Bulk feeder and component mounting machine

A bulk feeder includes a feeder main body, a track member having a reception region in which multiple components discharged from a component case accommodating the components in a bulk state are received, a supply region to which the components are supplied, and a conveyance path of the components from the reception region to the supply region, a vibration device configured to apply vibration to the track member such that the components on the conveyance path are conveyed, and a conveyance control section configured to execute a feeding operation of conveying the components on the conveyance path in a direction toward the supply region and a returning operation of conveying the components on the conveyance path in a direction toward the reception region.

TECHNICAL FIELD

The present disclosure relates to a bulk feeder and a component mounting machine.

BACKGROUND ART

A bulk feeder is mounted on a component mounting machine that mounts components on a board, and is used for supplying the components accommodated in a bulk state. There is a type of bulk feeder in which multiple components are supplied in a state of being aligned in a row by an alignment mechanism provided on a conveyance path, for example. In addition, as disclosed in Patent Literature 1, there is a type of bulk feeder in which the alignment mechanism as described above is omitted and the components are supplied in the bulk state in which the components are scattered in a supply region where the components can be collected by a suction nozzle.

PATENT LITERATURE

BRIEF SUMMARY

Technical Problem

In a case of the bulk feeder of the type that supplies multiple components in the bulk state to supply region as described above, there is a risk that the components that can be used as a collection target by the suction nozzle are insufficient regardless of whether components are oversupplied or undersupplied in the supply region. Therefore, the bulk feeder is required to have a function of appropriately enabling adjustment of the number of components present in the supply region.

The present description is to provide a bulk feeder in which multiple components are scattered in a supply region and the number of components can be adjusted, and a component mounting machine provided with the bulk feeder described above.

Solution to Problem

The present description discloses a bulk feeder including a feeder main body, a track member provided in the feeder main body and having a reception region in which multiple components discharged from a component case accommodating the components in a bulk state are received, a supply region to which the components are supplied, and a conveyance path of the components from the reception region to the supply region, a vibration device provided in the feeder main body and configured to apply vibration to the track member such that the components on the conveyance path are conveyed, and a conveyance control section configured to control an operation of the vibration device and execute a feeding operation of conveying the components on the conveyance path in a direction toward the supply region and a returning operation of conveying the components on the conveyance path in a direction toward the reception region.

Advantageous Effects

With such a configuration, the multiple components can be scattered in the supply region and the number of components can be adjusted. As a result, it is possible to suitably supply the multiple components to be collectable while reducing a size of the bulk feeder in the width direction. In addition, since the required time can be shortened by improving the efficiency of a component supplying process, the efficiency of a mounting process using the bulk feeder can be improved.

DESCRIPTION OF EMBODIMENTS

1. Configuration of Component Mounting Machine10

Component mounting machine10configures a production line for producing a board product together with multiple types of board work machines including, for example, another component mounting machine10. The board work machine configuring the production line described above can include a printer, an inspection device, a reflow furnace, or the like.

1-1. Board Conveyance Device

As shown inFIG.1, component mounting machine10includes board conveyance device11. Board conveyance device11sequentially conveys board91in a conveyance direction, and positions board91at a predetermined position in the machine.

Component mounting machine10includes component supply device12. Component supply device12supplies components to be mounted on board91. Component supply device12is equipped with feeder122in each of multiple slots121. A tape feeder that supplies the components to be collectable, for example, by feeding and moving a carrier tape accommodating a large number of components is applied to feeder122. In addition, bulk feeder20that supplies the components accommodated in a bulk state (in a loose state in which each posture is irregular) to be collectable is applied to feeder122. Details of bulk feeder20will be described below.

Component mounting machine10includes component transfer device13. Component transfer device13transfers the components supplied by component supply device12to a predetermined mounting position on board91. Component transfer device13includes head driving device131, moving table132, mounting head133, and suction nozzle134. Head driving device131moves moving table132in a horizontal direction (X-direction and Y-direction) by a linear motion mechanism. Mounting head133is detachably fixed to moving table132by a clamp member (not shown), and is provided to be movable in the horizontal direction in the machine.

Mounting head133supports multiple suction nozzles134to be able to be rotated and raised and lowered. Suction nozzle134is a holding member that collects and holds component92supplied by feeder122. Suction nozzle134picks up the components supplied by feeder122by supplied negative pressure air. As the holding member attached to mounting head133, a chuck or the like that holds the components by gripping the components can be adopted.

