JP2009302475A - Feeder diagnosis method, feeder diagnosis system, and torque load generation device - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a feeder diagnosis method and a system that excellently diagnose a tape feeder with high reliability; and to provide a torque load generation device suitable for feeder diagnoses. <P>SOLUTION: The engagement part 634 of the torque load generation device 6 is engaged with the sprocket 231 of a tape feeding mechanism 23, and a rotor (engagement member) 633 is engaged with the sprocket 231 to be driven according to driving of the tape feeding mechanism 23. A brake pad 635 comes into slide-contact with the rotor 633 to impose a torque load on the tape feeding mechanism 23. Thus, various feeder diagnoses are made while the torque load is imposed on the tape feeding mechanism 23 and even in a tape non-fitting state where no tape is fitted to a tape feeder 2, the feeder diagnoses are made in the same state as or in a state close to a tape fitting state. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

  The present invention relates to a feeder diagnosis method and system for diagnosing a tape feeder, in which a tape in which parts are stored at an equal pitch is pitch-fed by a tape feeding mechanism, and a torque load generator suitable for feeder diagnosis.

  Conventionally, a tape feeder is generally known as an apparatus for supplying components for mounting in a surface mounter. The tape feeder holds a tape containing components at regular intervals while being wound around a reel, and feeds the tape from the reel toward a preset component supply position. Then, at the component supply position, the component housed in the tape is sucked and held by the head of the surface mounter and taken out from the tape. In addition, with the completion of the component take-out, the tape is fed out in the feed direction at a predetermined pitch by the tape feed mechanism, and the next component is supplied to the component supply position.

  In the tape feeder, during repeated parts supply, various parts constituting the tape feeding mechanism for feeding the pitch of the tape may be worn or deteriorated, and the tape feeding accuracy may be lowered. When the performance of the tape feeder is reduced in this way, the component is positioned at a position deviated from the component supply position, and a pickup error such as the component being picked up in an unstable posture or dropping from the head nozzle occurs. Sometimes.

  Therefore, for example, as described in Patent Document 1, the tape feeding accuracy is detected using a dedicated system. In other words, the tape feeding accuracy is diagnosed based on the image obtained by imaging the parts accommodated on the tape and the observation hole of the tape jig and the image of the pickup position (component feeding position), and the tape feeding position is determined. Correction is being performed.

Japanese Patent Laying-Open No. 2007-158048 ([0017] to [0020], FIG. 4)

  By the way, in the apparatus described in Patent Document 1, the tape feed position accuracy is diagnosed using a tape or a tape jig, but the workability is improved, or the tape and the components housed in the tape are included. From the viewpoint of suppressing waste of tape, it has been proposed to diagnose a tape feeder without attaching a tape or the like to the tape feeder. However, even when it is diagnosed that the tape feeder is not attached to the tape feeder, that is, when the feeder diagnosis is performed with the tape not attached, the tape feeder is attached with the tape (tape attached state). When component mounting with a surface mounter is performed, it may not operate normally, and it is difficult to say that the reliability of feeder diagnosis is sufficiently secured. In addition, if it does not operate normally in this way, it is necessary to perform additional feeder diagnosis with the tape attached, and it may take more time and effort than necessary for feeder diagnosis, as well as poor adjustment and sudden failure. There was also a possibility that discovery of the cause of would be delayed.

  In addition, in order to verify the reliability of the tape feeder, it is necessary to diagnose the tape feeding accuracy after operating the tape feeding continuously or intermittently for a long time. When the apparatus described in Document 1 is used, it is necessary to use a relatively large amount of tape, resulting in a great cost for the reliability test.

  The present invention has been made in view of the above problems, and provides a feeder diagnosis method and system capable of performing tape feeder diagnosis satisfactorily and with high reliability, and a torque load generator suitable for the feeder diagnosis. For the purpose.

  The present invention is a feeder diagnosis method and a feeder diagnosis system for diagnosing a tape feeder, in which a tape in which parts are stored at an equal pitch is pitch-fed by a tape feeding mechanism, and is configured as follows to achieve the above object Has been. The feeder diagnosis method according to the present invention is characterized in that the tape feeder is diagnosed by driving the tape feeding mechanism in a tape non-attached state where the tape is not attached to the tape feeder while applying a torque load to the tape feeding mechanism. The feeder diagnostic system according to the present invention includes a torque load generating means for applying a torque load to the tape feeding mechanism, and a tape non-attached tape that is not attached to the tape feeder while the torque load generating means applies the torque load to the tape feeding mechanism. Control means for diagnosing the tape feeder by driving the tape feeding mechanism in the attached state is provided.

  In the invention thus configured (feeder diagnostic method and system), even when the tape is not attached to the tape feeder, a torque load is applied to the tape feeding mechanism, which is the same as or close to the tape attached state. Feeder diagnosis is executed in the situation. For this reason, feeder diagnosis is performed accurately and with high reliability. Here, if importance is placed on the reliability of the feeder diagnosis, it is desirable to apply a load equal to or higher than the load applied to the tape feeding mechanism by the tape when the tape is pitch-fed as the torque load.

  Moreover, the following can be employ | adopted as a specific diagnostic content of a feeder diagnosis. The first diagnosis content relates to the feed position accuracy. In other words, when positioning the component at the component supply position by pitch-feeding the tape by rotating the sprocket, the sprocket at or near the component supply position when the tape feed mechanism is driven while applying a torque load to the tape feed mechanism. After imaging (first imaging step), the feed position accuracy can be diagnosed based on the captured first sprocket image. Also, a sprocket image is taken at the component supply position or in the vicinity position when the tape feeding mechanism is driven without applying a torque load to the tape feeding mechanism (second imaging step), and the second sprocket obtained thereby The feed position accuracy may be diagnosed based on the image and the previous first sprocket image. In this case, it is possible to accurately cope with a case where the state of the tape feeding mechanism changes depending on the presence or absence of torque load, and it is possible to diagnose the feeding position accuracy more satisfactorily and with higher reliability. For example, the meshing state of the gear for transmitting the rotational driving force to the sprocket changes depending on the presence or absence of torque load, and in the situation where torque load is applied, the gear meshes normally, but the torque load is not applied or the torque load is small Even in the case where the meshing failure occurs in the situation, the feed position accuracy can be accurately diagnosed, and the reliability of the diagnosis can be further improved.

