81 before the left carriage recognition target G1 in the Y direction (arrow d 1). In fig. 19B, when the contact of the front end surface of the contact sensor 81 with the left back plate 74 is detected, the replacement control unit 46 stops the movement of the contact sensor 81 in the Y direction. Next, the replacement control unit 46 moves the contact sensor 81 in the X direction toward the left side plate 72 by bringing the front end surface of the contact sensor 81 into contact with the left back plate 74 (arrow d 2).
In fig. 19C, when the contact of the side surface of the contact sensor 81 with the left side plate 72 is detected, the replacement control unit 46 stops the movement of the contact sensor 81 in the X direction. Next, the replacement control unit 46 moves the contact sensor 81 in the Z direction toward the lower plate 71 by bringing the side surface of the contact sensor 81 into contact with the left side plate 72 (arrow d 3). When detecting that the side surface of the contact sensor 81 has contacted the lower plate 71, the replacement control section 46 stops the movement of the contact sensor 81 in the Z direction. Through this series of contact detection operations, the contact sensor 81 stops at the corner where the lower plate 71, the left side plate 72, and the left back plate 74 intersect.
Next, the recognition processing unit 36 calculates (recognizes) the position Q1 of the left cart recognition target G1 based on the position at which the contact sensor 81 is stopped. The position Q1 (recognition result) of the recognized left-side dolly recognition target G1 is stored in the transfer storage unit 44 as recognition result information 44 b. The order of the contact by the contact detection operation contact sensor 81 is not limited to the above. For example, the left back plate 74, the lower plate 71, and the left side plate 72 may be brought into contact in this order. In the cell recognition step (ST5), the position Q2 of the right bogie recognition target G2 may be recognized. By recognizing the positions Q1, Q2 of the 2 nd carriage recognition targets G1, G2, the position of the 2 nd component supply carriage 70 can be recognized more accurately.
In the feeding device identifying step (ST6), the replacement controller 46 controls the robot mechanism 31 to execute the contact detecting operation to identify the position Q3 of the left mounting portion recognition target G3 before the contact sensor 81 moves to the left mounting portion recognition target G3. In the feeding device identifying step (ST6), the position Q4 of the right mounting portion identifying target G4 may be identified. By identifying the positions Q3, Q4 of the 2 mounting part recognition targets G3, G4, the position of the feeder mounting part 12 can be recognized more accurately.
As described above, the carriage recognition targets G1, G2 and the mounting portion recognition targets G3, G4 are to-be-contacted bodies (unit recognition bodies) formed on the component supply unit (the 2 nd component supply carriage 70). The contact sensor 81 is a detection unit (recognition unit) that moves together with the end effector 34 and detects contact with the object to be contacted. Then, the recognition result by the contact sensor 81 (recognition unit) is the position where the detection unit is in contact with the body to be contacted (positions Q1 to Q4).
The recognition of the position Q2 of the right bogie recognition target G2 in the unit recognition step (ST5) may be performed in combination with the distance detection operation described below, in addition to the contact detection operation described above in which recognition is performed by sequentially contacting the right back plate 75, the right side plate 73, and the lower plate 71.
Here, the distance detecting operation will be described with reference to fig. 20. In the distance detecting operation, after the contact sensor 8 detects the position Q1 of the left cart recognition target G1 in the contact detecting operation, the exchange controller 46 controls the robot mechanism 31 to move the contact sensor 81 in the X direction toward the right side plate 73 while bringing the side surface of the contact sensor 81 into contact with the lower plate 71 (arrow e 1). When the side surface of the contact sensor 81 is detected to be in contact with the right side plate 73, the replacement control unit 46 stops the movement of the contact sensor 81 in the X direction.
