Electronic component mounting method and electronic component mounting apparatus

A position and orientation of an electronic component attitude are recognized, a mounting head is moved above the electronic component, a rotator is horizontally rotated so that a lower surface of the electronic component is oriented in a direction opposite to a pusher, the electronic component of the fallen-down attitude is sucked and held by the nozzle by lowering a component holder, a attitude of the electronic component that is held is changed to a stand-up attitude by vertically rotating the component holder, leads of the electronic component of which the attitude is changed to the stand-up attitude and insertion holes of the substrate into which the leads are inserted are positioned, and the leads are inserted into the insertion holes of the substrate by pushing the electronic component toward the substrate by causing the pusher to abut against an upper surface of the electronic component of the stand-up attitude.

BACKGROUND

1. Technical Field

The present disclosure relates to an electronic component mounting method for mounting an electronic component having protruded leads on a substrate by a mounting head and an electronic component mounting apparatus.

2. Description of the Related Art

In a component mounting line for producing an electronic substrate by mounting an electronic component on a substrate, various kinds of components are mounted on the substrate by an electronic component mounting apparatus. For these components, there is a surface mounting component such as a small chip-type component and a QFP which is to be soldered to an electrode surface of a circuit substrate. Otherwise, there is an insertion component such as a power transistor and a connector component which has leads protruded for connection and is mounted by inserting a lead into a mounting hole formed in the circuit substrate. A supply form of the insertion component in the electronic component mounting apparatus varies depending on component types. In a case where the component is supplied in a fallen-down attitude by being stored in a tray and the like, in a case where the component is supplied in a vertical attitude in a manner in which a plurality of the electronic components are connected by taping, and the like, the supply attitudes of the component are different by the component type.

In a case where the insertion component is supplied in the fallen-down attitude, since the insertion component is required to change the attitude to a stand-up attitude prior to mounting of the insertion component on the substrate, a component inserter including a function of changing the attitude of the insertion component from the fallen-down attitude to the stand-up attitude has been proposed (for example, see Japanese Patent Unexamined Publication No. 2008-23641). In a prior art example indicated in Patent Literature, a component holding hand for holding the component is configured as a link mechanism having two arms for pinching and gripping the component, and an suction device for sucking the component. The component holding hand handles the component and then the attitude of the component taken out from a component supply device is changed from the fallen-down attitude to the stand-up attitude.

SUMMARY

One exemplary embodiment of the disclosure is made for an electronic component which has protruded leads and is supplied in a fallen-down attitude, and an object thereof is to provide an electronic component mounting method and an electronic component mounting apparatus.

In the electronic component mounting method and the electronic component mounting apparatus, it is possible to efficiently mount the electronic component on a substrate by changing a attitude of the electronic component by a mounting head having a compact configuration.

An electronic component mounting method of an exemplary embodiment of the disclosure is an electronic component mounting method for mounting an electronic component on a substrate by inserting at least one lead protruding from a lower surface thereof into an insertion hole of the substrate. The electronic component mounting method includes a mounting head preparation step, an electronic component supply step, an electronic component recognition step, an electronic component suction preparation step, an electronic component pick-up step, a attitude change step, a positioning step, and an insertion step. In the mounting head preparation step, the mounting head is prepared. The mounting head has a component holder, a pusher, and a rotator. The component holder is configured such that a suction path opened downward is formed and has a nozzle for holding the electronic component at an opening end of the suction path by using negative pressure. The pusher abuts against the electronic component held by the nozzle and pushes the electronic component onto the substrate. The rotator is configured such that the component holder and the pusher are held, and is horizontally rotated therewith. The electronic component supply step supplies the electronic component in a fallen-down attitude. The electronic component recognition step recognizes a position and an orientation of the electronic component supplied in the fallen-down attitude in a horizontal direction. The electronic component suction preparation step horizontally rotates the rotator so that the lower surface of the electronic component is oriented in a direction opposite to the pusher while moving the mounting head so as to position the opening end above the electronic component recognized in the electronic component recognition step. The electronic component pick-up step sucks and holds the electronic component of the fallen-down attitude at the opening end of the nozzle by lowering the component holder. The attitude change step changes the electronic component held at the opening end to a stand-up attitude by vertically rotating the component holder. The positioning step positions leads of the electronic component of which the attitude is changed to the stand-up attitude and the insertion holes of the substrate into which the leads are inserted by moving the mounting head. The insertion step inserts the leads into the insertion holes of the substrate by causing the pusher to abut against an upper surface of the electronic component of the stand-up attitude and pushing the pusher toward the substrate.

An electronic component mounting apparatus of an exemplary embodiment of the disclosure having a mounting head for mounting an electronic component on a substrate, includes: an elevator, a rotator, a rotation device, a component holder, a attitude changing device, a pusher, and a pusher driving device. The elevator is configured such that the mounting head is lifted and lowered by the elevation device together with the elevation device. The rotation device causes the rotator that is held to be horizontally rotatable with respect to the elevator to horizontally rotate with respect to the elevator. The component holder has a suction path connected to a negative pressure generating source and a nozzle for holding the electronic component at an opening end of the suction path by using a negative pressure generated by the negative pressure generating source. The attitude changing device is mounted on the rotator and changes the attitude of the component holder so that the opening end of the nozzle is oriented downward or sideways. The pusher is able to abut against the electronic component held in the nozzle that is oriented sideways. The pusher driving device pushes the electronic component held in the nozzle toward the substrate by driving the pusher.

According to the electronic component mounting method of one exemplary embodiment of the disclosure, it is possible to efficiently mount the electronic component on the substrate by changing the attitude of the electronic component by the mounting head having a compact configuration for the electronic component having the protruded leads and supplied in the fallen-down attitude.

According to the electronic component mounting apparatus of one exemplary embodiment of the disclosure, it is possible to efficiently mount the electronic component on the substrate by changing the attitude of the electronic component by the mounting head having a compact configuration.

