Mounting device and mounting method

A mounting device for executing a mounting process of mounting a component on a board includes: a mounting head that includes at least one pickup section for picking up the component and moves the picked up component; a storage section configured to store at least a first correction value determined at a first position on XYZ axes on which the mounting head works and a second correction value determined at a second position different from the first position; and a control section configured to execute the mounting process by using the first correction value and/or the second correction value stored in the storage section.

TECHNICAL FIELD

The present specification discloses a mounting device and a mounting method.

BACKGROUND ART

In the conventional art, a mounting device is propose, for example, such that it measures the positional coordinates of marks on a jig board with multiple marks, mounts a dummy component on the jig board, measures the positional coordinate of the mounted dummy component, calculates the amount of error between the positional coordinates, and performs a mounting process in which the amount of error is corrected (for example, see Patent Literature 1). In this device, sufficient mounting accuracy can be ensured even in a high-speed operation. Further, a device, which forms multiple detection marks on a glass board, mounts an inspection chip on the glass board, and detects the mounting accuracy from the positional relationship between the detection mark and the inspection chip, is proposed (for example, see Patent Literature 2). In this mounting device, a jig that can more easily and accurately detect the mounting accuracy can be provided.

PATENT LITERATURE

BRIEF SUMMARY

Technical Problem

By the way, in recent years, the mounting device has handled finer components, and it is desired to further improve the mounting accuracy. Further, in order to improve accuracy and reduce a processing time of the mounting process, various configurations are added to a mounting member configured to execute the mounting process, and in the above-described mounting device disclosed in Patent Literatures 1 and 2, a case occurs in which sufficient mounting accuracy cannot be ensured.

The present disclosure has been made in view of such problems, and a main purpose of the present disclosure is to provide a mounting device and a mounting method which can further improve the mounting accuracy.

Solution to Problem

The mounting device and the mounting method disclosed in the present specification have adopted the following means in order to achieve the above-described main purpose.

A mounting device, which is disclosed in the present specification for executing a mounting process of mounting a component on a board, includes: a mounting head that includes at least one pickup section for picking up the component and moves the picked up component; a storage section configured to store at least a first correction value determined at a first position on XYZ axes on which the mounting head works and a second correction value determined at a second position different from the first position; and a control section configured to execute the mounting process by using the first correction value and/or the second correction value stored in the storage section.

In the mounting device, a correction value is set for each different position where the mounting head works, and the mounting process is performed using the correction value suitable for each position. In this mounting device, the mounting accuracy can be further improved using multiple correction values. The storage section stores the first correction value at the first position and the second correction value at the second position, but may further include correction values such as a third correction value at a third position and a fourth correction value at a fourth position.

DESCRIPTION OF EMBODIMENTS

The present embodiment will be described below with reference to the accompanying drawings.FIG. 1is a schematic explanatory view illustrating an example of mounting system10according to the present disclosure.FIG. 2is an explanatory view of board processing section12.FIG. 3is an explanatory view of head lifting and lowering section29of mounting head22.FIG. 4is an explanatory view in which mounting head22simultaneously picks up components P.FIG. 5is an explanatory view of mounting head22captured by component imaging section18.FIG. 6is an explanatory view illustrating an example of correction information34stored in storage section32. Mounting system10is, for example, a system configured to execute a mounting process of arranging component P on board S. Mounting system10includes mounting device11and management computer (PC)50. Mounting system10is configured as a mounting line in which multiple mounting devices11are arranged from an upstream side to a downstream side. InFIG. 1, for convenience of description, only one mounting device11is illustrated. Management PC50is configured as a server configured to manage information of each device of mounting system10. Management PC50creates mounting condition information including a mounting job used in the mounting process for component P, and transmits the created mounting condition information to the mounting device11. In the present embodiment, the left-right direction (X-axis), the front-rear direction (Y-axis), and the vertical direction (Z-axis) are as illustrated inFIGS. 1 to 5.

As illustrated inFIG. 1, mounting device11includes board processing section12, component supply section15, component imaging section18, mounting section20, and control section30.

