JP2642800B2 - Pallet knitting system - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

(Contents) Industrial application field Conventional technology Problems to be solved by the invention Means for solving the problems Actions Embodiments Effects of the invention

[0002]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a pallet knitting system applicable to a component mounter to which a pallet on which a cartridge of mounted components is mounted and a printed wiring board on which components are to be mounted are supplied. The present invention relates to a pallet knitting system that creates channel setting data indicating which cartridge is to be mounted on which channel of a pallet group including pallets.

In recent years, in the field of electronic equipment, products have been reduced in size, weight, and multifunctionality, and printed wiring board units constituting them have been increasingly mounted at high density. Accompanying this, it has become difficult to mount components manually due to an increase in the number of mounted components, miniaturization and complexity of components, and many automatic component mounting machines have been introduced. On the other hand, due to rising labor costs in factories, there is a demand for operating these expensive facilities efficiently and as unmanned as possible.

[0004]

2. Description of the Related Art Conventionally, there has been provided a component mounter that is supplied with a pallet on which a cartridge of mounted components is mounted and a printed wiring board on which components are to be mounted, and operates to mount the mounted components at predetermined positions on the printed wiring board. It is known. In this type of component mounter, mounted components are taken out of a cartridge mounted on each channel of a pallet in a predetermined order, and the taken out mounted components are mounted on a printed wiring board in a predetermined order. go. Therefore, when the component mounter is to be operated automatically, channel setting data indicating which cartridge is to be mounted on which channel and numerical control data for specifying the mounting position of the component are created in advance. deep.

[0005]

However, when different types of products are flowed in order to carry out high-mix low-volume production on a production line, in each process, processing conditions are set or changed, that is, equipment adjustment and material adjustment are performed. Preparations such as replacement (setup change) are required. For example, when performing the setup change in the above-mentioned component mounting machine, a large number of man-hours are required to change the pallet. Therefore, for printed wiring boards that can be processed under the same processing conditions, collectively process as much as possible. Is desirable. However, conventionally, no pallet knitting system considering such points has been proposed.

An object of the present invention is to make it possible to mount components on a printed wiring board using components common to each other before and after, so that even in the case of high-mix low-volume production, the number of operations such as setup change is reduced. An object of the present invention is to provide a pallet knitting system capable of greatly improving the operation rate of a component mounter by reducing the number of components.

[0007]

FIG. 1 is a principle block diagram showing a basic configuration of the present invention.

A pallet knitting system according to the present invention includes a pallet group including a plurality of pallets each having a plurality of cartridges each having a plurality of mounting parts of the same type, and placing the mounting parts on a predetermined position on a printed wiring board. A pallet knitting system for creating channel setting data indicating which cartridge of the pallet group is to be loaded with a cartridge when the component is mounted on a component mounter that operates to be mounted on the printed circuit board; A manufacturing order table 1 for storing manufacturing order information relating to a product type, a mounting table 2 for storing component mounting information obtained from the manufacturing order information for each of the printed wiring boards, and a manufacturing order information and the component mounting information. Each mounting part for each printed wiring board to be mounted From the settable type of component and the number of channels that can be set, so that the number of replacements of the pallet group in the component mounter can be minimized so that the printed wiring board can be mounted on the same pallet group. Grouping means 3 for grouping into various groups,
And a channel setting data creating means for creating the channel setting data for the corresponding pallet group based on the result of the grouping.

[0009]

When creating the component channel setting data, first, from the manufacturing order information of the manufacturing order table 1 and the component mounting information of the mounting table 2, the type of each component is determined for each printed wiring board to be mounted. Desired. For all of these components, the grouping means is set so that the number of pallet group exchanges in the component mounter is minimized, that is, the number of setup changeovers is minimized, based on the upper limit of the component type and channel that can be set. 3 groups the printed wiring boards. In this grouping, printed wiring boards that can be mounted on the same pallet group are grouped so as to belong to the same group. The channel setting data creating means 4 creates channel setting data for the corresponding pallet group based on the grouping result.

The pallet group includes, for example, seven pallets, and the maximum number of cartridge mounting channels of each pallet is, for example, 30. Therefore, in this case, the settable upper limit of the number of channels in the entire pallet group is 210.
The use of a pallet group consisting of a plurality of pallets in the present invention makes it possible to supply mounted components from the pallets to the component mounter more quickly than in the case where the above-mentioned 210 channels are set to a single pallet. Because you get it.

[0011]

DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, preferred embodiments of the present invention will be described in detail. Note that the same reference numerals represent the same objects throughout the drawings.

FIG. 2 is an explanatory diagram of a production line suitable for implementing the present invention. Reference numerals 11 to 22 denote cells of processing equipment constituting each step of this production line, and the specific functions of each cell are as follows.

The ID assigning machine 11 as a first step attaches an ID label to the supplied printed wiring board 28 and stores it in a rack 34 for each product type and carries it out.

The automatic knitting apparatus 12 accommodates the supplied cartridges 35 in a predetermined order on a pallet 36 and carries them out.

The solder printing machine 13 screen-prints a solder cream (solder paste) on a printed wiring board.

The adhesive applying machine 14 applies an adhesive for temporarily fixing the components to the printed wiring board when mounting the components on the back side of the printed wiring board. When components are mounted only on one side (front side) of the printed wiring board, the adhesive applicator 14 is not used.

