JP2021073732A - Production control method - Google Patents

Abstract

To provide a production control device that manages results of inspections by an inspection device as statistical information and can be used for measures to reduce production costs.SOLUTION: A production control device is applied to a production line that produces substrate products. The production line includes a component mounting machine that mounts a component on a circuit board under a specified mounting condition, and an inspection device that inspects a mounting state of the component mounted on the circuit board on a downstream side of the production line from the component mounting machine. The production control device includes an information management unit that stores statistical information in which results of multiple inspections by the inspection device are associated with a mounting condition when the component to be inspected is mounted on the circuit board.SELECTED DRAWING: Figure 1

Description

The present invention relates to a production control device.

The production control device is applied to a production line that produces a substrate product. As disclosed in Patent Document 1, the production line is configured by installing, for example, a component mounting machine and a visual inspection device in the transport direction of the circuit board. In such a production line, a visual inspection may detect a mounting error in which the mounting state of the components mounted on the circuit board does not meet a certain standard. In such a case, the error can be dealt with by skipping the mounting of the parts in the parts mounting machine located on the downstream side of the production line rather than the visual inspection. As a result, the disposal cost in the range where the mounting error is related to the substrate product (the entire substrate or a part of the multi-chamfered substrate) is minimized.

Japanese Unexamined Patent Publication No. 2012-248815

Production on a production line is required to reduce production costs by shortening the time required for production and suppressing the occurrence of mounting errors.
An object of the present specification is to provide a production control device that manages the results of inspection by the inspection device as statistical information and can be used for measures for reducing production costs.

The present specification is a production control device applied to a production line for producing a board product, wherein the production line includes a component mounting machine for mounting a component on a circuit board under specified mounting conditions, and the component. The production control device includes an inspection device for inspecting the mounting state of the parts mounted on the circuit board on the downstream side of the production line from the mounting machine, and the production control device is the result of a plurality of inspections by the inspection device. In addition, as statistical information associated with the mounting conditions when the component to be inspected is mounted on the circuit board, a series of the mounting errors in the result of the error determination associated with the same mounting conditions. The information management unit that stores the number of times or the occurrence rate of the mounting error and a plurality of types of error handling that can be performed on the production line for the mounting error are switched based on the statistical information, or a plurality of types of the above Disclose a production control device including a handling management unit that executes a combination of error handling.

According to such a configuration, the result of the inspection by the inspection device is stored as statistical information in association with the corresponding wearing condition. Such statistical information is useful information that can be used for analysis for grasping the execution state of error handling such as skipping on the downstream side of the production line and the tendency of the mounting state when identifying the cause of the mounting error. .. For example, if a tendency such as an execution state of error handling is grasped, it can be used as a material for determining whether or not maintenance should be performed while stopping the production line. As a result, the production cost can be reduced by reducing the number of circuit boards to be discarded while suppressing the decrease in production efficiency.

It is a top view which shows typically the production line in an embodiment. It is a schematic diagram which shows the structure of the component mounting machine in the production line of FIG. It is a top view which shows the circuit board. It is a figure which shows the mounting condition including the control program. It is a figure which shows the result of inspection by an inspection apparatus. It is a figure which shows the statistical information which the wearing condition is associated with the inspection result. It is a flowchart which shows the management of a production process by a production control apparatus.

1. 1. Embodiment 1-1. Configuration of Production Line 1 The production control device is applied to a production line that produces various substrate products. As shown in FIG. 1, the production line 1 is configured by installing a plurality of production devices in the transport direction (left-right direction of FIGS. 1 and 2) of the circuit board 90. Hereinafter, the "circuit board" is simply referred to as a "board". The above production devices include a printing machine 2, a printing inspection device 3, a buffer device 4, a plurality of component mounting machines 5, a visual inspection device 6, a reflow furnace 7, and a functional inspection device 8 in this order from the upstream side of the production line 1. Is included.

In the production process by the production line 1, the substrate 90 is carried into the printing machine 2 located at the head of the production line 1. Then, the substrate 90 is transported to the downstream side by the substrate transfer device of each production device (for example, the board transfer device 10 of the component mounting machine 5 shown in FIG. 2), and the functional inspection device 8 located at the end of the production line 1 Is carried out from. Further, the production devices are connected to each other so as to be able to communicate with each other and to be able to communicate with the host computer (hereinafter, referred to as "host PC") 70.

The printing machine 2 prints the paste-like solder at the mounting position of the component on the carried-in substrate 90. The print inspection device 3 inspects the printing state of the substrate 90 on which the solder is printed by the printing machine 2. The buffer device 4 is configured to be able to hold a specified number of substrates 90 in the production line 1. The buffer device 4 holds the substrate 90 carried out from the production device on the upstream side until the production device on the downstream side can carry in the board 90. Each of the plurality of component mounting machines 5 mounts components on the solder of the substrate 90 conveyed from the upstream side of the production line 1. The configuration of the component mounting machine 5 will be described later.

The visual inspection device 6 inspects the mounting state of the component to be inspected based on the appearance of the component mounted on the substrate 90 by the component mounting machine 5 on the upstream side. The mounting state of the above components includes the suitability of the components mounted on the substrate 90, the mounting position and the mounting posture of the components. Further, the inspection by the visual inspection device 6 includes an error determination for determining the presence or absence of a mounting error in which the mounting state does not satisfy a certain criterion.