Board processing section12is a section for conveying board S in, conveying board S, fixing board S at a mounting position, and conveying board S out. As illustrated inFIG. 2, board processing section12has a dual lane including first lane13for conveying board S by a first conveyor and second lane14for conveying board S by a second conveyor. First lane13and second lane14have a pair of conveyor belts which are provided by being opened in the front-rear direction at intervals and are stretched in the left-right direction. Board S is conveyed by these conveyor belts. In first lane13, three regions R1to R3are set in order from an upstream side in a conveyance direction of board S, board S is fixed to one of the regions, and the mounting process is executed. Further, similarly, in second lane14, three regions R4to R6are set in order from the upstream side in the conveyance direction of board S, board S is fixed to one of the regions, and the mounting process is executed. Board S conveyed on first lane13is referred to as board S1, and board S conveyed on second lane14is also referred to as board S2.

Component supply section15has multiple feeders16including reels and a tray unit, and is detachably attached to the front side of mounting device11. A tape is wound around each reel, and multiple components P are held on the top surface of the tape along the longitudinal direction of the tape. The tape is unwound from the reel to the rear side, and is sent out, by feeder16, to a pickup position where the tape is picked up by nozzle25in a state in which a component is exposed. The tray unit has a tray on which multiple components are arranged and placed, and moves this tray in and out of a predetermined pickup position.

Mounting section20picks up component P from component supply section15and disposes component P onto board S fixed to board processing section12. Mounting section20includes head moving section21, mounting head22, rotating body23, holder24, and nozzle25. Head moving section21includes a slider that is guided to a guide rail and moves in an XY direction and a motor configured to drive the slider. Mounting head22is detachably mounted on the slider and is moved in the XY direction by head moving section21. One or more nozzles25are detachably mounted on the lower surface of mounting head22through rotating body23. Multiple nozzles25of any one of multiple types are mounted on rotating body23. Multiple (for example, 16, 8, 4 or the like) nozzles25are mounted on rotating body23through holder24, so that multiple components P can be picked up at once. Holder24and nozzle25have uneven parts to be fitted therein, and nozzle25is mounted on holder24at a predetermined axial rotation position. Nozzle25is a pickup member configured to pick up a component using a negative pressure and is detachably mounted on mounting head22via holder24. The pickup member may be a holding member configured to hold and pick up component P.

Mounting head22is configured as a rotary type work head which is held by rotating body23in a rotatable state. As illustrated inFIG. 3, rotating body23of mounting head22includes head main body40attached to an X-axis slider and engagement shaft41disposed below head main body40. Rotating body23includes rotary section42that is a cylindrical member, R-axis gear43disposed below rotary section42, Q-axis gear44disposed above rotary section42, and long cylindrical multiple holders24each having nozzle25mounted on the lower end thereof. R-axis driving section26for pivoting rotary section42, Q-axis driving section27for pivoting the nozzle25, and Z-axis driving section28for elevating nozzle25by moving pressing section49are arranged in the head main body40. A rotation axis of rotary section42is referred to as an R-axis, and a rotation axis of nozzle25is referred to as a Q-axis. Engagement shaft41is disposed in head main body40to be pivotally, is inserted into a bottomed hole formed in the center of Q-axis gear44, and engages with rotating body23. Rotary section42is, for example, a cylindrical member that supports multiple holders24to be rotatable about central axes of holders24or to be vertically movable. R-axis gear43is a disc-shaped member that has an outer diameter larger than that of rotary section42, and has a gear groove formed on the outer peripheral surface thereof. R-axis gear43meshes with small gear45connected to a rotary shaft of R-axis driving section26and is rotationally driven by R-axis driving section26via small gear45. Q-axis gear44is a cylindrical member having a smaller outer diameter than that of rotary section42, and has a gear groove formed on the outer peripheral surface thereof. Holder24is a member that has small gear46disposed on the upper end side thereof and nozzle25mounted on the lower end side thereof. Small gear46meshes with the gear groove formed on the outer periphery of Q-axis gear44. Holders24are disposed at regular intervals along the outer periphery of Q-axis gear44. Holder24can adjust an angle of picked-up component P by rotating (rotating) about a rotary shaft (Q-axis) by a driving force of Q-axis driving section27transmitted through small gear47connected to Q-axis driving section27, Q-axis gear44, and small gear46disposed on the upper end side of holder24. In mounting head22, all holders24is synchronized and rotated in synchronization with the rotation of Q-axis gear44. Holder24is elevated in a Z-axis direction (vertical direction) by a driving force of Z-axis driving section28transmitted via pressing section49. In mounting head22, first Z-axis driving section28A elevates holder24in the Z-axis direction at first elevation position A located at a left end portion in an X-axis direction, and second Z-axis driving section28B elevates holder24in the Z-axis direction at second elevation position B located at a right end portion. (seeFIG. 3). When being fixed to the pickup position, mounting head22is configured to be able to pick up component P at the same time in two elevation positions.