DETAILED DESCRIPTION

Problems in an apparatus of the related art are briefly described prior to the description of an exemplary embodiment. As a supply form of an insertion component of Japanese Patent Unexamined Publication No. 2008-23641, a system, in which a plurality of components are stacked in an irregular fallen-down attitude in a component container such as a tray to be supplied, has been known. However, if a component holding hand indicated in the prior art example described above is applied to the supply form of such an insertion component, there are the following disadvantages due to a configuration of the component holding hand. That is, in order to impart a handling function such as a attitude change of the component to a link device used in the component holding hand, a complex device such as an articulated driving device is needed. Therefore, it is difficult to make the component holding hand to be a simple and compact configuration and to apply the component holding hand to an electronic component mounting field in which it is an essential requirement to make a mounting head for mounting the component to be compact. A configuration for mounting the component on the substrate, after the component supplied in the irregular fallen-down attitude is taken out and the attitude is changed, is not disclosed. In the related art including the prior art described above, for a plurality of insertion components supplied in the irregular fallen-down attitude, it is difficult to efficiently execute a component mounting operation by changing the attitude.

Next, an exemplary embodiment of the disclosure will be described with reference to the drawings. First, an entire configuration of electronic component mounting apparatus1will be described with reference toFIGS. 1 and 2. InFIG. 1, substrate transport device3is disposed on an upper surface of base2in an X direction (substrate transport direction). Substrate transport device3takes out substrate4for mounting component from an upstream side device (not illustrated) to transport substrate4in the X direction and substrate4is positioned in a mounting operation position by a component mounting device described below to be held.

First component supply5and second component supply6are disposed on one side (front side inFIG. 1) of substrate transport device3and third component supply7is disposed on the other side. First component supply5is a tray feeder for supplying tray8that is a plane container in which electronic components9of fallen-down attitudes are stored in a random state. The “fallen-down attitude” refers to as a stored attitude in tray8in which the electronic component of a shape which cannot be stably self-standing in a mounting attitude mounted on substrate4in an individual piece such as the electronic component having leads in such a manner that a side surface capable of being mounted in a stable attitude is a holding bottom surface. In order to mount electronic component9of the “fallen-down attitude” on substrate4, it is necessary to convert the electronic component into the mounting attitude to the substrate by vertically rotating the electronic component by 90 degrees in a vertical plane. In the exemplary embodiment, electronic components9are disposed only one layer in tray8and electronic components9are supplied in a state where a plurality of electronic components9or partial electronic components9are not overlapped vertically as little as possible.

Second component supply6is a radial component feeder for supplying a plurality of radial lead type electronic components10connected to each other by being taped in a stand-up attitude. Here, the “stand-up attitude” refers to as the same attitude as the mounting attitude in which the electronic component is mounted on the substrate. That is, the electronic component of the “stand-up attitude” can be mounted on substrate4by holding the electronic component without performing attitude conversion.

Third component supply7is a tape feeder for supplying a surface mounting component such as a chip type component held by a carrier tape. All of first component supply5, second component supply6, and third component supply7supply the stored electronic components to a position in which the electronic components are taken out by multiple-head14of a component mounting device described below. As illustrated inFIG. 2, multiple-head14is a multiple type head in which a plurality of mounting heads17are configured in parallel. The plurality of mounting heads17are enclosed by head cover14a.

Supply recognition camera11of which an imaging direction faces downward is disposed above tray8. First component supply5used in the exemplary embodiment does not supply the component of a take-out target in a lattice-like regular array as a tray feeder that is generally used. First component supply5has a form having tray8storing electronic components9of the fallen-down attitude having leads9aprotruding from a lower surface in a random state. When taking out electronic component9from tray8by multiple-head14, mounting heads17having multiple-head14are individually positioned to electronic components9based on a position recognition result recognizing by imaging electronic component9by supply recognition camera11.

Y-axis tables13are disposed in a Y direction on upper surfaces of a pair of frames12disposed in both ends of base2in the Y direction. Multiple-head14is movably mounted on X-axis table15which is laid in Y-axis tables13in the X direction. All of Y-axis tables13and X-axis table15have direct-acting devices driven by linear motors. Multiple-head14is moved in the X direction and the Y direction by driving Y-axis tables13and X-axis table15.

Therefore, mounting heads17having multiple-head14hold the electronic components supplied from any of first component supply5, second component supply6, and third component supply7. The electronic components are mounted on substrate4which is positioned and held on substrate transport device3in the stand-up attitude. That is, electronic component mounting apparatus1has a function of mounting the electronic components supplied in different attitudes such as the fallen-down attitude and the stand-up attitude on substrate4in the stand-up attitude. In the configuration described above, Y-axis tables13, X-axis table15, and multiple-head14configure the component mounting device for mounting the electronic components on substrate4.

Component recognition camera16of which an imaging direction is upward is disposed between first component supply5, second component supply6, and substrate transport device3. Multiple-head14takes out the electronic components from first component supply5, second component supply6, and third component supply7. Thereafter, component recognition camera16images the electronic component in a state of being held in each mounting head17of multiple-head14by positioning multiple-head14above component recognition camera16. Position recognition of the electronic component is executed by recognizing an imaging result. When mounting the electronic components taken out from the component supplies by multiple-head14on substrate4, a mounting position correction is performed based on the position recognition result.

Next, a structure of mounting head17will be described with reference toFIGS. 3, 4 and 5. First, an entire configuration of mounting head17will be described with reference toFIG. 3illustrating a side surface of mounting head17.FIG. 3illustrates one side surface among those of the plurality of mounting heads17covered by head cover14ain multiple-head14. Mounting head17has vertical mounting base17ain which each element described below is disposed. Mounting head17is incorporated as a unit mounting head configuring multiple-head14by coupling mounting base17ato a base plate (not illustrated) configuring multiple-head14.