Further, the inspection by the visual inspection apparatus 6 includes acquisition of the amount of deviation between the mounted state of the component mounted on the substrate 90 and the ideal state including the ideal mounting position and mounting posture as the degree of the mounting state. As described above, when the visual inspection is performed, the visual inspection device 6 sends out whether or not a mounting error is detected and the degree of the mounting state to the host PC 70 as a result of the visual inspection.

The reflow furnace 7 heats the substrate 90 conveyed from the upstream side of the production line 1 to melt the solder on the substrate 90 and perform soldering. The function inspection device 8 performs a function inspection of the soldered substrate 90. Specifically, the functional inspection device 8 gives a predetermined input signal to the substrate 90 and acquires an output signal for the input signal. Then, the function inspection device 8 inspects whether or not the function as a substrate product is normal based on the acquired output signal.

In this way, the production line 1 sequentially conveys the substrate 90 to each production apparatus, executes a production process including an inspection process, and produces a substrate product. The configuration of the production line 1 can be appropriately added or changed according to, for example, the type of substrate product to be produced. For example, the production line 1 may be configured such that another production device is installed on the upstream side of the printing machine 2, the intermediate position of the production line 1, or the downstream side of the functional inspection device 8. Other production devices include, for example, a substrate supply device, a substrate reversing device, a shield mounting device, an adhesive coating device, an ultraviolet irradiation device, and the like.

The host PC 70 monitors the operating status of the production line 1 and controls each production apparatus. The host PC 70 has a storage device 71 composed of a hard disk, a flash memory, or the like. The storage device 71 stores various data for controlling a plurality of production devices constituting the production line 1. Specifically, the storage device 71 stores control data M1 such as a control program for operating each production device.

1-2. Configuration of the component mounting machine 5 As shown in FIG. 2, the component mounting machine 5 includes a board transfer device 10, a component supply device 20, a component transfer device 30, a component camera 41, a board camera 42, and a control device. With 50. In the following description, the horizontal width direction of the component mounting machine 5 (horizontal direction in FIG. 2) is the X-axis direction, the horizontal depth direction of the component mounting machine 5 (vertical direction in FIG. 2) is the Y-axis direction, and the X-axis and The vertical direction perpendicular to the Y-axis (front-back direction in FIG. 2) is defined as the Z-axis direction.

The substrate transfer device 10 is composed of a belt conveyor or the like, and sequentially conveys the substrate 90 in the transfer direction (in the present embodiment, the X-axis direction). The board transfer device 10 carries the board into the machine of the component mounting machine 5 and positions the board 90 at a predetermined position in the machine. The board transfer device 10 carries out the board 90 to the outside of the component mounting machine 5 after the component mounting process by the component mounting machine 5 is completed.

The component supply device 20 supplies components to be mounted on the substrate 90. The component supply device 20 has a plurality of slots 21 arranged side by side in the X-axis direction. The feeders 22 are interchangeably set in the plurality of slots 21. The feeder 22 feeds and moves a carrier tape that stores a large number of parts, and supplies the parts so that the parts can be collected at a supply position located on the tip side of the feeder 22.

The component transfer device 30 includes a head drive device 31, a moving table 32, and a mounting head 33. The head drive device 31 is configured so that the moving table 32 can be moved in the X-axis direction and the Y-axis direction by a linear motion mechanism. The mounting head 33 collects the components supplied by the component supply device 20 and mounts them at a predetermined mounting position on the board 90. The mounting head 33 is fixed to the moving table 32 by a clamp member (not shown).

Further, the mounting head 33 has a plurality of suction nozzles 34 that are detachably provided. The mounting head 33 supports the suction nozzle so as to be rotatable and ascending / descending around the R axis parallel to the Z axis. The suction nozzle 34 controls the elevating position and angle with respect to the mounting head 33, and the supply state of negative pressure. The suction nozzle 34 sucks the parts supplied by the feeder 22 of the parts supply device 20 by supplying a negative pressure.

The component camera 41 and the substrate camera 42 are digital image pickup devices having an image pickup device such as a CCD (Charge Coupled Device) or a CMOS (Complementary Metal Oxide Semiconductor). The component camera 41 and the board camera 42 take an image in a range within the camera field of view based on a control signal by the control device 50 connected communicably, and send the image data acquired by the image pickup to the control device 50.

The component camera 41 is fixed to the base of the component mounting machine 5 so that the optical axis faces upward in the vertical direction (Z-axis direction). The component camera 41 is configured so that the component held by the suction nozzle 34 of the mounting head 33 can be imaged from below the component transfer device 30. The board camera 42 is provided on the moving table 32 of the component transfer device 30 so that the optical axis faces downward in the vertical direction (Z-axis direction). The substrate camera 42 is configured so that the substrate 90 can be imaged.

The control device 50 is mainly composed of a CPU, various memories, and a control circuit. The control device 50 inputs information output from various sensors provided in the component mounting machine 5 and the result of recognition processing by image processing or the like in the mounting process of mounting the component on the substrate 90. Then, the control device 50 sends a control signal to the component transfer device 30 based on a control program, preset mounting conditions, and the like. As a result, the position and rotation angle of the suction nozzle 34 supported by the mounting head 33 are controlled.

