WORK MACHINE FOR BOARD AND BOARD MANUFACTURING METHOD

A component mounter includes a cutting device that cuts a lead of a taped component in which a radial lead component is taped on a carrier tape to separate the radial lead component from the carrier tape, and a bad lead cut detection sensor that detects that the cutting device has failed to separate the radial lead component from the carrier tape.

TECHNICAL FIELD

The present disclosure relates to a technique for supplying a lead component to be mounted on a board.

BACKGROUND ART

Patent Literature 1 describes a board work machine in which after a lead wire of a lead component is inserted into a board, the lead wire protruding from the back surface of the board is cut and bent.

PATENT LITERATURE

BRIEF SUMMARY

Technical Problem

However, the board work machine described in Patent Literature 1 does not consider the supply of a lead component to the board work machine, and cannot deal with a problem that may occur when, for example, each lead component is separated and supplied from a taped lead component that is taped on a carrier tape.

Specifically, in this case, the lead component is separated from the carrier tape by cutting the lead of the taped lead component, but the lead is sometimes not cut properly, and the lead component may be supplied with the carrier tape still attached. When the lead component supplied with the carrier tape attached thereto is inserted into a board in this manner, the carrier tape becomes an obstacle to the insertion, and the gripping claws (gripping claws180inFIG.8described later) used when the lead component is inserted into the board may be damaged.

An object of the present disclosure is to provide a technique capable of detecting that a cutting device has failed to separate a lead component from a carrier tape before the lead component is inserted into a board.

Solution to Problem

In order to achieve the above object, a board work machine of the present disclosure includes a cutting device configured to cut the lead of a taped lead component that is taped on a carrier tape to separate the lead component from the carrier tape, and a detection device configured to detect that the cutting device has failed to separate the lead component from the carrier tape.

Advantageous Effects

According to the present disclosure, it is possible to detect that a cutting device has failed to separate a lead component from a carrier tape before the lead component is inserted into a board.

DESCRIPTION OF EMBODIMENTS

Embodiments of the present disclosure will be described in detail below with reference to the accompanying drawings.

FIGS.1and2illustrate component mounter10. Component mounter10is a device that executes mounting work of a component on circuit base material12. Component mounter10includes device main body20, board holding device22, component supply device24, component mounting device26, and control device28(seeFIG.15). Examples of circuit base material12include a circuit board, a base material having a three-dimensional structure, and the like, and examples of the circuit board include a printed wiring board, a printed circuit board, and the like.

Device main body20includes frame30and beam32suspended on frame30. Board holding device22is disposed on the upper surface of frame30, and includes conveyance device50, clamp device52, and moving device54. Conveyance device50is a device that conveys circuit base material12, and clamp device52is a device that holds circuit base material12. Accordingly, board holding device22conveys circuit base material12by conveyance device50, and securely holds the circuit base material12conveyed to a predetermined position by clamp device52. The conveyance direction of circuit base material12is referred to as an X direction, a horizontal direction perpendicular to that direction will be referred to as a Y direction, and a vertical direction is referred to as a Z direction. Further, moving device54includes X-direction moving device56(seeFIG.15) and Y-direction moving device58(seeFIG.15). X-direction moving device56is a device that moves circuit base material12held by clamp device52in the X direction, and Y-direction moving device58is a device that moves circuit base material12held by clamp device52in the Y direction. Accordingly, circuit base material12held by clamp device52is moved to a position on the frame by X-direction moving device56and Y-direction moving device58, and is positioned and stopped.

Component supply device24includes sliding device60, a tape feeder (not illustrated), and cutting device64. Sliding device60includes holding wall66, sliding rail68, and feeder holding stand70, and holding wall66is provided upright on the edge of the upper surface of frame30in the Y direction so as to extend in the X direction. Sliding rail68is fixed to holding wall66so as to extend in the X direction, and feeder holding stand70is slidably held by sliding rail68. Feeder holding stand70slides to a position in accordance with the operation of electromagnetic motor72(seeFIG.15). Accordingly, feeder holding stand70slides to a position in the X direction along holding wall66, and is positioned and stopped. The side on which holding wall66of component mounter10is disposed is referred to as a front side, and the opposite side is referred to as a rear side. That is, the Y direction is the front-rear direction in component mounter10, and the X direction is the left-right direction in component mounter10.

Further, multiple slots76are formed side by side in the X direction in feeder holding stand70, and the tape feeder is detachably positioned and mounted in each of multiple slots76by one touch of an operator. The tape feeder is a device that feeds taped component78(seeFIG.3) toward cutting device64. Taped component78includes multiple radial lead components80and carrier tape82, as illustrated inFIG.3. Radial lead component80includes substantially cylindrical main body86and two leads88extending in the same direction from the lower surface of main body86. Two leads88of radial lead component80are taped to carrier tape82at the lower end portions thereof. Further, multiple feeding holes90are formed at a uniform pitch in carrier tape82. Multiple radial lead components80are taped to carrier tape82at the same pitch as the formation pitch of feeding holes90.