Small component mounter 15 and odd-shaped component mounter 1
6 automatically mounts small parts and odd-shaped parts respectively on the printed wiring board.

Small parts are delivered in the form of a strip-shaped part case in which a number of parts of the same specification are accommodated at equal intervals in the longitudinal direction and wound around a reel. The reel 31 having many small components is mounted on a cartridge 35 and supplied to a component mounter in a state where the reel 31 is accommodated in the pallet 36 described above.

The reflow furnace 17 performs reflow soldering on a printed wiring board on which components are mounted on the front surface.
The entire surface cleaning machine 18 cleans the printed wiring board to which the reflow soldering has been performed. The curing furnace 19 cures the adhesive applied to the printed wiring board by the adhesive applying machine 14.

The appearance inspection apparatus 20 inspects the appearance of the printed wiring board after soldering optically or by X-rays. The manual correction device 21 includes the visual inspection device 20
The printed wiring board is supplied to a position near an operator who manually corrects a defective product or the like, or the printed wiring board is discharged from the position. The discharging station 22 as a final step discharges the printed wiring board unit which has been inspected and corrected to be a completed product by a belt conveyor or the like.

Reference numeral 23 denotes a rack / pallet storage for temporarily storing racks and pallets. Each cell 11
The transfer of the racks and pallets between the carry-in and / or carry-out ports of the storage devices 22 or between the ports and the storage 23 is performed by the transfer device 24.

The transfer device 24 includes a rail 25 laid between each cell and the storage, and a single or a plurality of self-propelled vehicles 26 mounted on a rack or pallet and traveling on the rail 25.
And a transport control system 27 for controlling the operation of the self-propelled vehicle 26
Consists of

The printed wiring board 28 delivered to the factory is
After the data is input to the personal computer 29 for board receipt management, it is temporarily stored in the member storage shelf 30. Further, components (or a group of components) such as the reel 31 are stored in the member storage shelf 30 after the data is input to the personal computer 32 for component receipt management, with the ID label 33 attached thereto.

The printed wiring board supplied to the line from the ID assigning machine 11 is transported by the self-propelled vehicle 26 between each cell excluding the automatic knitting apparatus 12 and the storage 23 while being housed in the rack 34. The reels 31 are supplied to the automatic knitting apparatus 12 while being mounted on the corresponding cartridges 35, and the reels 31 and the cartridges 35 are supplied to the line while being mounted on the pallet 36 in a predetermined order. The pallet 36 is moved by the self-propelled vehicle 26 to the automatic knitting apparatus 12, the small component mounter 15, and the storage 23.
Conveyed between.

The application of the present invention to such a production line can be realized, for example, in a case where a cartridge is mounted on a pallet in the automatic knitting apparatus 12 and is loaded into the small component mounter 15.

FIG. 3 is a perspective view showing a state where a cartridge is mounted on a pallet. The reel 31 has a large number (for example, 1
000 to 2000) are wound in a reel shape around a band-shaped component case in which the same type of mounted components (chip components and the like) are accommodated at equal intervals in the longitudinal direction. This reel 31 is used to feed the band-shaped component case. Is set in the cartridge 35.

The cartridge 35 is mounted on each channel of the pallet 36 in a predetermined order. In this example, the number of channels of one pallet is 30 and the cartridge 3
If the occupied width of 5 corresponds to one channel, 30 cartridges can be mounted on one pallet. When the occupied width of the cartridge extends over two channels, the maximum mountable number of cartridges is reduced by that amount.

In the present embodiment, the pallets on which the cartridges are mounted are simultaneously set in a plurality of (for example, seven) small component mounters to increase the apparent number of channels.

The outline of the function of the small component mounter will be described with reference to FIG. The rack 34 carried in from the self-propelled vehicle to the small component mounter 15 is provided with a supply belt conveyor 41.
Is supplied onto the lifter 42, and the desired printed wiring board 28 is sent to the small component mounter 15 by the pusher 43.

On the other hand, a plurality of pallets 36 on which cartridges are mounted are loaded for each operation unit of the small component mounter 15. Hereinafter, the plurality of pallets 36 to be loaded for each operation unit of the small component mounter will be referred to as a pallet group (36A).

In the small component mounter 15, the pallet group 36
A small component supplied from A is mounted at a predetermined position on the printed wiring board 28. The printed wiring board 28 on which the component mounting is completed is returned to the rack 34 again, and is carried out to the self-propelled vehicle by the discharge conveyor 44. Cell controller 4
Numeral 5 monitors a series of operations as described above, and based on the carry-in request signal and carry-out request signal output from the cell controller 45, the transport of racks and pallets is controlled.

FIG. 5 is a diagram for explaining pallet circulation in the small component mounting machine. Small component mounter 15
Is configured to circulate the loaded pallet group and receive the mounted components from the pallets which are sequentially fed to the component receiving position.

In the illustrated example, the pallet 36-1 is located at the component receiving position, and the pallet 36-2 is the pallet 36.
The pallet moves to the component receiving position after -1. Reference symbol SP indicates a standby position where the pallet can be immediately moved to the component receiving position.

In the small component mounter configured as described above, the movement of each pallet is limited due to mechanical restrictions.
Instead of being performed completely synchronously, it is performed with a slight time lag.