  Further, the malfunction of the tape feeding mechanism may be diagnosed by measuring the rotational speed of the sprocket. That is, the malfunction of the tape feeding mechanism may be diagnosed based on the first rotational speed of the sprocket when the tape feeding mechanism is driven while applying a torque load to the tape feeding mechanism. Further, the malfunction of the tape feeding mechanism may be diagnosed based on the second rotation speed of the sprocket and the first rotation speed when the tape feeding mechanism is driven without applying a torque load to the tape feeding mechanism. In this case, it is possible to accurately cope with a case where the state of the tape feeding mechanism changes depending on the presence or absence of torque load, and it is possible to diagnose a malfunction of the tape feeding mechanism more satisfactorily and with high reliability.

  Further, when the tape feeding mechanism has a motor for pitch feeding the tape, it is possible to diagnose malfunction of the tape feeding mechanism by detecting the current value of the motor as follows. That is, it is possible to diagnose a malfunction of the tape feeding mechanism based on the first current value of the motor when the tape feeding mechanism is driven while applying a torque load to the tape feeding mechanism. The malfunction of the tape feeding mechanism may be diagnosed based on the second current value of the motor and the first current value when the tape feeding mechanism is driven in a state where no torque load is applied to the tape feeding mechanism. In this case, it is possible to accurately cope with a case where the state of the tape feeding mechanism changes depending on the presence or absence of torque load, and it is possible to diagnose a malfunction of the tape feeding mechanism more satisfactorily and with high reliability.

  In another aspect of the feeder diagnostic method according to the present invention, in order to achieve the above object, the tape feeding mechanism is continuously installed in a tape non-attached state in which the tape is not attached to the tape feeder while applying a torque load to the tape feeding mechanism. And a second step of diagnosing the tape feeder by driving the tape feeding mechanism with the tape attached to the tape feeder after the first step. Yes.

  In the invention configured as described above (feeder diagnosis method), the tape feeding mechanism is continuously or intermittently driven in a tape non-attached state while applying a torque load to the tape feeding mechanism, and then the tape is attached to the tape feeder. The tape feeder is diagnosed by driving the tape feeding mechanism with the tape attached. In this way, while the tape is not attached, the torque feeding is applied to the tape feeding mechanism, and the tape feeding mechanism is driven in the same or similar state as the tape attached state. The tape feeder is diagnosed. Therefore, the amount of tape required for the feeder diagnosis can be greatly suppressed, and the reliability test (feeder diagnosis) of the tape feeder can be performed with high reliability while reducing the cost.

  Furthermore, the torque load generator according to the present invention can be applied to a feeder diagnosis method and system for diagnosing a tape feeder, in which a tape in which parts are stored at an equal pitch is pitch-fed by a tape feeding mechanism. That is, the apparatus engages with the tape feeding mechanism in a state where the tape is not attached to the tape feeder and the driven member operates in response to the driving of the tape feeding mechanism, and applies a braking force to the engaging member. And a braking member for applying a torque load to the tape feeding mechanism.

  In the torque load generating apparatus configured as described above, the engaging member engages with the tape feeding mechanism in the tape non-attached state, and is driven in accordance with the driving of the tape feeding mechanism. The braking member applies a braking force to the engaging member to apply a torque load to the tape feeding mechanism. By using the torque load generator configured as described above, the above-described feeder diagnosis can be performed satisfactorily and with high reliability.

  According to the feeder diagnosis method and system according to the present invention, a torque diagnosis is applied to the tape feeding mechanism and the feeder diagnosis is executed in the same or similar state as the tape attachment state. Feeder diagnosis can be performed satisfactorily and with high reliability.

  In addition, the torque load generator according to the present invention engages with the tape feeding mechanism in a state where the tape is not attached, and applies a braking force to the engaging member that is driven in accordance with the driving of the tape feeding mechanism. Since the mechanism is configured to give a torque load, the feeder diagnosis can be performed satisfactorily and with high reliability.

(First embodiment)
FIG. 1 is a perspective view showing a first embodiment of a feeder diagnostic system according to the present invention, and FIG. 2 is a side view of the feeder diagnostic system according to the first embodiment. FIG. 3 is a block diagram showing an electrical configuration of the feeder diagnostic system of FIG. The feeder diagnosis system 1 includes a stage 3 on which a tape feeder 2 to be diagnosed is installed, a recognition camera 4 (FIG. 3) and a camera disposed above the component supply position of the tape feeder 2 installed on the stage 3. Lighting unit 5 (FIG. 3), a torque load generator 6 that is installed on the stage 3 and applies a torque load to the tape feeding mechanism of the tape feeder 2, and a controller that controls the tape feeder 2 during system diagnosis and feeder diagnosis 7.

  The stage 3 includes a base plate 31, two side plates 32 erected from the base plate 31, and a table 33 that is stretched over and fixed to the upper ends of the side plates 32. A plurality of guides 34 are arranged in parallel on the table 33, and the tape feeder 2 can be attached to and detached from the table 33 along each guide 34. As is well known in the art, the tape feeder 2 feeds out a tape containing components at regular intervals toward a preset component supply position, and is configured as follows. Hereinafter, the schematic configuration of the tape feeder 2 will be described with reference to FIGS.

  As shown in FIGS. 1 and 2, the tape feeder 2 has a box-type feeder body 21 that is flat in the width direction (X direction). Inside the feeder body 21, a tape guide portion is provided in the front-rear direction (Y direction), and a reel (not shown) around which the tape is wound is rotated behind the tape guide portion (right end portion in FIG. 2). It can be retained. A tape guide extending in the front-rear direction (left-right direction in FIG. 2) is provided on the upper portion of the feeder main body 21, and a cover member 22 is provided so as to cover the upper portion. Then, the tape led out from the reel is guided below the cover member 22 along the tape guide.