As illustrated inFIG.1, storage container92is disposed below feeder holding stand70on which the tape feeder is mounted, and taped component78is stored in a folded state in storage container92. One end of taped component78is pulled out from storage container92, and the one end is inserted into the tape feeder.

Further, cutting device64is a device that separates radial lead component80from taped component78by cutting leads88taped to taped component78fed from the tape feeder, and is attached and fixed to the lower surface side of beam32as illustrated inFIG.1. Specifically, plate-shaped bracket110illustrated inFIG.3is fixed to the lower surface of beam32in a position extending downward. Further, cutting device64has a pair of substantially block-shaped sliders112, and the pair of sliders112are held by bracket110on the front side of bracket110so as to move toward and away from each other in the X direction. The pair of sliders112are controllably moved toward and away from each other by the operation of air cylinder114(seeFIG.15).

The upper surface of each of the pair of sliders112is substantially a horizontal surface, and the front surface of each of the pair of sliders112is substantially a vertical surface. A pair of lead cutters116are fixed to the upper surfaces of the pair of sliders112with the cutting edges facing each other. The pair of lead cutters116are fixed to the upper surfaces of the pair of sliders112with the cutting edges protruding from the ends of sliders112in the X direction. Further, a pair of tape cutters118are fixed to the front surfaces of the pair of sliders112with the cutting edges facing each other. The pair of tape cutters118are fixed to the front surfaces of the pair of sliders112with the cutting edges protruding from the ends of sliders112in the X direction.

Lead88taped on carrier tape82extends upward from the gap between the pair of sliders112and is inserted between the pair of lead cutters116fixed to the upper surfaces of the pair of sliders112. In a state where a pair of leads88of one radial lead component80are inserted between the pair of lead cutters116, the pair of sliders112are brought closer to the operation of air cylinder114, whereby the pair of leads88are cut by the pair of lead cutters116. Thus, one radial lead component80is separated from taped component78in cutting device64.

Further, component mounting device26is a device for mounting radial lead component80separated from taped component78by cutting device64on circuit base material12, and is disposed on beam32as illustrated inFIGS.1and2. Specifically, as illustrated inFIGS.4and5, component mounting device26is disposed on a surface of bracket110on a side opposite to cutting device64where cutting device64is disposed. That is, cutting device64is disposed on the front side surface of bracket110, and component mounting device26is disposed on the rear side surface of bracket110.FIG.4is a view illustrating a rear side surface of bracket110, andFIG.5is a view illustrating a front side surface of bracket110.

Component mounting device26includes three chucks of first chuck140, second chuck142, and third chuck144. First chuck140grips radial lead component80separated from taped component78by cutting device64, second chuck142grips radial lead component80transferred from first chuck140, and third chuck144grips radial lead component80transferred from second chuck142to mount radial lead component80on circuit base material12.

As illustrated inFIG.6andFIG.7which is a cross-sectional view taken along the line B-B ofFIG.6, first chuck140includes a pair of gripping claws150and spline shaft152. Spline shaft152is disposed on the rear side of the pair of sliders112so as to extend in the X direction, and is held by bracket110so as to be rotatable about the axis. The pair of gripping claws150are held by spline shaft152so as to move toward and away from each other in the X direction, and the respective positions are controllably moved toward and away from each other by the operation of electromagnetic motor154(seeFIG.15). Further, spline shaft152is controllably rotated by the operation of electromagnetic motor156(seeFIG.15), and the pair of gripping claws150held by spline shaft152rotate 90° in the front-rear direction.

When the pair of gripping claws150are rotated forward, gripping claws150are positioned above the pair of lead cutters116as illustrated inFIG.6. Therefore, when the pair of gripping claws150are rotated forward by the operation of electromagnetic motor156and move toward each other by the operation of electromagnetic motor154, leads88of radial lead component80separated from taped component78can be gripped by the pair of gripping claws150. When the pair of gripping claws150are rotated rearward, the pair of gripping claws150are rotated to a position where radial lead component80gripped by the pair of gripping claws150can be delivered to second chuck142.

As illustrated inFIG.6, a pair of sensor brackets120are fixed to bracket110in a position extending downward. Each of sensor brackets120has a quadrangular prism shape, and each of sensor brackets120is fixed in a state in which one of four surfaces constituting a peripheral wall thereof faces each other. Component detection sensor122and bad lead cut detection sensor124are provided on each of the opposing surfaces of each sensor bracket120. In the present embodiment, transmissive optical sensors are used for both sensors122and124. Accordingly, light emitting parts of both sensors122and124are provided on one opposing surface of a first one of sensor brackets120, and light receiving parts of both sensors122and124are provided on one opposing surface of a second one of sensor brackets120.