Head lifting and lowering section29is disposed in mounting head22. Head lifting and lowering section29includes a guide formed in the Z-axis direction and a driving section configured to move mounting head22along the guide, and elevates mounting head22in the Z-axis direction (seeFIG. 4). For example, when component P having a low height is handled, mounting section20can lower mounting head22and shorten an elevation distance of nozzle25so as to further shorten a processing time. Further, when component P having a high height is handled, mounting section20can pick up mounting head22while further lifting up mounting head22. In this way, mounting section20can continuously pick up components having different heights without replacing mounting head22. As illustrated inFIG. 4, for example, head lifting and lowering section29is configured to be able to change the height of nozzle25between heights H1to H5.

Component imaging section18(imaging section) is a device that captures an image, and is a unit that captures one or more components P picked up and held by mounting head22. Component imaging section18is disposed between component supply section15and board processing section12. An imaging range of component imaging section18is above component imaging section18. When mounting head22holding component P passes through the upper side of component imaging section18, component imaging section18captures an image, and outputs the captured image data to control section30. As illustrated inFIG. 5, mounting section20includes nozzles25(holders24) #1 to #8, and image ranges F1to F8are defined in which an image of component P is extracted from the captured image and image processing is performed on the image. In the conventional art, #1 nozzle25performs image processing while being disposed in image range F1. However, in this mounting head22, it is set that #1 to #8 nozzles25perform the image processing regardless of where #1 to #8 nozzles25are arranged in image ranges F1to F8. In this way, since it is not necessary to move specific nozzle25to a specific position, in the image processing, it is possible to shorten a time during which rotating body23is rotated.

As illustrated inFIG. 1, control section30is configured as a microprocessor centered on CPU31serving as a control section, and includes storage section32that stores various data. Control section30outputs a control signal to board processing section12, component supply section15, component imaging section18, and mounting section20, and receives input of signals from mounting section20, component supply section15, and component imaging section18. Storage section32stores mounting condition information33and correction information34. Mounting condition information33includes a mounting job such as a mounting order in which components P are mounted on board S and arrangement positions of components P. Mounting device11executes a mounting process based on mounting condition information33. Correction information34is information including correction values used for correction of the pickup position and an arrangement position in the mounting process and correction of a range in which the image processing is performed. Correction information34includes at least a first correction value determined at a first position on the XYZ axis where mounting head22works and a second correction value determined at a second position different from the first position. In detail, correction information34includes identification information (ID) of rotating body23, an elevation position correction value corresponding to the ID of holder24, a head height correction value, a rotation correction value, a region correction value, and the like. The elevation position correction value includes a correction value for correcting the pickup position of the pickup member when holder24is in first elevation position A (seeFIGS. 3 and 5) and a correction value for correcting the pickup position of the pickup member when holder24is in second elevation position B. Since deviation of the pickup position may change when the elevation position is changed, mounting device11defines the correction value associated with holder24for each elevation position. The head height correction value is a correction value for correcting the pickup position of the pickup member mounted on holder24when mounting head22is in any one of heights H1to H5(seeFIG. 4). Since the deviation of the pickup position may change when the height of mounting head22is changed, mounting device11defines the correction value associated with holder24for each height of mounting head22. The rotation correction value is a correction value for correcting the pickup position of the pickup member mounted on holder24when holder24is in any one of image ranges F1to F8(seeFIG. 5). When the position of holder24is changed, deviation of the position or the angle of component P may change according to holder24due to an engagement relationship between gears. Therefore, mounting device11defines the correction value associated with holder24for each of the positions of image ranges F1to F8where holder24exists. The region correction value is a correction value for correcting the pickup position of the pickup member mounted on holder24when board S is in any one of regions R1to R6(seeFIG. 2). Although mounting head22is moved in the XY direction by the slider, the guide rail is a beam and may be deflected slightly at the center portion. Therefore, the amount and the direction of the deviation of the pickup member may change depending on which region in the XY direction mounting head22works. Therefore, the mounting device11defines the correction value associated with holder24for each region where the board S is fixed. InFIG. 6, for convenience of description, the correction values of correction information34are represented in a table format. However, correction information34may include a correction value in a map format in which the elevation position, the head height, the rotation position, and the region in the XY directions are associated with each other. Mounting device11performs advanced position correction using correction information34, and executes the mounting process.