Here, as mounting head133described above, various types can be adopted. Specifically, as mounting head133, there is a type in which multiple holding members are supported by a rotary head provided to be rotatable around an R-axis parallel to a vertical axis (Z-axis). In the present embodiment, mounting head133supports 24 suction nozzles134by the rotary head. In addition, as mounting head133, there are a type in which the multiple holding members arranged linearly or in a matrix are supported, a type in which one holding member is supported, and the like. The type of mounting head133can be appropriately selected in accordance with, for example, a type of board product to be produced.

Component mounting machine10includes part camera14and board camera15. Part camera14and board camera15are digital imaging devices having imaging elements, such as a CMOS. Part camera14and board camera15execute imaging based on control signals and send image data acquired by the imaging. Part camera14is configured to image the components held by suction nozzle134from below. Board camera15is provided on moving table132to be movable in the horizontal direction integrally with mounting head133. Board camera15is configured to image board91from above.

In addition to using a surface of board91as an imaging target, board camera15can use various devices and the like as the imaging target as long as various devices are within a movable range of moving table132. For example, in the present embodiment, board camera15can image supply region As (seeFIG.4) to which bulk feeder20supplies components92. As described above, board camera15can be used for imaging different imaging targets to acquire the image data used for various pieces of image processing.

Component mounting machine10includes control device16. Control device16is mainly composed of CPU, various memories, or a control circuit. Control device16includes a storage device (not shown). The storage device is composed of an optical drive device, such as a hard disk device or a flash memory. The storage device of control device16stores various data, such as a control program used for controlling a mounting process. The control program indicates the mounting position and a mounting order of the components mounted on board91in the mounting process.

Control device16executes recognition processing of a holding state of the component held by each of multiple holding members (suction nozzles134). Specifically, control device16executes the image processing on the image data acquired by the imaging of part camera14and recognizes a position and an angle of each component with respect to a reference position of mounting head133. It should be noted that, in addition to part camera14, control device16may execute the image processing on the image data acquired by imaging the components by a head camera unit or the like provided integrally with mounting head133from side, below, or above.

Control device16controls a mounting operation of the components by mounting head133based on the control program to execute the mounting process. Here, the mounting process includes a process of repeating a pick-and-place cycle (hereinafter, referred to as “PP cycle”) including a collection operation and the mounting operation multiple times. The “collection operation” described above is an operation of collecting the components supplied by component supply device12by suction nozzle134.

In the present embodiment, in a case where the collection operation described above is executed, control device16controls the operation of component supply device12including bulk feeder20and executes recognition processing of a supply state of components92in supply region As of bulk feeder20. The “recognition processing of the supply state” described above includes processing of recognizing whether components92that can be collected are present in supply region As, and recognizing the positions of components92in a case where components92are present, as needed. Moreover, control device16controls an operation of mounting head133in the collection operation based on a result of the recognition processing of the supply state.

In addition, the “mounting operation” described above is an operation of mounting the collected components at the predetermined mounting position on board91. In the mounting process, control device16controls the operation of mounting head133based on information output from various sensors, the result of image processing, a control program, or the like. As a result, the positions and the angles of multiple suction nozzles134supported by mounting head133are controlled.

2. Configuration of Bulk Feeder20

Bulk feeder20is mounted on component mounting machine10and functions as at least a part of component supply device12. Since, unlike the tape feeder, bulk feeder20does not use the carrier tape, there is an advantage in that loading of the carrier tape, collection of used tape, or the like can be omitted. On the other hand, since bulk feeder20supplies components92accommodated in the bulk state which are not aligned like the carrier tape, the supply state of components92can affect the collection operation by the holding member, such as suction nozzle134.

Specifically, in a case where components92are close enough to be in contact with each other or are deposited (state of overlapping in the up-down direction) in supply region As, components92cannot be used as a collection target. In addition, in a case where components92are supplied to supply region As in an irregular posture, the image processing of recognizing the supply state (whether components92can be collected and posture of components92that can be collected) is required. Therefore, it is desired that bulk feeder20be in a state of being supplied with multiple components92that can be collected in supply region As without being insufficient in the required number, and is further appropriately dispersed.

On the other hand, it is assumed that bulk feeder20adopts a configuration in which multiple components92are aligned in a row by, for example, an alignment mechanism provided on a conveyance path before components92reach supply region As. However, in the configuration described above, it is necessary to provide the alignment mechanism on the conveyance path, and it is further necessary to maintain an aligned state and convey components92to supply region As. Therefore, bulk feeder20of the present embodiment adopts a configuration in which components92are conveyed by using vibration and components92are aligned by using the vibration in supply region As.