Slider18aslidably mounted on guide rail18vertically disposed in mounting base17ais fixed to vertical elevation base19. Z-axis motor21fixed to mounting base17avia bracket21ais disposed above elevation base19in a attitude in which an output shaft faces downward. Feed screw23is coupled to the output shaft of Z-axis motor21via coupling22. Feed screw23is screwed to nut member24coupled to an upper end of elevation base19and elevation base19is lifted and lowered by driving Z-axis motor21. Z-axis original-point sensor25is disposed in bracket21a. In an elevating operation of elevation base19, Z-axis original-point sensor25detects detection dog26provided in an upper portion of elevation base19and thereby a Z-axis original-point in the elevating operation of elevation base19is detected. Z-axis motor21has built-in encoder and a Z-axis position in the elevating operation of elevation base19is obtained by an output pulse signal of the encoder and a Z-axis original-point detection signal by Z-axis original-point sensor25.

Rotator holder20in which fitting hole20ais provided by vertically passing through rotator holder20is coupled to a lower end of elevation base19. Rotator37to which component holder41for holding electronic component9of mounting target is coupled is mounted on fitting hole20avia bearing20b(FIG. 4). Rotator37is horizontally rotatably held in rotator holder20. Component holder41has nozzle42for holding electronic component9. Component holder41can change the attitude of nozzle42downward or sideways by attitude changing device40.

Upper bracket27is mounted on a front surface (left side toward paper surface ofFIG. 3) of the upper portion of elevation base19. Upper bracket27protrudes forward to a position in which an upper portion of rotator holder20is covered. Lower bracket27bis mounted on a front surface of rotator holder20. A side surface of upper bracket27and a side surface of lower bracket27bare connected by connection plate27a.

Pusher driving cylinder28of which rod28a(FIG. 4) faces downward is disposed in an upper surface of upper bracket27. Elevation connector29is coupled to rod28aand an upper end of pusher30vertically passing through rotator37is engaged with elevation connector29. Elevation connector29is lifted and lowered together with pusher30by driving pusher driving cylinder28. Pusher30is disposed in a position which is able to abut against electronic component9held by suction pad42aof nozzle42of which the attitude is laterally positioned. Pusher30is lowered together with elevation connector29by driving pusher driving cylinder28. Therefore, contact30aof pusher30is pressed by coming into contact with electronic component9held by component holder41and can push leads9ainto insertion holes4aof substrate4.

That is, in the configuration described above, pusher driving cylinder28and elevation connector29are the pusher driving device for driving pusher30to be lifted and lowered. The pusher driving device has a function of pushing electronic component9held by nozzle42toward substrate4by driving pusher30. Pusher30is disposed so as to vertically pass through rotator37. Pusher30has contact30acausing electronic component9to abut against a lower end of pusher30protruding downward rotator37and is configured to couple the upper end of pusher30to elevation connector29of the pusher driving device.

Dog plate32for mounting determination of electronic component9is disposed in elevation connector29. In the elevating operation by which dog plate32is lifted and lowered together with elevation connector29, slits32aand32b(seeFIG. 10) formed in dog plate32are detected by mounting determination sensor31fixed to connection plate27a. Therefore, it is possible to determine whether or not electronic component9is correctly mounted on the substrate.

θ-axis motor33, of which rotary shaft33a(FIG. 4) faces downward, is disposed on an upper surface of lower bracket27b. Belt36is suspended between driving pulley34coupled to rotary shaft33aand driven pulley35coupled to the upper end of rotator37. θ shaft original-point sensor38for detecting detection dog39fixed to an upper surface of driven pulley35is provided in elevation base19. In a θ rotating operation of rotator37, θ shaft original-point sensor38detects detection dog39and thereby an original point in a θ direction is detected. Rotator37is rotated around perpendicular rotational axis AX (FIG. 4) by driving θ-axis motor33. In the rotation of rotator37, pusher30provided by vertically passing through rotator37is also horizontally rotated around rotational axis AX. It is possible to constantly keep a relative positional relationship between pusher30and nozzle42regardless of the orientation of rotator37by such a configuration.

InFIG. 4illustrating a main portion of mounting head17, guide rail29fis vertically disposed in elevation base19. Upper member29aconfiguring elevation connector29is coupled to slider29bslidably fitted to guide rail29fin a vertical direction. Rod28aof pusher driving cylinder28is engaged with upper member29aand lower member29dis coupled to a lower surface of upper member29avia needle bearings29cin a state where relative rotation around rotational axis AX is allowed. Fitting protrusion30bprovided at the upper end of pusher30is engaged with engagement recess29eformed in lower member29d. Dog plate32described above is mounted on upper member29a.

Elevation connector29and pusher30are lifted and lowered by driving pusher driving cylinder28. In this case, since lower member29dis coupled to upper member29avia needle bearings29c, the relative rotation which is horizontally rotated together with rotator37with respect to upper member29aof pusher30is not hindered.

In the configuration described above, Z-axis motor21, feed screw23, guide rail18, and slider18aconfigure the elevation device. Elevation base19and rotator holder20configure the elevator which is lifted and lowered by the elevation device. θ-axis motor33, driving pulley34, driven pulley35, and belt36configure the rotation device which horizontally rotates rotator37with respect to the elevator. Upper member29a, slider29b, and guide rail29fconfigure a sub-elevator which is relatively vertically moved with respect to the elevator having the configuration described above by pusher driving cylinder28that is a driving source. Lower member29dis horizontally rotatably mounted below the sub-elevator and is a coupler coupled to the upper end of pusher30. That is, the pusher driving device indicated in the exemplary embodiment is configured to have the sub-elevator having the configuration described above and the coupler horizontally rotatably mounted below the sub-elevator and coupled to the upper end of pusher30.