  The tape feeder 2 is provided with a tape feeding mechanism 23 in the feeder main body 21 for feeding along the tape guide. In the tape feeding mechanism 23, a sprocket 231 is disposed at a position where a component is picked up by the surface mounter, that is, below the component supply position 24. A part of the outer edge part faces the tape guide through an opening formed in the inner ceiling part of the feeder main body 21, and a part of the pin (sprocket pin) provided on the outer periphery of the sprocket 231 is a part of the tape. The tape can be engaged by fitting into the engagement hole. In the tape feed mechanism 23, a feed motor 232 as a drive source is connected to the sprocket 231 via a gear (not shown). When the sprocket 231 is rotationally driven by the motor 232, the tape is fed from the reel with this rotation. While being pulled out, the tape is intermittently sent out at a constant pitch feed amount corresponding to the pitch of the component storage portion of the tape.

  Further, in order to enable component supply at the component supply position 24, the cover tape is peeled off from the tape on the upstream side of the component supply position 24. That is, on the upstream side of the component supply position 24 (right hand side in FIG. 2), the cover tape is peeled off by a part of the cover member from the tape guided along the tape guide, and the rear side (right hand side in FIG. 2). Wrapped to As a result, the component storage portion of the tape (carrier tape) is opened upward and is sent to the component supply position 24 as it is. On the other hand, the cover tape folded back as described above is fed to the rear side by the take-up mechanism 25 and further fed into the rear cover tape accommodating portion 26.

  The take-up mechanism 25 is provided in the feeder main body 21 on the rear side (the right hand side in FIG. 2) of the tape feed mechanism 23. The take-up motor 251 and the take-off gear pair 252 (only one is shown in FIGS. Are shown). The cover tape peeled off from the tape is guided between the take-off gear pair 252. At the time of supplying parts, the take-off gear pair 252 is driven to rotate by the operation of the take-off motor 251, and its take-off force (rotation) Force), the cover tape is peeled off from the carrier tape.

  The tape feeder 2 configured as described above has a controller 27 for controlling the tape feeder 2 as shown in FIG. The controller 27 includes an arithmetic processing unit 271 configured by a CPU, a storage unit 272 such as a nonvolatile memory, a motor control unit 273 that controls the feed motor 232 and the take-up motor 251, and current values of the respective motors. A current detection unit 274 to detect, a position detection unit 275 that performs position detection based on signals from encoders 233 and 253 attached to each motor, and a communication control unit 276 are provided. Reference numeral 28 in FIG. 3 is a display / operation unit for displaying various information and instructions to the worker, and for inputting information such as various data and commands to the controller 27 by the worker. .

  When the tape feeder 2 is mounted on the feeder mounting portion of the mounting machine body, the communication control unit 276 can communicate with the mounting machine, and bidirectional communication of the pitch feed amount between the two is possible. On the other hand, when the tape feeder 2 is mounted on the table 33 of the feeder diagnostic system 1, the communication control unit 276 becomes communicable with the controller 7 of the feeder diagnostic system 1 as shown in FIG. The communication method performed between the tape feeder 2 and the mounting machine and the feeder diagnosis system 1 can be a wired method or a wireless method, and the communication mode is also arbitrary.

  The feeder diagnosis system 1 includes a controller 7 for performing feeder diagnosis while performing communication with the tape feeder 2. As shown in FIG. 3, the controller 7 includes an arithmetic processing unit 71 configured by a CPU or the like, a storage unit 72 such as a nonvolatile memory, and image processing for performing image processing on an image signal from the recognition camera 4. Unit 73, camera illumination control unit 74 that controls camera illumination unit 5, and feeder communication control unit 75. Then, in a state where a torque load is applied to the tape feeding mechanism 23 by the torque load generating device 6 described below, the arithmetic processing unit 71 performs the system 1 and the table according to the diagnostic program stored in the storage unit 72 in advance. Feeder diagnosis is performed by controlling the tape feeder 2 attached to 33. Reference numeral 8 in FIG. 3 is a display / operation unit for displaying various information and instructions to the worker, and for inputting information such as various data and commands to the controller 7 by the worker. .

  FIG. 4 is a diagram showing the overall configuration of the torque load generator. FIG. 5 is a main sectional view of the torque load generator of FIG. The torque load generator 6 has a device body 61 that can be placed on the table 33. And the grip mechanism 62 is provided in the rear end side (right hand side of FIG.4 (b)) of the apparatus body 61, and when the operator operates the grip mechanism 62, the torque load generator 6 is made with respect to the stage 3 It is detachable. That is, the fixing portion 35 is attached to the side surface of the table 33 on the side where the tape feeder 2 is attached to and detached from the table 33, that is, on the right hand side in FIG. An engaging portion 351 having an inverted triangular cross-sectional shape is extended on the lower surface of the fixing portion 35 in the arrangement direction of the guides 34, and the lever tip of the torque load generator 6 is opposed to the engaging portion 351. The torque load generator 6 can be fixed to the stage 3 by engaging the portions.

  The grip mechanism 62 of the torque load generating device 6 includes a grip 621 fixed to the rear end portion of the device body 61 and a lever 622. A shaft support pin 623 is inserted in a substantially central portion of the lever 622, and the lever 622 is supported by the shaft support pin 623 so as to be swingable with respect to a lower end of the grip 621. A coil spring 624 is inserted between the center upper surface of the lever 622 and the center lower surface of the grip 621 so that the rear end of the lever 622 is separated from the grip 621. Located on the body 61 side. Although not shown in FIG. 4, the apparatus body 61 is provided with a stopper for regulating the amount of rotation of the lever 622 to prevent the lever 622 from rotating more than necessary. ing.