In the above image processing, the control device 50 recognizes the state of the component held by the suction nozzle 34 based on the image data acquired by the imaging of the component camera 41. More specifically, the control device 50 matches the part data as the outer shape data indicating the outer shape of the part with the part in the image data, and recognizes the presence / absence of the part, suitability, the held position and the posture. Then, the control device 50 adjusts the position and rotation angle of the suction nozzle 34 according to the state of the recognized component, and the component held by the suction nozzle 34 is mounted at the mounting position on the substrate 90 in an appropriate posture. To control.

Further, the control device 50 may perform various image processing as necessary, in addition to the image processing for the image data acquired by imaging the above-mentioned parts from below. For example, the control device 50 performs image processing on the image data acquired by imaging the component from the side and the image data acquired by imaging the component mounted on the substrate 90 from above, and determines the quality of the component and mounting the component. It may also be inspected for good condition.

As described above, external shape data indicating the outer shape of the component is used for such image processing. Specifically, the external shape data is composed of data showing the outline of the part, data showing a part of the outline of the part such as a feature portion, and a plurality of seek lines arranged corresponding to the outline of the part. Data is included. In addition, the external shape data includes shape data that is used as a reference for determining the quality of the mounted state by regarding a plurality of parts as one part. By the way, even if the parts are of the same type, if the suppliers of the parts are different, the material, the lead length, and the like may be different, and the appearance in the image data may be changed. Therefore, as for the above-mentioned external shape data, different types of data are managed for each supplier, for example.

1-3. Configuration of Substrate 90 Here, as shown in FIG. 3, the substrate 90 in this embodiment is a multi-chamfered substrate composed of a plurality of unit substrates 91 (in this embodiment, 12 unit substrates 91). .. At least a part of the plurality of unit substrates 91 in the multi-chamfered substrate has the same substrate type. Here, the "board type" in the multi-chamfered board indicates each type of the plurality of unit boards 91. The multi-chamfered substrate is divided into individual substrate products after the mounting process is executed for each of the plurality of unit substrates 91.

When different types of mounting processes are executed on a plurality of unit substrates 91 having the same substrate type, a plurality of types of substrate products are produced from one substrate 90. That is, in the production targeting the multi-chamfered substrate, each of the plurality of unit substrates 91 is regarded as one substrate 90, and a predetermined type of mounting process is executed for each of the plurality of unit substrates 91 to obtain the product. Multiple substrate products of the same species or the same species are produced.

Further, two reference marks 92 and an identification code 93 are provided on the upper surface of the substrate 90. Each of the two reference marks 92 indicates a reference position of the substrate 90. The control device 50 recognizes the reference mark 92 based on the image data obtained by photographing the reference mark 92 with the substrate camera 42. Then, the control device 50 recognizes the reference position of the substrate 90 positioned by the substrate transfer device 10 based on the position of the recognized reference mark 92.

The identification code 93 indicates an identification code (ID) which is unique information of the substrate 90. As the identification code 93, a bar code, a two-dimensional code, or the like can be applied. In the present embodiment, the identification code 93 employs a barcode configured by arranging a plurality of bars having different line widths and intervals between the lines in parallel. The control device 50 reads the ID of the substrate 90 based on the image data acquired by photographing the identification code 93 with the substrate camera 42.

Then, the control device 50 acquires identification information including the substrate type of the substrate 90 based on the substrate type data (not shown) in which the ID of the substrate 90 and the substrate type are associated in advance. Here, since the substrate 90 is a multi-chamfered substrate, the control device 50 acquires the quantity and positional relationship of the plurality of unit substrates 91 constituting the substrate 90 and the substrate type for each of the plurality of unit substrates 91 as identification information. ..

1-4. Mounting process by the component mounting machine 5 Each of the plurality of types of mounting processes executed by the component mounting machine 5 is executed based on a common control program when executed on the unit board 91 of the multi-chamfered board. Sometimes. In the above common control program, as shown in Table 1 of FIG. 4, the mounting coordinates of the electronic component are associated with the mounting angle of the electronic component and the reference code.

The above mounting coordinates (X-axis coordinates (X1, X2, X3, X4, ...), Y-axis coordinates (Y1, Y2, Y3, Y4, ...)) Are electronic components on a plurality of unit boards 91. It is a value indicating the mounting position. The mounting angle of the electronic component (θ-axis angle (θ1, θ2, θ3, θ4 ...)) Is a value indicating the angle of the electronic component in the mounting coordinates. The reference code (Ref1, Ref2, Ref3, Ref4, ...) Is a code for instructing reference to the component type of the electronic component to be mounted at the mounting coordinates.

As shown in Tables 3 and 4 of FIG. 4, the component types (U1, U2, ...) Of the plurality of corresponding data (BOM (Bills of Materials) 1, BOM2, ...) Are different from the reference code.・ ・) Data associated with each. Specifically, the first correspondence data BOM1 used for the production of the first product type U1 has the component type (Pa, Pb, of the electronic component) of the electronic component with respect to the reference code (Ref1, Ref2, Ref3, Ref4, ...). Pc, Pb ...) And the type of external data (Da, Db, Dc, Db, ...) Showing the outer shape of the component are associated with each other.

As shown in Table 2 of FIG. 4, a plurality of product types (U1, U2, ...) And a plurality of corresponding data (BOM1, BOM2, ...) Are paired by the product type-BOM data. Is associated with. According to such a configuration, for example, when the production of the substrate product of the first product type U1 is executed, the first corresponding data BOM1 associated with the first product type U1 is used, and the first mounting coordinates ( X1, Y1) are mounted with electronic components of the component type (Pa) referenced by the first reference code (Ref1) at the first mounting angle (θ1).