Next, a process of setting correction information34in an operation of mounting system10of the present embodiment configured as described above will be firstly described. The process of setting correction information34may be performed manually or may be performed automatically by control section30. For example, in setting of the elevation position correction value, in a state in which holder24for setting the correction value is disposed in first elevation position A, holder24is lowered, and the amount of the deviation of the center position of nozzle25is measured. Then, the correction value for offsetting the amount of the deviation is set, and is stored in correction information34in which holder24, first elevation position A, and the correction value are associated with each other. By performing this process for all holders24at all the elevation positions, the elevation position correction value can be set. Correction information34can be set by executing this process for all the head height correction value, the rotation correction value, and the region correction value. Each correction value is set such that proper position correction can be executed by combining other correction values. The setting of correction information34may be performed periodically after a predetermined period has elapsed.

Next, the operation of mounting system10, particularly, the mounting process in mounting device11will be described.FIG. 7is a flowchart illustrating an example of a mounting process routine executed by CPU31of control section30. This routine is stored in storage section32and is executed based on a mounting start input of an operator. When this routine is started, CPU31first reads out and acquires mounting condition information33and the correction information34(S100) and causes board processing section12to convey and fix board S (S110). Next, CPU31sets component P that is an arrangement target picked up by nozzle25based on an arrangement order of mounting condition information33(S120). Next, CPU31acquires the elevation position correction value, the head height correction value, and the region correction value corresponding to holder24on which nozzle25is mounted (S130). CPU31acquires, as a state of holder24, each correction value according to the elevation position, the height of mounting head22, the region where board S is fixed, and the like.

Next, CPU31executes a process of picking up component P while correcting the pickup position of the pickup member (nozzle25) mounted on holder24using the acquired elevation position correction value, the acquired head height correction value, and the acquired region correction value (S140). In the pickup process, CPU31replaces or mounts nozzle25as needed, moves mounting head22to the pickup position of component supply section15, and lowers nozzle25at first elevation position A and/or the second elevation position B to pick up component P. At this time, the correction value is used so that, component P can be picked up with extremely high positional accuracy. After picking up component P to nozzle25mounted on rotating body23, CPU31executes a moving process of causing mounting head22to pass over component imaging section18and an imaging process of component imaging section18to capture an image of mounting head22(S150).

Next, CPU31acquires, from correction information34, the rotation correction value corresponding to holder24and the rotation position of holder24(S160). Next, CPU31corrects the position and the angle of an image region to be image-processed using the acquired rotation correction value (S170), and processes an image of the corrected image region to calculate the amount of the deviation from an ideal position (S180). In mounting device11, the image processing is performed on the image region corrected using the rotation correction value, so that the image region to be image-processed can be made smaller, and the processing time can be further shortened. Then, CPU31executes a process of correcting the calculated amount of the deviation and arranging component P (S190).

CPU31determines whether the mounting process of a current board is completed (S200), and executes the process after S120when the mounting process is not completed. That is, CPU31sets component P to be picked up next, replaces nozzle25as needed, and corrects the amount of the deviation using the correction value, so as to execute the pickup process of component P, the imaging process of the image, and an arrangement process to board S. On the other hand, when the mounting process of the current board is completed in S200, CPU31causes board processing section12to unload board S on which the mounting process is completed (S210), and determines whether production is completed (S220). CPU31executes the process after S110when the production is not completed, and terminates the routine as it is when the production is completed.