  In the grip mechanism 62 configured as described above, when the operator rotates the lever 622 in the direction opposite to the biasing direction by the coil spring 624, the distal end portion of the lever 622 moves away from the apparatus body 61 and the distal end portion of the lever 622. A gap larger than the fixed portion 35 can be formed between the device bodies 61. When the operator releases the lever 622 after moving the torque load generator 6 so that the lever tip and the device body 61 are positioned below and above the fixed portion 35 with the large gap formed in this way, The lever 622 rotates toward the device body 61 side by the urging force of the coil spring 624 to grip the fixed portion 35. In this embodiment, a pin 625 protrudes from the apparatus body 61 side to the stage 3 side. When the torque load generator 6 is moved to the stage 3 side, the pin 625 is drilled on the side surface of the fixing portion 35. It fits into the provided recess (not shown). Thus, the torque load generator 6 is firmly installed and fixed to the stage 3 by fitting the pin 625 into the recess and engaging the engaging portion 351 of the lever tip.

  A load generating mechanism 63 is provided on the upper surface of the apparatus body 61 on the front end side of the apparatus body 61 (the left hand side in FIG. 4B). The load generating mechanism 63 includes a columnar shaft member 631 that is erected from the upper surface of the apparatus body 61. In this shaft member 631, the outer diameter of the upper end portion is smaller than that of the lower end portion, and the boundary portion between both is a stepped portion 631a. A thrust bearing 632 is disposed at the stepped portion 631a, and the rotor 633 is rotatably attached to the shaft member 631 via the thrust bearing 632. The rotor 633 has a substantially disk shape, and engaging portions 634 that can be engaged with the pins of the sprocket 231 are formed on the outer periphery of the rotor 633 at the same pitch as the sprocket pins. When the torque load generator 6 is installed on the table 33 of the stage 3 as described above, the sprocket pin and the engagement portion 634 can be engaged. When the sprocket 231 is driven with the sprocket pin and the engaging portion 634 engaged in this manner, the rotor 633 rotates following the sprocket 231.

  A brake pad 635 is disposed on the upper surface of the rotor 633. The brake pad 635 has a substantially donut shape, and a hollow portion of the brake pad 635 is inserted into the upper end portion of the shaft member 631, and a key 636 is inserted into a key groove provided in the brake pad 635. Has been. For this reason, although the lower surface of the brake pad 635 contacts the upper surface of the rotor 633, the rotation of the brake pad 635 is restricted. Therefore, the rotor 633 rotates following the rotation of the sprocket 231 while sliding on the brake pad 635, and the frictional resistance generated between the brake pad 635 and the rotor 633 at this time becomes the rotation resistance of the sprocket 231 and this is the tape. A torque load is applied to the feed mechanism 23. Thus, in this embodiment, the rotor 633 functions as the “engaging member” of the present invention and the brake pad 635 functions as the “braking member” of the present invention. The configuration of the “member” is not limited to this.

  In this embodiment, the key 636 is fixed to the shaft member 631 by a fastening member such as a bolt, but the brake pad 635 is movable in the vertical direction with respect to the key 636. A coil spring 637 is disposed on the upper surface side of the brake pad 635, and a cap member 638 is disposed so as to cover the coil spring 637 from above. Further, on the upper side of the cap member 638, a nut 639 is screwed to a male screw threaded on the upper end portion of the shaft member 631. For this reason, when the operator sends the nut 639 to the cap member 638 side, the coil spring 637 is compressed and the frictional resistance generated between the brake pad 635 and the rotor 633 can be increased. That is, according to the present embodiment, the torque load on the tape feeding mechanism 23 can be adjusted over a wide range by adjusting the nut.

  Next, a feeder diagnosis method using the feeder diagnosis system 1 configured as described above will be described with reference to FIGS. 6 and 7. FIG. 6 is a flowchart showing a feeder diagnosis method by the feeder diagnosis system according to the first embodiment of the present invention. FIG. 7 is a schematic diagram showing a feeder diagnosis method. In this embodiment, the operator sets the tape feeder 2 to be diagnosed on the stage 3. Here, the tape feeder 2 is mounted on the table 33 in a tape non-attached state where no tape is attached. Further, as shown in FIG. 1, the worker installs the torque load generator 6 on the table 33 adjacent to the tape feeder 2. At this time, the operator adjusts the installation position of the torque load generating device 6 on the table 33 so that the sprocket pin of the tape feeder 2 and the engaging portion 634 of the torque load generating device 6 are engaged with each other. The amount of the nut 639 fed into the cap member 638 is set to adjust the torque load on the tape feeding mechanism 23. For example, the operator can adjust the torque load to the same extent as the load applied to the tape feeding mechanism 23 by the tape at the time of tape pitch feeding. Moreover, you may adjust so that the load exceeding the load added to the tape feeding mechanism 23 may be given with the said tape.

  When the controller 7 of the feeder diagnostic system 1 confirms that such a series of diagnostic preparation work is completed (step S11), the controller 7 controls each part of the system according to the diagnostic program stored in the storage unit 72 in advance. At the same time, communication with the tape feeder 2 is controlled to execute data acquisition processing and diagnosis processing.

  In the data acquisition process, first, the controller 7 transmits a request for rotating the sprocket 231 n times at a minimum feed pitch of component feeding to the tape feeder 2 (a request for pitch feeding a × n times) (step S12). ). At this time, when the tape feeder 2 is fed at the minimum component feed pitch, the sprocket 231 can be rotated once by a pitch feed. The controller 27 of the tape feeder 2 that has received this request command executes steps S21 to S27 to feed the sprocket 231 pitch by a × n times. That is, the variable m is set to the initial value 1 in step S21. Then, the feed motor 232 is driven by the motor control unit 273, and the m-th sprocket pitch feed is started (step S22). In this embodiment, the rotor 633 of the torque load generating device 6 is engaged with the sprocket 231, and the rotor 633 rotates following the sprocket rotation while being in sliding contact with the brake pad 635. For this reason, a torque load acts on the tape feeding mechanism 23 in spite of a so-called tape non-attached state in which no tape is attached to the tape feeder 2.