As shown inFIG.2, bulk feeder20includes feeder main body21. Feeder main body21is formed in a flat box shape. Feeder main body21is set in slot121of component supply device12. Connector211and two pins212are formed on a front part of feeder main body21. In a case where bulk feeder20is set in slot121, connector211is communicably connected to a main body side of component mounting machine10. In addition, bulk feeder20is supplied with power via connector211. Two pins212are used for positioning in a case where feeder main body21is set in slot121.

In the present embodiment, component case22accommodating multiple components92in the bulk state is detachably attached to feeder main body21. Component case22is configured to discharge components92to the outside. In the present embodiment, component case22is an external device of bulk feeder20, for example, one of various types suitable for the mounting process is selected and attached to feeder main body21.

Bulk feeder20includes discharge device23. Discharge device23adjusts the number of components92discharged from component case22. Discharge device23supplies multiple components92discharged from component case22to reception region Ar of track member30, which will be described below. Bulk feeder20includes cover24. Cover24is detachably attached to a front upper part of feeder main body21. Cover24prevents components92conveyed along conveyance path R of track member30, which will be described below, from scattering to the outside.

Bulk feeder20includes track member30. Track member30is provided on the front upper part of feeder main body21. As shown inFIGS.3and4, track member30is formed to extend in a front-rear direction (right-left direction ofFIGS.3and4) of feeder main body21. Pair of side walls31protruding upward are formed on both edges of track member30in the width direction (up-down direction inFIG.4). Pair of side walls31surround the peripheral edge of conveyance path R together with distal end portion32of track member30to prevent leakage of components92conveyed along conveyance path R. Circular reference mark33indicating the reference position of bulk feeder20is attached to an upper face of distal end portion32.

Track member30having the configuration described above has reception region Ar, supply region As, and conveyance path R. Here, “reception region Ar” is a region in which components92in the bulk state, which are discharged from component case22, are received. Reception region Ar of the present embodiment is positioned below a discharge port of component case22. In addition, “supply region As” is a region to which components92are supplied. In other words, “supply region As” is a region in which components92can be collected by suction nozzle134supported by mounting head133, and is included in the movable range of mounting head133.

In addition, “conveyance path R” of track member30is a path of components92from reception region Ar to supply region As. In the present embodiment, conveyance path R is formed in a groove shape in which a groove bottom face is horizontal. A groove side face of conveyance path R is formed by pair of side walls31. A groove opening on an upper side of conveyance path R is largely closed by cover24. Track member30is supported to be slightly displaceable (that is, can vibrate) with respect to feeder main body21in a virtual vertical plane formed in the front-rear direction and the up-down direction.

Bulk feeder20includes vibration device40. Vibration device40is provided on feeder main body21. Vibration device40applies the vibration to track member30such that components92on conveyance path R are conveyed. Specifically, vibration device40includes multiple first support sections41, multiple first piezoelectric elements42, multiple second support sections43, multiple second piezoelectric elements44, and driving section45. First support section41and second support section43are connecting members that connect feeder main body21and track member30.

First support section41is formed in a shape that is inclined and extends forward with respect to the vertical direction. Second support section43is formed in a shape that is inclined and extends rearward with respect to the vertical direction. First piezoelectric element42and second piezoelectric element44vibrate at a frequency corresponding to the power supplied from driving section45. First piezoelectric element42is attached to first support section41. Second piezoelectric element44is attached to second support section43. In a case where first piezoelectric element42vibrates, the vibration is applied to track member30via first support section41. Similarly, in a case where second piezoelectric element44vibrates, the vibration is applied to track member30via second support section43.

In addition, amplitude of track member30is changed in accordance with the voltage applied to first piezoelectric element42or second piezoelectric element44. Vibration device40applies the vibration to track member30by causing first piezoelectric element42attached to first support section41that is inclined forward to vibrate. As a result, as shown inFIG.5, vibration device40causes track member30to execute clockwise elliptical movement in the horizontal direction (the front-rear direction inFIG.5) orthogonal to the conveyance direction of components92in conveyance path R. In this case, vibration device40causes track member30to vibrate such that external force directed forward and upward is applied to components92on conveyance path R.

In addition, vibration device40applies the vibration to track member30by causing second piezoelectric element44attached to second support section43that is inclined rearward to vibrate. As a result, vibration device40causes track member30to execute counterclockwise elliptical movement in the horizontal direction (the front-rear direction inFIG.5) orthogonal to the conveyance direction of components92in conveyance path R. In this case, vibration device40causes track member30to vibrate such that external force directed rearward and upward is applied to components92on conveyance path R.