1-5. Outline of the production control device 80 When the production process is executed by the production line 1 configured as described above, each process is executed in the production devices such as the printing machine 2 and the component mounting machine 5, and the process is moved to the downstream side. The substrate 90 is conveyed in this order. During the execution of such a production process, the visual inspection device 6 may detect a mounting error. In such a case, for example, it is possible to stop the production on the production line 1 and try to repair the substrate 90 related to the mounting error.

However, stopping production may affect the entire production line 1. Therefore, from the viewpoint of preventing a decrease in production efficiency, it is possible to continue production on the production line 1 and deal with an error in which production is skipped for a range in which a mounting error is related as a substrate product on the downstream side of the production line 1 from the visual inspection device 6 ( Hereinafter, "first error handling") may be applied.

The above-mentioned "range in which the mounting error is related to the board product" is the range of the board 90 which is a board product composed of electronic components whose mounting state is determined to be defective in the visual inspection. Therefore, the "range in which the mounting error is involved as a substrate product" corresponds to one of the individual unit substrates 91 if the substrate 90 is a multi-chamfered substrate, and the substrate 90 if the entire substrate 90 is a single substrate product. Corresponds to the whole.

According to the above-mentioned first error handling, for example, the unit substrate 91 whose production is partially skipped has a demerit that the substrate 90 is divided and then discarded. On the other hand, according to the first error handling, since the production of the production line 1 can be continued, the decrease in production efficiency can be suppressed, and the unit board 91 which is discarded by preventing the mounting of parts on the unit board 91 related to the mounting error. There is a merit that the disposal cost can be reduced.

By the way, the above mounting error occurs accidentally due to multiple factors such as changes in the mounting environment and variations in the shape of parts, and in terms of operation such as malfunction of the mounting head 33 and an error in the type of parts supplied. It may occur due to the factors of. If a mounting error occurs due to operational factors, there is a high possibility that a similar mounting error will occur thereafter. However, while the first error countermeasure is being executed on the production line 1, production is continued even though a mounting error occurs.

The operator may recognize that maintenance is required to eliminate operational factors, for example because of an increasing number of substrates 90 or unit substrates 91 that are discarded or required to be repaired. However, when the increase in the number of discarded substrates 90 and the like is not remarkable, it is properly determined whether to continue the production of the production line 1 by dealing with the first error or to interrupt the production of the production line 1 for maintenance. It's not easy.

Therefore, the production control device 80 is applied to the production line 1 that produces the substrate product, and the production process in the production line 1 is performed in order to reduce the production cost in the production line 1 by taking the provision of the material for the above judgment as an example. To manage. In this embodiment, as shown in FIG. 1, an embodiment in which the production control device 80 is incorporated in the host PC 70 is illustrated.

1-6. Detailed configuration of the production control device 80 As shown in FIG. 1, the production control device 80 includes an information management unit 81 and a response management unit 82. The information management unit 81 associates the results of a plurality of inspections by the visual inspection device 6 with the mounting conditions when the component to be inspected is mounted on the substrate 90, respectively, as statistical information M3 (Table 1 in FIG. 6). See)).

Here, the component mounting machine 5 constituting the production line 1 mounts the components on the substrate 90 under the specified mounting conditions. As shown in each table of FIG. 4, the above mounting conditions include the type of substrate product (product type), the type of substrate 90 (board type), the type of component (component type), and the mounting position of the component on the substrate 90. , And the type of external shape data indicating the external shape of the part used as a criterion for determining the suitability of the part. The mounting position and external shape data included in the mounting conditions are stored in the storage device 71 as control data M1 used for controlling the mounting of parts (see FIG. 1).

The above-mentioned "mounting condition when mounted" is the mounting condition applied to the component mounting machine 5 at the time of inspection because the visual inspection is executed as a post-process on the downstream side of the component mounting machine 5. It means the mounting conditions that were applied when the part to be inspected was mounted. This mounting condition is recorded in the control data M1 in association with, for example, the ID of the substrate.

In addition, the visual inspection device 6 determines an error and acquires the degree of wearing state in the visual inspection. As a result, as shown in FIG. 5, the inspection result by the visual inspection apparatus 6 shows the mounting position of the component, the amount of deviation in the XY direction, and the θ-axis parallel to the Z-axis for each unit substrate 91 of the substrate 90 to be inspected. The amount of displacement around and the quality of the mounting condition of each part are shown. The results of these inspections are accumulated each time the visual inspection is performed, and are stored in the storage device 71 as inspection data M2 (see FIG. 1).

The statistical information M3 is information in which at least one of a plurality of wearing conditions is associated with the result of the inspection by the visual inspection apparatus 6. In the present embodiment, as shown in Table 1 of FIG. 6, the statistical information M3 has the inspection results (see FIG. 5) for each of the mounting conditions (see each table of FIG. 4) exemplified above. It is configured in association with. Specifically, the statistical information M3 indicates, for example, the number of times the mounting state with respect to the mounting position (Ref1) of the component is determined to be defective in a plurality of inspections as the number of mounting errors (N31).

Further, in the present embodiment, the information management unit 81 stores as statistical information M3 the number of consecutive mounting errors and the occurrence rate of mounting errors in the result of error determination associated with the same mounting conditions. The number of consecutive mounting errors is, for example, the number of consecutive times when the mounting state is determined to be defective in mounting for the same mounting position (Ref1), and the current number of consecutive times (C31) and the maximum number of consecutive times including the past (M31). ) And may be managed separately.