  The feed motor 232 of the tape feed mechanism 23 operates in such a state that the torque load is applied, and the current value at this time is detected by the current detection unit 274 (step S23).

  The position detection unit 275 detects the position of the sprocket 231 based on the signal from the encoder 233, and the arithmetic processing unit 271 determines whether or not the mth pitch feed of the sprocket 231 is completed based on the position detection result. When the controller 27 on the second side confirms the completion of the m-th pitch feed, a signal indicating that the m-th rotation is confirmed, and the maximum current value of the motor 232 in the m-th pitch feed, that is, the current peak value Im Is transmitted from the tape feeder 2 side to the controller 7 of the feeder diagnostic system 1 (step S24).

  In the next step S25, it is determined whether or not the variable m is a × n, that is, whether or not the current sprocket rotation is the a × n-th pitch feed, and is not the a × n-th (step S25). If "NO"), the variable m is incremented by "1" in step S26, the process returns to step S22, and the next sprocket pitch feed is executed. When it is confirmed in step S25 that “m = a × n”, that is, the rotation of the n-th sprocket is completed, the controller 27 on the tape feeder 2 side confirms the completion of the requested n-rotation of the sprocket 231. A signal is transmitted from the tape feeder 2 side to the controller 7 of the feeder diagnostic system 1 (step S27).

  As described above, the “mth pitch feed confirmation transmission” and the “current peak value” are sent to the controller 7 of the feeder diagnosis system 1 every m-th pitch feed of the sprocket 231 and “n-rotation rotation”. Completion confirmation transmission "is transmitted after the completion of n-round rotation of the sprocket 231. Based on these signals, the controller 7 as shown in FIG. 7 shows the sprocket image, the time required for the sprocket to send one pitch (the sprocket pin (Transmission speed) and current peak value are acquired and stored in the storage unit 72. That is, every time the controller 7 receives “mth pitch feed confirmation transmission”, the controller 7 of the feeder diagnosis system 1 captures the sprocket image after the mth pitch feed by the recognition camera 4 (step S13). Further, a time Tm required for the mth pitch feed is obtained (step S14). That is, for the first pitch feed, the time T1 required from the n-th rotation request to the first pitch feed, and for the second pitch feed, the time required from the completion of the first pitch feed to the completion of the second pitch feed. For T2, and for the mth pitch feed, the time Tm required from the (m-1) th pitch feed to the mth pitch feed is obtained. Further, the current peak value Im of the m-th pitch feed motor 232 is stored in the storage unit 72 (step S15). Thus, the data acquisition process is completed.

  Further, when the controller 7 receives “n-round rotation completion confirmation transmission”, it performs feeder diagnosis based on all images and all acquired data, that is, (1) feed positioning accuracy, (2) feed speed, (3 ) Sudden failure detection by current measurement is performed (step S16).

(1) Feed positioning accuracy The image processing unit 73 performs various image processing on the sprocket image (corresponding to the “first sprocket image” of the present invention) of the component supply position 24 acquired as described above, and the controller 7 Measures the position of the sprocket pin at the component supply position 24 and obtains the amount of positional deviation from the position of the sprocket pin in a preset reference state. Here, the controller 7 obtains the positional deviation amount in the tape feeding direction Y and the positional deviation amount in the direction X orthogonal to the tape feeding direction Y, and further calculates the average value and variation statistics of the positional deviation amounts from the reference position. calculate. Then, the absolute value and the variation of the average deviation value are compared with the non-defective product reference value set in advance and stored in the storage unit 72, and when both are below the reference value, the tape feeder 2 Diagnosed as good. When the reference value is exceeded, the tape feeder 2 is calibrated and repaired by the operator.

(2) Feed speed The controller 7 calculates the time required for each sprocket pin stored in the storage unit 72 to feed one pitch (corresponding to the “first rotation speed” of the present invention) T1, T2,. Read out, and calculate the average time, maximum value and minimum value required for the sprocket pin to send one pitch. Then, these calculation results are compared with the non-defective product reference average value Tav, the non-defective product reference maximum value Tmax and the non-defective product reference minimum value Tmin which are set in advance and stored in the storage unit 72. In the following cases, the tape feeder 2 is diagnosed as being non-defective with respect to the feeding speed. When the reference value is exceeded, the tape feeder 2 is repaired by the operator.

(3) Sudden failure detection by current measurement In the tape feeding mechanism 23 of the tape feeder 2, a gear is provided to transmit the driving force of the motor 232 to the sprocket 231. A sudden failure such as a meshing failure may occur. In this embodiment, feeder diagnosis based on the current value of the motor 232 is performed in order to detect such a sudden failure. That is, the controller 7 reads out current peak values (corresponding to the “first current value” of the present invention) I1, I2,... Im stored in the storage unit 72, and averages the current peak value, the maximum value, and the minimum value. Calculate the value. Then, these calculation results are compared with the non-defective product reference average value Iav, non-defective product reference maximum value Imax, and non-defective product reference minimum value Imin that are set in advance and stored in the storage unit 72, and all of them are the reference values Iav, Imax, Imin. In the following cases, it is diagnosed that the tape feeding mechanism 23 is operating normally. When the reference value is exceeded, the tape feeder 2 is repaired by the operator.

  As described above, according to the present embodiment, the engagement portion 634 of the torque load generator 6 is engaged with the sprocket 231 of the tape feed mechanism 23 to apply torque load to the tape feed mechanism 23, and various Feeder diagnosis is performed. Further, the torque load is set to the same level as the load applied to the tape feeding mechanism 23 by the tape at the time of tape pitch feeding by adjusting the feeding amount of the nut 639. Therefore, the feeder diagnosis is executed in the same or similar state as the tape attachment state, even though the tape is not attached to the tape feeder 2 as described above. As a result, feeder diagnosis can be performed accurately and with high reliability.