Here, a correspondence relationship between the components of the present embodiment and the components of the present disclosure will be clarified. Mounting head22of the present embodiment corresponds to the mounting head of the present disclosure, holder24and nozzle25correspond to the pickup section, storage section32corresponds to the storage section, and control section30corresponds to the control section. Further, head lifting and lowering section29corresponds to an elevation mechanism, component imaging section18corresponds to an imaging section, rotating body23corresponds to a rotating body, board processing section12corresponds to a conveyance section, first lane13corresponds to a first lane, and second lane14corresponds to a second lane. In the present embodiment, an example of a mounting method of the present disclosure is clarified by describing the operation of control section30.

In above-described mounting device11of the present embodiment, a correction value for position correction of component P is set for each of different positions where mounting head22works, and the mounting process is performed using an appropriate correction value for each of the positions. In mounting device11, by using multiple correction values, the mounting accuracy can be further enhanced. Further, mounting head22stores a first elevation correction value as a first correction value corresponding to a combination of first elevation position A and holder24and a second elevation correction value as a second correction value corresponding to a combination of second elevation position B and holder24. Mounting device11has multiple elevation positions of holder24and the correction values associated with holders24are provided for the elevation positions, so that the mounting accuracy can be further improved by using multiple correction values according to the elevation positions.

Further, mounting device11can change the height of mounting head22in multiple stages (H1to H5), and the correction values associated with holders24are provided for the heights, so that the mounting accuracy can be further improved by using the multiple correction values according to the heights of mounting head22. Further, mounting device11can rotate multiple holders24, holders24have multiple rotation positions F1to F8, and the correction values associated with holders24are provided for the rotation positions, so that the mounting accuracy can be further improved by using the multiple correction values according to the rotation position. Furthermore, mounting device11can fix board S to multiple regions R1to R6, and the correction values associated with holders24are provided for the fixing regions, so that the mounting accuracy can be further improved by using the multiple correction values according to the fixing position (work region of mounting head22) of board S.

Further, board processing section12has regions R1to R3or regions R4to R6in the conveyance direction of the board, and the correction values are provided for the multiple regions, so that the mounting accuracy can be further improved according to the fixing position along the conveyance direction of the board. Further, board processing section12has first lane13and second lane14for conveying board S, and the correction values are provided for the lanes, so that the mounting accuracy can be further improved by using multiple correction values according to the conveyance lanes. In mounting device11, for example, various factors, which degrade the mounting accuracy, such as a mechanical assembly error due to the Z-axis, a mechanical assembly error due to a base of head lifting and lowering section29, a mechanical assembly error of a conveyor of board processing section12, and a mechanical assembly error due to the XY directions of mounting head22, can be eliminated, so that the mounting process can be executed more accurately.

It is obvious that the control device and the mounting device of the present disclosure are not limited to the above-described embodiments, and can be implemented in various modes as long as the modes belong to the technical scope of the present disclosure.

For example, in the above-described embodiments, it has been described that the elevation position correction value, the head height correction value, the rotation correction value, and the region correction value are used. However, the present disclosure is not particularly limited thereto, and one or more of the correction values may be omitted or a correction value other than these correction values may be used in a combination. Further, although mounting head22has the two elevation positions, the number of the elevation positions may be one or more, and the correction values may be adjusted accordingly. Further, although mounting head22has the five head heights, the number of the head heights may be one or more and the correction values may be adjusted accordingly. Further, although mounting head22has eight holders24, the number of holders24may be one or more, and the rotation correction value may be adjusted accordingly. Further, in board processing section12, although board S is fixed to one of six locations obtained by multiplying the number of the2lanes and the number of 3 locations in the conveyance direction, the number of the lanes may be one or more, the number of the locations in the conveyance direction may be one or more, and the correction values may be adjusted accordingly. It is preferable that the number of types of the correction values is larger in order to improve the mounting accuracy.

In the above-described embodiment, although examples of the correction values are illustrated inFIG. 6, in the case of a comprehensive correction value such as a manual offset, correction values of all combinations (or some combinations) may be provided.

Although the present disclosure has been described as mounting device11in the above-described embodiment, the present disclosure may be a mounting method or a program that executes this mounting method.

Here, the mounting device and the mounting method of the present disclosure may be configured as follows. In the mounting device according to the present disclosure, the mounting head may have a first elevation position as the first position where the pickup section is elevated on a Z-axis and a second elevation position as the second position where the pickup section is elevated at a position different from the first elevation position, and the storage section may store a first elevation correction value corresponding to a combination of the first elevation position and the pickup section and serving as the first correction value for position correction of the component and a second elevation correction value corresponding to a combination of the second elevation position and the pickup section and serving as the second correction value for position correction of the component. The mounting device has the elevation positions of the multiple pickup sections, and the correction value associated with the pickup section is provided for each of the elevation positions, so that the mounting accuracy can be further improved by using the multiple correction values according to the elevation positions.