When cutting device64performs an operation of separating one radial lead component80from taped component78, component detection sensor122detects whether the pair of leads88of radial lead component80to be separated is inserted between the pair of lead cutters116. Specifically, control device28(seeFIG.15) checks the output from component detection sensor122at the timing when one radial lead component80is fed out from the tape feeder to cutting device64, and determines that radial lead component80to be separated is at an appropriate cutting position when a decrease in the output is detected. Component detection sensor122is installed at a position where the optical axis is blocked by, for example, one lead88of the pair of leads88of radial lead component80when radial lead component80to be separated is at an appropriate cutting position. Of course, the installation position of component detection sensor122is not limited thereto as long as it is possible to detect that radial lead component80to be separated is at an appropriate cutting position.

Bad lead cut detection sensor124detects that cutting device64has failed to cut the pair of leads88of radial lead component80to be separated and a part of carrier tape82remains attached to leads88. Specifically, control device28(seeFIG.15) checks the output from bad lead cut detection sensor124at a predetermined timing while radial lead component80after the cutting operation by cutting device64is gripped by the pair of gripping claws150, the pair of gripping claws150are rotated rearward, and radial lead component80gripped by the pair of gripping claws150reaches a position where radial lead component80can be delivered to second chuck142. When a decrease in the output is detected from bad lead cut detection sensor124, control device28determines that a part of carrier tape82remains attached to leads88, that is, cutting device64has failed to cut the pair of leads88of radial lead component80to be separated. The predetermined timing is a timing at which bad lead cut detection sensor124can detect a part of carrier tape82remaining attached to the pair of leads88of radial lead component80in the middle of being conveyed by the pair of gripping claws150, that is, a timing at which the pair of gripping claws150are in a predetermined range of rotation. Conversely, bad lead cut detection sensor124is installed at a position where a part of carrier tape82remaining attached to the pair of leads88of radial lead component80can be detected when the pair of gripping claws150are in the predetermined range of rotation.

As illustrated inFIGS.7and8, second chuck142includes a pair of gripping claws160, placement plate162, and bracket164.FIG.8is a view illustrating second chuck142viewed from the front side. The pair of gripping claws160are held by bracket164so as to move toward and away from each other in the X direction, and the respective positions are controllably moved toward and away by the operation of electromagnetic motor166(seeFIG.15). Further, placement plate162is fixedly held by bracket164between the pair of gripping claws160. Placement plate162is curved in an arc shape according to cylindrical main body86of radial lead component80.

Further, bracket164is sandwiched between a pair of support walls170(only one of the pair of support walls170is illustrated inFIG.8) on both side surfaces in the X direction. A pair of cam grooves172are formed in the pair of support walls170, and a pair of rollers174having an axis in the X direction are disposed on both side surfaces of bracket164in the X direction. When the pair of rollers174are fitted into the pair of cam grooves172, bracket164is held by the pair of support walls170. The shape of cam groove172is substantially an arc shape, is curved upward toward the rear, and is curved downward toward the front. As illustrated inFIG.8, bracket164is moved down with respect to support wall170, and roller174is moved toward the lower end of cam groove172, whereby the pair of gripping claws160and placement plate162are in a position extending in the vertical direction. At this time, the distal ends of the pair of gripping claws160face downward. Meanwhile, as illustrated inFIG.6, bracket164is moved up with respect to support wall170, and roller174moves toward the upper end of cam groove172, whereby the pair of gripping claws160and placement plate162are in a position extending in the front-rear direction. At this time, the distal ends of the pair of gripping claws160face forward. Bracket164is controllably moved up and down with respect to support wall170by the operation of electromagnetic motor178(FIG.15).

In addition, when bracket164is moved up with respect to support wall170and the pair of gripping claws160and placement plate162of second chuck142are in a position extending in the front-rear direction, placement plate162is positioned behind radial lead component80gripped by the pair of gripping claws150of first chuck140. At this time, the pair of gripping claws160of second chuck142are separated from each other. Therefore, when the pair of gripping claws150of first chuck140are rotated rearward, main body86of radial lead component80gripped by the pair of gripping claws150is placed on placement plate162. When main body86of radial lead component80is placed on placement plate162, the pair of gripping claws160of second chuck142move toward each other, whereby main body86of radial lead component80placed on placement plate162is gripped by the pair of gripping claws160. Further, after main body86of radial lead component80is placed on placement plate162, the pair of gripping claws150are separated from each other, whereby the gripping of radial lead component80by first chuck140is released. Thus, radial lead component80gripped by first chuck140is transferred to second chuck142and gripped by second chuck142.