  Further, in the conventional technology (for example, the device described in Patent Document 1), the feeder diagnosis is performed only for the feed positioning accuracy, and it cannot be said that the sufficient feeder diagnosis has been performed. On the other hand, in this embodiment, in addition to feed positioning accuracy, feed speed and sudden failure detection can be performed, and more reliable feeder diagnosis can be performed.

  Further, since the feeder diagnosis can be performed without using a tape, the running cost required for the feeder diagnosis can be suppressed at the same time while ensuring excellent reliability as described above.

  Furthermore, various methods can be adopted as a method for applying a torque load to the tape feeding mechanism 23. However, the torque load generator 6 described above is detachable from the stage 3 of the feeder diagnosis system 1. Excellent operability. Further, since the load applied to the tape feeding mechanism 23 can be adjusted over a wide range and with high accuracy by adjusting the feeding amount of the nut 639, feeder diagnosis for various tape feeders 2 becomes possible, and high versatility is obtained. .

(Second Embodiment)
By the way, the state of the tape feeding mechanism 23 may vary greatly depending on the load state. For example, when the tape feeding mechanism 23 transmits the driving force of the motor 232 to the sprocket 231 with a gear, the gear meshing state changes depending on the presence or absence of a torque load, and operates normally when a torque load is applied. However, malfunction may occur when torque load is not applied. Therefore, in order to further improve the reliability of the feeder diagnosis, the feeder diagnosis may be performed as follows. Hereinafter, a second embodiment of the present invention will be described with reference to FIG. Since the system configuration is the same as that of the first embodiment, only the feeder diagnosis method will be described here.

  FIG. 8 is a flowchart showing a second embodiment of the feeder diagnostic method. In this second embodiment, the controller 7 controls each part of the system according to the diagnostic program stored in the storage unit 72 in order to perform feeder diagnosis for the tape feeder 2 mounted on the stage 3 of the feeder diagnostic system 1. At the same time, communication with the tape feeder 2 is controlled to execute data acquisition processing and diagnosis processing.

  The controller 7 gives an instruction to install the torque load generator 6 to the display / operation unit 8 and thereby displays the installation request on the display / operation unit 8 (step S31). According to this display, the operator adjusts the installation position of the torque load generating device 6 on the table 33 while engaging the sprocket pin of the tape feeder 2 and the engaging portion 634 of the torque load generating device 6. Is confirmed (step S32), the same processing as the data acquisition processing in the first embodiment is performed, and a sprocket image (first sprocket image) is applied while applying a torque load to the tape feeding mechanism 23. Is rotated a desired number of times, and the time required for the sprocket to send one pitch (first rotation speed of the sprocket 231) and the current peak value (first current value) are acquired (step S33).

  In the next step S34, the controller 7 gives an instruction to remove the torque load generator 6 to the display / operation unit 8, and thereby displays the removal request on the display / operation unit 8 (step S34). . According to this display, the operator removes the torque load generator 6 from the tape feeder 2 and the stage 3 while leaving the tape feeder 2 on the stage 3, and confirms that the removal operation is completed (step S35). The data acquisition process is executed again (step S36). This data acquisition process is the same as the data acquisition process of the first embodiment except that no torque load is applied to the tape feed mechanism 23, and the tape feed mechanism is driven without receiving the torque load. The sprocket image (second sprocket image), the time required for the sprocket to send one pitch (second rotation speed of the sprocket 231) and the current peak value (second current value) are acquired.

  When sprocket images and the like are acquired in two different states (torque load application state and no-load state) in this way, feeder diagnosis is performed based on all the images and all acquired data (step S37). That is, the average value and the variation statistical value of the displacement amount from the reference position are calculated for each of the torque load application state and the no-load state, and when all the values are equal to or less than the reference value, the tape feeder 2 with respect to the feed positioning accuracy. Is diagnosed as good. When the reference value is exceeded, the tape feeder 2 is calibrated and repaired by the operator. Further, the average time, maximum value and minimum value of one pitch of the sprocket are calculated for each of the torque load application state and the no load state, and when all the values are below the reference value, the tape feeder 2 Diagnosed as good. When the reference value is exceeded, the tape feeder 2 is repaired by the operator. Further, the average time, the maximum value, and the minimum value of the current peak value of the motor 232 are calculated for each of the torque load application state and the no-load state, and when all the values are below the reference value, the tape feeding mechanism 23 is normal. Is diagnosed as operating. When the reference value is exceeded, the tape feeder 2 is repaired by the operator.

  As described above, according to the second embodiment, the feeder diagnosis can be accurately performed even when the state of the tape feeding mechanism 23 changes depending on the presence or absence of torque load, and the feeding position accuracy, feeding speed, and sudden failure detection can be performed. Can be diagnosed better and with higher reliability.

(Third embodiment)
There is a reliability test as a diagnostic item of the tape feeder. This is because the accuracy of the tape feeding position is maintained well even when a good tape feeder with the adjusted tape feeding position is driven continuously or intermittently for a relatively long time. This is a test to diagnose this. Therefore, if the tape is fed out by the tape feeding mechanism and the reliability test is executed even during continuous driving or intermittent driving, the tape consumption required for the test increases. Therefore, in the third embodiment of the present invention, the reliability test is performed while the tape consumption is suppressed by using the torque load generator 6. Hereinafter, a third embodiment of the present invention will be described with reference to FIG. Since the system configuration is the same as that of the first embodiment, only the feeder diagnosis method (reliability test) will be described here.

  FIG. 9 is a flowchart showing a feeder diagnosis method by the feeder diagnosis system according to the third embodiment of the present invention. In the third embodiment, the controller 7 stores the reliability stored in the storage unit 72 in order to perform a reliability test which is one of the feeder diagnoses on the tape feeder 2 mounted on the stage 3 of the feeder diagnostic system 1. Each part of the system is controlled in accordance with the sex test program, and communication with the tape feeder 2 is controlled to execute data acquisition processing and diagnosis processing.

