Robot apparatus for soldering

The robot apparatus includes a solder pot having a nozzle from which solder flows out, a flux ejection tool for ejecting flux, and a support tool for supporting the solder pot. The robot apparatus includes a table for supporting a workpiece, and a placement member on which the operation tools and the solder pot can be placed. The controller performs a flux application control for coupling the flux ejection tool to the robot and applying flux to the workpiece, a preheating control for coupling the support tool to the robot and arranging the solder pot below the workpiece so as to heat the workpiece, and a supply control for moving the nozzle of the solder pot closer to the workpiece and supplying the solder.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a new U.S. Patent Application that claims benefit of Japanese Patent Application No. 2019-040966, dated Mar. 6, 2019, the disclosure of this application is being incorporated herein by reference in its entirety for all purposes.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a robot apparatus that performs soldering.

2. Description of the Related Art

The processes for manufacturing products include a process for securing parts by soldering. For example, electronic components are secured to a printed board by soldering, and are connected to an electric circuit formed on the printed board. In the prior arts, a spot soldering device that solders small areas of a workpiece one by one is known (for example, Japanese Unexamined Patent Publication No. 2005-167142A). In the spot soldering device, a table that moves in the X-axis direction and the Y-axis direction is disposed, and the relative position of the solder pot with respect to the workpiece is changed so that a desired portion can be soldered.

In order to perform soldering, flux is applied to a portion to be soldered so as to remove oxides and improve wettability. Further, preheating for heating the board is performed. Thereafter, molten solder is supplied to a portion to be soldered in order to perform soldering.

In the prior arts, a soldering device that performs a process of supplying solder to a board as well as a process of applying flux and a process of preheating for heating the board (for example, Japanese Patent No. 2761204B, Japanese Unexamined Patent Publication No. 11-298134A, and Japanese Patent No. 4414642B).

SUMMARY OF THE INVENTION

In spot soldering devices commercially available, a flux applying process, a board preheating process, and a solder supplying process are performed by different devices. Thus, in order to perform each process, it is necessary to convey a board between the devices. However, components that are not soldered may fall over or tilt with respect to the board while the workpiece is being conveyed. Further, in order to shift one process to another process, there is the problem that a complicated device for conveying the board is necessary.

Further, in the conventional spot soldering devices capable of performing the flux applying process, the preheating process, and the solder supplying process, devices for performing respective processes are arranged on the lower side. Further, the board moves above each device. In such a structure, there is the problem that the size of the soldering device tends to be increased, since the devices for performing the respective processes are formed separately. Thus, in order to arrange the soldering device, it is necessary to secure a large space.

A robot apparatus according to a first aspect of this disclosure includes a robot having a plurality of joints and operation tools each of which is connected to the robot. The robot apparatus includes a solder pot having a container for melting and storing solder and a nozzle from which the solder is flowed out. The robot apparatus includes a table that is disposed above the robot and supports a workpiece, and a placement member on which the operation tools and the solder pot can be placed. The robot apparatus includes a controller for controlling the robot. The operation tools include a flux ejection tool that ejects soldering flux, and a support tool that supports the solder pot. The robot has a function of automatically replacing operation tools. The operation tools and the solder pot are placed on the placement member. The controller performs a flux application control for coupling the flux ejection tool to the robot and applying flux to a portion to be soldered of the workpiece. The controller performs a preheating control for coupling the support tool to the robot and arranging the solder pot below the workpiece so as to heat the workpiece by the heat released from the solder pot. The controller performs a supply control for moving the nozzle of the solder pot closer to the workpiece so as to supply solder to a portion of the workpiece to be soldered.

A robot apparatus according to a second aspect of this disclosure includes a robot having a plurality of joints and operation tools each of which is connected to the robot. The robot apparatus includes a solder pot having a container for melting and storing solder and a nozzle from which the solder flows out. The robot apparatus includes a table that is disposed above the robot and supports a workpiece, and a placement member on which the operation tools and the solder pot can be placed. The robot apparatus includes a controller that controls the robot. The operation tools includes a flux ejection tool that ejects soldering flux, a preheating tool having a heater the temperature of which can be increased, and a support tool that supports the solder pot. The robot has a function of automatically replacing operation tools. The operation tools and the solder pot are placed on the placement member. The controller performs a flux application control for coupling the flux ejection tool to the robot and applying the flux to a portion to be soldered of the workpiece. The controller performs a preheating control for coupling the preheating tool to the robot and moving the preheating tool closer to the workpiece so as to heat the workpiece. The controller performs a supply control for coupling the support tool to the robot and moving the nozzle of the solder pot closer to the workpiece so as to supply solder to a portion of the workpiece to be soldered.

DETAILED DESCRIPTION

A robot apparatus according to an embodiment will be described with reference toFIGS.1to32. The robot apparatus of the present embodiment performs a soldering operation in order to secure an electronic component to a printed board as a workpiece. The robot apparatus of the present embodiment performs an operation of applying flux, an operation of heating the printed board, and an operation of supplying solder by changing an operation tool so as to secure a component to the printed board.