Here,FIG.5is an enlarged view of elliptical track Be of track member30that executes the elliptical movement. In a case where track member30executes the clockwise elliptical movement along elliptical track Be, components92on conveyance path R of track member30spring up to be slightly separated from conveyance path R by applying the external force directed forward and upward. In addition, in a case where falling component92collides with track member30that executes the elliptical movement, the external force directed forward and upward is applied to components92in the same manner.

Driving section45changes the frequency of the power supplied to first piezoelectric element42and second piezoelectric element44and the applied voltage based on a command of feeder control device70, which will be described below. As a result, the frequency and the amplitude of the vibration applied to track member30are adjusted, and a rotation direction of the elliptical movement of track member30is determined. In a case where the frequency or the amplitude of the vibration of track member30and the rotation direction of the elliptical movement due to the vibration are changed, a conveyance speed of components92to be conveyed, a degree of dispersion of components92, the conveyance direction, and the like are changed.

With the configuration described above, vibration device40applies predetermined vibration to track member30, and multiple components92discharged from component case22to reception region Ar of track member30can be conveyed to supply region As via conveyance path R. In addition, with the configuration described above, even in a case where many components92are supplied to conveyance path R to be close to each other and deposited, the external force in the conveyance direction can be applied to the component group. As a result, track member30and vibration device40can convey the component group as a whole.

In addition, in addition to the configuration described above, vibration device40may apply the vibration to track member30such that components92on conveyance path R are conveyed in the width direction of conveyance path R. Such vibration device40is further provided with, for example, a pair of support sections and a piezoelectric element attached to each of support sections, and can optionally convey components92to both sides in the width direction by appropriately supplying the power to the piezoelectric elements.

In the following, an operation of vibration device40of conveying components92on conveyance path R in a direction toward supply region As is referred to as a “feeding operation”. In addition, an operation of vibration device40of conveying components92on conveyance path R in a direction toward reception region Ar is referred to as a “returning operation”. It should be noted that the elliptical movement of track member30becomes reverse rotation by switching between the feeding operation and the returning operation of vibration device40.

Bulk feeder20includes alignment member50. Alignment member50is provided in supply region As of track member30. Alignment member50guides multiple components92conveyed by the vibration of track member30and aligns multiple components92with respect to feeder main body21. For example, alignment member50has multiple cavities51that individually accommodate multiple components92, as shown inFIG.6. Specifically, multiple cavities51are arranged in a matrix in supply region As. For example, alignment member50has 120 cavities 51 in total in which 10 cavities are regularly arranged in the conveyance direction and 12 cavities are regularly arranged in the width direction of conveyance path R.

In addition, as shown inFIG.7, each of multiple cavities51is open on an upper face of conveyance path R, and accommodates component92in a posture in which a thickness direction of component92is the up-down direction. The opening of cavity51is set to a size slightly larger than an outer shape of component92in an upward view. Depth Dc of cavity51can be appropriately set in accordance with the type (shape, mass, or the like) of component92. In a state in which depth Dc of cavity51is set shallow and component92protrudes from the upper face of conveyance path R, interference between suction nozzle134and alignment member50in the collection operation can be reliably prevented.

On the other hand, in a state in which depth Dc of cavity51is set deep and component92is lower than the upper face of conveyance path R, component92once accommodated in cavity51is prevented from coming out again. Therefore, depth Dc of each of multiple cavities51in alignment member50is set to be equal to or larger than thickness Tp of component92. It should be noted that, in a case where depth Dc of cavity51is too deep, there is a risk that another component92is prevented from moving in the conveyance direction on the upper side of cavity51in a state of accommodating component92.

Therefore, it is preferable that depth Dc of cavity51be set such that an upper end of component92accommodated in cavity51is slightly lower than the upper face of conveyance path R. As described above, the shape (opening, depth, or the like) of cavity51is appropriately set. In a case where it is assumed that components92are accommodated in the carrier tape and supplied by the tape feeder, the shape of cavity51of alignment member50is similar to the shape of the cavity formed in the carrier tape.

The shape of cavity51is appropriately set in accordance with the shape of component92and the accommodating posture. Specifically, cavity51may be formed in a shape that accommodates component92in a posture in which the longitudinal direction of component92is in the up-down direction. In addition, in a case where the shape of cavity51is set, an occupied area of one cavity51in supply region As is determined. Further, the number of cavities51in alignment member50is appropriately set in consideration of the shape, the required number, and the degree of density of the cavities51, which can affect the conveyance property.