Attitude changing device40protruding downward from a lower surface of rotator37is mounted on a lower portion of rotator37which is horizontally rotatably held with respect to the elevator having the configuration described above and is horizontally rotated by the rotation device described above. Component holder41having nozzle42for sucking and holding electronic component9is mounted on output shaft66(seeFIGS. 5, 6, and 7) provided in a lower portion of attitude changing device40. Attitude changing device40is mounted on rotator37and has a function of changing the attitude of component holder41so that suction pad42a, which is at an opening end of nozzle42, is oriented downward or sideways.

As illustrated inFIG. 4, first annular flow path20cand second annular flow path20dare formed on an inner circumferential surface of fitting hole20a(seeFIG. 3) into which rotator37is fitted in rotator holder20. First annular flow path20cand second annular flow path20drespectively communicate with first connector50and second connector51. All of first connector50and second connector51are connected to positive pressure generation source58and negative pressure generation source59via valve unit57. First internal flow path52and second internal flow path53, which are opened to a height position communicating with first annular flow path20cand second annular flow path20d, are formed on an inside of rotator37. According to the configuration, first internal flow path52and second internal flow path53are always in a communication state with first annular flow path20cand second annular flow path20dregardless of the position of rotator37in the rotating direction.

First internal flow path52communicates with third connector54provided on the lower surface of rotator37and second internal flow path53communicates with air introduction hole61a(seeFIG. 6) provided in attitude changing device40. Third connector54is connected to fourth connector55provided in component holder41via tube piping56. Here, third connector54communicates with suction pad42athat is at the opening end of nozzle42via suction path41aprovided in component holder41.

Positive pressure air is supplied to attitude changing device40via valve unit57, second annular flow path20d, and second internal flow path53by driving positive pressure generation source58. Therefore, it is possible to change the attitude of component holder41by operating attitude changing device40. Vacuum suction is performed from suction pad42avia valve unit57, first annular flow path20c, first internal flow path52, third connector54, tube piping56, fourth connector55, and suction path41aby driving negative pressure generation source59. It is possible to hold electronic component9by vacuum suction in suction pad42a.

That is, component holder41has a form having suction path41aconnected to negative pressure generation source59and nozzle42which holds electronic component9in suction pad42apositioned at the opening end of suction path41aby using the negative pressure generated by negative pressure generation source59. The positive pressure air is exhausted from suction pad42avia valve unit57, first annular flow path20c, first internal flow path52, third connector54, tube piping56, fourth connector55, and suction path41aby driving positive pressure generation source58. Therefore, it is possible to separate electronic component9that is sucked and held by suction pad42afrom nozzle42.

In vacuum suction or positive pressure exhaustion from suction pad42a, a vacuum suction flow rate or a positive pressure exhaustion flow rate is detected by flow rate sensor75(FIG. 11) and is compared with a threshold set in advance. Therefore, it is possible to detect whether or not nozzle42normally holds electronic component9using suction pad42a. In the exemplary embodiment, success or failure of component mounting on substrate4is determined by detecting a component holding state by nozzle42after a component mounting operation by component holder41.

Disposition of component holder41, attitude changing device40, and pusher30on the lower surface of rotator37will be described with reference toFIG. 5illustrating a view of the lower surface of rotator holder20. InFIG. 5, attitude changing device40and pusher30further protrude from the lower surface of rotator37protruding from the lower surface of rotator holder20. Component holder41having suction pad42ais vertically rotatably provided on an inner side surface of attitude changing device40in rotator37. Here, a state where suction pad42ais oriented downward (surface orientation in the view), that is, a attitude when sucking the electronic component by suction pad42ais illustrated.

Here, a relative positional relationship between contact30aof pusher30and suction pad42ais in a disposition in which rotation center37aof rotator37is positioned in an intermediate portion on a line connecting contact30aand suction pad42a. That is, the position of contact30aabutting against electronic component9in pusher30is disposed in a position separated from rotation center37aof rotator37in the horizontal direction. The position of contact30ais formed such that a center of suction pad42a, which is in the opening end of nozzle42oriented downward, is disposed in a position in which rotation center37aof rotator37is interposed between the center of suction pad42aand contact30aof pusher30in a plan view.

In the example illustrated inFIG. 5, an example, in which rotation center37ais positioned on the line connecting contact30aand suction pad42a, is illustrated, but rotation center37ais no need to be essentially positioned on the line connecting contact30aand suction pad42a. Rotation center37amay be formed by being interposed between the center of suction pad42aand contact30ain a plan view. In short, the center of suction pad42aand contact30aare respectively disposed in positions separated from rotation center37aon both sides in the horizontal direction in the lower surface of rotator37. Therefore, it is possible to reduce a radius of rotation of contact30aor nozzle42with respect to the rotation center37a. Therefore, component holder41and pusher30can be disposed within an extremely compact space and thereby it is possible to realize mounting head17having a small occupying space in the plane.

Next, an internal structure and a function of attitude changing device40will be described with reference toFIGS. 6 and 7. As illustrated inFIG. 6, attitude changing device40is mainly configured of rectangular block-shaped main body40aelongated in the vertical direction. Driving cylinder61and return cylinder62are formed on an inside of main body40ain a longitudinal direction, and fan-shaped housing63is formed below driving cylinder61and return cylinder62. Driving piston64and return piston67respectively having rods64aand67aare fitted into driving cylinder61and return cylinder62. Substantially semi-circular swing member65having output shaft66that is the horizontal shaft in a center portion is rotatably fitted into housing63.

Air introduction hole61athrough which air pressure for driving is introduced is provided in a top portion of driving cylinder61into which driving piston64is fitted. Driving piston64is lowered, driving end65ais pushed down, and thereby swing member65is rotated by introducing air pressure from air introduction hole61ainto driving cylinder61. Component holder41is mounted on output shaft66coupled to swing member65. That is, attitude changing device40is configured to have swing member65that is rotatable around output shaft66that is the horizontal shaft and driving piston64that rotates swing member65by being driven by air pressure in the vertical direction. Component holder41is mounted on output shaft66(seeFIGS. 3 and 4) rotating together with swing member65.

Spring member68that is a compression spring for a returning operation is mounted on an upper portion of return piston67in return cylinder62. In a state where the air pressure for driving is not introduced in driving cylinder61, return piston67is pushed down by a biasing force of spring member68and is positioned at a bottom dead center. In this state, a lower end of rod67apushes down return end65bof swing member65, swing member65is positioned in a rotation limit in the counterclockwise direction, and driving piston64is positioned at a top dead center in driving cylinder61. In this state, component holder41coupled to output shaft66is held in a attitude in which suction pad42ais oriented downward.

FIG. 7illustrates a state where the air pressure for driving is introduced (arrow a) from air introduction hole61ain attitude changing device40. That is, driving piston64is driven by the air pressure and rod64ais lowered (arrow b) in driving cylinder61. Therefore, driving end65aof swing member65is pushed down, swing member65is rotated, and thereby output shaft66is rotated (arrow c) in a clockwise direction. Therefore, component holder41coupled to output shaft66changes the attitude of suction pad42ato the fallen-down attitude. At the same time, rod67ais pushed up (arrow d) by return end65band spring member68is compressed by return piston67within return cylinder62. Introduction of the air pressure from air introduction hole61ais stopped and thereby return piston67is pushed down by an elastic force of spring member68. Therefore, attitude changing device40is returned to the state illustrated inFIG. 6and component holder41is in a attitude in which suction pad42ais oriented downward.

Next, the mounting operation and mis-mounting detection of electronic component9by mounting head17will be described with reference toFIGS. 8, 9, and10. First,FIG. 8illustrate a state where mounting head17of a state of sucking and holding electronic component9by suction pad42aof component holder41is moved with respect to substrate4of the mounting target and leads9aof electronic component9are positioned in insertion holes4aof substrate4. In this case, leads9aare not inserted into insertion holes4aand the lower ends of leads9aare in a state of being positioned directly above insertion holes4a. Pusher30driven by pusher driving cylinder28is in a lifted position and contact30aof the lower end is in a position separated from electronic component9. This state is confirmed by detecting second slit32b(seeFIG. 10) for detecting the lifted position formed in the lower end of dog plate32by mounting determination sensor31.

Next,FIG. 9illustrate a state where mounting of electronic component9is completed by inserting leads9ainto insertion holes4aof substrate4. That is, pusher30is lowered (arrow e) by driving pusher driving cylinder28and contact30aabuts and presses the upper surface of electronic component9in a state of being sucked and held by suction pad42a. Therefore, electronic component9in a state of being held by suction pad42aslides downward with the stand-up attitude and leads9aare completely pushed into insertion holes4aof substrate4. Therefore, mounting of electronic component9on substrate4is completed. In this case, mounting determination sensor31detects first slit32a(seeFIG. 10) formed for detecting mounting success in dog plate32lowered together with elevation connector29and thereby mounting success is detected.

Here, the mounting determination by mounting determination sensor31and dog plate32will be described. As illustrated inFIGS. 8, 9, dog plate32illustrated inFIG. 10are disposed in elevation connector29that is lifted and lowered together with pusher30by pusher driving cylinder28. Two slits of first slit32aand second slit32bfrom the upper side are formed in dog plate32. Second slit32bof the lower side is a slit for confirming a state illustrated inFIG. 8(a), that is, pusher30is in the lifted position. Mounting determination sensor31detects second slit32band thereby it is detected that pusher30is positioned in the lifted position.

First slit32aof the upper side is a slit corresponding to a detection position of mounting determination sensor31in a state where contact30aabuts against electronic component9that is normally mounted. Mounting determination sensor31detects first slit32aand thereby pusher30presses electronic component9and it is detected that leads9aare normally inserted into insertion holes4a.

A pattern example of mounting success and mounting failure will be described with reference toFIG. 10.FIG. 10(a)illustrates an example in which leads9aare completely inserted into insertion holes4aand the mounting is succeeded by pressing electronic component9against substrate4by contact30aof pusher30. In this case, detection optical axis31aof mounting determination sensor31coincides with first slit32aof dog plate32, mounting determination sensor31detects light transmission, and it is determined that the component mounting is succeeded.

On the other hand, inFIG. 10(b), as a result of misalignment of leads9awith respect to insertion holes4a, even if electronic component9is pressed against substrate4by contact30aof pusher30, leads9aare not inserted into insertion holes4a. In this case, detection optical axis31aof mounting determination sensor31is in a light shielding position in which the slit is not present in dog plate32, a light transmission signal is not output, and it is determined that the component mounting is failed.

InFIG. 10(c), in a state where component holder41does not hold electronic component9to be mounted, a state where pusher30is lowered is illustrated. In this case, since electronic component9to be pressed is not present, pusher30is lowered below a normal abutting position. As a result, dog plate32is lowered to a position in which first slit32ais overrun below with respect to detection optical axis31aof mounting determination sensor31. Also in this case, detection optical axis31aof mounting determination sensor31is in the light shielding position in which the slit is not present in dog plate32, the light transmission signal is not output, and it is determined that the component mounting is failed.

A mis-mounting detecting process of electronic component9described above is executed by mis-mounting detector72(seeFIG. 11) included in electronic component mounting apparatus1. That is, mis-mounting detector72detects the position of pusher30when the pusher driving device pushes electronic component9held by component holder41in pusher30toward substrate4, and thereby the mis-mounting of electronic component9is detected. Here, the detection of the position of pusher30is performed by dog plate32. First slit32aand second slit32bare formed in predetermined positions in dog plate32. Dog plate32is lifted and lowered together with pusher30disposed in elevation connector29and it is detected whether detection optical axis31aof mounting determination sensor31is in a light shielding state or a light transmitting state by dog plate32.

Next, a configuration of a control system will be described with reference toFIG. 11. InFIG. 11, electronic component mounting apparatus1has controller70in which storage71and mis-mounting detector72are built. Operation and input73is connected to controller70. An input of an operation command for operating electronic component mounting apparatus1and a data input into storage71are performed by operation and input73. An operation program necessary for the component mounting operation by electronic component mounting apparatus1, component information regarding the electronic component that is the mounting target, and the like are stored in storage71. Here, as illustrated inFIG. 13, information regarding suction target position PC in the side surface of electronic component9is included in the component information stored in storage71.

In the component information, suction target position PC when sucking the side surface of electronic component9by nozzle42by positioning mounting head17to the electronic component is defined. In an example illustrated inFIG. 13, as a feature point of electronic component9, two end points P1of upper surface9cthat is a surface opposite to lower surface9bin which leads9aare provided in electronic component9are defined. A point that is separated by a predetermined distance D to be set appropriately depending on a component type from a center point PM of the two end points P1toward a center portion of electronic component9is set as suction target position PC. When taking out electronic component9in the fallen-down attitude stored in tray8of first component supply5by mounting head17, mounting head17is positioned so as to suck suction target position PC described above by nozzle42.

Controller70is connected to substrate transport device3, first component supply5, second component supply6, third component supply7, X-axis table15, and Y-axis table13. Controller70is connected to Z-axis motor21and θ-axis motor33which configure mounting head17, and air pressure circuit74. Air pressure circuit74is valve unit57, first annular flow path20c, second annular flow path20d, first annular flow path20c, second annular flow path20d, first connector50, second connector51, and the like illustrated inFIG. 4. Air pressure circuit74is a fluid circuit for applying a positive pressure or performing vacuum suction for operating each portion of mounting head17, and is connected to positive pressure generation source58and negative pressure generation source59.

Controller70controls air pressure circuit74and thereby a positive pressure or a negative pressure is supplied to component holder41, attitude changing device40, and pusher driving cylinder28at a necessary timing. Therefore, the component suction by nozzle42of component holder41, the attitude change of component holder41by attitude changing device40, and the push-down operation of pusher30by pusher driving cylinder28are executed. Flow rate sensor75is interposed in a flow path leading to component holder41and a flow rate measurement result by flow rate sensor75is transmitted to mis-mounting detector72of controller70.

In the component mounting operation described above, controller70controls each portion described above based on various programs or data stored in storage71. Therefore, a substrate transporting operation for transporting substrate4in electronic component mounting apparatus1and the component mounting operation for mounting the electronic component on substrate4by taking out the electronic component by mounting head17from first component supply5, second component supply6, and third component supply7are executed. In these operation controls, a detection result transmitted from mounting determination sensor31, Z-axis original-point sensor25, and0shaft original-point sensor38provided in mounting head17to controller70is referred.

An imaging result by supply recognition camera11and component recognition camera16is recognized-processed by an image recognizing function built in controller70. The plurality of electronic components9stored in tray8in the fallen-down attitude in a random state are recognized by the imaging result that is recognized-processed by supply recognition camera11. Therefore, the direction of each electronic component9within the horizontal plane and suction target position PC (seeFIG. 13) to be sucked by nozzle42are acquired. The imaging result by component recognition camera16is recognized-processed and thereby electronic component9of a state of being held by mounting head17and the positions of the leads of electronic component10are acquired.

Next, a function of mis-mounting detector72will be described. In electronic component mounting apparatus1indicated in the exemplary embodiment, it is possible to selectively use two types of the mis-mounting detection methods depending on the type of the electronic component that is the mounting target. That is, a first mis-mounting detector and a second mis-mounting detector are set in mis-mounting detector72. For electronic component9supplied by first component supply5, the first mis-mounting detector detects presence or absence of the mis-mounting of electronic component9by detecting the position of pusher30when pushing electronic component9held in component holder41by pusher30toward substrate4. For electronic component10supplied by second component supply6, the second mis-mounting detector detects mis-mounting of electronic component10by detecting presence or absence of electronic component10in suction pad42athat is at the opening end of nozzle42after mounting electronic component10.

Presence or absence of electronic component10in suction pad42ais performed by comparing the flow rate measurement result of flow rate sensor75with a threshold that is set in advance. As the flow rate measurement result of flow rate sensor75, a vacuum suction flow rate in a state of being vacuum-sucked from suction pad42ain the component sucking operation may be used. Otherwise, any of the positive pressure exhaustion flow rates in a state of being positive pressure exhausted from suction pad42ain a component disengagement operation may be used.

Electronic component mounting apparatus1indicated in the exemplary embodiment is configured as described above and the component mounting operation by electronic component mounting apparatus1will be described in below. First, In electronic component mounting apparatus1having the configuration described above, an example, in which the component mounting operation is performed in first component supply5and second component supply6as the component taking-out targets, will be described. That is, in the example indicated in here, mounting head17disposed in multiple-head14holds electronic component9supplied from first component supply5or electronic component10supplied from second component supply6and mounts electronic component9or electronic component10on substrate4in the stand-up attitude.

As described above, mounting head17has component holder41, attitude changing device40, and pusher30, and mounting head17having the configuration described above is prepared prior to the component mounting operation (mounting head preparing step). Next, first component supply5supplying electronic component9in the fallen-down attitude and second component supply6supplying electronic component10in the stand-up attitude are prepared (component supply preparing step). When executing the component mounting operation, controller70controls mounting head17and thereby the following operation is performed.

That is, in a case where electronic component9supplied from first component supply5is mounted on substrate4, electronic component9of the fallen-down attitude is held by nozzle42in which suction pad42apositioned at the opening end is oriented downward. Thereafter, suction pad42ais oriented sideways and thereby electronic component9held by suction pad42ais changed to the stand-up attitude by attitude changing device40. Electronic component9of the stand-up attitude held by suction pad42athat is oriented sideways is mounted on substrate4by being pushed toward substrate4by pusher30(first electronic component mounting step).

In a case where electronic component10supplied from second component supply6is mounted on substrate4, electronic component10of the stand-up attitude is held by nozzle42in which suction pad42apositioned at the opening end is oriented downward. Electronic component10of the stand-up attitude held by nozzle42in which suction pad42ais oriented downward is mounted on substrate4(second electronic component mounting step).

In the electronic component mounting steps described above, in a case where the mis-mounting of electronic component9supplied from first component supply5is detected in the first electronic component mounting step, the detection is performed by the first mis-mounting detector that is set in mis-mounting detector72(first mis-mounting detecting step). That is, presence or absence of the mis-mounting of electronic component9is detected by detecting the position of pusher30in the first electronic component mounting step. In a case where the mis-mounting of electronic component10supplied from second component supply6is detected in the second electronic component mounting step, the detection is performed by the second mis-mounting detector that is set in mis-mounting detector72(second mis-mounting detecting step). That is, the mis-mounting of electronic component is detected by detecting presence or absence of electronic component10in suction pad42aof nozzle42after the second electronic component mounting step.

Next, the electronic component mounting method by electronic component mounting apparatus1indicated in the exemplary embodiment will be described with reference toFIG. 12. Here, the electronic component mounting method, in which in electronic component mounting apparatus1, electronic component9supplied by first component supply5is mounted on substrate4by inserting leads9aprotruding from the lower surface thereof into insertion holes4aof substrate4, will be described.

First, mounting head17necessary for executing the mounting operation is prepared prior to start of the electronic component mounting operation (mounting head preparing step). Here, as illustrated inFIGS. 3 and 4, mounting head17having component holder41, attitude changing device40, pusher30, and rotator37is prepared. In conjunction with this, electronic component9is supplied in the fallen-down attitude (electronic component supplying step). That is, in first component supply5, tray8in which electronic components9are stored in the fallen-down attitude and in random is prepared. Therefore, it becomes a state where execution of the electronic component mounting operation can be performed.

If the electronic component mounting operation is started, first, imaging of the electronic component is executed (ST1). That is, electronic component9that is the target of the mounting operation among the plurality of electronic components9in a random state within tray8is imaged from above by supply recognition camera11. Therefore, an image illustrated inFIG. 14Ais acquired. Here, an example, in which four electronic components9of electronic components9(1), (2), (3), and (4) among the plurality of electronic components9within tray8are imaging objects, is illustrated.

Next, the electronic component recognition is executed for the acquired image (ST2). That is, the position and orientation of electronic component9that is supplied in the fallen-down attitude in the horizontal direction is recognized (electronic component recognizing step). In the example illustrated in here, the four electronic components9of electronic components9(1), (2), (3), and (4) which are respectively disposed in different horizontal directions are the targets. Lower surface9bthat is a surface on a side from which leads9aof electronic component9are extended, the orientation (direction angle orthogonal to lower surface9b) in the horizontal direction, and suction target position PC defined by definition illustrated inFIG. 13are acquired by the recognizing process.

Next, suction position movement for moving mounting head17is performed based on the position recognition result acquired inFIG. 14A(ST3). Here, a mounting operation turn of one time in which multiple-head14is moved from first component supply5to substrate4, an example, in which the plurality of mounting heads17disposed in multiple-head14are sequentially positioned in electronic components9, is indicated. That is, in each mounting head17, the plurality of mounting heads17of multiple-head14are sequentially moved so that suction pad42athat is at the opening end is positioned above the plurality of electronic components9recognized in the electronic component recognizing step. At the same time of the movement, lower surface9bfrom which leads9aprotrude in electronic component9is oriented in a direction opposite to pusher30and rotator37is horizontally rotated (electronic component suction preparing step).

In this case, component information (FIG. 13) stored in storage71is read prior to the electronic component suction preparing step and information regarding suction target position PC in the side surface of electronic component9is referred (component information referring step). In the electronic component suction preparing step, mounting head17is moved so that suction pad42athat is at the opening end of nozzle42is correctly positioned above suction target position PC.

FIG. 14Billustrates a state when mounting heads17(1), (2), (3), and (4) included in multiple-head14are respectively and sequentially positioned in four electronic components9(1), (2), (3), and (4) illustrated inFIG. 14A. For example, when positioning mounting head17(1) in electronic component9(1), suction pad42aof mounting head17(1) is positioned in suction target position PC of electronic component9(1). At the same time, mounting head17(1) is positioned so that pusher30and rotation center37aare positioned on a straight line perpendicular to lower surface9bas suction target position PC, and rotation center37ais interposed between suction target position PC and pusher30.

Next, electronic component pick-up is executed (ST4). Here, first, electronic component9(1) is picked up by mounting head17(1) described above. That is, in mounting head17(1), component holder41is lowered by driving Z-axis motor21, suction target position PC of electronic component9(1) of the fallen-down attitude is sucked and held by suction pad42aof nozzle42(electronic component pick-up step). The electronic component pick-up step is repeatedly executed until the pick-up of all electronic components9that is scheduled in the component mounting turn is completed (ST5). That is, similarly, electronic components9(2), (3), and (4) are sequentially picked up by following mounting heads17(2), (3), and (4).

Next, the attitude change of component holder41is executed (ST6). That is, in each mounting head17which picks up and holds electronic component9, component holder41is vertically rotated by attitude changing device40. Therefore, the attitude of electronic component9held by being sucked in suction pad42ais changed to the stand-up attitude in which lower surface9bfrom which leads9aprotrude is oriented downward (attitude changing step).

Next, lead imaging is executed. That is, multiple-head14is moved above component recognition camera16and, in here, leads9aof electronic component9held in each mounting head17of multiple-head14in the stand-up attitude are imaged by component recognition camera16from below (ST7). Next, lead recognition is performed. That is, the positions of leads9aare recognized in each electronic component9by recognizing an image acquired by imaging by the recognition processing function built in controller70(lead recognizing step) (ST8).

Thereafter, positioning of mounting head17is performed (ST9). That is, multiple-head14is moved above substrate4, the plurality of mounting heads17included in multiple-head14are sequentially positioned in the component mounting positions of substrate4, and the component mounting operation is executed. Here, first, leads9aof electronic component9of which the attitude is changed to the stand-up attitude and insertion holes4a(seeFIGS. 8 and 9) of substrate4into which leads9aare inserted are positioned by moving mounting head17(1) (positioning step). The positioning step is performed based on the positions of leads9arecognized in the lead recognizing step that is executed after the attitude changing step.

A plurality of leads9aare included in electronic component9and a direction in which the plurality of leads9aare disposed in parallel is, as illustrated inFIGS. 14A and 14B, different by each electronic component9in a state where electronic component9is sucked and held by suction pad42aof component holder41. In order to correctly mount electronic component9on substrate4by inserting leads9aof such a state into insertion holes4aformed in substrate4in a predetermined direction, it is necessary to match a row direction of the plurality of leads9ato a row direction of insertion holes4acorresponding thereto. Thus, in positioning step described above, the row direction of leads9ais matched to the row direction of insertion holes4aby horizontally rotating rotator37around rotation center37a.

Next, lead preliminary inserting is performed (ST10). Here, only the lower ends of leads9aof electronic component9of the stand-up attitude are inserted into insertion holes4aof substrate4by lowering component holder41to substrate4between the positioning step in which leads9aand insertion holes4aare positioned, and the following inserting step described below (preliminary inserting step). Thereafter, lead inserting is performed (ST11). That is, electronic component9is pushed to substrate4and leads9aare completely inserted into insertion holes4aof substrate4by causing pusher30to abut against the upper surface of electronic component9of the stand-up attitude (inserting step).

Next, mis-mounting determination is performed (ST12). Here, after the inserting step, presence or absence of the mis-mounting of the electronic component mounting is determined by detecting the position of pusher30(mis-mounting determining step). The determination of the mis-mounting is performed by the method illustrated inFIG. 10. Here, in a case where it is determined that the mis-mounting is present (see the mounting failure example illustrated inFIGS. 10(b) and 10(c)), an error is notified and the apparatus is stopped (ST13). That is, the fact of the mis-mounting is notified by a notification unit (not illustrated) such as a notification lamp, a notification screen, and the like included in electronic component mounting apparatus1, and the apparatus is stopped.

In a case where it is determined that the mis-mounting is absent in (ST12) and after a predetermined treatment is executed in (ST13), and then the apparatus operation is restarted, the operating process of (ST9) or later is repeatedly executed (ST14) for the next mounting head17included in multiple-head14. Completion of all operations is confirmed for mounting head17of the mounting operation target in multiple-head14in (ST14), and then the electronic component mounting operation is completed.

As described above, in electronic component mounting apparatus1indicated in the exemplary embodiment, attitude changing device40is provided in mounting head17in which electronic component9is mounted on substrate4by changing the attitude of electronic component9having the leads. Attitude changing device40changes the attitude of component holder41having nozzle42for holding electronic component9by using the negative pressure so that suction pad42aof nozzle42is oriented downward or sideways. Leads9aare inserted by pushing electronic component9of the fallen-down attitude held by nozzle42toward substrate4by pusher30and attitude changing device40is mounted on rotator37that is horizontally rotatable with respect to the elevator that is lifted and lowered by the elevation device. Therefore, it is possible to mount electronic component9on substrate4by changing the attitude of electronic component9by mounting head17having a compact configuration.

In electronic component mounting apparatus1and the electronic component mounting method indicated in the exemplary embodiment, in the electronic component mounting in which electronic component9supplied by first component supply5in the fallen-down attitude and electronic component10of the stand-up attitude supplied by second component supply6are mounted on substrate4by common mounting head17, mounting head17is operated as described below. In a case where electronic component9supplied in the fallen-down attitude is mounted, electronic component9of the fallen-down attitude is held by nozzle42that is oriented downward. After being held, electronic component9, of which the attitude is changed to the stand-up attitude by causing nozzle42to be oriented sideways by attitude changing device40, is mounted on substrate4by being pushed toward substrate4by the pusher. In a case where electronic component10supplied in the stand-up attitude is mounted, electronic component10of the stand-up attitude is mounted on substrate4while holding electronic component10of the stand-up attitude by nozzle42that is oriented downward. Thus, a plurality of electronic components9and10supplied in different attitudes are taken out and it is possible to efficiently mount electronic components9and10on substrate4by changing the attitudes of the electronic components as needed.

In the electronic component mounting method for mounting electronic component9having leads9aprotruding from the lower surface on substrate4by electronic component mounting apparatus1indicated in the exemplary embodiment, the position and orientation of electronic component9supplied in the fallen-down attitude in the horizontal direction are recognized. Mounting head17is moved so that nozzle42of mounting head17is positioned above electronic component9. Rotator37is horizontally rotated so that the lower surface of electronic component9is oriented in the direction opposite to the pusher. Electronic component9of the fallen-down attitude is sucked and held by nozzle42by lowering component holder41, and the attitude of electronic component9, which is held by vertically rotating component holder41, is changed to the stand-up attitude. Leads9aof electronic component9of which the attitude is changed to the stand-up attitude and insertion holes4aof substrate4into which leads9aare inserted are positioned. Leads9aare inserted into insertion holes4aof substrate4by causing pusher30to abut against the upper surface of electronic component9of the stand-up attitude and push the electronic component onto substrate4. Therefore, it is possible to efficiently mount electronic component9on substrate4by changing the attitude of electronic component9by mounting head17having a compact configuration for electronic component9having protruded leads9asupplied in the fallen-down attitude.

The electronic component mounting method of the disclosure has an effect, in which it is possible to efficiently mount the electronic component on the substrate by changing the attitude of the electronic component by the mounting head having a compact configuration for the electronic component having the protruded leads supplied in the fallen-down attitude. It is useful in a field in which the electronic component is mounted on the substrate by the mounting head.