Therefore, it takes a certain time from when the pallet 36-1 is set at the component receiving position to when the next pallet 36-2 is set at the standby position SP.

For this reason, if the parts reception for the pallet 36-1 is completed before the pallet 36-2 is set at the standby position SP, a loss time will occur.

For example, when a component supplied from each pallet is mounted on a certain printed wiring board, if there are pallets involved in component reception and pallets not involved,
Pallets that are not involved in receiving parts are circulating simply to cause loss time for the printed wiring board.

On the other hand, with respect to the pallet involved in the component receiving, if the time involved in the component receiving is longer than the time from the time when the pallet is set at the component receiving position to the time when the next pallet is set at the standby position. ,
No loss time will occur.

Therefore, when creating channel setting data indicating which cartridges are to be mounted on which channels of the pallet group, each pallet is involved in the printed wiring board on which components are to be mounted, for as much time as possible. It is desirable to be considered as follows. As a result, loss time can be reduced.

FIG. 6 is a related diagram of a database related to the pallet knitting system in the embodiment of the present invention. 5
1 is a floor controller for controlling the entire floor on which the production line shown in FIG. 2 is installed, and 52 is a line controller for controlling the production line shown in FIG.

Information from the order file 59 and the CAM data file 60 in the floor controller 51 is taken into the line controller 52 via the interface 58, and after necessary data conversion processing is performed, the parts specification table 53 and the order The information is stored in the management table 54, the drawing number master table 55, the source data table 56, and the parts data table 57. Reference numeral 61 denotes a label issuing machine control process for controlling the label issuing machine based on the ID code from the component specification table 53. Data relating to the reel ID from this process is stored in the reel management table 62.

Based on information from the parts specification table 53, the order management table 54, the figure number master table 55, the source data table 56, the parts data table 57, and the reel management table 62, the pallet knitting process 63 performs processing such as pallet knitting. Is made. Information on the pallet knitting results and the like is stored in the pallet management table 64,
Rack management table 65, group management table 66,
It is stored in the NC management table 67 and the NC data table 68.

Reference numeral 69 denotes a loading control process for controlling the loading of racks and pallets based on the results of pallet knitting and the like, and reference numeral 70 denotes a cell management process for managing cells of a component mounter and the like based on the results of pallet knitting and the like. The input control process 69 and the cell management process 70 are connected to the physical distribution control process 72 and the cell control process 73 via the socket interface 71 or directly. 74
Is an operation result table for storing operation result data from the cell management process 70.

Information on the number of components actually used in the component mounter is sent from the cell management process 70 to the reel management table 62, whereby the remaining component count on each reel is managed. 75 is a reel management table 6
2 is a component ID management process for sending data relating to the cartridge ID to the second component.

Reference numeral 76 denotes an automatic knitting apparatus control process connected to the reel management table 62 and pallet management table 64, and reference numeral 77 denotes an ID assigning machine control process connected to the rack management table 65. Logistics control process 7
2 is provided with a storage management table 79,
The automatic knitting apparatus control process 76 has an address management table 80. The order management table 54 is updated based on the data on the process progress from the input control process 69, and the order file 59 is updated accordingly.

The main functions of the pallet knitting process 63 are as follows.

Work Order Extraction Function Automatically extracts orders that can be palletized from various work orders. In addition, an order to be subjected to pallet knitting is manually selected from various work orders.

The grouping function groups product types of printed wiring boards so that the number of setup changes in the component mounter is minimized. In this case, it is determined in advance whether or not the grouping of the product type of the printed wiring board is appropriate by a method taking into account the loss time associated with the movement of the pallet to the standby position. here,
"Product type" refers to the type of product in which the completed printed wiring board unit is used, and in the present specification,
In the sense of the number common to the blueprints of product components,
It may be called "drawing number".

A function for determining which cartridge of a pallet group is to be loaded with which cartridge in a function pallet group for creating channel setting data. When creating the channel setting data, it is considered that each of the pallets constituting the pallet group participates in the printed wiring board on which the components are to be mounted as equally as possible in time.

When there are a plurality of cartridges having the same type of reel, consideration is given to giving priority to a cartridge having a small number of components.

In addition, consideration is given to mounting relatively short components on the printed wiring board prior to relatively tall components.

The created channel setting data is issued as a mounting instruction on a monitor screen and / or a form, or sent to an automatic knitting apparatus. In the former case, the mounting of the cartridge on the pallet is done manually.
In the latter case, the mounting of the cartridge on the pallet is automatically performed by an automatic knitting device.

Hereinafter, the function of the pallet knitting process will be described step by step with reference to the flowchart shown in FIG. 7A is a flowchart of the first part of the pallet knitting process, FIG. 7B is a flowchart of the middle part of the pallet knitting process, and FIG. 7C is a flowchart of the second part of the pallet knitting process.

First, in step 201, referring to the order management table 54, all orders corresponding to the pallet organization are extracted from the work orders. Next, the process proceeds to step 202, where the type and quantity of the component to be used and the required number of channels are obtained for each drawing number with reference to the source data table 56, the component specification table 53 and the part data table 57.

Subsequently, the process proceeds to step 203, where the number of components to be used and the remaining number of printed wiring boards are checked with reference to the reel management table 62 and the like, and the work order is determined in the order of delivery date of the product. The determined work order is displayed on a monitor screen or the like in step 204. FIG. 8A shows an example of the display content at this time.