  When the controller 7 confirms that the tape feeder 2 subject to the reliability test is installed on the stage 3 (“YES” in step S41), it is determined whether or not a tape is attached to the tape feeder 2. Is determined (step S42). Here, when it is determined that the tape is not attached to the tape feeder 2, the controller 7 gives an instruction to attach the tape to the tape feeder 2 to the display / operation unit 8 and displays it. / The tape attachment request is displayed on the operation unit 8 (step S43). The operator attaches a tape (or tape jig) to the tape feeder 2 in accordance with this display. When the controller 7 confirms that the tape feeder 2 to be tested is in the tape attachment state in step S42, the tape feed position is adjusted based on the image captured by the recognition camera 4 (step S44). Note that the tape feed position adjustment process is a well-known technique (see, for example, Patent Document 1), and thus the description thereof is omitted here.

  When this adjustment process is completed, the controller 7 gives a tape removal request command from the tape feeder 2 to the display / operation unit 8, thereby displaying the tape removal request on the display / operation unit 8 ( Step S45). According to this display, the operator removes the tape from the tape feeder 2. When the controller 7 confirms that the tape feeder 2 is not attached in step S46, the controller 7 gives an instruction to install the torque load generator 6 to the display / operation unit 8, thereby displaying / The installation request is displayed on the operation unit 8 (step S47). According to this display, the operator adjusts the installation position of the torque load generating device 6 on the table 33 while engaging the sprocket pin of the tape feeder 2 and the engaging portion 634 of the torque load generating device 6. When the controller 7 confirms that the sprocket 231 is rotated (step S48), the controller 7 transmits a request to the tape feeder 2 to rotate the sprocket 231 n times (step S49). On the other hand, the controller 27 of the tape feeder 2 receiving this request command gives an operation command to the motor control unit 273 to rotate the sprocket 231 n times. In this embodiment, the sprocket 231 is continuously driven while applying a torque load to the tape feeding mechanism 23. However, the sprocket 231 may be intermittently rotated.

  When the above-described continuous or intermittent drive of the sprocket 231 is completed, the controller 7 gives the display / operation unit 8 a command to remove the torque load generator 6 from the stage 3, and this causes the display / operation unit 8 to be displayed. The removal request is displayed (step S50). According to this display, the operator removes the torque load generator 6 from the tape feeder 2 and the stage 3 while leaving the tape feeder 2 on the stage 3, and confirms that the removal work is completed (step S51). Proceed to the next Step S53.

  In step S53, the controller 7 gives a tape attachment request command to the tape feeder 2 to the display / operation unit 8, thereby displaying the tape attachment request on the display / operation unit 8 (step S52). The operator attaches a tape (or tape jig) to the tape feeder 2 in accordance with this display. When the controller 7 confirms that the tape feeder 2 to be tested is in the tape attachment state in step S53, the positioning accuracy of the tape feeding position is measured based on the image captured by the recognition camera 4 (step S54). Based on the measurement result, a pass / fail diagnosis of the feeder is performed (step S55). Note that the measurement processing of the positioning accuracy of the tape feed position and the pass / fail diagnosis processing are well-known techniques (for example, see Patent Document 1), and thus the description thereof is omitted here.

  As described above, according to the third embodiment of the present invention, after the tape feeding mechanism 23 is continuously or intermittently driven in a tape non-attached state while applying a torque load to the tape feeding mechanism 23, the tape (Or a tape jig) is attached to the tape feeder 2, and the tape feeder 2 is diagnosed by driving the tape feeding mechanism 23 in this tape attached state. As described above, a torque load is applied to the tape feeding mechanism 23 while the tape is not attached, and the tape feeding mechanism 23 is driven in the same or similar state as the tape attached state. The diagnosis of the tape feeder 2 is executed in the state. Therefore, the amount of tape required for the reliability test (feeder diagnosis) can be greatly suppressed, and the reliability test of the tape feeder can be performed with high reliability while reducing the cost.

(Other)
The present invention is not limited to the above-described embodiment, and various modifications other than those described above can be made without departing from the spirit of the present invention. For example, in the above embodiment, a sprocket image of the component supply position 24 is captured. However, a sprocket image in the vicinity of the component supply position 24 is captured, or a position detection mark is separately provided on the sprocket and the image is captured. Then, the feeder diagnosis may be performed. Furthermore, in the above embodiment, the sprocket image is picked up from above the component supply position of the tape feeder 2 by the recognition camera 4, but the recognition camera 4 is arranged on the side of the tape feeder 2 (X direction in FIG. 1). Alternatively, feeder diagnosis may be performed by taking an image of the side of the tape feeding mechanism 23. Although the feeder diagnosis is performed based on the current peak value of the motor 232, the effective value of the motor current may be measured instead of the current peak value or together with the current peak value, and the feeder diagnosis may be performed based on the effective value. Further, although the position of the sprocket 231 is detected based on the signal from the encoder 233, the rotation of the sprocket 231 may be detected by directly detecting the rotational operation of the sprocket 231 with an optical sensor or the like.

  Further, in the above embodiment, the feed positioning accuracy is diagnosed based on the sprocket image for a case where the minimum feed pitch of component feed matches one pitch of the sprocket pins. For this reason, in the reference state, the picked-up image of the sprocket is the same no matter how many times the sprocket is pitch-fed at the minimum feed pitch of parts feed. Therefore, in the above embodiment, it is sufficient to prepare one “reference image at the time of pitch feeding” in the reference state as shown in FIG. On the other hand, in the case where the minimum feed pitch of component feed and one pitch of sprocket pins do not match, it is necessary to prepare a “reference image at the time of pitch feed” corresponding thereto. That is, in the case where the minimum feed pitch of component feed is (1 / k) of one sprocket pin pitch, it is necessary to prepare k types of reference images. For example, in the case where the minimum feed pitch of component feed is (1/2) of one pitch of the sprocket pin, as shown in FIG. 10, “reference image at odd pitch feed” and “even pitch feed” Two types of “reference image” are prepared, and the amount of positional deviation can be obtained based on the captured image and “reference image at odd-numbered pitch feed” during the first, third,... (2m−1) th pitch feed. In the second, fourth,..., 2m pitch feed, the positional deviation amount can be obtained based on the captured image and the “reference image at even pitch feed”.