FIG.1is a perspective view of the robot apparatus according to the present embodiment. The robot apparatus5of the present embodiment is a spot soldering device that performs soldering in a predetermined partial area of a workpiece. The robot apparatus5includes an operation tool as an end effector and a robot1that moves the operation tool. The robot apparatus5includes a solder pot7having a nozzle31afrom which the solder is flowed out toward the workpiece. The operation tools of the present embodiment include a flux ejection tool2for applying flux to a printed board and a support tool3for supporting the solder pot7for supplying solder to the printed board. The flux ejection tool2has a function of ejecting soldering flux.

FIG.2is a perspective view of a robot of the present embodiment. The robot1of the present embodiment is an articulated robot including a plurality of joints. The robot1includes a base14and a turning base13supported by the base14. The base14is secured to a frame body26via a panel27. The turning base13is formed so as to rotate with respect to the base14. The robot1includes an upper arm11and a lower arm12. The lower arm12is rotatably supported by the turning base13via a joint. The upper arm11is rotatably supported by the lower arm12via a joint. Further, the upper arm11rotates around a rotation axis parallel to the extending direction of the upper arm11.

The robot1includes a wrist15coupled to an end of the upper arm11. The wrist15is rotatably supported by the upper arm11via a joint. The wrist15includes a flange16that is rotatably formed. The operation tool is secured to the flange16. The robot1of the present embodiment has six drive axes, but is not limited to this configuration. Any robot that can change the position and the orientation of the operation tool can be adopted.

Referring toFIG.1, the robot apparatus5includes the frame body26that supports the devices and components constituting the robot apparatus5, and a placement member28supported by the frame body26. The panel27is disposed around the frame body26. The placement member28is disposed on the side of the robot1. The placement member28is formed so that the flux ejection tool2, the support tool3, and the solder pot7can be placed thereon.

In the present embodiment, the side indicated by arrow91, on which the placement member28is disposed, is referred to as the front side of the robot apparatus5. The placement member28is disposed at the front side of the robot1. The placement member28is disposed within a range in which the robot1can operate the components placed on the placement member28. For example, the placement member28is disposed at a position where the robot1can replace the operation tool placed on the placement member28.

The robot apparatus5includes a robot controller4as a controller for controlling the robot1. The robot controller4controls the flux ejection tool2and the support tool3. Further, the robot controller4controls a table drive motor20for driving a table6.

The robot apparatus5includes a flux supply device58for supplying pressurized flux to the flux ejection tool2. The flux supply device58has a tank for storing flux and a pump for pressurizing the flux. The flux supply device58is controlled by the robot controller4. The flux pressurized in the flux supply device58is supplied to the flux ejection tool2through a flux supply tube57. The flux supply device58is placed on the panel27disposed at the bottom of the frame body26.

The solder pot7is connected to the robot controller4via a cable79. The solder pot7is powered via the cable79. The solder pot7has a function of melting and storing the solder and discharging the solder from the nozzle31a.

FIG.3is an enlarged perspective view of the table and the table drive motor for driving the table according to the present embodiment. Referring toFIGS.1and3, the robot apparatus5has the table6disposed above the robot1. The table6of the present embodiment is formed so as to have a circular planar shape. The table6supports printed boards34aand34bas workpieces. The table6has openings6aand6bin which the printed boards34aand34bare disposed. In the present embodiment, pallets33on which a plurality of printed boards34aand34bare placed are disposed in the openings6aand6b. It should be noted that the table may be formed so that the workpieces are placed directly thereon without using the pallets.

The robot apparatus5includes a table drive device38for driving the table6. The table drive device38includes a table drive motor20for rotating the table6. The rotational force output by the table drive motor20is transmitted to the table6via a shaft21. The shaft21is connected to the center of the circular planar shape of the table6. The table drive motor20is driven so as to rotate the table6in the circumferential direction. It should be noted that the table drive device may be formed so as to rotate the table with air pressure.

FIG.4is an enlarged perspective view of a support member according to the present embodiment. Referring toFIGS.1,3and4, the table6is supported by a support member29. The support member29is secured to the frame body26. The support member29includes a roller30athat supports the outer peripheral surface of the table6and a roller30bthat supports the bottom surface of the table6. The roller30arestricts the movement of the table6in the radial direction. The roller30brestricts the movement of the table6in the vertical direction. Moreover, the roller30bsuppresses bending of the table6.

Referring toFIG.1, a plurality of support members29are arranged in the robot apparatus5. In the present embodiment, the support members29are arranged at four locations. Thus, it is possible to suppress the table6from moving in the radial direction or from bending by supporting the table6with the plurality of support members29. As a result, the position of the printed board supported by the table6can be prevented from deviating from a predetermined position. In the present embodiment, four support members are arranged, but the embodiment is not limited to this. Any number of support members can be arranged in order to support the table.

FIG.5is an enlarged perspective view of the placement member according to the present embodiment. The placement member28of the present embodiment is formed into a plate shape. The placement member28is secured to the frame body26. Referring toFIGS.1and5, the placement member28is formed so as to extend in the horizontal direction. The solder bar32, the flux ejection tool2, the support tool3, and the solder pot7are placed on the placement member28of the present embodiment. Further, nozzles31b,31cand31dwith which the nozzle31aof the solder pot7can be replaced are placed on the placement member28.