When the production order is selected manually, referring to the display contents in step 204,
At step 205, an order is selected.

Subsequently, in step 206, prior to the grouping of the product types of the printed wiring boards, it is determined whether or not the grouping of the target printed wiring boards is appropriate. Here, the group condition table 82 is referred to, and a matrix having the number of channels of the pallet group and the number of mounted components as parameters is set in this table. The determination as to whether the grouping with reference to this matrix is appropriate will be described later.

Next, the process proceeds to step 207, where the grouping is performed on the object for which the grouping is determined to be valid. A specific method of this grouping will be described later.

Subsequently, the process proceeds to step 208, where the number of parts used for each group is calculated.
By referring to the reel management table 62, it is checked whether or not a reel having a required quantity of parts is in stock with the reel mounted on the cartridge.

If there is a group having a shortage of reels in step 210, the flow advances to step 211 to delete the corresponding figure number, display the shortage reels in step 212, return to step 207, and perform grouping again. Execute FIG. 8B shows an example of the display content of the shortage reel.

If it is determined in step 210 that there is no group with a shortage of reels, the process proceeds to step 213, and it is determined whether or not empty cartridges are insufficient. Step 2 if empty cartridges are insufficient
Go to 14 and delete the corresponding figure number, and
Is displayed in step 207 to display the missing cartridge.
Return to and execute grouping again. FIG. 8C shows an example of the display content in step 215.

If it is determined in step 213 that the number of empty cartridges is not insufficient, the process proceeds to step 216,
Channel assignment is performed for each group. That is, channel setting data indicating which cartridge of the pallet group is to be loaded with which cartridge is created.

In preparing the channel setting data, firstly, it is considered that each of the pallets constituting the corresponding pallet group is involved in the printed wiring board on which components are to be mounted at an even time as much as possible. You.

Second, when there are a plurality of cartridges having the same type of reel, consideration is given to assigning a cartridge having a small number of components to a corresponding channel with priority. This prevents occurrence of a large number of reels (so-called insect-eating reels) in which parts remain halfway.

Third, when there are a tall component and a short component as components to be mounted on the same printed wiring board, it is considered that the short component is mounted first.
The reason is that when mounting components on a printed wiring board, it is necessary to move the printed wiring board at a relatively high speed, and if a tall component is mounted first, the acceleration during the movement of the printed wiring board is required. This is because the tall parts may fall down due to the inertial force generated as a result.

Then, the process proceeds to a step 217, wherein it is determined whether or not channel over occurs in the pallet group to be used. If the channel is over, the process proceeds to step 218, where the corresponding figure number is deleted from the group, and the process returns to step 207 to perform the grouping again. If the channel does not overflow, the process proceeds to step 219.

In step 219, the results of the pallet knitting are displayed on a monitor screen or the like. FIG. 8D shows an example of the display content. Then, the result of the pallet knitting is determined in step 220, and it is determined in step 221 whether or not to execute the pallet knitting. If it is determined not to execute, the pallet knitting process is stopped and the routine exits from this routine via step 222, or returns to step 204, where the order is reselected based on the displayed order contents. .

If it is determined in step 221 that the pallet knitting is to be executed, the process proceeds to step 223, where the pallet knitting result is output, and
In step 225, a pallet knitting result is displayed, and in step 225, a knitting instruction is issued. FIGS. 8E and 8F show examples of display contents in steps 224 and 225, respectively.

Subsequently, at step 226, the database is maintained based on the output pallet knitting result. The target databases here are a reel management table 62, an order management table 54, a rack management table 65, a pallet management table 64, a group management table 66, and an NC management table 67.

Next, at step 227, NC data for operating the small component mounter is created, and its contents are stored in the NC management table 67 and the NC data table 68. The NC data created in the above process is automatically extracted by the cell controller when the rack is supplied to the cell, and sent to the small component mounter. Then, component mounting is automatically performed.

FIG. 9 is a diagram showing an example of a matrix used when it is determined in advance at step 206 in FIG. 7A whether the grouping is appropriate.

This matrix uses, as parameters, the number of channels of the pallet group and the number of mounted components required when components are mounted on a certain printed wiring board.

The matrix elements correspond to the upper limit of the number of pallets determined so as not to cause a loss time when the pallets circulate and move to the standby position in the small component mounter, and the number of mounted components. The lower limit of the number of pallets required to secure the channel is set.

For example, when looking at a matrix element having a row number x of 3 and a column number y of 5, the number of channels is 91 to 91.
120, and the number of parts is 121 to 140. Under this condition, the upper limit of the number of pallets is 6, and the lower limit of the number of pallets is 4.

That is, at least four pallets are required to secure the number of channels corresponding to the number of mounted components, and to prevent loss time, the number of pallets is six.
It is required that:

Looking at a matrix element having a row number x of 3 and a column number y of 3, the number of channels is 91 to 91.
120, the number of parts is 81 to 100, and it is understood that both the upper limit and the lower limit of the number of pallets are 4. Therefore, those corresponding to this matrix element have no degree of freedom in the number of pallets.

In this matrix, the number of channels, which is a parameter of a row, is divided by a multiple of 30, because the number of channels per pallet is 30.