In addition, it is preferable that the number of cavities51in alignment member50be set to be larger than the maximum number of components92collected by the collection operation in one PP cycle. It should be noted that the “maximum number” described above corresponds to the number of suction nozzles134supported by mounting head133. In the present embodiment, since mounting head133supports 24 suction nozzles134, the number of cavities51is set to be more than at least 24.

Bulk feeder20includes feeder control device70. Feeder control device70is mainly composed of CPU, various memories, or a control circuit. Feeder control device70is supplied with the power via connector211in a state in which bulk feeder20is set in slot121, and is in a state of being capable of communicating with component mounting machine10and control device16.

As shown inFIG.3, feeder control device70includes storage section71. Storage section71is composed of a flash memory or the like. Storage section71stores various data, such as a program used for controlling the component supplying process or conveyance parameter F1. “Conveyance parameter F1” described above is a parameter for controlling the operation of vibration device40such that the vibration applied to track member30is appropriate in a case where components92are conveyed in the component supplying process, and is set in advance in association with the types of components92, for example.

Feeder control device70includes conveyance control section72. Conveyance control section72controls the operation of vibration device40and executes the feeding operation and the returning operation described above. Specifically, conveyance control section72sends a command to driving section45of vibration device40in a case of executing the feeding operation. As a result, by driving section45supplying predetermined power to first piezoelectric element42, the vibration is applied to track member30via first support section41. As a result, components92on conveyance path R are conveyed by receiving the external force to move to the front side in the conveyance direction.

In addition, conveyance control section72realizes various conveyance aspects by combining the execution time of the feeding operation and the returning operation of vibration device40, or the like. For example, in a case where alignment member50has multiple cavities51, conveyance control section72may execute an accommodation step and a retraction step as described below. The “accommodation step” described above is a step of accommodating components92in at least a part of multiple cavities51by executing the feeding operation until at least a part of multiple components92on conveyance path R reaches supply region As.

In this case, conveyance control section72may repeatedly execute the feeding operation and the returning operation and may retain multiple components92in supply region As in a state in which track member30vibrates after at least a part of multiple components92on conveyance path R reaches the supply region As, in the accommodation step. In addition, the “retraction step” described above is a step of retracting remaining components92in a direction from supply region As toward reception region Ar by executing the returning operation in a state in which at least a part of multiple components92on conveyance path R is accommodated in multiple cavities51, after executing the accommodation step.

Conveyance control section72can appropriately set the execution time of the feeding operation or the returning operation in each step, the time of the retention operation in the accommodation step, and the number of executions of the repetitive operation. In addition, in accordance with the number of remaining components92on conveyance path R, the retention operation in the accommodation step or the retraction step may be omitted. Further, conveyance control section72may adjust at least one of the frequency and the amplitude of the vibration applied to track member30by vibration device40in accordance with the type of components92accommodated in component case22.

Specifically, in a case where component case22is attached to bulk feeder20, the types of components92replenished in component case22and identification information of bulk feeder20are verified. Moreover, in a case where bulk feeder20is set in slot121, conveyance control section72acquires parameters in accordance with the types of components92from conveyance parameter F1. As a result, conveyance control section72adjusts the command to be sent to driving section45of vibration device40.

As a result, the frequency or the like of the vibration applied to track member30by vibration device40is adjusted in accordance with the types of the components. A configuration may be adopted in which conveyance parameter F1described above is appropriately switched in accordance with various aspects adopted for alignment member50in addition to the types of components92. As a result, the accommodation step, the retention operation, or the retraction step is suitably executed. Further, conveyance parameter F1may be updated by an administrator based on the result (including the success rate or the like) of the component supplying process executed in the past.

In addition, in a case where vibration device40is configured to convey components92in the width direction of conveyance path R, conveyance control section72controls the operation of vibration device40and executes an operation of conveying components92on conveyance path R or supply region As to one side or the other side of a width direction of track member30. The operation of conveying components92in the width direction as described above is executed to, for example, disperse multiple components92in the width direction in conveyance path R or supply region As. In particular, in a case where the operation of conveying components92is executed in the accommodation step or the retention operation as needed, it is possible to improve an accommodation rate (ratio of the number of accommodated components that can be collected to the number of cavities51).

Here, a configuration may be adopted in which alignment member50of bulk feeder20is attached to track member30to be exchangeable. Specifically, in a case of setting up bulk feeder20, for example, multiple types of alignment members corresponding to various aspects are prepared to be exchangeable. Moreover, in bulk feeder20, one selected from multiple types of alignment members50having different shapes from each other corresponding to the types of components92to be supplied is attached to track member30.