The mounting error occurrence rate is a value indicating the frequency of occurrence of mounting errors when parts are mounted under certain mounting conditions. For example, the number of detected mounting errors with respect to the total number of parts mounted at the mounting position (Ref1). It is calculated as a ratio (R31) with. The occurrence rate of the mounting error may be the ratio of the number of detections of the mounting error to the specified number of times for mounting over the most recent specified number of times, or both occurrence rates may be included in the statistical information M3. Further, the information management unit 81 has a margin of how much the mounting state of the component to be inspected has a margin from the threshold value which is a criterion of good or bad based on the degree of the mounting state (in the case of a defect, how much is below the threshold value). (Taka) is shown in the statistical information M3 as a margin (A31, etc.).

The information management unit 81 inputs various data and updates the statistical information M3 every time the production process progresses and parts are mounted, and every time the inspection by the visual inspection device 6 is executed. Such statistical information M3 is useful for analysis for grasping the execution state of error handling such as skipping on the downstream side of the production line 1 and the tendency of the mounting state when identifying the cause of the mounting error. Information.

Specifically, when the mounting condition is, for example, the mounting position (Ref1) of the component, the result of the inspection relating to the mounting state of the component mounted at the same mounting position is extracted to grasp the tendency of the mounting state. can do. For example, if the number of mounting errors related to mounting parts for the same mounting position tends to increase, or if the mounting error rate is high, the mounting error may occur in the control program or external data related to the mounting position. It is presumed that there is a factor.

Further, when a plurality of wearing conditions are associated with the inspection result as in the present embodiment, multifaceted analysis based on the statistical information M3 becomes possible. As a result, when mounting errors occur continuously over a specified number of times, or when the mounting error occurrence rate reaches a specified value, whether the cause of the mounting error is in a specific product type or in a specific board type. Since it is possible to grasp whether or not the statistical information M3 is present or at a specific mounting position, it is possible to improve the accuracy of identifying the cause of the mounting error with the statistical information M3.

Further, the margin of the statistical information M3 can be used for analysis of whether the accuracy of the mounting process by the component mounting machine 5 is preferably maintained or whether it tends to deteriorate. As a result, even if it is determined that the mounting condition is good, it can be recognized that the time when maintenance is required is approaching, for example, if the margin is reduced. As a result, by performing proper maintenance, it is possible to prevent the occurrence of mounting errors and maintain production efficiency.

The response management unit 82 switches a plurality of types of error countermeasures that can be executed on the production line 1 for a mounting error based on the statistical information M3, or causes the response management unit 82 to execute a combination of a plurality of types of error countermeasures. As described above, in the conventional configuration, when a mounting error is detected, preset error handling (such as skipping production) is executed on the downstream side. On the other hand, when the handling management unit 82 switches between a plurality of types of error handling, the decrease in production efficiency is suppressed, and the operator and the like can recognize the necessity of maintenance at an early stage.

In the present embodiment, the plurality of types of error handling include a second error handling and a third error handling in addition to the above-mentioned first error handling. The first error handling skips the processing on the downstream side of the production line 1 for a part or all of the substrate 90 in which the mounting error is detected without stopping the production line 1. As a result, the range in which the mounting error is involved as a substrate product (the entire substrate 90 or a part of the unit substrate 91 in the case of a multi-chamfered substrate) is subject to disposal, etc. Can be secured.

The second error handling is to stop the production on the production line 1 and enable the maintenance of the component mounting machine 5. As a result, the operator can recognize the need for maintenance and perform maintenance to eliminate the cause of the mounting error. At this time, the operator can use the statistical information M3 as a material for investigating the cause of the mounting error. As a result, even if the production line 1 is stopped for a time that requires time for maintenance, it is possible to prevent an increase in the cycle time and an increase in the number of discarded substrates, so that the production cost can be reduced.

The third error handling notifies that maintenance of the component mounting machine 5 is required. Specifically, for example, the operator is notified that the occurrence rate of mounting errors is increasing. As a result, the operator can perform maintenance within a range that does not require the stop of the production line 1 (for example, a proper set of feeder 22), or stop the production line 1 at an appropriate timing as necessary to perform maintenance. To do. As a result, the operator can perform maintenance as appropriate in consideration of the degree of progress of the production plan on the production line 1.

In the present embodiment, the handling management unit 82 switches and executes the above-mentioned first to third error handling. Further, when the response management unit 82 executes the first error response and the second error response, the first error is determined according to the setting of whether or not the operator or the administrator also executes the third error response. The third error handling is combined with the second error handling and the second error handling.

Here, if the mounting error occurs not accidentally but due to operational factors, it is assumed that there is an error in the setting or work in the change event in the component mounting machine 5. Therefore, when the handling error is detected before the specified time elapses from the change event in the component mounting machine 5 including the change of the mounting condition, the handling management unit 82 sets the threshold value set in advance according to the mounting condition. Based on the statistical information M3, a plurality of types of error handling are switched, or a plurality of types of error handling are combined and executed on the production line 1.

The change event in the component mounting machine 5 can be appropriately set by the operator or the manager as long as the component mounting machine 5 can detect before and after the change. In the present embodiment, the change event includes the replacement of the replacement elements constituting the component mounting machine 5, as shown in Table 2 of FIG. The above-mentioned "replacement element" may include a feeder 22, a mounting head 33, a suction nozzle 34, a nozzle tool that holds the suction nozzle 34 and is replaceably provided on the mounting head 33, and the like. In addition to being replaced by the operator's work, these replacement elements may be automatically replaced by the component mounting machine 5 or an external device.