Also, if the number of parts, which is a column parameter, is 20
It is separated by a multiple of for the following reason. That is, in the component mounter used in the present embodiment, the time required from setting one of the pallets at the component receiving position to setting the next pallet at the standby position is 8 seconds. It takes 0.4 seconds per part to receive a part from a pallet set at the part receiving position. Therefore, if the mounter receives 20 or more parts from one pallet, the standby state of the next pallet is considered. This is because there is no loss time associated with the movement to the position.

In the following description, when it is necessary to specify a matrix element, a GT code G (x, y) using its row number x and column number y is used.

In this matrix, when the row number x increases, that is, when the number of channels increases, the lower limit of the number of pallets also increases.

When the column number y increases, that is, when the number of parts increases, the upper limit of the number of pallets also increases.

In a matrix element having the same row number x and column number y, the upper limit of the number of pallets matches the lower limit of the number of pallets, and there is no degree of freedom in the number of pallets.

Therefore, prior to the grouping, when it is determined whether the drawing number (product type) of a certain printed wiring board and the drawing number of another printed wiring board can belong to the same group, When the row number x and the column number y of the matrix element corresponding to one figure number are equal,
It is determined whether or not the other figure number can be rounded to the one figure number based on the one figure number.

More specifically, regarding the figure numbers corresponding to the matrix elements having the same column number y, the figure numbers corresponding to the matrix elements having the small row number x are replaced with the figure numbers corresponding to the matrix elements having the large row number x. It can be rounded to a number.

As for the figure numbers corresponding to the matrix elements having the same row number x, the figure numbers corresponding to the matrix elements having the large column number y are rounded to the figure numbers corresponding to the matrix elements having the small column number y. It is possible.

More specifically, as shown in FIG. 10, the figure number corresponding to G (1, 4) is G (1, 4).
1), G (2,2), G (3,3), G (4,4) can be rounded to the figure number corresponding to any of them. That is,
The figure numbers corresponding to G (1, 4) are G (5, 5), G
There is no grouping in the same group as the figure number corresponding to (6, 6).

As described above, by judging whether the grouping is appropriate before the grouping,
In grouping, the number of combinations of drawing numbers to be grouped is significantly reduced, and the amount of calculation for grouping can be reduced.

FIG. 11 is a diagram for explaining the concept of grouping in step 207 and channel setting in step 216 of FIG. 7B. The manufacturing order table 93 (1) that stores manufacturing order information relating to the drawing number (product type) of the printed wiring board is, specifically, manufactured based on the manufacturing order for each drawing number (Z1 to Z6) of the printed wiring board. The number of commands is stored.

The mounting table 91 (2) stores component mounting information obtained from the manufacturing order information for each of the printed wiring boards. Such component mounting information is
The part symbol attached to the part, the mounting position of the part (X,
Y), the mounting angle (θ), the type of component (component name), and the like.

Then, the drawing numbers are first grouped based on the manufacturing order information and the component mounting information, and channel setting data is created based on the grouping result. The created channel setting data is stored in the component channel setting table 92. The component channel setting data is the type (component name) of the component of the cartridge to be mounted, which is set corresponding to each channel. Note that the component channel setting table 92 is created for each pallet group.

FIG. 12 is a block diagram showing a specific configuration example of the grouping means. In this example, the grouping means includes a component use table 101, a component channel setting preparation table 102, and a component unmatch number table 103.
And an arithmetic unit 104 for exchanging information with each of these tables to execute an operation for grouping.

The component use table 101 stores the types of all mounted components used for the printed wiring board on which components are to be mounted. Component channel setting preparation table 102
Sequentially stores the information stored in the component use table 101. The parts unmatch number table 103 is
When sequentially storing in the component channel setting preparation table 102, the number of unmatches represented by the number of types of mounted components stored in the component use table 101 but not stored in the component channel setting preparation table 102 is determined by the product. It is stored sequentially for each species.

The processing process in the arithmetic unit 104 includes the following steps.

(A) For all the printed wiring boards specified by the manufacturing order information, the type of the mounting component used for each printed wiring board in the component mounting information from the mounting table 91 corresponding to each of the printed wiring boards. The component information is read out, and the component information is stored in the component use table 101.
Step to write to.

(B) Component channel setting preparation table 10
When the component information is sequentially stored in No. 2, the component use table 101 and the component channel setting preparation table 102 are compared, and each time the number of unmatches is sequentially written in the component unmatch number table 103, the result is obtained. From each of the obtained contents of the component unmatch number table 103, a product type that minimizes the number of unmatches is selected each time, and the component information is transferred to the component channel setting preparation table 102 within a range not exceeding the settable upper limit of the number of channels. Step to write to.

FIG. 13 is a diagram for explaining the flow of creating each table shown in FIG. In the component use table 101, based on the manufacturing order information and the component mounting information, a required number (6 in this example) of product types Z1 to Z6 for which an order has been issued, and components used for each of the product types Z1 to Z6. Is written for all component types a to o. Also, in this example, the component channel setting preparation table 102 has two table units 102.
A, 102B.