It is a perspective view which shows 1st Embodiment of the feeder diagnostic system concerning this invention. It is a side view of the feeder diagnostic system concerning a 1st embodiment. It is a block diagram which shows the electrical structure of the feeder diagnostic system of FIG. It is a figure which shows the whole structure of a torque load generator. It is principal sectional drawing of the torque load generator of FIG. It is a flowchart which shows the feeder diagnostic method by the feeder diagnostic system concerning 1st Embodiment. It is a schematic diagram which shows a feeder diagnostic method. It is a flowchart which shows the feeder diagnostic method by the feeder diagnostic system concerning 3rd Embodiment of this invention. It is a flowchart which shows the feeder diagnostic method by the feeder diagnostic system concerning 3rd Embodiment of this invention. It is a schematic diagram which shows the feeder diagnostic method concerning other embodiment of this invention.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 ... Feeder diagnostic system 2 ... Tape feeder 6 ... Torque load generator 7 ... Controller (control means)
DESCRIPTION OF SYMBOLS 23 ... Tape feed mechanism 24 ... Parts supply position 63 ... Load generating mechanism 71 ... Operation processing part 231 ... Sprocket 232 ... Feed motor 633 ... Rotor (engaging member)
635 ... Brake pad (braking member)

Claims (11)

It is a feeder diagnostic method for diagnosing a tape feeder, in which a tape is fed by a tape feeding mechanism with tapes in which parts are stored at an equal pitch,
A feeder diagnosis method comprising diagnosing the tape feeder by driving the tape feeding mechanism in a tape non-attached state where the tape is not attached to the tape feeder while applying a torque load to the tape feeder. 2. The feeder diagnosis method according to claim 1, wherein the tape feeding mechanism has a sprocket that can be engaged with the tape, and pitches the tape by rotation of the sprocket to position the component at a component supply position. Because
A first imaging step of imaging the sprocket at or near the component supply position when the tape feeding mechanism is driven while applying the torque load to the tape feeding mechanism;
A feeder diagnostic method comprising: a position accuracy diagnosis step of diagnosing the feed position accuracy based on the first sprocket image imaged in the first imaging step. A second imaging step of imaging the sprocket image at or near the component supply position when the tape feeding mechanism is driven without applying the torque load to the tape feeding mechanism;
The feeder diagnostic method according to claim 2, wherein the position accuracy diagnosis step is a step of diagnosing a feed position accuracy based on the first sprocket image and the second sprocket image captured in the second imaging step. The feeder diagnosis method according to claim 1, wherein the tape feeding mechanism has a sprocket provided to be engageable with the tape, and pitch-feeds the tape by the rotation of the sprocket.
A first measuring step of measuring a rotational speed of the sprocket when the tape feeding mechanism is driven while applying the torque load to the tape feeding mechanism;
A feeder diagnostic method comprising: a first malfunction diagnosis step that diagnoses malfunction of the tape feeding mechanism based on the first rotation speed measured in the first measurement process. A second measuring step of measuring a rotation speed of the sprocket when the tape feeding mechanism is driven in a state where the torque load is not applied to the tape feeding mechanism;
5. The feeder according to claim 4, wherein the first malfunction diagnosis step is a step of diagnosing malfunction of the tape feeding mechanism based on the first rotation speed and the second rotation speed measured in the second measurement process. Diagnosis method. The feeder diagnosis method according to claim 1, wherein the tape feeding mechanism has a motor for pitch feeding the tape.
A first detection step of detecting a current value of the motor when the tape feeding mechanism is driven while applying the torque load to the tape feeding mechanism;
A feeder diagnostic method comprising: a second malfunction diagnosis step of diagnosing malfunction of the tape feeding mechanism based on the first current value detected in the first detection process. A second detection step of detecting a current value of the motor when the tape feeding mechanism is driven without applying the torque load to the tape feeding mechanism;
7. The feeder diagnosis according to claim 6, wherein the second malfunction diagnosis step is a step of diagnosing malfunction of the tape feeding mechanism based on the first current value and the second current value detected in the second detection step. Method. It is a feeder diagnostic method for diagnosing a tape feeder, in which a tape is fed by a tape feeding mechanism with tapes in which parts are stored at an equal pitch,
A first step of driving the tape feeding mechanism continuously or intermittently in a tape non-attached state where a tape is not attached to the tape feeder while applying a torque load to the tape feeding mechanism;
A feeder diagnostic method comprising: a second step of diagnosing the tape feeder by driving the tape feeding mechanism in a tape attachment state in which a tape is attached to the tape feeder after the first step.   The feeder diagnosis method according to any one of claims 1 to 8, wherein the torque load is equal to or greater than a load applied to the tape feeding mechanism by the tape when the tape is pitch-fed. It is a feeder diagnostic system for diagnosing a tape feeder that feeds a tape in which parts are stored at an equal pitch by a tape feeding mechanism.
Torque load generating means for applying a torque load to the tape feeding mechanism;
Control means for diagnosing the tape feeder by driving the tape feeding mechanism in a tape non-attached state where the tape is not attached to the tape feeder while the torque load is applied to the tape feeding mechanism by the torque load generating means; A feeder diagnostic system characterized by comprising: A torque load generator suitable for diagnosing a tape feeder that feeds a tape in which parts are stored at an equal pitch by a tape feeding mechanism.
An engaging member that engages with the tape feeding mechanism in a tape non-attached state in which the tape is not attached to the tape feeder, and is driven according to the driving of the tape feeding mechanism;
A torque load generating device, comprising: a braking member that applies a braking force to the engaging member to apply a torque load to the tape feeding mechanism.

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