By this distance detecting operation, the contact sensor 81 stops at a position of a corner where the lower plate 71, the right side plate 73, and the right back plate 75 intersect. Next, the recognition processing unit 36 calculates the distance R traveled after the contact sensor 81 detects the position Q1 of the left carriage recognition target G1. Further, the recognition processing unit 36 calculates (recognizes) the position Q2 of the right dolly recognition target G2 from the position Q1 of the left dolly recognition target G1 and the distance R traveled by the contact sensor 81. The distance detection operation can shorten the time for recognizing the position Q2 of the right-side dolly recognition target G2.
In fig. 20, the recognition of the position Q4 of the right mounting portion recognition target G4 in the feeding device recognition process (ST6) may be performed in combination with the contact detection operation and the distance detection operation. That is, after the left attachment recognition target G3 is recognized, the contact sensor 81 is moved in the X direction along the upper plate 78 (arrow e2), and the position Q4 of the right attachment recognition target G4 may be calculated based on the distance the contact sensor 81 has moved. The recognition result by the contact sensor 81 (recognition unit) in the distance detection operation includes the distance until the detection unit (contact sensor 81) comes into contact with the object to be contacted (the right cart recognition target G2 and the right attachment unit recognition target G4).
Although the objects to be contacted which are detected by the contact sensor 81 (detecting portion) are the carriage recognition objects G1 and G2 formed in the lower portion 5a of the 2 nd component feeding carriage 70 and the mounting portion recognition objects G3 and G4 formed in the feeder mounting portion 12, the objects to be contacted (objects to be contacted) may be formed in other objects and detected (recognized) by the contact sensor 81. For example, instead of the tape feeder marks Mt formed on the tape feeders 13 and the lever feeder marks Ms formed on the lever feeders 14 as the feeding device recognition body forming recognition targets, the positions of the component feeding devices may be ascertained (recognized) by the contact sensors 81.
Industrial applicability of the invention
The automatic exchange system, the management device, and the automatic exchange method according to the present disclosure have an effect of enabling accurate exchange of the component container, and are useful in the field of mounting components on substrates.
Description of the symbols
1 parts mounting system
2 communication network
3 management computer
3a wireless management communication unit
4 parts supply part
5 parts supply trolley
5a lower part
5B lower reel holder
5U Upper reel holder
6 tray feeder
7 base station
8 base plate transport mechanism
9 base plate
10 mounting head
10a adsorption nozzle
12 feeder fitting part
13 tape feeder
13a with insertion opening
14-bar feeder
14a loading part
15 parts storage belt
16-component reel
17 rod-shaped shell
18 mounting control part
20 feeder placing part
21 Rack part
22 pallet moving part
23 tray
24 support plate
25 Material Box
26 Cartridge holder
26a rack door
27 pallet placing part
27a opening and closing cover
28 pallet table
28a take-out mechanism
29 lifting mechanism
30 trolley parts
30a wheel
31 robot mechanism (moving mechanism)
32 storage part
32a storage rack
33 running gear
34 end effector
35 Mobile camera (recognition part)
36 recognition processing part
37 head camera
40 management storage unit
40a part information
40b cell information
40c outside dimension information
40d supply device information
40e replacement work information
41 work instruction generating part
42 management input unit
43 management display part
44 transfer and storage part
44a job instruction information
44b identification result information
45 travel control unit
46 replacement control part
47 route setting unit
50 unit number
51 unit type
52. 62 identification method
53 reel correction value
Offset in 53x, 54x, 63x X directions
Offset in 53z, 54z, 63z Z directions
54 groove correction value
Cell 55 unique information
56 holding part number
57 holding part position
Position 57x X
Position 57z Z
60 feeder number
61 feeder type
63 feeder correction value
64 supply device specific information
70 nd 2 nd parts supply trolley
71 lower plate
72. 73 side plate
74. 75, 79 and 80 inner plates
76. 77 support plate
78 Upper plate
81 contact sensor
D part
E parts supply position
G1, G2 trolley recognition target
G3, G4 assembly part recognition target
Ma assembly part mark
Mc trolley mark
Ml rack marker
Mo opening and closing mark
Ms stick feeder marker
Mt tape feeder marker
T wireless communication unit
V transfer device
V1 transfer 2.

Claims (15)

1. An automatic exchange system that exchanges at least one of a component supply device and a component container of a component supply unit, the component supply unit including the component container that contains a component and the component supply device that moves the component contained in the component container to a component supply position, the automatic exchange system comprising:
an end effector that holds the component supply device or the component container;
a moving mechanism configured to move the end effector;
a recognition unit configured to recognize a unit recognition object provided in the component supply unit and used for recognizing the component supply unit;
a path setting unit that sets a movement path for moving the end effector; and
a transfer device having a control unit for controlling the moving mechanism,
the control unit moves the end effector to at least one of the component supply device and the component container based on the set movement path and the recognition result by the recognition unit.
2. The automatic change system according to claim 1,
further comprising a management device having a work instruction generation unit for generating a work instruction including a movement target of the end effector based on the outside dimension information of the component supply unit,
the route setting unit sets the movement route based on the work instruction.
3. The automatic change system according to claim 2,
the work instruction generation unit generates the work instruction so as to include information of the unit identifier identified by the identification unit.
4. The automatic change system according to claim 2,
the work instruction generation unit corrects the movement target of the end effector based on any one of the following values, and generates the work instruction including the corrected movement target:
a unit position correction value for correcting the moving target of the end effector based on a positional deviation of the unit recognition object; and
a feeder position correction value for correcting the movement target of the end effector based on a positional deviation of a feeder recognition body for recognizing the component feeder provided to the component feeder.
5. The automatic change system according to claim 1,
a supply device recognition body for recognizing the component supply device is provided in the component supply device,
the identification unit further identifies the supply device identification body,
the control unit moves the end effector to the component supply device based on the set movement path and a recognition result of the supply device recognition object based on the recognition unit.
6. The automatic change system according to claim 1,
the unit recognition object is a mark formed at the component supply unit,
the recognition unit is an imaging unit that images the mark.
7. The automatic change system according to claim 1,
the unit recognition object is a contacted object formed at the component supply unit,
the recognition unit is a detection unit that moves together with the end effector and detects contact with the body to be contacted.
8. The automatic change system according to claim 7,
the recognition result is a position where the detection portion is in contact with the body to be contacted.
9. The automatic change system according to claim 7,
the recognition result includes a distance until the detection unit comes into contact with the body to be contacted.
10. A management device that generates a work instruction to a transfer device including a movable end effector that replaces at least one of a component supply device and a component container of a component supply unit including the component container that contains a component and the component supply device that moves the component contained in the component container to a component supply position, the management device comprising:
a storage unit for storing the outer dimension information of the component supply unit; and
and a work instruction generating unit that generates a work instruction including a movement target of the end effector, based on the outside dimension information of the component supply unit stored in the storage unit.
11. An automatic replacement method for replacing at least one of a component supply device and a component container of a component supply unit by a transfer device having a movable end effector, the component supply unit including the component container for accommodating a component and the component supply device for moving the component accommodated in the component container to a component supply position,
the automatic replacement method comprises the following steps:
identifying a unit identifier provided in the component supply unit to identify the component supply unit;
setting a movement path for moving the end effector; and
moving the end effector to at least one of the component supplying device and the component container based on the set moving path and a recognition result of the unit recognition object.
12. The automatic change method according to claim 11,
further comprising a step of generating a work instruction including a moving target of the end effector based on the outside dimension information of the component supply unit,
setting the movement path based on the job instruction.
13. The automatic change method according to claim 12,
the job instruction is generated so as to include information of the identification target of the identification portion.
14. The automatic change method according to claim 12,
correcting the movement target of the end effector based on any one of the following values, and generating the job instruction including the corrected movement target:
a unit position correction value for correcting the moving target of the end effector based on a positional deviation of the unit recognition object; and
a feeding device position correction value for correcting the movement target of the end effector based on a positional deviation of a feeding device recognition body provided to the component feeding device for recognizing the component feeding device.
15. The automatic change method according to claim 11,
further comprising a step of identifying a supply device identifier provided in the component supply device and used for identifying the component supply device,
moving the end effector to the component feeding device based on the set moving path and a recognition result of the feeding device recognition body.
CN201980028913.5A 2018-07-31 2019-06-18 Automatic replacement system, management device, and automatic replacement method Active CN112042285B (en)

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JP2018-143144 2018-07-31
PCT/JP2019/024056 WO2020026619A1 (en) 2018-07-31 2019-06-18 Automatic replacement system, management device, and automatic replacement method

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JP7403047B2 (en) 2023-12-22
CN117062427A (en) 2023-11-14
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WO2020026619A1 (en) 2020-02-06
JP2024012692A (en) 2024-01-30

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