As for the component channel setting preparation table 102, first, the table section 102A is created. The setting of the table unit 102A is cleared by the first write operation, and the use setting write operation is performed on the used components a, b, d, e, g, and h of the product type Z1 by the second operation. Next, in the third operation, for the product type Z2 with the minimum number of unmatches “2” in the second calculation in the component unmatch number table 103, a writing operation added to the used components f and i for the unmatch is performed. In the fourth operation, the parts unmatch number table 103
Minimum unmatch number "2" for the third calculation in
With respect to the product type Z5, a writing operation added to the used parts j and k for the unmatch is performed.

As described above, in the table section 102A, one of the parts a, b, d, e, f, g, h, i, j, k is stored.
Use setting writing is performed for the 0 component.

Thereafter, the table unit 102B is created in the same manner.
Use writing is performed for b, c, h, j, k, l, m, n, and o.

In the illustrated example, the number of components to be mounted on each printed wiring board is about 6 to 7, and the number of channels is 10 (No. 1 to 10). The number is set small for the sake of convenience in explanation, and the number of parts and the number of channels are actually much larger than this.

FIG. 14 is a flowchart of a processing process in the grouping means shown in FIG.

First, a grouping process is started by inputting a start flag (step 301), and mounting tables (see FIG. 11) for the product types Z1 to Z6 for which an order has been instructed are selected from the manufacturing order information. The component use table 101 is created from the mounting table (step 302). That is, for the product type Z1, the parts a,
Use settings are made for b, d, e, g, and h. Hereinafter, for product type Z2, parts d, e, f, g, h, i, and Z3
For parts c, h, k, l, m, n, o, for Z4, parts b, c, j, k, m, o, and for Z5, parts a, b, f, i, j, k, Z6 For parts a,
Usage settings are made for c, h, j, k, n, and o, respectively.

Thereafter, in steps 303 and 304, a variable I indicating the number of times and a flag K are reset and cleared to zero. In step 305, I = 1, and the number of times in the table section 102A of the component channel setting preparation table 102 is set. The space of 1 is cleared (step 306).

Next, the control variable J indicating the product type is cleared and reset (step 307).
It is determined whether the flag K is zero. Since K = 0 at first, the process jumps to step 310 where J = J + 1 and to step 311 for determining whether there is a product type (J) already set in the component channel setting preparation table 102. At step 309, J = J + 1
Then, the process of step 312 is performed.

In step 312, a comparison operation is performed between the contents of the component channel setting preparation table 102 and the product type J (= 1: Z1) of the component use table 101. In this case, the table of the component channel setting preparation table 102 is used. Since the part of the number 1 in the part 102A has been cleared, the number of parts "6" of the product type Z1 is written as the number of unmatched parts at the position of the number of times 1 and J = 1 in the parts unmatch table 103 (step). 313).

Next, it is determined whether or not the calculations for the product types J = 1 to 6 have been completed (step 314).
Since it is 1, the process returns to step 309 via step 308, and the comparison operation for J = 2 is performed.

That is, the number of component unmatches is written at the position of frequency 1, J = 2 in the component unmatch number table 103.

Such an operation is sequentially repeated for J = 2 to 6. When J = 6, since the calculation of the number of unmatches has been completed for all product types, the operation shifts from step 314 to step 315, and : The minimum value of the number of unmatches in J = 1 to 6 is considered. In this case, since the minimum value is “6”, the initially set J
= 1 is output as the minimum number of unmatches.

Then, in order to confirm whether or not all component channel settings have been completed, it is determined whether or not the number of unmatches for all product types J = 1 to 6 is zero (step 31).
6) In this case, the unmatch number is not zero for all Js, so the process proceeds to the NO side.

Next, the number of empty channels is obtained (step 317). In this case, the channel-settable component type is set to “10”, so the number of empty channels is “1”.
0 ". Thereafter, the difference between the number of unused channels and the number of used channels is obtained (step 318).

Since all the channels have been cleared this time, the number of empty channels at this stage is “10”. This “10” is compared with the number of unmatches “6”, and the number of empty channels is larger. Therefore, the process proceeds to step 319 assuming that the channel can be set. Here, after setting I = I + 1, in step 320, the components a, b, d, e, g, and h corresponding to the product type J = 1 are read. These parts are stored in the table section 10 of the part channel setting preparation table 102.
It is set at the frequency I (2) of 2A.

Thereafter, the flow returns to step 307, and the operation of the next number 2 is performed. That is, the reset is performed to J = 0 (step 307), and via the YES route of step 308, J = 1 is set in the space 309, and the table section 102A of the component channel setting preparation table 102 and the component use table 101 Product type Z1 corresponding to J = 1
Is used (step 312).

In this case, since the component set in the table section 102A of the component channel setting preparation table 102 is a component used for the product type Z1, the number of unmatches is “0”.
And the number of times in the parts unmatch number table 103 is J
“0” is written at the position of = 1.

Then, after step 314, and further through step 308, the process returns to step 309, where J is "2".
And the contents of the table section 102A of the component channel setting preparation table 102 and J = 2 of the component use table
Used parts d, e, f, g, h, and
i is compared (step 312).

In this case, since the table section 102A of the component channel setting preparation table 102 is in the state of the number of times 2, the unmatched components are the components f and i, and the unmatched number is “2”.

The number of unmatches “2” is the number of times 2, J = 2
(Step 313), and Step 31
After step 4 and step 308, the process returns to step 309.

Further, such an operation is repeated up to J = 3 to 6, and is written at the number of times 2 and J = 3 to 6 in the component unmatch number table 103, respectively.