Further, in the present embodiment, the change event includes a change of the control data M1 (see FIG. 1) used for controlling the mounting of parts. The control data M1 includes a control program indicating the mounting position of the component on the substrate 90, and external data indicating the outer shape of the component used as a reference for determining the suitability of the component. Since the component mounting machine 5 executes the mounting process based on the control program, if there is a defect in the operation command including the mounting position and mounting angle of the control program, a mounting error due to a change event such as a change in the control program occurs. Can be done.

Further, the external shape data may be managed for each supplier of parts even if the parts type is the same. If there is a defect in the setting of the external shape data used for such mounting processing, a mounting error due to a change event such as a change in the external shape data may occur. Therefore, the coping management unit 82 monitors the mounting state of the parts in the period before the specified time elapses from the above-mentioned change event (replacement of the replacement element or change of the control data M1) to change the change. We are trying to speed up the handling of mounting errors caused by events.

The above-mentioned "specified time" may be the time counted by the timer from the change event, or may be the time until the change event operates a specified number of times. That is, when the change event is the replacement of the replacement element, the specified time is the time from the replacement of the replacement element until the replacement element is used a specified number of times for mounting the component. Specifically, when the suction nozzle 34 is automatically replaced as a replacement element, the specified time is set until the mounting using the suction nozzle 34 is executed a predetermined number of times.

When the change event is a change in the product type or the substrate type, the specified time may be the time until the mounting process is executed on the specified number of substrates 90. Further, when the change event is a change of the component type, the time may be set until the specified number of the components are used in the mounting process. The above-mentioned specified time, specified number of times, and specified number are arbitrarily set by an operator or the like. When monitoring a plurality of change events, the response management unit 82 manages a specified time for each of the plurality of change events.

Here, it can be considered that the mounting error detected after the lapse of the specified time is more likely to be caused by other accidental factors than by the change event. Therefore, when a mounting error occurs due to such a factor, it may not be appropriate to stop the production line 1 and perform maintenance from the viewpoint of maintaining production efficiency. Therefore, when the mounting error is detected after the specified time has elapsed from the change event, the handling management unit 82 causes the production line 1 to execute the first error handling regardless of the statistical information M3. As a result, it is possible to prevent the production line 1 from being stopped in order to deal with a mounting error caused by an accidental factor or the like.

1-7. Management of Production Processing by Production Control Device 80 The management of production processing by the above-mentioned production control device 80 will be described with reference to FIGS. 6 and 7. The production control device 80 starts the management of the production process with the start of the production process by the production line 1. When various data are input from the production apparatus constituting the production line 1, for example, the information management unit 81 updates the statistical information M3 as shown in FIG. 7 (step 11 (hereinafter, “step” is referred to as “S”). write)).

Specifically, the information management unit 81 updates the statistical information M3 by inputting, for example, the progress of the mounting process from the component mounting machine 5 and the notification that various change events have been detected (Table 1 in FIG. 6). And Table 2). Further, the information management unit 81 inputs the inspection result from, for example, the visual inspection device 6, updates the inspection data M2, and mounts the inspection result when the component to be inspected is mounted on the substrate 90. The statistical information M3 is updated by associating the conditions with each other. By this update process (S11), items such as the degree of passage from the change event and the number of occurrences of mounting errors are updated.

Next, the coping management unit 82 determines whether or not a mounting error has been detected based on the inspection data M2 (S12). When a mounting error is detected (S12: Yes), the handling management unit 82 starts from a change event related to all mounting conditions associated with the result of the mounting error (see Table 2 in FIG. 6). It is determined whether or not there is an item for which the specified time has not passed (S13).

For example, when a certain part is replenished to the feeder 22, the external shape data used is changed due to the change of the supplier, and the specified number of times is not attached due to the change of the external shape data. The management unit 82 determines that some data have not passed the specified time (S13: Yes). On the other hand, for all product types, board types, component types, etc. as mounting conditions for a certain component, if the specified time has elapsed from each change event, it is determined that the specified time has passed ( S13: No).

If a mounting error is detected before the specified time elapses from the change event in the component mounting machine 5, the handling management unit 82 (S13: Yes) sets a threshold value preset according to the mounting condition and statistical information. The items corresponding to the mounting conditions in M3 and updated based on the inspection results are compared (S14). Specifically, as shown in the broken line frame in Table 1 of FIG. 6, for example, a mounting error is detected when the component is mounted at the mounting position (Ref1), which is a mounting condition (S12: Yes), and the component is supplied. It is assumed that the specified time has not elapsed from the replacement (change event) of the feeder 22 to be performed (S13: Yes).

In such a case, the handling management unit 82 sets a threshold value (Th1, Th2, ...) For each item preset according to the mounting position of the component, and each item of the statistical information M3 (number of mounting errors (number of mounting errors). N31), the occurrence rate of mounting errors (R31), ...) Are compared (S14). If there is an item of statistical information M3 that exceeds the threshold value for each item (S14: Yes), the response management unit 82 switches to the second error response (S15). As a result, the production on the production line 1 is stopped, and the maintenance of the component mounting machine 5 becomes feasible.

On the other hand, if there is no item of statistical information M3 that exceeds the threshold value for each item (S14: No), or if it is determined in S13 that the specified time has elapsed (S13: No), a countermeasure is taken. The management unit 82 switches to the first error handling (S16). As a result, production is continued without stopping the production line 1, and processing on the downstream side of the production line 1 with respect to the substrate 90 or the unit substrate 91 in which the mounting error is detected is skipped.

Subsequently, the handling management unit 82 also executes the third error handling according to the setting of whether or not to notify the operator or the like when the first error handling or the second error handling is switched. (S17). As a result, for example, when switching to the first error handling (S16), although a mounting error has occurred, the production line 1 is not stopped and the handling is performed by skipping or the like, and the operator or the like is notified that the production will be continued. Is done (S17).

Further, when the second error handling is switched to (S15), the operator or the like is notified that maintenance of the component mounting machine 5 is required (S17). At this time, in the above example, the component mounting machine 5 in which the component is mounted is specified at the component mounting position (Ref1), and it is notified that the maintenance target is the component mounting machine 5. Further, based on the item of the statistical information M3 exceeding the threshold value, for example, when it is presumed that the control program or the suction nozzle has a maintenance factor, that information may also be notified.

Further, the information management unit 81 determines whether or not each item of the statistical information M3 is maintained within an appropriate range when a mounting error is not detected in the input inspection result (S12: No). Judgment (S18). For example, if the information management unit 81 determines that the occurrence rate of mounting errors exceeds the threshold value or the margin is lowered to less than the threshold value and each item is not maintained within an appropriate range ( S18: No), the handling management unit 82 switches to the third error handling and executes it (S17). As a result, the operator and the like are notified that maintenance will be required in the future, together with the item of the statistical information M3 that tends to deteriorate (S17).

The production control device 80 appropriately repeatedly executes the above-mentioned processing during the execution of the production processing on the production line 1. As a result, when a mounting error is detected (S12: Yes), the first error handling for continuing production and the second error handling for stopping production are automatically switched. If no mounting error is detected (S12: No), the mounting state is grasped based on each item that is the result of the analysis of the statistical information M3, and maintenance is appropriately performed to prevent the occurrence of the mounting error. Will be done.

2. Effect of Configuration of Embodiment According to the production control device 80 described above, the result of the inspection by the visual inspection device 6 is stored as statistical information M3 in association with the corresponding mounting conditions. Such statistical information M3 is useful information that can be used for analysis for grasping the execution state of error handling such as skipping on the downstream side of the production line 1 and the tendency of the mounting state when identifying the cause of the mounting error. Is. As illustrated in the embodiment, when a mounting error is detected, it is possible to switch between a plurality of types of error handling, and even if a mounting error is not detected, it is possible to determine whether or not maintenance needs to be performed based on the mounting state. it can. As a result, the production cost can be reduced by reducing the number of discarded substrates 90 while suppressing the decrease in production efficiency.

3. 3. Deformation mode of the embodiment 3-1. Statistical information In the embodiment, the statistical information M3 is configured by associating a plurality of mounting conditions such as a product type, a substrate type, and a component type with an inspection result. On the other hand, the statistical information M3 may be configured such that one wearing condition is associated with the inspection result, or other wearing conditions other than the wearing conditions exemplified in the embodiment are associated with the inspection result. .. Other mounting conditions may include the component mounting machine 5 when the production line 1 is composed of a plurality of component mounting machines 5, each of the replacement elements applied when the parts are mounted, and the like.

According to such a configuration, the statistical information M3 records which component mounting machine 5 was mounted and which replacement element was used for mounting a certain component for inspection. Then, when a mounting error is detected, for example, if it can be recognized that the occurrence rate of the mounting error is high in mounting using a certain suction nozzle, it is presumed that the malfunction of the suction error is the cause of the mounting error. Will be done. By increasing the mounting conditions in this way, it becomes easy to investigate the cause of the mounting error, and the time required for maintenance can be shortened.

In the embodiment, the production control device 80 is configured to use the statistical information M3 for countermeasures when a mounting error is detected (switching of error handling, identification of the component mounting machine 5 having a maintenance factor, etc.). In this way, the production control device 80 can be used for various measures for reducing the production cost by managing the statistical information M3.

Specifically, the production control device 80 can use the statistical information M3 as a material for determining whether or not the wearing state is properly maintained. Further, the production control device 80 can use the statistical information M3 as a material for determining the suitability of the configuration of the production line 1 and the suitability of various commands (for example, the moving speed of the mounting head) in the control program. Further, the production control device 80 can be used as a material for determining the suitability of an imaging command (for example, imaging method, exposure time, etc.) for the component camera 41 and the substrate camera 42.

3-2. In another embodiment, an embodiment in which the inspection device for acquiring the inspection result is the visual inspection device 6 for performing the visual inspection is illustrated. On the other hand, the inspection device may be other than the visual inspection device 6 as long as the parts mounted on the substrate 90 can be inspected by the component mounting machine 5. Specifically, the inspection device may be a component mounting machine 5 in which the mounting head 33 is replaced with an inspection head having an inspection camera.

Further, the inspection device may be a functional inspection device 8 constituting the production line 1. In this case, the production control device 80 inputs the correctness and degree of the function for each functional inspection as a result of the functional inspection by the functional inspection device 8. Then, the information management unit 81 associates the wearing conditions with the results of the functional tests over a plurality of times and stores them as statistical information. According to such a configuration, it is not possible to obtain the degree of the mounted state as illustrated in the embodiment, but the occurrence rate of defects can be grasped according to the mounted parts, and the product type, substrate type, and part can be grasped. Statistical information can be used as a basis for judging the suitability of mounting conditions according to the type of product.