The placement member28has support pillars28a. Solder bars32for replenishing the solder pot7with solder are placed between a plurality of the support pillars28a. The solder bars32are arranged between the support pillars28a. The placement member28of the present embodiment is formed into a plate shape, but is not limited to this configuration. Any shape can be applied to the placement member if components such as an operation tool and a solder pot can be placed thereon.

The positions of the devices and members placed on the placement member28are predetermined. The robot1is driven to the position and posture set in an operation program41so as to operate the device and the member placed on the placement member28.

Referring toFIG.1, plate-like panels27are disposed around the frame body26. An opening27athrough which an operator can check the internal state is formed in the panel27disposed on the front side of the frame body26. An exhaust cylinder25is connected to the panel27disposed on the upper portion of the frame body26. The exhaust cylinder25has a function of releasing, for example, vapor generated from the solder within the frame body26to the outside. It should be noted that the exhaust cylinder25may be connected to a duct for discharging the vapor to the outside of the building.

The devices and members, which constitute the robot apparatus5of the present embodiment, are disposed inside the frame body26. For example, the robot1, the placement member28, the table6, the table drive motor20, the flux supply device58, and the robot controller4are arranged inside the frame body26.

InFIG.2and the subsequent figures, the panels27secured to the side portion and the upper portion of the frame body26are omitted. The panels27do not necessarily have to be arranged. Moreover, the panels27may be arranged on the side part, the upper part, and the lower part of the frame so as to seal the space inside the frame26.

FIG.6is an enlarged perspective view of the flux ejection tool in the present embodiment.FIG.6shows that the flux ejection tool2is coupled to the flange16of the wrist15of the robot1. The robot apparatus5in the present embodiment has an automatic tool changer (ATC) that can automatically replace operation tools with one another. The automatic tool changer includes a robot-side plate51attached to the flange16of the robot1and a tool-side plate52attached to the operation tool.

The tool-side plate52is formed so as to be coupled to or released from the robot-side plate51. The automatic tool changer of the present embodiment is controlled by the robot controller4. The robot1changes its position and posture so as to couple the robot-side plate51to the tool-side plate52and support the operation tool. Thus, the robot1of the present embodiment has a function of automatically replacing operation tools including the flux ejection tool2and the support tool3.

The flux ejection tool2includes a base member55secured to the tool-side plate52. The base member55is formed into a plate shape. The flux ejection tool2has a nozzle56secured to the base member55. The nozzle56of the present embodiment is a spray nozzle. A flux supply tube57for supplying flux is connected to the nozzle56. A valve is disposed on the nozzle56. The valve is opened so as to eject the flux from the tip of the nozzle56. The nozzle56of the present embodiment is controlled by the robot controller4.

FIG.7is an enlarged perspective view of the support tool according to the present embodiment. The support tool3of the present embodiment includes a base member61that supports the solder pot7and a chuck part62attached to the base member61. The base member61is formed into an L shape when viewed from the side. A tool-side plate53of the automatic tool changer is secured to the base member61of the support tool3. Thus, the robot1can automatically couple and release the support tool3.

The chuck part62has two claws64that face each other. Further, the chuck part62has a cylinder63for opening and closing the claws64. The cylinder63is driven and thereby causes the claws64facing each other to move so as to grasp or release any component.

FIG.8is an enlarged perspective view of the support tool before supporting the solder pot according to the present embodiment. When the solder pot7is not used, the solder pot7is placed on the placement member28(seeFIG.5). A notch is formed in the placement member28. The support tool3supports the bottom of the solder pot7through the notch. When supporting the solder pot7, the robot1raises the support tool3from below the solder pot7as indicated by arrow92.

The base member61of the support tool3has, on its surface contacting the bottom surface of the solder pot7, a plurality of protrusions61a. Recesses, each of which has a shape corresponding to the shape of the protrusion61a, are formed in the bottom surface of the container71of the solder pot7. The protrusions61aof the base member61are fitted into the recesses of the container71, and thus the position of the solder pot7is determined with respect to the support tool3. Further, the protrusions61aare fitted into the recesses of the solder pot7, and thus the solder pot7is prevented from moving with respect to the support tool3.

FIG.9is an enlarged perspective view of the support tool after supporting the solder pot according to the present embodiment. The base member61of the support tool3contacts the side surface and the bottom surface of the container71of the solder pot7. The solder pot7is heavy, due to molten solder being disposed therein. Thus, the protrusions61aformed on the base member61of the support tool3are fitted into the recesses formed in the container71of the solder pot7, and thus the solder pot7can be reliably supported by the support tool3.

The solder pot in the present embodiment will now be described in detail.FIG.10is a perspective view of the solder pot according to the present embodiment. The solder pot7has a container71that stores molten solder, and a lid member72that covers the upper opening of the container71. The container71is formed so as to have the nozzle31afrom which the solder flows out. In the present embodiment, the nozzle31ais disposed so that the opening of the nozzle31afaces upward. The solder pot7has a motor73for pressurizing the solder so as to discharge the solder from the nozzle31a.

The solder pot7in the present embodiment has a securing mechanism80that secures and releases the nozzle31a. The securing mechanism80of the solder pot7has a turning member74for securing the nozzle31ato the solder pot7. The securing mechanism80includes a support member75for supporting the turning member74. The nozzle31ahas an engagement part35that engages with the turning member74. The turning member74is engaged with the engagement part35, and thus the nozzle31ais secured to the solder pot7.

The solder pot7is formed so that a plurality of types of nozzles can be arranged thereon. For example, areas to be soldered may be small or large. Alternatively, the planar shapes of the areas to be soldered are different from one another in some cases. In such a case, spot soldering can be performed for areas having various shapes or sizes by replacing the nozzle31awith another nozzle.

The lid member72of the solder pot7has a wall part72aextending in the vertical direction. The wall part72ais formed so as to surround the nozzle31a. Further, an opening which communicates with the inner space of the solder pot7is formed between the wall part72aand the nozzle31a. A hole72bwhich is shaped so that the solder bar can be inserted therein is formed in the lid member72.

FIG.11is a perspective view of the solder pot when the lid member is removed. The container71according to the present embodiment has an inner member71amade of a metal such as stainless steel, and a heat insulating member71bformed so as to cover the inner member71a. The heat insulating member71bis made of a material such as ceramics or glass which is thermally resistant and has low thermal conductivity. The heat insulating member71bis disposed so as to cover the entirety of the outer peripheral surface of the inner member71a. Further, the lid member72of the present embodiment has an inner member and a heat insulating member formed so as to cover the inner member in the same way as the container71. An electric heater as a heater is disposed on the back side of the bottom surface of the inner member71a. The electric heater is driven and thereby melts the solder disposed inside the inner member71a.

In the container71and the lid member72according to the present embodiment, the heat insulating member71bis disposed so as to cover the outer surface thereof. This configuration enables the heat to be prevented from transferring from the solder pot7. The power consumption of the electric heater for melting the solder disposed inside the solder pot7can be reduced.

FIG.12is a perspective view of the solder pot when the motor is removed. Referring toFIGS.11and12, a fitting member76into which the nozzle31ais fitted is disposed inside the inner member71a. The fitting member76is formed so as to be fitted with the nozzle31awhen the nozzle31ais inserted from above. The solder pot7includes an impeller78for pressurizing the molten solder. The molten solder is supplied to the nozzle31athrough the inner space of the fitting member76by the impeller78rotated by the motor73. Further, the molten is discharged from the tip of the nozzle31a.

Referring toFIG.10, excessive solder which has been discharged from the nozzle31aflows downward through the tubular member of the nozzle31aas indicated by arrow98. Thereafter, the solder returns to the inside of the container71through the space between the nozzle31aand the wall part72a.

FIG.13is a perspective view of the solder pot which stores therein the molten solder when the lid member is removed. The molten solder83is stored inside the inner member71a. Referring toFIGS.10and13, the molten solder is exposed through the opening between the wall part72aof the lid member72and the nozzle31a. Hot air rises from the space between the wall part72aand the nozzle31a.

FIG.14is a block diagram of the robot apparatus according to the present embodiment. The robot1includes a robot drive device that changes the position and posture of the robot1. The robot drive device includes a plurality of robot drive motors17that drive components such as the arm and the wrist. The robot drive motors17are disposed for respective components. The orientation of each component is changed by the corresponding robot drive motor17that is driven.

The controller of the robot apparatus5includes a robot controller4. The robot controller4includes an arithmetic processing device (computer) having a CPU (Central Processing Unit) serving as a processor. The arithmetic processing unit includes, for example, a RAM (Random Access Memory) and a ROM (Read Only Memory), which are connected to the CPU via a bus. In order to control the robot apparatus5, an operation program41which has been previously made is input to the robot controller4. The robot controller4includes a storage unit42that stores information related to the control of the robot apparatus5. The storage unit42can be configured by a storage medium capable of storing information, such as a volatile memory, a nonvolatile memory, or a hard disk. The operation program41is stored in the storage unit42. The robot controller4of the present embodiment controls a soldering operation based on the operation program41.

The robot controller4includes an operation control unit43that sends an operation command. The operation control unit43corresponds to the processor that is driven according to the operation program41. The processor functions as the operation control unit43, i.e., reads the operation program41and performs a control defined in the operation program41.

The operation control unit43sends an operation command for driving the robot1to a robot drive unit45based on the operation program41. The robot drive unit45includes an electric circuit that drives the robot drive motors17. The robot drive unit45supplies electricity to the robot drive motors17based on the operation command.

Further, the operation control unit43sends an operation command for driving the operation tool to an operation tool drive unit44based on the operation program41. The operation tool drive unit44includes an electric circuit that drives the operation tool. The operation tool drive unit44supplies electricity to the valve of the flux ejection tool2based on the operation command. The operation tool drive unit44supplies electricity to a flux supply device58based on the operation command. The operation tool drive unit44supplies electricity to drive devices including an air pump and a valve for driving the chuck part62based on the operation command.

The operation control unit43sends an operation command for driving a table to a table drive unit46based on the operation program41. The table drive unit46includes an electric circuit for driving the table drive motor20. The table drive unit46supplies electricity to the table drive motor20based on the operation command.

The robot1includes a state detector for detecting the position and posture of the robot1. The state detectors in the present embodiment includes position detectors18which are attached to the robot drive motors17corresponding to the drive axes of the components such as an arm, etc. The robot controller4detects the position and posture of the robot1based on the output of the position detectors18.

Further, a position detector22is attached to the table drive motor20. The output of the position detector22is input to the robot controller4. The rotation angle of the table6can be detected by the output of the position detector22of the table drive motor20. The operation control unit43controls the table drive motor20so that the table6has a rotation angle set in the operation program41. The rotation angle of the table drive motor20is controlled so that the printed board can be disposed at a desired position. Further, the robot1changes its position and posture based on the operation program41, and thereby the flux can be ejected to a desired part of the printed board, the desired part of the printed board can be preheated, and the solder can be supplied to the desired part of the printed board.

FIG.15is a perspective view of the robot apparatus of the present embodiment for explaining the first process of soldering performed by the robot apparatus. The table6according to the present embodiment is divided into two areas. The table6includes a first area in which the opening6ais formed and a second area in which the opening6bis formed. In the example shown inFIG.15, the first area in which the opening6ais formed is disposed on the front side, and the second area in which the opening6bis formed is disposed on the rear side. In the present embodiment, a soldering operation is performed for each area.

In the present embodiment, the printed board is transferred to and from the area disposed on the front side. First, a plurality of printed boards34aare arranged in the opening6a. Electronic components36that are not secured are disposed on each printed board34a. Also in the present embodiment, the pallets33, on which a plurality of printed boards34aare placed, are conveyed. The pallets33can be conveyed by a robot for conveying pallets. Alternatively, an operator may arrange the pallets33in the opening6aof the table6. Subsequently, the robot controller4rotates the table6as indicated by arrow93.

FIG.16is a perspective view of the robot apparatus for explaining the second process of soldering. The table6is rotated and thereby transfers the printed board34adisposed in the opening6aof the first area to the rear side.

FIG.17is an enlarged perspective view of the placement member and the robot for explaining the third process of soldering. A flux application control for applying flux to the printed board34aplaced in the first area is performed. The robot controller4causes the robot1to change its position and posture so as to couple the flux ejection tool2to the wrist15of the robot1. The position of the flux ejection tool2on the placement member28is predetermined. Thus, the robot1changes its position and posture based on the operation program41so as to couple the flux ejection tool2.

FIG.18is an enlarged perspective view of the robot apparatus for explaining the fourth process of soldering. The robot1changes its position and posture so as to arrange the flux ejection tool2below the printed board34ato which the flux is applied. The table6is disposed so as to have a predetermined rotation angle. Thus, each printed board34ais disposed at a predetermined position. The robot1changes its position and posture based on the operation program41and thereby the nozzle56of the flux ejection tool2is arranged so as to face a desired portion of the printed board34a.

The robot controller4causes the valve of the nozzle56to be opened so as to eject flux therethrough. Further, the flux is applied to a portion to be soldered of each printed board34a. In this way, the robot controller4causes the flux to be applied to a portion to be soldered. It should be noted that, in the flux application control, a plurality of flux ejecting operations may be performed in one printed board34awhile the position of the flux ejection tool2is changed.

FIG.19is a perspective view of the robot apparatus for explaining the fifth process of soldering. While the robot1applies the flux to the printed board34adisposed in the first area of the table6, printed boards34b, which are new workpieces, are arranged in the opening6bin the second area. The printed boards34bof the present embodiment are placed on the pallet33and conveyed.

After a control for applying flux to all the printed boards34adisposed in the first area is completed, the robot controller4causes the table6to rotate as indicated by arrow94. The robot controller4causes the printed boards34adisposed in the first area to move to the front side. The new printed boards34bdisposed in the second area move to the rear side.

FIG.20is an enlarged perspective view of the robot apparatus for explaining the sixth process of soldering. The robot controller4controls the robot so that the operation tool connected to the wrist15is changed from the flux ejection tool2to the support tool3. The robot1places the flux ejection tool2at a predetermined position of the placement member. The robot1couples the wrist15to the support tool3. The position of the support tool3in the placement member28is predetermined. Thus, the robot1changes its position and posture based on the operation program41so as to be coupled to the support tool3.

FIG.21is an enlarged perspective view of the solder pot and the robot for explaining the seventh process of soldering. The robot1changes its position and posture and thereby couples the base member61of the support tool3to the bottom surface of the solder pot V. The robot1supports the solder pot7via the support tool3. The position of the solder pot7on the placement member28is predetermined. Thus, the robot1changes its position and posture based on the operation program41and thereby supports the solder pot7with the support tool3.

FIG.22is an enlarged perspective view of the robot apparatus for explaining the eighth process of soldering. The robot controller4performs a preheating control for heating the printed board34aby heat released from the solder pot7. The robot controller4controls the robot1so that the solder pot7is moved closer to a portion to be soldered of each printed board34a. The table6is disposed so as to have a predetermined rotation angle. Thus, each printed board34ais disposed at a predetermined position. The robot1changes its posture based on the operation program41so as to move the solder pot7to a predetermined position with respect to the printed board34a. The solder pot7is spaced from the printed board34aby a predetermined distance. In the present embodiment, the area surrounded by the wall part72aof the solder pot7is disposed directly below a portion to be soldered.

In the solder pot7of the present embodiment, an opening is formed between the wall part72aand the nozzle31a(seeFIG.10). Molten solder is stored within the solder pot7. The temperature of the solder is, for example, 200° C. or more and 300° C. or less. High-temperature air rises from the area surrounded by the wall part72a, as indicated by arrow95. The printed board34acan be heated by the high-temperature air which is brought into contact with the back surface of the printed board34a. For example, the printed board34acan be preheated by disposing the solder pot7near the printed board34ain a predetermined time length.

Thus, the area surrounded by the wall part72ais disposed below a portion to be soldered, and thus the portion to be soldered can be locally heated. When a plurality of portions are soldered in one printed board, the robot controller4may perform the preheating control for the plurality of portions. Further, the robot controller4performs the preheating control for all the printed boards34adisposed in the first area.

In the preheating control of the present embodiment, a preheating operation before the solder is applied can be performed by using heat released from the solder pot7. Thus, it is not necessary to provide a device for heating a portion to be soldered, and the robot apparatus can be reduced in size.

FIG.23is an enlarged perspective view of the robot apparatus for explaining the ninth process of soldering. After the preheating of a printed board34ais completed, the robot controller4performs a supply control for moving the nozzle31acloser to the printed board34aso as to supply solder to a portion to be soldered. Based on the operation program41, the robot controller4causes the robot1to change its position and posture and thereby causes the opening at the tip of the nozzle31ato face the portion to be soldered. The nozzle31ais arranged so as to be away from the printed board34aby a predetermined distance. In the present embodiment, the solder pot7is disposed at a position closer to the printed board34athan the position in the preheating control.

Subsequently, the motor73of the solder pot7is driven and thereby the solder flows out from the tip of the nozzle31a. The solder flowed out from the tip of the nozzle31acomes into contact with the printed board34a, and thus the solder can be applied to the printed board34a. The electronic components36are secured to the printed board34aand connected to an electric circuit of the printed board.

The robot controller4performs a supply control for supplying solder to all the printed boards34adisposed in the first area. Further, when a plurality of portions in one printed board are soldered, the solder may be supplied to a plurality of portions in one printed board.

After the supply of the solder is completed, the robot controller4controls the robot1so that the solder pot7is disposed at a predetermined position in the placement member28. A notch28bis formed in the placement member28. The robot controller4can control the robot1so that the tool-side plate53is disposed inside the notch28b.

Subsequently, the robot apparatus5starts a soldering operation for the printed boards34barranged in the second area on the rear side (seeFIG.20). A flux application control for applying flux to the printed boards34barranged in the opening6bis performed. While the robot apparatus5applies the flux to the printed boards34barranged in the opening6bin the second area, the printed boards34aarranged in the opening6ain the first area are discharged. The printed boards34acan be discharged by a robot for discharging the printed boards34a. Alternatively, the operator may discharge the printed boards34a. Further, new printed boards34acan be disposed in the opening6a.

In the robot apparatus5of the present embodiment, while flux is applied to the printed boards in the area on the rear side, the printed boards arranged in the area on the front side are discharged. Further, new printed boards can be arranged in the area on the front side. Thus, the table6has a plurality of areas in which workpieces are arranged. The robot controller4continuously performs a flux application control, a preheating control, and a supply control for the areas one by one. By performing these controls, while the flux is applied to the printed boards arranged in one area, the printed boards that have been soldered can be discharged or new printed boards can be introduced. As a result, the soldering operation time can be shortened.

It should be noted that the table of the present embodiment is divided into two areas, but is not limited to this configuration. The table may be divided into three or more areas. Even in this case, the flux application control, the preheating control, and the supply control can be continuously performed for each area.

In the robot apparatus5in the present embodiment, one robot apparatus can continuously perform operations, i.e., from a flux applying operation to a solder supplying operation. A conveying device, such as a conveyor for conveying printed boards between a flux applying device, a preheating device, and a solder supplying device, is not necessary. In the robot apparatus5of the present embodiment, the robot1applies flux by using an operation tool. Further, the robot moves the solder pot7so as to preheat the printed boards34aand34band supply solder to the printed boards. The robot apparatus5for soldering of the present embodiment is small and can automatically perform soldering.

Furthermore, the robot apparatus5according to the present embodiment can automatically replace the nozzle31aof the solder pot7with another nozzle. Referring toFIG.5, a plurality of types of nozzles31b,31cand31dare placed on the placement member28of the present embodiment. The robot apparatus5of the present embodiment can replace the nozzle31adisposed in the solder pot7with any of the nozzles31b,31cand31d.

FIG.24is an enlarged perspective view of the support tool and the solder pot for explaining the first process of nozzle replacement of the present embodiment. The robot controller4causes the wrist15of the robot1to be coupled to the support tool3. The robot controller4causes the robot1to change its position and posture and thereby causes the chuck part62of the support tool3to be disposed so as to face the turning member74of the solder pot7.

FIG.25is an enlarged perspective view of the support tool and the solder pot for explaining the second process of replacing the nozzle of the solder pot. The robot controller4controls the robot1and the support tool3so that the claws64grasp the tip of the turning member74of the solder pot7. The robot controller4causes the chuck part62to move downward as indicated by arrow96after the claws64grasp the tip of the turning member74. As indicated by arrow99, the turning member74rotates about the axis as a rotation center supported by the support member75.

FIG.26is an enlarged perspective view of the support tool and the solder pot for explaining the third process of replacing the nozzle of the solder pot. As the turning member74is turned, the turning member74moves away from the engagement part35of the nozzle31a. In this way, the securing of the nozzle31ais released.

FIG.27is an enlarged perspective view of the support tool and the solder pot for explaining the fourth process of replacing the nozzle of the solder pot. After the turning member74is separated from the engagement part35of the nozzle31a, the chuck part62releases the turning member74.

FIG.28is an enlarged perspective view of the support tool and the solder pot for explaining the fifth process of replacing the nozzle of the solder pot. Subsequently, the robot controller4controls the robot1and the chuck part62so that the claws64of the chuck part62grasp the engagement part35of the nozzle31a. Further, after the chuck part62grasps the engagement part35, the robot controller4causes the robot1to change its position and posture so as to pull out the nozzle31afrom the container71of the solder pot7.

The robot controller4performs a control in which the nozzle31areciprocates in a predetermined direction immediately after the nozzle31ais removed from the solder pot7. In the present embodiment, the robot1stops when the nozzle31ais slightly away from the solder pot7. Subsequently, the robot1performs a control in which the nozzle31areciprocates in the vertical direction as indicated by arrow100. By performing this control, the molten solder that adheres to the nozzle31acan be dropped. The dropped solder returns to the inside of the container71through the space within the wall part72a.

Alternatively, the robot1may reciprocate the nozzle31ain the horizontal direction. Furthermore, the robot1may move the nozzle31ain the horizontal direction and may cause the nozzle31ato collide with the inner surface of the wall part72a. These controls also cause the molten solder that adheres to the nozzle31ato be dropped. Thus, the solder that adheres to the nozzle31acan be returned to the inside of the container71.

Subsequently, the robot controller4causes the robot1to change its position and posture and thereby causes the removed nozzle31ato be placed at a predetermined position of the placement member28. After the robot1changes its position and posture, the chuck part62of the support tool3releases the nozzle31a, and thus the nozzle31acan be placed on the placement member28.

Subsequently, the robot controller4performs a control for arranging a nozzle different from the nozzle31ain the solder pot7. The robot controller4can perform controls in reverse procedure to the control for removing the nozzle31afrom the solder pot7, and thus a new nozzle is attached to the solder pot7. In other words, the chuck part62of the support tool3grasps the engagement part35of one of the nozzles31b,31cand31d. Further, the robot1changes its position and posture and thereby inserts the nozzle into the space surrounded by the wall part72aof the solder pot7. The nozzle fits into the fitting member76of the solder pot (seeFIG.12). Thereafter, the chuck part62releases the nozzle.

Subsequently, the robot1changes its position and posture and thereby causes the chuck part62of the support tool3to grasp the tip of the turning member74of the solder pot7. Further, the robot1changes its position and posture so as to turn the turning member74. The turning member74is turned and thereby the tip of the turning member74is engaged with the engagement part35of the nozzle. The nozzle is secured to the solder pot7.

In this way, the chuck part62of the support tool3of the present embodiment can operate the securing mechanism80of the nozzles31a,31b,31cand31d. The solder pot7is formed so that a plurality of types of nozzles31a,31b,31cand31dcan be attached thereto. The robot controller4performs a control for operating the securing mechanism80by the chuck part62. The robot controller4performs a control for grasping the nozzle by the chuck part62. The robot controller4performs a replacement control for replacing the nozzle disposed in the solder pot7with a nozzle placed on the placement member28. The replacement control for nozzles can be performed based on the operation program41.

It is preferable that the shape of the tip of the nozzle of the solder pot and the size of the opening at the tip correspond to the shape and size of a portion to be soldered. For example, when the portion to be soldered is small, it is preferable that the opening at the tip of the nozzle is small. Alternatively, not only components may be disposed on the upper side of the printed board, but also components may be disposed on the back side of the printed board. When the diameter of the tip of the nozzle is large, the nozzle may interfere with the components disposed on the back side of the printed board. In such a case, it is preferable to use a nozzle having a small tip diameter. Further, when a plurality of types of printed boards are soldered, it is preferable to replace the nozzle depending on the type of each printed board.

In the robot apparatus of the present embodiment, the nozzle of the solder pot can be automatically replaced depending on the size and shape of a portion to be soldered. Alternatively, when a plurality of portions in one type of printed board are soldered, the nozzle may be replaced with another nozzle during the period of soldering the one type of printed board in order to solder the plurality of portions.

Subsequently, the robot apparatus of the present embodiment can automatically perform a control for replenishing solder when the amount of solder stored in the solder pot decreases. The control for replenishing solder can be performed based on the operation program41. Referring toFIG.5, auxiliary solder bars32are placed on the placement member28. The robot controller4performs a control for inserting the solder bar32into the solder pot7based on the operation program41.

In the solder pot7of the present embodiment, a sensor for detecting the amount of solder stored in the solder pot is disposed. Any sensor that can detect the amount of solder, such as a water level sensor, can be used as the sensor. The robot controller4detects the amount of solder inside the solder pot7. The robot controller4detects that the amount of solder is small. For example, the robot controller4detects the amount of solder that is less than a predetermined determination value.

FIG.29is an enlarged perspective view of the robot apparatus for explaining the first process of a control for replenishing the solder pot with solder. The robot controller4controls the robot1and the chuck part62so that a solder bar32is grasped by the chuck part62of the support tool3. The chuck part62grasps one of the solder bars32placed on the placement member28.

FIG.30is an enlarged perspective view of the robot apparatus for explaining the second process of the control for replenishing the solder pot with solder. The robot controller4causes the robot1to change its position and posture and thereby causes the solder bar32to be inserted into a hole72bas an insertion port formed in the lid member72of the solder pot7as indicated by arrow97. The solder bar32is inserted into the solder pot7and then melted.

In this way, the robot1and the chuck part62of the support tool3are controlled so as to replenish the solder bar32. In the robot apparatus5of the present embodiment, it is not necessary to arrange a device for supplying solder, and the configuration of the device for soldering can be simplified. It is also conceivable to arrange a device for supplying solder formed in a linear shape to the solder pot. However, when the solder formed in a linear shape is supplied, there is the problem that it takes a long time to supply the solder. By supplying the solder bar as in the present embodiment, the time required for supplying the solder can be shortened.

The support tool for supporting the solder pot in the present embodiment has a chuck part that can grasp a workpiece, but is not limited to this configuration. Apart from the support tool, an operation tool such as a hand tool for grasping the workpiece can be disposed. This operation tool can also be placed on the placement member. However, as in the present embodiment, the chuck part is disposed on the support tool, and thus the number of operation tools can be reduced, and the size of the robot apparatus can be reduced.

FIG.31shows another flux ejection tool according to the present embodiment. Another flux ejection tool8of the present embodiment has a surrounding member59disposed around the nozzle56. The surrounding member59is formed so as to surround the nozzle56. Further, the surrounding member59in the present embodiment is formed into a conical shape. The surrounding member59is formed so that the inner diameter increases toward the tip of the nozzle56.

When the flux is ejected from the tip of the nozzle56, the flux may scatter and may contaminate members inside the robot apparatus5. The surrounding member59is disposed in the flux ejection tool8, and thus the flux can be suppressed from being scattered around. For example, it is possible to suppress the flux from adhering to the surface of the device disposed inside the frame body26.

In the above embodiments, the workpiece is preheated with high-temperature air generated in the solder pot, but the embodiment is not limited to this. An operation tool for preheating the workpiece may be disposed separately from the solder pot.

FIG.32is a perspective view of a preheating tool of the present embodiment. The preheating tool9is an operation tool coupled to the wrist15of the robot1. The preheating tool9includes a base member66and an electric heater67serving as a heater disposed on the surface of the base member66. The temperature of the electric heater67increases when the electricity is supplied via a cable68. The preheating tool9is coupled to the robot-side plate51, which is secured to the wrist15of the robot1, via the tool-side plate54.

The preheating tool9can be placed on the placing member when not in use. For example, a notch corresponding to the electric heater67can be formed in the placement member. The preheating tool9can be placed on the placement member so that the electric heater67is disposed inside the notch.

When the robot apparatus includes the preheating tool9, the flux application control can be performed in the same manner as the above-described control. In a preheating control, the robot controller4changes the operation tool coupled to the robot1from the flux ejection tool2to the preheating tool9. The robot controller4causes the robot1to change its position and posture so as to move the preheating tool9closer to one printed board34a,34b. The robot1arranges the electric heater67so that the electric heater faces the printed board34a,34b. This control enables the printed board34a,34bto be heated. Thereafter, the robot controller4changes the operation tool coupled to the robot1to the support tool3. The robot controller4can perform a supply control for supporting the solder pot7by the robot1and supplying solder to a portion to be soldered.

Even in the robot apparatus provided with the preheating tool of the present embodiment, it is not necessary to convey the printed board among a flux applying device, a substrate preheating device, and a solder supplying device. Thus, the size of the apparatus for soldering can be reduced.

In the present embodiment, the position and posture of the robot are controlled so as to be the position and posture which are predetermined in the operation program, but are not limited to this configuration. For example, a camera may be disposed on a wrist or a chuck part of the robot. The robot controller may detect a position of an object to be operated based on the image captured by the camera. For example, the robot controller may detect, for example, the position of the operation tool placed on the placement member, the position of the printed board, and the position of the turning member of the solder pot, based on the image captured by the camera.

The workpiece of the present embodiment is a printed board, but is not limited to this configuration. Any workpiece can be adopted as a workpiece to be soldered.

In the present embodiment, all operation tools and members necessary for soldering are arranged on the surface of one placement member, but are not limited to this configuration. The robot apparatus may include a plurality of placement members. For example, operation tools and members necessary for soldering may be separately placed on a plurality of placement members.

According to an aspect of this disclosure, it is possible to provide a small robot apparatus that can perform soldering.

In each of the above-described controls, the order of the steps can be appropriately changed within a range where the function and the action are not changed.

The above embodiments can be combined as appropriate. In the respective drawings described above, the same or equivalent parts are denoted by the same reference numerals. It should be noted that the above embodiments are for purposes of illustration and do not limit the invention. Further, in the embodiments, modifications of the embodiments shown in the claims are included.