Thus, the examination for all product types J = 1 to 6 is completed (step 314), and in step 315, the smallest product type having a non-zero number of unmatches is found from the number of times 2 in the unmatch number table.

In this case, since the unmatch number “2” of J = 2 corresponds, this J = 2 is output, and all product types J = 1
Since the number of unmatches in to 6 is not all zero (step 316), an empty channel is obtained in step 316,
Proceed to step 318.

In step 318, the number of empty channels is compared with the number of unmatches. In this case, since the number of empty channels is "4" and the number of unmatches is "2", I = 3 in step 319. Then, step 320 is executed, and the used parts d, e, f, g, h, and i of the product type Z2 corresponding to J = 2 are added to the part of the table section 102A of the part channel setting preparation table 102 where the number of times is 3. Is registered.

At this time, since the components d, e, g, and h are duplicately registered, the components f and g are additionally registered.

Then, the same operation as described above is performed for the number of times 3, and at the number of times 3 in the table section 102A of the component channel setting preparation table 102, J = 5 corresponding to the minimum number of unmatches “2”: product Used parts a, b, f, i, j, and k of the seed Z5 are registered.

At this time, since the components a, b, f, and i are duplicately registered, the components j and k are newly added and registered.
Table part 1 of medium part channel setting preparation table 102
The registration setting state shown in the number 4 of 02A is set, and a total of 10 parts are registered.

Then, the same operation is performed for the number of times 4. In this case, the number of empty channels is "0", and in step 318, the number of empty channels is smaller than the number of unmatches. In step 321, the flag K = 1 is set, and the process returns to step 305.

In this case, at step 305, I = I + 1
Therefore, the creation operation of the table unit 102B of the component channel setting preparation table 102 starts from I = 5.

Then, in the same operation as described above, J = 5
Calculation of the number of unmatches corresponding to 1 to 6 is performed. Here, since the production of the product types Z1, Z2, and Z5 has been completed at the stage of the table unit 102A of the component channel setting preparation table 102, steps 308, 310, and 3 are performed.
By the operation of 11, J = 3, 4, and 6 are targeted from this time.

That is, for the number of times 5, the unmatched numbers “7”, “6”, and “7” for J = 3, 4, and 6 are calculated (step 313), and the product type Z4 of the unmatched number “6” is calculated.
Are registered and set (step 320), and the table unit 102B of the component channel setting preparation table 102 enters the state indicated by the number of times 6 in the figure.

Next, with respect to the number of times 6, the number of unmatches “3”, “0”, and “3” for J = 3, 4, and 6 are calculated (step 313), and correspond to the minimum number of unmatches other than “0”. J = 3 is output, and J of the number of unmatches “3” is output.
= 3, the component types c, h, used for the product type Z3 corresponding to
k, l, m, n, and o are registered and set (step 32).
0), the table section 102B of the component channel setting preparation table 102 is in the state indicated by frequency 7 in the figure.

Further, with respect to the number of times 7, the number of unmatches “0”, “0”, and “1” for J = 3, 4, and 6 are calculated (step 313), and the number of unmatches other than “0” is minimized to “1”. The corresponding J = 6 is output, and the component types a, c, h, j, k, and the component types used for the product type Z6 corresponding to J = 6 are output.
n and o are registered and set (step 320), and the table unit 102B of the component channel setting preparation table 102 enters the state indicated by the number 8 in the figure.

Then, with respect to the number of times 8, the number of unmatches “0”, “0”, “0” for J = 3, 4, 6 is calculated (step 313), and for all product types J = 3, 4, 6. Since the number of unmatches is “0”, step 316
A YES route is taken to end the calculation.

As described above, according to the present embodiment, the printed wiring boards are grouped into a group in which components can be mounted on the same pallet group, so that a printed wiring board unit using mutually common components can be manufactured. This can be performed before and after, and the number of operations such as setup change can be reduced.

Further, since the determination as to whether the grouping is appropriate or not is made in advance using the specific matrix prior to the grouping, the amount of calculation for the grouping can be significantly reduced, and the pallet knitting can be performed quickly. Becomes possible.

Further, when creating the channel setting data based on the above grouping, it is considered that each of the pallets constituting the pallet group is involved in the printed wiring board on which components are to be mounted at an even time as much as possible. Therefore, the occurrence of a loss time in the component mounter is minimized, and the component mounter can operate efficiently.

[0134]

As described above, according to the present invention,
Even in the case of high-mix low-volume production, it is possible to provide a pallet knitting system capable of greatly improving the operation efficiency of a component mounter by reducing the number of operations such as setup change.

[Brief description of the drawings]

FIG. 1 is a principle block diagram of the present invention.

FIG. 2 is an explanatory diagram of a production line suitable for applying the present invention.

FIG. 3 is a perspective view showing a state where a cartridge is mounted on a pallet.

FIG. 4 is an explanatory diagram of functions of the small component mounter.

FIG. 5 is a diagram for explaining pallet circulation in the small component mounter.

FIG. 6 is a related diagram of a database relating to the pallet knitting system.

FIG. 7A is a flowchart of the first part of the pallet knitting process.

FIG. 7B is a flowchart of the middle part of the pallet knitting process.

FIG. 7C is a flowchart of the latter part of the pallet knitting process.