In the mounting device according to the present disclosure, the mounting head may be disposed in an elevation mechanism that holds the mounting head at a first height as the first position and a second height as the second position different from the first height, and the storage section may store a first position correction value corresponding to a combination of the first height and the pickup section and serving as the first correction value for position correction of the component and a second position correction value corresponding to a combination of the second height and the pickup section and serving as the second correction value for position correction of the component. The mounting device can change the height of the mounting head to multiple values, and the correction value associated with the pickup section is provided for each height, so that the mounting accuracy can be further improved by using the multiple correction values according to the heights of the mounting head.

The mounting device of the present disclosure may further includes an imaging section configured to capture an image of the mounting head, in which the mounting head may have a rotating body configured to rotate the pickup section at a first rotation position as the first position where the multiple pickup sections are arranged on a circumference and are pivotally supported and a second rotation position as the second position different from the first rotation position, the storage section may store a first rotation correction value corresponding to a combination of the first rotation position and the pickup section and serving as the first correction value for position correction of the component and a second rotation correction value corresponding to a combination of the second rotation position and the pickup section and serving as the second correction value for position correction of the component, and the control section may execute the mounting process of performing correction of a selection region of the captured image captured by the imaging section and/or correction of a position of the rotating body of the mounting head using the first rotation correction value and/or the second rotation correction value stored in the storage section. This mounting device can rotate the multiple pickup sections, the pickup sections have the multiple rotation positions, and the correction value associated with the pickup section is provided for each rotation position, so that the mounting accuracy can be further improved by using the multiple correction values according to the rotation positions. Here, the “first rotation correction value” and the “second rotation correction value” may be a correction value of the rotation angle of the component.

The mounting device of the present disclosure may further include a conveyance section configured to convey the board and fix the board to a first region as the first position on the XY axes and a second region as the second position different from the first region, in which the storage section may store a first region correction value corresponding to a combination of the first region and the pickup section and serving as the first correction value for position correction of the component and a second region correction value corresponding to a combination of the second region and the pickup section and serving as the second correction value for position correction of the component, and the control section may execute the mounting process of performing correction of a position of the board fixed by the conveyance section and/or correction of a position of the mounting head using the first region correction value and/or the second region correction value stored in the storage section. The mounting device can fix the board at multiple regions, and the correction value associated with the pickup section is provided for each fixing region, so that the mounting accuracy can be further improved by using the multiple correction values according to the fixing positions of the board.

In the mounting device of the present disclosure having the first region and the second region, the conveyance section may have the first region and the second region in the conveyance direction of the board. In the mounting device, the correction value is provided for each of the multiple regions along the conveyance direction of the board, so that the mounting accuracy can be further improved according to the fixing position along the conveyance direction of the board. Alternatively, in the mounting device of the present disclosure, the conveyance section may include a first lane for conveying the board and a second lane juxtaposed to the first lane, the first lane may include the first region, and the second lane may include the second region. In this mounting device, the correction value is provided for each lane for conveying the board, so that the mounting accuracy can be further improved by using the multiple correction values according to the conveyance lanes.

A mounting method for executing a mounting process of mounting a component on a board using a mounting head including at least one pickup section for picking up the component and configured to move the picked up component according to the present disclosure includes executing the mounting process using at least one of a first correction value determined at a first position on the XYZ axes where the mounting head works and a second correction value determined at a second position different from the first position.

In this mounting method, similarly to the above-described mounting device, the correction value is determined for each different position where the mounting head works, and mounting process is performed using the correction value suitable for each position. In this mounting device, the mounting accuracy can be further improved using multiple correction values. In this mounting method, various aspects of the above-described mounting device may be adopted or a configuration for realizing each function of the above-described mounting device may be added.

INDUSTRIAL APPLICABILITY

The present disclosure can be used in a technical field of a device configured to perform a mounting process of picking up and arranging a component.

REFERENCE SIGNS LIST