Further, a configuration may be adopted track member30of bulk feeder20is attached to feeder main body21to be exchangeable. In this case, alignment member50may be formed integrally with track member30, or may be exchangeable. Specifically, in a case of setting up bulk feeder20, for example, multiple types of track members30in which multiple types of alignment members50corresponding to various aspects are formed, and track member30having no alignment member50are prepared to be exchangeable.

Moreover, in bulk feeder20, one selected from multiple types of track members30is attached to feeder main body21. With such a configuration, bulk feeder20can share feeder main body21or vibration device40, and can handle the types or the supply aspects of components92by exchanging alignment member50or track member30. As a result, a range of use of bulk feeder20can be enlarged, and a production cost of the board product can be reduced.

4. Mounting Process by Component Mounting Machine10

The mounting process by component mounting machine10will be described with reference toFIGS.8and9. Here, a configuration is adopted in which bulk feeder20includes alignment member50in which multiple cavities51are formed in a matrix. In addition, after bulk feeder20described above is set in slot121, control device16executes calibration processing and recognizes the position of alignment member50in the machine.

In the calibration processing described above, control device16first moves board camera15above reference mark33of bulk feeder20and acquires the image data by the imaging of board camera15. Moreover, control device16recognizes the position of alignment member50in the machine based on the position of reference mark33included in the image data by the image processing and the position of board camera15when the image is captured.

In addition, control device16includes arrangement information indicating the shape of alignment member50included in bulk feeder20, that is, a positional relationship of multiple cavities51. Control device16may acquire the arrangement information described above from feeder control device70of bulk feeder20, or may acquire the arrangement information from a host device or the like in accordance with the type of alignment member50identified based on the image data acquired by imaging reference mark33. Control device16recognizes the position of alignment member50, specifically the position of individual cavity51, by the calibration processing.

In the mounting process, first, board conveyance device11of component mounting machine10executes convey-in processing of board91(S11). As a result, board91is conveyed in the machine and is positioned at a predetermined position in the machine. Control device16executes a first component supplying process by bulk feeder20after S11or in parallel with S11. Specifically, first, control device16causes bulk feeder20to execute alignment processing of aligning components92in supply region As (S21). As a result, conveyance control section72of bulk feeder20executes the accommodation step or the retraction step described above. The details of the alignment processing will be described below.

Next, control device16executes the recognition processing the supply state of components92in supply region As (S22). Specifically, control device16first moves board camera15above alignment member50in supply region As of bulk feeder20, and acquires image data M by the imaging of board camera15. Moreover, as shown inFIG.9, control device16executes predetermined image processing on image data M and recognizes components92accommodated in multiple cavities51, respectively.

Specifically, control device16determines whether components92can be collected based on the positions of multiple cavities51recognized by the calibration processing and the posture of components92in image data M subjected to the image processing. Specifically, control device16determines that components92appropriately accommodated in cavities51can be collected (“OK” inFIG.9). Control device16determines that components92accommodated in an inappropriate posture, such as a tilted posture, in cavities51or multiple components92in a state of being deposited on each other cannot be collected (“NG” inFIG.9).

As described above, in the recognition processing of the supply state (S22), control device16recognizes the supply state indicating whether components92are accommodated in multiple cavities51to be collectable by the image processing on image data M. It should be noted that, in addition to this, control device16may recognize the positions of components92by using components92that can be collected as targets. That is, control device16calculates a coordinate value of the reference position.

The “reference position” described above of the components that can be collected is a position optionally set on the upper face of component92, and is set to, for example, a center, a centroid, or a flat region of component92suitable for pick-up by suction nozzle134in a case where suction nozzle134is used for the collection operation. In the image processing, control device16calculates the coordinate value of the reference position in the component that can be collected by recognizing, for example, the outer shape, or the center position of the component that can be collected.

Subsequently, in a case where the number (supply number) of components92that can be collected is less than the number of components92, which is scheduled to be collected in the current PP cycle, in the result of the recognition processing (S22) of the supply state (S23: No), control device16cause bulk feeder20to execute the alignment processing (S21) again. For example, in a case where components92supplied by bulk feeder20are collected by 20 suction nozzles134among 24 suction nozzles134in the collection operation of the current PP cycle, the number (required number) of components92, which is scheduled to be collected, is 20.

As described above, in a case where the required number of components92cannot be collected in the current PP cycle in the current supply state of components92in supply region As, control device16repeatedly executes the alignment processing (S21) and the recognition processing of the supply state (S22). It should be noted that in a case where the required number is large, the current supply number of components92may be first collected out of the required number thereof, and then the alignment processing (S21) and the recognition processing of the supply state (S22) may be executed to try the collection again.

On the other hand, in a case where the current supply number is equal to or larger than the required number in the current PP cycle (S23: Yes), control device16executes the PP cycle. In the PP cycle, control device16repeatedly executes the collection operation of collecting the components using multiple suction nozzles134(S12). In this case, control device16controls the operation of mounting head133in the collection operation to sequentially position mounting head133in accordance with the positions of components92that can be collected based on the result of the recognition processing of the supply state (S22).

Here, it is assumed that the result of the recognition processing of the supply state (S22) indicates whether component92that can be collected is present for each of multiple cavities51. In this case, in the collection operation, control device16controls the operation of mounting head133to position suction nozzle134at the center of cavity51that accommodates component92to be collectable. In addition, in a case where the result of the recognition processing of the supply state (S22) includes the coordinate value of the reference position in the component that can be collected, control device16may control the operation of mounting head133to position suction nozzle134to the coordinate value of the reference position described above, not the center of cavity51.

Subsequently, control device16executes the recognition processing of the holding state of components92held by multiple suction nozzles134(S13). Specifically, control device16moves mounting head133above part camera14and sends an imaging command to part camera14. Control device16executes the image processing on the image data acquired by the imaging of part camera14to recognize the posture (position and angle) of component92held by each of multiple suction nozzles134.

Thereafter, control device16repeatedly executes the mounting operation of mounting the components using multiple suction nozzles134(S14). It should be noted that in mounting operation (S14), control device16controls the operation of mounting head133to mount components92at the mounting positions designated by the control program. Further, mounting head133controls the operation of mounting head133such that suction nozzle134is positioned and angled with respect to the mounting position based on the result of the recognition processing (S13).

In addition, control device16causes bulk feeder20to execute the alignment processing of aligning components92in supply region As in a period from termination of the collection operation (S12) of the current PP cycle described above to start of the collection operation (S12) of the next PP cycle (second component supplying process). Specifically, after the collection operation (S12) of the current PP cycle is terminated, in a case where the current supply number is less than the required number in next PP cycle (S31: No), control device16causes bulk feeder20execute the preceding alignment processing (S32). Since this preceding alignment processing (S32) is the same as the alignment processing (S21), the detailed description thereof will be omitted.

On the other hand, in a case where the current supply number is equal to or larger than the required number in the next PP cycle (S31: Yes) or after the preceding alignment processing (S32) is executed, control device16terminates the second component supplying process executed in parallel with the current PP cycle. Control device16determines whether all the PP cycles are terminated based on the control program (S15). In a case where all the PP cycles are not terminated (S15: No), control device16determines whether the preceding alignment processing (S32) is executed during the execution of the immediately preceding PP cycle (S16).

In a case where the preceding alignment processing (S32) is executed (S16: Yes), since the current state of supply region As is unknown, control device16executes the recognition processing of the supply state (S22) in the first component supplying process again, and then executes the next PP cycle (S12to S14). On the other hand, in a case where the preceding alignment processing (S32) is not executed (S16: No), the first component supplying process is omitted and the next PP cycle (S12to S14) is executed.

As described above, in accordance with the number of cavities51, the number (supply number) of components92that can be collected in the result of the recognition processing of the supply state (S22) in the first component supplying process may be equal to or larger than the sum of the number of components92which is scheduled to be collected in the current PP cycle and in the next PP cycle. In such a case, control device16omits the execution of the alignment processing (S21) for the next PP cycle scheduled after the collection operation of the current PP cycle is terminated. Further, control device16controls the operation of mounting head133of the collection operation (S12) of the next PP cycle based on the result of the recognition processing of the supply state (S22) executed previously.

In a case where all the PP cycles are terminated (S15: Yes), control device16executes convey-out processing of board91(S17). In the convey-out processing of board91, board conveyance device11unclamps positioned board91and carries board91out of the outside of component mounting machine10.

5. Alignment Processing of Components92

The alignment process of components92by bulk feeder20will be described with reference toFIGS.10and11. The alignment processing (S21and S32inFIG.8) of components92is executed in the component supplying process by bulk feeder20in a case of the configuration in which bulk feeder20includes alignment member50. Conveyance control section72first determines whether the number of components92on conveyance path R is appropriate (S41).