FIG. 8A is a diagram showing an example of display contents in step 204 of FIG. 7A.

FIG. 8B is a diagram showing an example of display contents in step 212 of FIG. 7B.

FIG. 8C is a diagram showing an example of display contents in step 215 of FIG. 7B.

FIG. 8D is a diagram showing an example of display contents in step 219 of FIG. 7C.

FIG. 8E is a diagram showing an example of display contents in step 224 of FIG. 7C.

FIG. 8F is a diagram showing an example of display contents in step 225 of FIG. 7C.

FIG. 9 is a diagram showing an example of a matrix created in step 206 of FIG. 7A.

FIG. 10 is an explanatory diagram of rounding on the matrix of FIG. 9;

FIG. 11 is an explanatory diagram of the concept of grouping and channel setting.

FIG. 12 is a block diagram illustrating a specific configuration example of a grouping unit.

FIG. 13 is a diagram for explaining a flow of creating each data table in FIG. 12;

FIG. 14 is a flowchart of a processing process in a grouping unit in FIG. 12;

[Explanation of symbols]

 1,93 Manufacturing order table 2,91 Mounting table 3 Grouping means 4 Channel setting data creation means

 ────────────────────────────────────────────────── ─── Continuation of the front page (72) Inventor Hiroshi Wakisaka 1015 Kamikodanaka, Nakahara-ku, Kawasaki City, Kanagawa Prefecture Inside Fujitsu Limited (56) References JP-A-1-192200 (JP, A)

Claims (6)

(57) [Claims] A pallet group (36A) comprising a plurality of pallets (36) each having a plurality of cartridges (35) each provided with a plurality of mounting parts of the same type, and mounting the mounting parts on a printed wiring board ( 28) A pallet knitting system that creates channel setting data indicating which cartridge of the pallet group is to be loaded with a cartridge when the component mounting machine (15) is operated to be mounted at a predetermined position on the pallet. A manufacturing order table (1) for storing manufacturing order information relating to a product type of the printed wiring board, and a mounting table (2) for storing component mounting information obtained from the manufacturing order information for each of the printed wiring boards. ) And the type of each mounted component for each printed wiring board to be mounted based on the manufacturing order information and the component mounting information, From the settable upper limit of the type of the mounted component and the number of channels, such that the number of replacements of the pallet group in the component mounter is minimized,
Grouping means (3) for grouping printed wiring boards into groups in which components can be mounted on the same pallet group; and channel setting data creating means (4) for creating the above-described channel setting data for the corresponding pallet group based on the result of this grouping. A pallet knitting system comprising: The grouping means sequentially stores a component use table (101) for storing all types of mounted components used for a printed wiring board on which components are to be mounted, and information stored in the component use table. The component channel setting preparation table (102) to be stored, and the component channel setting preparation table stored in the component use table (101) when sequentially storing the component channel setting preparation table (102). (102) has a component unmatch number table (103) for sequentially storing the number of unmatches represented by the number of types of mounted components that are not stored for each product type, and the processing process in the grouping means includes: For all the printed wiring boards specified by the above manufacturing order information, the mounting table (91) corresponding to each of these printed wiring boards
Reading the component information relating to the type of mounted component used for each of the printed wiring boards from the component mounting information, and writing the component information in the component use table (101); and ), The component use table (101) and the component channel setting preparation table (10).
2), and each time, the number of unmatches is sequentially written in the component unmatch number table (103),
Resulting part unmatch count table (103)
For each time, select a product type that minimizes the number of unmatches from the contents of the above, and, within the range that does not exceed the settable upper limit of the number of channels, enter the component information corresponding to the selected product type into the component Writing to a channel setting preparation table.
The pallet knitting system according to 1. 3. The pallet group, wherein the component mounting machine (15) is
(36A) is circulated to receive the mounted components from the pallet that has been sequentially fed to the component receiving position, and
After one of the pallets (36-1) is set at the part receiving position, the next pallet (36-2) is set at the standby position (SP) where the pallet can be immediately moved to the part receiving position. A predetermined time is required until the grouping is performed, and the grouping is performed on a printed wiring board for which it has been previously determined whether the grouping is appropriate. The pallet knitting system according to 1. 4. The method according to claim 1, wherein the determining is performed using a matrix having parameters of the number of channels of the pallet group and the number of mounted components required when components are mounted on the printed wiring board. A matrix in which the upper limit of the number of pallets determined so as not to cause loss time due to the movement to the standby position and the lower limit of the number of pallets required to secure the number of channels according to the number of mounted components are set. 4. The pallet knitting system according to claim 3, wherein the judgment is made by comparing the upper limit and the lower limit of the number of pallets among the product types to which the printed wiring boards to be determined belong. 5. When creating the channel setting data, it is considered that each of the pallets constituting the corresponding pallet group is involved in the printed wiring board on which components are to be mounted at an even time as much as possible. The pallet knitting system according to claim 3, wherein 6. The cartridge (35) includes a reel (3) in which a large number of the same type of mounted components are accommodated in a band-shaped component case.
When the channel setting data is created, when there are a plurality of cartridges having the same type of reel, the cartridge having the reel having the smaller number of stored parts is preferentially assigned to the channel of the pallet group. The pallet knitting system according to any one of claims 1 to 5, wherein: