MALFUNCTION DETERMINING DEVICE AND MALFUNCTION DETERMINING METHOD FOR COMPONENT MOUNTING MACHINE

A malfunction determining device includes a head including a pickup member for picking up a component, a moving device configured to move the head, an inspection section, a determining section, and a notification section. The inspection section executes multiple inspections including a first inspection for performing a mounting operation under control of the head and the moving device to inspect whether the mounting operation is good or bad, and a second inspection for performing a calibration measurement of the head to inspect whether the calibration measurement is good or bad. The determining section determines presence or absence of a malfunction and a malfunction location in the head and the moving device based on a combination of results of the multiple inspections.

TECHNICAL FIELD

The present specification discloses a malfunction determining device and a malfunction determining method of a component mounting machine.

BACKGROUND ART

In the related art, in a component mounting line, a malfunction detecting system for detecting a malfunction of a device during manufacturing of a mounting board is known (refer to Patent Literature 1, for example). The system includes a data collection section, a determining section, and a notification processing section. The data collection section collects operation status data from a component mounting line including multiple component mounting machines. The determining section determines whether the tendency of one or more feature amount data included in the operation status data collected by the data collection section deviates from the tendency of the feature amount data at the time of normal operation. When the determining section determines that the tendency of the feature amount data deviates from the tendency at the time of normal processing, the notification processing section causes a display section to notify that the device corresponding to the feature amount data is malfunctioning.

PATENT LITERATURE

BRIEF SUMMARY

Technical Problem

Incidentally, as one of the methods for inspecting the malfunction of a device, it is conceivable to inspect whether the mounting accuracy is good or bad by measuring the deviation of a mounting location after a mounting operation for picking up a component and mounting the component on a board is performed. In this case, even if the inspection result indicates that there is a malfunction, if it is not known where the malfunction location is, an operator will require a long work time to investigate the malfunction location, and the work load will be excessive.

It is a main object of the present disclosure to provide a malfunction determining device capable of determining the malfunction location of a component mounting machine including a head and a moving device for mounting a component on a board when it is determined that the component mounting machine is malfunctioning.

Solution to Problem

The present disclosure employs the following means in order to achieve the above-mentioned main object.

A malfunction determining device of a component mounting machine according to the present disclosure includes a head including a pickup member for picking up a component, a moving device configured to move the head, an inspection section configured to execute multiple inspections including a first inspection for performing a mounting operation under control of the head and the moving device to inspect whether the mounting operation is good or bad and a second inspection for performing a calibration measurement of the head to inspect whether the calibration measurement is good or bad, and a determining section configured to determine presence or absence of a malfunction and a malfunction location in the head and the moving device based on a combination of results of the multiple inspections.

In the first inspection, data is measured in association with an operation of the parts constituting the head and an operation of the parts constituting the moving device. On the other hand, in the second inspection, data is measured in association with the operation of the parts constituting the head. Therefore, according to the malfunction determining device of a component mounting machine according to the present disclosure, it is possible to appropriately determine presence or absence of a malfunction and a malfunction location in the head and the moving device based on a combination of a result of the first inspection and a result of the second inspection.

DESCRIPTION OF EMBODIMENTS

Next, an embodiment of the present disclosure will be described with reference to drawings.FIG.1is a schematic configuration diagram of a component mounting system.FIG.2is a top view of a component mounting machine.FIG.3is a schematic configuration diagram of a mounting head.FIG.4is a schematic configuration diagram of a ZS-axis driving device.FIG.5is a block diagram illustrating an electrical connection relationship between a control device and a management device of the component mounting machine. InFIGS.1and2, a left-right direction is set as an X-axis direction, a front-rear direction is set as a Y-axis direction, and an up-down direction is set as a Z-axis direction.

As illustrated inFIG.1, component mounting system1includes printer2, print inspection device3, multiple component mounting machines10, mounting inspection device (not illustrated), and management device100(refer toFIG.5) that manages the entire system. Printer2is a device for printing solder on board S. Print inspection device4is a device for inspecting a state of solder printed by printer2. Component mounting machine10is a device for mounting a component on board S. The mounting inspection device is a device for inspecting a mounting state of a component mounted on component mounting machine10. Printer2, print inspection device3, multiple component mounting machines10, and the mounting inspection device are arranged and installed in this order in the conveyance direction of board S to constitute a production line.

As illustrated inFIG.2, component mounting machine10includes housing12mounted on base11, feeder21, board conveyance device22, head moving device30, mounting head40, and control device90(refer toFIG.5). In addition to these, component mounting machine10also includes part camera23, mark camera24, nozzle station25, and the like. Part camera23is provided between feeder21and board conveyance device22for imaging component P picked up by suction nozzle45of mounting head40from the bottom side. Mark camera24is provided on mounting head40for imaging and reading a reference mark affixed to board S from the top side. In addition, nozzle station25accommodates multiple types of suction nozzles for replacement, as well as jig nozzle IN used for calibration measurement of mounting head40described later.

As illustrated inFIG.2, feeders21are arranged on a front face portion of component mounting machine10along an X-axis direction (left-right direction). Although not illustrated, feeder21includes a tape reel around which a tape is wound, and a tape feeding mechanism that pulls the tape from the tape reel and feeds the tape to a component supply position. Cavities are formed in the tape at predetermined intervals along the longitudinal direction of the tape. Component P is accommodated in the cavity. Feeder21feeds the tape by a predetermined amount by a feeder feeding mechanism (motor), thereby sequentially supplying components P accommodated in the tape to the component supply position. Component P housed in the tape is protected by a film covering the surface of the tape, and when the film is peeled off before the component supply position, component P is exposed at the component supply position, and component P can be picked up by suction nozzle45.

Board conveyance device22includes a pair of conveyor belts that are provided at intervals in the front-rear direction ofFIG.1and spanned in the X-axis direction (the left-right direction). Board S is conveyed from the left to the right in the drawing by the conveyor belt of board conveyance device22.

Head moving device30moves mounting head40in the XY-axis direction (front-rear left-right direction), and includes X-axis slider32and Y-axis slider34, as illustrated inFIG.2. X-axis slider32is supported by a pair of upper and lower X-axis guide rails31provided on the bottom face of Y-axis slider34so as to extend in the X-axis direction (the left-right direction), and is movable in the X-axis direction by the driving of X-axis motor36(refer toFIG.5). Y-axis slider34is supported by a pair of left and right Y-axis guide rails33provided on the upper stage portion of housing12so as to extend in the Y-axis direction (the front-rear direction), and is movable in the Y-axis direction by the driving of Y-axis motor38(refer toFIG.5). The position of X-axis slider32in the X-axis direction is detected by X-axis position sensor37(refer toFIG.5), and the position of Y-axis slider34in the Y-axis direction is detected by Y-axis position sensor39(refer toFIG.5). Mounting head40is attached to X-axis slider32. Therefore, mounting head40is movable along an XY plane (horizontal plane) by driving and controlling head moving device30(X-axis motor36and Y-axis motor38).

Mounting head40is configured as a rotary head, and as illustrated inFIG.3, includes head main body41, rotation body42, multiple nozzle holders44(eight in the embodiment), multiple suction nozzles45(eight in the embodiment), R-axis driving device50, Q-axis driving device60, two Z-axis driving devices70, and ZS-axis driving device80(refer toFIG.4).

Rotation body42is rotatably supported by head main body41via rotation axis43coaxially coupled. Mark forming member46on which a reference mark (head reference mark HM) detected by a camera (part camera23) is formed is provided at an axial center of the lower surface of rotation body42.

Nozzle holders44are arranged at predetermined angular intervals (in the embodiment, at intervals of 45 degrees) on the same circumference about the axial center of rotation body42, and are supported so as to be freely lifted and lowered by rotation body42. Suction nozzle45is mounted on the distal end portion of nozzle holder44. Suction nozzle45includes a suction port at the distal end, and picks up component P by a negative pressure supplied from a negative pressure source (not illustrated) to the suction port via pressure adjustment valve47(refer toFIG.5). Suction nozzle45is detachable from nozzle holder44, and is replaced with a nozzle suitable for picking up component P according to the type of component P to be picked up.

R-axis driving device50rotates rotation body42to pivot (revolve) multiple nozzle holders44(multiple suction nozzles45) circumferentially around the center axis of rotation body42. As illustrated inFIG.3, R-axis driving device50includes R-axis motor51, driving gear52provided on the rotation axis of R-axis motor51, and R-axis gear53coaxially provided on the outer circumferential surface of rotation body42and having external teeth meshing with driving gear52. R-axis driving device50rotates rotation body42by rotationally driving R-axis gear53by R-axis motor51. Each nozzle holder44pivots (revolves) in the circumferential direction integrally with suction nozzle45by the rotation of the rotation body42. In addition, R-axis driving device50includes R-axis position sensor55(refer toFIG.5) for detecting the rotational position of R-axis gear53, that is, the pivoting position of each nozzle holder44(suction nozzle45).

Q-axis driving device60rotates (spins) each nozzle holder44(each suction nozzle45) about the center axis thereof. As illustrated inFIG.3, Q-axis driving device60includes Q-axis motor61, driving gear62provided on the rotation axis of Q-axis motor61, pinion gear63provided coaxially with each nozzle holder44, and Q-axis gear64meshing with driving gear62and meshing with each pinion gear63. Pinion gear63is provided on the upper portion of each nozzle holder44and slidably meshes with Q-axis gear64in the Z-axis direction (up-down direction). Q-axis gear64is configured as a cylindrical member inserted so as to be coaxial with and relatively rotatable with rotation axis43. Q-axis driving device60rotationally drives Q-axis gear64by Q-axis motor61, thereby collectively rotating each pinion gear63meshing with Q-axis gear64in the same direction. Each nozzle holder44rotates (spins) about the center axis thereof integrally with suction nozzle45by the rotation of pinion gear63. In addition, Q-axis driving device60includes Q-axis position sensor65(refer toFIG.5) for detecting the rotational position of Q-axis gear64, that is, the rotational position of each nozzle holder44(suction nozzle45).

Each Z-axis driving device70is configured to individually lift and lower nozzle holder44at two locations on the pivot (revolving) trajectory of nozzle holder44. Suction nozzle45attached to nozzle holder44moves up and down together with nozzle holder44. Any of Z-axis driving devices70includes Z-axis slider71and Z-axis motor72for lifting and lowering Z-axis slider71, as illustrated inFIG.3. In addition, each Z-axis driving device70also includes Z-axis position sensor73(refer toFIG.5) for detecting the lifting and lowering position of corresponding Z-axis slider71, that is, the lifting and lowering position of corresponding nozzle holder44(suction nozzle45). Each Z-axis driving device70drives Z-axis motor72to lift and lower corresponding Z-axis slider71, thereby contacting nozzle holder44located below Z-axis slider71to lift and lower nozzle holder44integrally with suction nozzle45. Each Z-axis driving device70may be configured by using a linear motor, or may be configured by using a rotation motor and a feeding screw mechanism.

ZS-axis driving device80is a device for lifting and lowering mounting head40(head main body41) in the up-down direction (ZS-axis direction). As illustrated inFIG.4, ZS-axis driving device80includes guide rail81extending in the ZS-axis direction, and ZS-axis motor82for lifting and lowering head main body41along guide rail81. In addition, ZS-axis driving device80includes ZS-axis position sensor83(refer toFIG.5) for detecting the up-down position of head main body41. ZS-axis driving device80may be configured by using a linear motor, or may be configured by using a rotation motor and a feeding screw mechanism. In a case where, for example, component P having a low height is picked up and mounted, since component mounting machine10can shorten the up-down stroke of suction nozzle45by lowering mounting head40in advance, the operation time can be shortened. On the other hand, in a case where component P having a high height is picked up and mounted, component mounting machine10can prevent suction nozzle45from interfering with component P when performing the suction operation by lifting mounting head40in advance. As a result, component mounting machine10can handle multiple types of components P having different heights without replacing mounting head40.

As illustrated inFIG.5, control device90is configured as a microprocessor centered on CPU91, and includes ROM92, HDD93, RAM94, an input/output interface (not illustrated), and the like in addition to CPU91. Various detection signals from X-axis position sensor37, Y-axis position sensor39, R-axis position sensor55, Q-axis position sensor65, Z-axis position sensor73, ZS-axis position sensor83, and the like are input to control device90via the input/output interface. In addition, image signals and the like from part camera23and mark camera24are also input to control device90via the input/output interface. On the other hand, control device90outputs various control signals to feeder21, board conveyance device22, X-axis motor36, Y-axis motor38, R-axis motor51, Q-axis motor61, Z-axis motor72, ZS-axis motor82, pressure adjustment valve47, mark camera24, part camera23, and the like via the input/output interface.

As illustrated inFIG.5, management device100is a general-purpose computer including CPU101, ROM102, HDD103(storage device), RAM104, and the like. Input signals from input device105including a mouse and a keyboard are input to management device100. Management device100outputs a display signal to display106.

Next, the operation of component mounting machine10according to the embodiment configured as described above will be described. First, CPU91of control device90controls head moving device30so that suction nozzle45moves above the component supply position of feeder21that supplies component P to be picked up. CPU91controls corresponding Z-axis driving device70so that suction nozzle45moves down, and controls pressure adjustment valve47so that the negative pressure is supplied to the suction port of suction nozzle45. As a result, component P is picked up by suction nozzle45.

When component P is picked up by suction nozzle45, CPU91controls head moving device30so that mounting head40moves above part camera23, and images component P picked up by suction nozzle45by part camera23from the bottom side. Subsequently, CPU91processes the captured image, measures the suction deviation amount of component P picked up by suction nozzle45(each suction deviation amount in the X-axis direction and the Y-axis direction) (suction inspection), and corrects the mounting position of board S based on the measured suction deviation amount. Next, CPU91controls head moving device30so that component P picked up by suction nozzle45is located above the corrected mounting position. Then, CPU91controls corresponding Z-axis driving device70so that suction nozzle45moves down, and controls pressure adjustment valve47so that the supply of the negative pressure to the suction port of suction nozzle45is canceled. As a result, component P is mounted on the mounting position of board S.

Next, inspection processing for inspecting component mounting machine10and malfunction determination processing for determining presence or absence of a malfunction and a malfunction location based on an inspection result will be described.FIG.6is a flowchart illustrating an example of inspection processing executed by CPU91of control device90.

In the inspection processing, CPU91of control device90first determines whether a command to execute an inspection has been received from management device100(S100). The command to execute an inspection may be transmitted from management device100to control device90of each component mounting machine10, for example, when a predetermined operation is performed by an operator via input device105. In addition, the command to execute an inspection may be transmitted from management device100to control device90of each component mounting machine10(timer setting), for example, when the setting time registered in advance by an operation of the operator is reached.

When receiving the execution command, CPU91next determines whether inspection board IS for performing a mounting accuracy inspection, which is one of the inspections, is set in board conveyance device22(S110). Inspection board IS is, for example, a rectangular plate-shaped member having an identification mark detectable by a camera on the surface thereof, and is held by carrier200together with inspection component IP.FIG.7is an appearance perspective view of carrier200. As illustrated in the drawing, carrier200includes rectangular carrier main body201on which inspection board IS is disposed at the center portion of the surface thereof, and elongated component accommodation tray205attached to the outer circumferential portion of the surface of carrier main body201. Inspection board IS is accommodated in a rectangular recess formed in the center portion of the surface of carrier main body201, and is held by carrier main body201by fastener202. Multiple inspection components IP are accommodated in multiple component accommodation pockets205aformed so as to line up in the longitudinal direction on the surface of component accommodation tray205in a state of being overlapped respectively. The determination in S110is performed, for example, by performing an operation of transporting inspection board IS (carrier200) into the machine by board conveyance device22, imaging the conveyance position with mark camera24, processing the captured image, and determining whether an identification mark affixed to inspection board IS can be recognized in the captured image.

When determining that inspection board IS is not set in board conveyance device22, CPU91transmits a predetermined warning signal to management device100(S120), and returns to5110. Management device100that has received a warning signal displays a message on display108prompting the operator to set inspection board IS. When determining that inspection board IS is set in board conveyance device22, CPU91initiates the mounting accuracy inspection (S130).

The mounting accuracy inspection is performed in the following manner. CPU91controls head moving device30and mounting head40so that suction nozzle45moves above inspection component IP accommodated in component accommodation pocket205aand inspection component IP is picked up by suction nozzle45. Subsequently, CPU91controls head moving device30and mounting head40so that inspection component IP that is picked up moves above a target mounting position of inspection board IS and inspection component IP is mounted on the target mounting position. The mounting operation of inspection component IP with respect to inspection board IS is performed for each suction nozzle45provided in mounting head40. Next, CPU91controls head moving device30and mark camera24so that mark camera24moves above inspection board IS and mark camera24images inspection component IP mounted on inspection board IS. Then, CPU91measures the mounting deviation amount of inspection component IP (mounting deviation amount ΔXp in the X-axis direction, mounting deviation amount ΔYp in the Y-axis direction, and angle deviation amount Δθp) with respect to the target mounting position of inspection board IS for each suction nozzle45used in the mounting operation by performing the image processing on the captured image. When the measurement is completed, CPU91controls head moving device30and mounting head40so that suction nozzle45moves above inspection component IP mounted on inspection board IS and inspection component IP is picked up by suction nozzle45. Next, CPU91controls head moving device30and mounting head40so that inspection component IP picked up by suction nozzle45is accommodated (returned) in a vacant pocket among component accommodation pockets205a.CPU91controls board conveyance device22so that carrier200accommodating inspection board IS and inspection component IP is transported to downstream component mounting machine10. As a result, carrier200accommodating inspection board IS and inspection component IP is delivered to next component mounting machine10, and a similar mounting accuracy inspection is executed in next component mounting machine10. As described above, by sequentially executing the mounting accuracy inspection from the upstream side to the downstream side by multiple component mounting machines10constituting the production line, the mounting accuracy inspection of all component mounting machines10can be efficiently performed.

FIG.8is an explanatory diagram illustrating an example of mounting accuracy data. As illustrated in the drawing, the mounting accuracy data includes mounting deviation amount ΔXp in the X-axis direction, mounting deviation amount ΔYp in the Y-axis direction, and angle deviation amount Δθp as measured values. This mounting accuracy data is generated for each suction nozzle45used in the mounting operation.

When determining that the mounting accuracy inspection is completed, CPU91next determines whether jig nozzle IN used for head calibration measurement is accommodated in nozzle station25(S150).FIG.9is a schematic configuration diagram of a jig nozzle. Jig nozzle IN has substantially the same outer shape as suction nozzle45. A reference mark (nozzle reference mark NM) detected by a camera (part camera23) is formed on the end surface of jig nozzle IN. The processing of S150is performed, for example, by imaging nozzle station25with mark camera24, processing the captured image, and determining whether the identification mark affixed to jig nozzle IN can be recognized in the captured image. When determining that jig nozzle IN is not accommodated in nozzle station25, CPU91transmits a predetermined warning signal to management device100(S160), and returns to S150. Management device100that has received a warning signal displays a message on display108prompting the operator to accommodate jig nozzle IN. In step S170, when determining that jig nozzle IN is accommodated in nozzle station25, CPU91initiates the head calibration measurement.

The head calibration measurement includes ZS-axis inclination measurement for measuring the inclination of a ZS axis, nozzle mounting position measurement for measuring the mounting position of suction nozzle45for each nozzle holder44(bending of nozzle holder44, and the like).

The ZS-axis inclination measurement is performed in the following manner. First, CPU91controls ZS-axis driving device80so that mounting head40moves up to the lifting end in the ZS axis. Subsequently, CPU91controls head moving device30and part camera23so that mark forming member46of mounting head40moves above part camera23and head reference mark HM formed on mark forming member46is imaged. Next, CPU91controls ZS-axis driving device80so that mounting head40moves down to the lowering end in the ZS axis, and then controls part camera23so that head reference mark HM is imaged in the same manner. That is, CPU91images head reference mark HM of mounting head40at each position of the lifting end and lowering end in the ZS axis. Then, CPU91recognizes each of head reference marks HM by performing image processing on the obtained two captured images, measures the positional deviation amount between the recognized head reference marks HM in the X-axis direction as inclination amount ΔXzs in the X-axis direction, and measures the positional deviation amount in the Y-axis direction as inclination amount ΔYzs in the Y-axis direction.

The nozzle mounting position is measured in the following manner. First, CPU91controls head moving device30and mounting head40so that mounting head40moves above nozzle station25and jig nozzle IN is mounted on each nozzle holder44of mounting head40. Subsequently, CPU91controls head moving device30and part camera23so that nozzle reference mark NM formed at the distal end of jig nozzle IN is imaged in a state in which jig nozzle IN moves above part camera23and jig nozzle IN is located at the lifting end in the Z-axis direction. Next, CPU91controls Z-axis driving device70so that jig nozzle IN moves down to the lowering end in the Z-axis, and then controls part camera23so that nozzle reference mark NM is imaged in the same manner. That is, CPU91images nozzle reference mark NM of jig nozzle IN at each position of the lifting end and the lowering end in the Z axis. Then, CPU91recognizes each of nozzle reference marks NM by performing image processing on the two obtained captured images, measures the positional deviation amount between recognized nozzle reference marks NM in the X-axis direction as inclination amount ΔXn in the X-axis direction, and measures the positional deviation amount in the Y-axis direction as inclination amount ΔYn in the Y-axis direction.

FIG.10is an explanatory diagram illustrating an example of calibration data. As illustrated in the drawing, the calibration data includes, as measured values, a ZS axis inclination, a nozzle mounting position for each nozzle, and the like. The ZS-axis inclination includes inclination amount ΔXzs in the X-axis direction and inclination amount ΔYzs in the Y-axis direction. The nozzle mounting position includes inclination amount ΔXn in the X-axis direction and inclination amount ΔYn in the Y-axis direction.

When determining that the head calibration measurement is completed, CPU91transmits the obtained measured values (mounting accuracy data and calibration data) to management device100(S190). In step S200, CPU91determines whether a shutdown has been instructed. If it is determined that there is no instruction of the shutdown, CPU91ends the malfunction inspection processing as it is, whereas if it is determined that there is a instruction of the shutdown, CPU91shuts down (S210) and ends the malfunction inspection processing. The shutdown is instructed by the operator inputting in advance to management device100via input device105. In a case where the operator has set the inspection processing to be executed after the day's work is completed, by instructing in advance the shutdown after the inspection is completed, the operator can leave without waiting for the inspection to complete.

Next, the malfunction determination processing performed by using the result of the malfunction inspection processing will be described.FIG.11is a flowchart illustrating an example of the malfunction determination processing executed by CPU101of management device100.

In the malfunction determination processing, CPU101of management device100first waits to receive measured values from component mounting machine10(S300). When receiving the measured values, CPU101stores the received measured values in HDD103(storage device) and analyzes the received measured values (S310).FIG.12is an explanatory diagram illustrating an example of the measured values stored in the storage device. As illustrated in the drawing, HDD103(storage device) stores the mounting accuracy data and the calibration data as measured values in association with the execution date of the inspection.

The analysis of the mounting accuracy data is performed in the following manner. First, CPU101calculates average value μ and standard deviation a of the deviation amount received so far for each deviation amount among mounting deviation amounts ΔXp and ΔYp, and angular deviation amount Δθp. Subsequently, CPU101determines whether the deviation amount received this time falls within a range determined by a lower limit value (μ−3σ) obtained by subtracting 3σ from average value μ and an upper limit value (μ+3ρ) obtained by adding 3σ to average value μ, for each deviation amount. The lower limit value and the upper limit value may be a value determined by using 2σ instead of 3σ, or may be a value determined by using σ, or may be a value selected by the operator. Then, when determining that any of the deviation amounts received this time falls within the range determined by the lower limit value and the upper limit value (refer to, for example,FIG.13(a), CPU101determines that there is no sign of a malfunction (‘no malfunction’). On the other hand, when determining that any of the deviation amounts received this time does not fall within the range determined by the lower limit value and the upper limit value (refer to, for example,FIG.13(b)), CPU101determines that there is a sign of a malfunction (‘malfunction’). As described above, the mounting accuracy inspection is performed by using inspection component IP held by carrier200together with inspection board IS, instead of component P supplied from feeder21. Therefore, the analysis result of the mounting accuracy data is not affected by the malfunction of feeder21, and reflects the influence of the malfunction of head moving device30or mounting head40.

The analysis of the calibration data (the ZS-axis inclination and the nozzle mounting position) is performed in the following manner. When analyzing the ZS-axis inclination, CPU101first calculates average value μ and standard deviation σ of the inclination amount received so far for each inclination amount among inclination amounts ΔXzs and ΔYzs. Subsequently, CPU101determines whether the inclination amount received this time falls within a range determined by a lower limit value (μ−3σ) obtained by subtracting 3σ from average value μ and an upper limit value (μ+3σ) obtained by adding 3σ to average value μ, for each inclination amount. The lower limit value and the upper limit value may be a value determined by using 2σ instead of 3σ, or may be a value determined by using σ, or may be a value selected by the operator. Then, when determining that any of the indication amounts received this time falls within the range determined by the lower limit value and the upper limit value, CPU101determines that there is no sign of a malfunction (‘no malfunction’), and determines that there is an indication of a malfunction (‘malfunction’) when determining that any of the inclination amounts received this time does not fall within the range determined by the lower limit value and the upper limit value. CUP101can also be similarly performed when analyzing the nozzle mounting position (inclination amount ΔXn in the X-axis direction and inclination amount ΔYn in the Y-axis direction). As described above, the head calibration measurement is performed by operating the parts constituting mounting head40. Therefore, only the influence of the malfunction of mounting head40is reflected in the analysis result of the calibration data.

As described above, in the present embodiment, CPU101analyzes the measured values by determining whether the measured value received this time falls within a predetermined range of the distribution centered on average value μ of the measured values received so far (inFIG.13, the area surrounded by the dashed line). Then, when determining that the measured value received this time falls within the predetermined range (refer toFIG.13(a)), CPU101determines that there is no malfunction, and determines that there is a malfunction when determining that the measured value received this time does not fall within the predetermined range (refer toFIG.13(b)).

In step S320, CPU101determines whether the result of the mounting accuracy inspection is a result of a malfunction as a result of the analysis of the mounting accuracy data. When determining that the result of the mounting accuracy inspection is a result of no malfunction, CPU101determines that neither head moving device30nor mounting head40is malfunctioning (S330).

On the other hand, when determining that the result of the mounting accuracy inspection is a result of a malfunction, CPU101further determines whether the result of the head calibration measurement is a result of a malfunction (S340). When determining that the result of the head calibration measurement is a result of no malfunction, CPU101determines that there is a malfunction in head moving device30(S350). On the other hand, when determining that the result of the head calibration measurement is the result of a malfunction, CPU101determines that mounting head40is malfunctioning (S360).

When determining the presence or absence of a malfunction and a malfunction location in this manner, CPU101displays the determination result on display108(S370) in order to notify the operator of the determination result, and ends the malfunction determination processing.FIG.14is an explanatory diagram illustrating an example of a notification screen of a malfunction determination result. The drawing is an example of a notification screen when there is a malfunction in mounting head40.

Here, a correspondence relationship between main elements of the embodiment and main elements of the present disclosure described in the scope of claims will be described. That is, mounting head40of the embodiment corresponds to the head of the present disclosure, head moving device30corresponds to a moving device, CPU91of control device90that executes the inspection processing corresponds to an inspection section, CPU101of management device100that executes the malfunction determination processing corresponds to a determining section, and display106corresponds to a notification section.

It goes without saying that the present disclosure is not limited to the above-mentioned embodiment and may be carried out in various aspects within the technical scope of the present disclosure.

For example, in the above embodiment, in the malfunction determination processing, CPU101determines the presence or absence of a malfunction by determining whether the measured value received this time falls within the predetermined range of the distribution centered on average value μ of the measured values received so far. However, CPU101may determine the presence or absence of a malfunction by determining whether the measured value received this time falls within a predetermined range centered on a value determined from the tendency of change in the measured values received so far. For example, when the current measured value is set to X0, CPU101determines the presence or absence of a malfunction by determining whether the value falls within a range determined by a lower limit value obtained by multiplying tendency Xa of the change in the measured values received so far by coefficient k1smaller than value 1 and an upper limit value obtained by multiplying tendency Xa by coefficient k2larger than value 1. However, tendency Xa of the change in the measured values received so far is defined by the following equation (1) when X1is a measured value received one time before, X2is a measured value received two times before, Xi is a measured value received i times before, and a1, a2, . . . , ai are weighting parameters, respectively. Predetermined values may be used as coefficients k1and k2, or values designated by the operator may be used.

In the above embodiment, CPU101determines the malfunction of head moving device30and mounting head40provided in component mounting machine10, but may additionally determine the malfunction of feeder21. The determination of a malfunction of feeder21is performed in the following manner. CPU101receives the above-described suction deviation amount (each suction deviation amount in the X-axis direction and the Y-axis direction) measured in the suction inspection executed after the suction operation is executed in each component mounting machine10from control device90, and analyzes the received suction deviation amounts. The analysis of the suction deviation amount can be performed in the same manner as the analysis of the mounting accuracy data and the calibration data described above. Then, when the result of the mounting accuracy inspection is a result of no malfunction and the result of the suction inspection is a result of a malfunction, CPU101determines that there is a malfunction in feeder21.

As described above, a malfunction determining device of a component mounting machine according to the present disclosure includes a head configured to include a pickup member for picking up a component, a moving device configured to move the head, an inspection section configured to execute multiple inspections including a first inspection for performing a mounting operation under control of the head and the moving device to inspect whether the mounting is good or bad and a second inspection for performing calibration measurement of the head to inspect whether the measurement is good or bad, and a determining section configured to determine presence or absence of a malfunction and a malfunction location in the head and the moving device based on a combination of results of the multiple inspections.

In such a malfunction determining device of a component mounting machine according to the present disclosure, when the result of the first inspection is a result of a malfunction, the determining section may determine that the moving device is malfunctioning if the result of the second inspection is a result of no malfunction, and may determine that the head is malfunctioning if the result of the second inspection is a result of a malfunction. By doing so, it is possible to more appropriately determine which of the head and the moving device has a malfunction.

In the malfunction determining device of the component mounting machine according to the present disclosure, the inspection section may shut down the component mounting machine after the first inspection and the second inspection are completed. As a result, the operator can leave the holding site after the work is completed without waiting for component mounting machine10to end the inspection.

Further, in the malfunction determining device of the component mounting machine according to the present disclosure, the first inspection is an inspection for determining whether the mounting operation is good or bad by sequentially mounting multiple components of the same type on an inspection board by sequentially picking up the multiple components by the pickup member by the pickup member and detecting a positional deviation of each mounted component, and the inspection section initiates the first inspection when the inspection board is set and a command to initiate an inspection is issued.

In the malfunction determining device of the component mounting machine according to the present disclosure, the inspection section may initiate the second inspection when a preset time is reached or when a command to initiate an inspection is issued.

In addition, in the malfunction determining device of the component mounting machine according to the present disclosure, a notification section for notifying of a result of the determination may be provided.

The present disclosure is not limited to the form of the malfunction determining device of the component mounting machine, but may also be the form of the malfunction determining method of the component mounting machine. That is, a malfunction determining method for a component mounting machine according to the present disclosure is a malfunction determining method for a component mounting machine for determining a malfunction of the component mounting machine including a head configured to include a pickup member for picking up a component and a moving device configured to move the head, the method including executing multiple inspections including a first inspection for performing a mounting operation under control of the head and the moving device to inspect whether the mounting is good or bad and a second inspection for performing calibration measurement of the head to inspect whether the measurement is good or bad, and determining presence or absence of malfunction and a malfunction location including the head and the moving device based on a combination of results of the multiple inspections.

INDUSTRIAL APPLICABILITY

The present disclosure can be applied to, for example, the manufacturing industry of a malfunction determining device for a component mounting machine.

REFERENCE SIGNS LIST

1component mounting system

3print inspection device

4print inspection device

10component mounting machine

30head moving device

31X-axis guide rail

33Y-axis guide rail

39Y-axis position sensor

41head main body

46mark forming member

50R-axis driving device

55R-axis position sensor

60Q-axis driving device

65Q-axis position sensor

70Z-axis driving device

73Z-axis position sensor

80ZS-axis driving device

83ZS-axis position sensor

201carrier main body

205component accommodation tray

205acomponent accommodation pocket

HM head reference mark

IN jig nozzle

IP inspection component

IS inspection board

NM nozzle reference mark

P component

S board