Conveyance control section72may estimate the number of components92on conveyance path R based on the number of executions of the collection operation of components92using suction nozzles134after components92are discharged by the previous operation of discharge device23. In a case where the number of components92on conveyance path R is insufficient (S41: No), conveyance control section72executes discharge processing of components92from component case22(S42). As a result, the predetermined number of components92is discharged to reception region Ar of track member30.

Next, in a case where the number of components92on conveyance path R is appropriate (S41: Yes) or after the discharge processing (S42) of components92is executed, conveyance control section72executes the accommodation step (S50). Specifically, conveyance control section72first starts the feeding operation of vibration device40in the accommodation step (S51). Next, conveyance control section72determines whether at least a part of multiple components92on conveyance path R reaches supply region As (S52). In a case where component92does not reach supply region As (S52), the feeding operation of vibration device40is continued.

It should be noted that conveyance control section72makes a determination in S52based on the execution time of the feeding operation. In addition, conveyance control section72may make a determination of S52based on a detection result by a detection device that detects the state of component92. In a case where component92reaches supply region As (upper stage ofFIG.11, S52: Yes), conveyance control section72determines the necessity of the retention operation in supply region As (S53). Specifically, conveyance control section72acquires, for example, the necessity of the retention operation and the execution time in a case where the retention operation is executed, based on conveyance parameter F1.

Conveyance control section72executes the retention operation (S54) in a case where the retention operation is required (S53: Yes). Specifically, conveyance control section72repeatedly executes the feeding operation and the returning operation in the accommodation step (S50), and retains multiple components92in supply region As in a state in which track member30vibrates. As a result, component group Gp, which is a set of components92on conveyance path R, reciprocates in the conveyance direction on the upper side of alignment member50, as shown in the middle stage ofFIG.11.

In this case, conveyance control section72sets the execution time or the number of executions of the feeding operation and the returning operation in the retention operation based on conveyance parameter F1. In addition, in this alignment processing, it is an object to appropriately accommodate component92in each of multiple cavities51formed in alignment member50. From such a viewpoint, it is preferable that a large number of components92be in a state of being discharged to conveyance path R, as compared with a configuration in which components are supplied to the supply region in the bulk state, for example, as in the conventional art.

Thereafter, conveyance control section72executes the retraction step (S60). Specifically, conveyance control section72first determines necessity of the returning operation of retracting components92from supply region As (S61). Specifically, conveyance control section72acquires, for example, the necessity of the returning operation and the execution time in a case where the returning operation is executed, based on conveyance parameter F1. Conveyance control section72executes the returning operation (S62) in a case where the returning operation is required (S61: Yes).

Specifically, conveyance control section72retracts multiple components92which are not accommodated in cavities51of alignment member50, in a direction from supply region As toward reception region Ar by, for example, executing the returning operation by a predetermined time. As a result, as shown in the lower stage ofFIG.11, component group Gp is conveyed in the direction from supply region As toward reception region Ar, and is in a retracted state not to affect the collection operation to be executed later. Conveyance control section72terminates the alignment processing of components92in a case where the returning operation is not required in the retraction step (S60) (S61: No) or after the defined returning operation is executed (S62).

With the configuration described above, bulk feeder20conveys components92by appropriately combining the feeding operation and the returning operation, and also retains components92in supply region As. As a result, bulk feeder20can scatter multiple components92in supply region As and can adjust the number of components92. Therefore, it is possible to efficiently supply components92in supply region As without enlarging supply region As to secure the supply number of components92that can be collected. As a result, it is possible to suitably supply multiple components92to be collectable while reducing the size of bulk feeder20in the width direction. In addition, since the required time can be shortened by improving the efficiency of the component supplying process, the efficiency of the mounting process using bulk feeder20can be improved.

6. Modification Aspect of Embodiment

In the embodiment, the configuration has been adopted in which bulk feeder20includes alignment member50in which multiple cavities51are formed. On the other hand, a configuration may be adopted in which alignment member50is omitted. That is, in supply region As of track member30, a concave-shaped portion in which components92are dispersed at a position lower than the upper face of conveyance path R or a planar portion uniform with the upper face of conveyance path R may be formed, and components92may be supplied in the bulk state.

It should be noted that, from the viewpoint of improving the efficiency of the component supplying process or reducing the load of the image processing in the recognition processing of the supply state in supply region As, the configuration described in the embodiment is preferable. That is, bulk feeder20includes alignment member50in which multiple cavities51are formed, and accommodates components92in multiple cavities51by moving component group Gp, which is a set of components92for which the certain number is secured in the alignment processing above alignment member50. As a result, components92can be supplied in a state of being aligned by the number of cavities51at the maximum.

REFERENCE SIGNS LIST