In the embodiment, the production control device 80 illustrates the embodiment incorporated in the host PC 70. On the other hand, the production control device 80 may be an external device of the host PC 70. For example, the production control device 80 may be configured to be incorporated in the production device. Further, the production control device 80 may be configured as a dedicated device that is communicably connected to the component mounting machine 5 and the host PC 70.

1: Production line, 5: Parts mounting machine, 6: Visual inspection device, 8: Functional inspection device, 20: Parts supply device, 22: Feeder (replacement element), 30: Parts transfer device, 33: Mounting head (replacement) Element), 34: Suction nozzle (replacement element), 70: Host computer (host PC), 80: Production control device, 81: Information management department, 82: Handling management department, 90: Board (circuit board), 91: Unit Board, M1: Control data, M2: Inspection data, M3: Statistical information

The present invention relates to a production control method .

Production on a production line is required to reduce production costs by shortening the time required for production and suppressing the occurrence of mounting errors.
Herein, it accumulates inspection results, and to provide a production control method of the available measures to reduce the production cost.

Disclosed herein is a production control method definitive production line including a plurality of production apparatuses for producing a substrate product, check the mounting state of the component mounting apparatus by the circuit board is mounted the parts and assemblies as the production device Te, a first step of determining whether the mounting error of the mounting condition does not meet certain criteria, to accumulate a determination result of the first step, the incidence of consecutive times or the mounting error of the mounting errors a second step of updating, the incidence of consecutive number or the mounting error of the second said mounting errors that are updated by the process, the threshold for the incidence of consecutive number or the mounting error of the preset said mounting error The mounting error was detected in the third step of determining whether or not to exceed, the fourth step of monitoring a change event including the replacement of the replacement element constituting the component mounting machine, and the first step . The fifth step of determining whether or not the specified time, which is the time from the detection of the change event in the fourth step to the use of the replacement element for mounting the component a specified number of times, has elapsed, and the fifth step. It is determined in the third step that the number of consecutive mounting errors or the occurrence rate of the mounting error exceeds the threshold value, and the mounting error is detected in the fifth step before the specified time elapses. When it is determined that there is, in the sixth step of stopping the production in the production line and in the fifth step, the mounting error is detected after the lapse of the specified time. , The seventh step of continuing the production on the production line and skipping the production for the range in which the mounting error is related to the substrate product after the first step , regardless of the determination result of the third step . Disclose the production control method provided with.

Claims (4)

A production control device applied to a production line that produces board products.
The production line includes a component mounting machine for mounting components on a circuit board under specified mounting conditions, and a mounting state of the components mounted on the circuit board on the downstream side of the production line from the component mounting machine. Equipped with an inspection device to inspect
The inspection by the inspection device includes an error determination for determining the presence or absence of a mounting error in which the mounting state does not meet a certain standard.
The production control device is
The same mounting conditions are associated with the results of a plurality of inspections by the inspection device as statistical information in which the mounting conditions when the component to be inspected is mounted on the circuit board are associated with each other. An information management unit that stores the number of consecutive mounting errors in the result of the error determination or the occurrence rate of the mounting error.
It is provided with a handling management unit that switches between a plurality of types of error handling that can be executed on the production line for the mounting error based on the statistical information, or executes a combination of the plurality of types of the error handling.
The mounting conditions indicate the type of the board product, the type of the circuit board, the type of the component, the mounting position of the component on the circuit board, and the outer shape of the component used as a criterion for determining the suitability of the component. Includes at least one type of external data,
When the mounting error is detected before the specified time elapses from the change event in the component mounting machine including the change of the mounting condition, the handling management unit sets the mounting condition in advance according to the mounting condition. Based on the number of consecutive mounting errors or the threshold value for the occurrence rate of the mounting error and the statistical information, a plurality of types of the error handling are switched, or a plurality of types of the error handling are combined and executed on the production line.
When the mounting error is detected after the specified time has elapsed, the handling management unit continues production on the production line regardless of the statistical information and downstream of the inspection device on the production line. On the side, error handling is executed on the production line to skip production for the range in which the mounting error is related to the substrate product.
The change event includes the replacement of the replacement elements that make up the component mounting machine.
The production control device, wherein the specified time is a time from when the replacement element is replaced until the replacement element is used a specified number of times for mounting the component. To deal with the plurality of types of errors, the first error handling is to continue the production on the production line and skip the production for the range in which the mounting error is related to the substrate product on the downstream side of the production line from the inspection device. Claim 1 includes a second error handling that stops production on the production line to enable maintenance of the component mounting machine, and a third error handling that notifies that maintenance of the component mounting machine is required. The production control device described. The change event includes a change in control data used for controlling the mounting of the component, and the control data includes a control program indicating the mounting position of the component on the circuit board, and the suitability of the component. The production control device according to claim 1 or 2, which includes external shape data indicating the external shape of the component used as a criterion for determination. The inspection by the inspection device includes the acquisition of the amount of deviation between the mounted state of the component mounted on the circuit board and the ideal state including the ideal mounting position and mounting posture as the degree of the mounting state. Item 3. The production control device according to any one of Items 1-3.

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