As illustrated inFIG.9, third chuck144is disposed below the pair of support walls170and includes a pair of gripping claws180. Hanging member182is fixed to the rear side of the pair of support walls170, and hanging member182extends downward from the lower ends of the pair of support walls170. The pair of gripping claws180are disposed at the lower end of hanging member182so as to move toward and away from each other, and the pair of gripping claws180extend forward. That is, the pair of gripping claws180of third chuck144are disposed on the pair of support walls170via hanging member182and extend downward from the pair of support walls170. The pair of gripping claws180are controllably moved toward and away from each other by the operation of electromagnetic motor186(seeFIG.15).

Further, when bracket164held by the pair of support walls170is moved down with respect to support walls170, the distal ends of the pair of gripping claws160of second chuck142held by bracket164face downward as described above. At this time, the distal ends of the pair of leads88of radial lead component80gripped by gripping claws160of second chuck142also face downward. When bracket164moves down, the pair of gripping claws180of third chuck144are separated from each other. Then, the pair of leads88whose distal ends face downward are inserted between the pair of gripping claws180of third chuck144. At this time, as the pair of gripping claws180are moved toward each other, the pair of leads88of radial lead component80are gripped by the pair of gripping claws180as illustrated inFIG.8. Further, after the pair of leads88of radial lead component80are gripped by the pair of gripping claws180of third chuck144, as the pair of gripping claws160of second chuck142are separated from each other, the gripping of radial lead component80by second chuck142is released. Thus, radial lead component80gripped by second chuck142is transferred to third chuck144and gripped by third chuck144.

As illustrated inFIG.8, the pair of support walls170on which the pair of gripping claws180of third chuck144are disposed are fixed to flange188at the upper end. Flange188is controllably moved up and down by the operation of electromagnetic motor190(seeFIG.15). Accordingly, the position of radial lead component80gripped by the pair of gripping claws180of third chuck144in the vertical direction can be changed freely. Flange188is controllably rotated on the XY plane by the operation of electromagnetic motor192(seeFIG.15).

Further, pusher196is disposed above radial lead component80gripped by third chuck144. Pusher196is held by bracket164so as to move up and down, and is controllably moved up and down by the operation of electromagnetic motor198(seeFIG.15). As a result, as pusher196moves down, radial lead component80gripped by third chuck144is pushed downward by pusher196.

Further, as illustrated inFIG.15, control device28includes controller200and multiple drive circuits202. Multiple drive circuits202are connected to conveyance device50, clamp device52, X-direction moving device56, Y-direction moving device58, air cylinder114, and electromagnetic motors72,154,156,166,178,186,190,192, and198. Controller200includes CPU, ROM, RAM, and the like, is mainly a computer, and is connected to multiple drive circuits202. Controller200is also connected to component detection sensor122and bad lead cut detection sensor124. Accordingly, operations of board holding device22, component supply device24, and component mounting device26are controlled by controller200.

FIG.10illustrates a state before taped component78is conveyed to cutting device64. At this time, light is emitted from each light emitting part of component detection sensor122and bad lead cut detection sensor124. That is, component detection sensor122and bad lead cut detection sensor124are always in the ON state during the operation of component mounter10before or after taped component78is conveyed to cutting device64.

FIG.11illustrates a state in which one radial lead component80is normally cut from taped component78, the pair of leads88of radial lead component80to which part of carrier tape82is not attached are being conveyed to the delivery position of second chuck142by the pair of gripping claws150. In this state, the optical axis of bad lead cut detection sensor124is not blocked, and a decrease in the output is not detected from bad lead cut detection sensor124. Accordingly, control device28determines that the pair of leads88of radial lead component80in the middle of being conveyed have been cut more properly by cutting device64, and performs normal insertion control of radial lead component80into circuit base material12.

FIG.12illustrates a state in which part82aof carrier tape82is attached to the pair of leads88of radial lead component80although the conveyance timing of radial lead component80is the same as that inFIG.11. In this state, since the optical axis of bad lead cut detection sensor124is blocked, a decrease in the output is detected from bad lead cut detection sensor124. Accordingly, control device28determines that the pair of leads88of radial lead component80in the middle of being conveyed are not cut by cutting device64more properly, and stops the operation of component mounter10. Then, control device28executes a component discarding command for radial lead component80in the middle of being conveyed.

FIGS.13and14illustrate a state in which radial lead component80in the middle of being conveyed is conveyed to a takeout position by executing a component discarding command. Hereinafter, radial lead component80in which part82aof carrier tape82is attached to the pair of leads88is referred to as radial lead component80having a bad lead cut. As illustrated inFIG.13, radial lead component80having a bad lead cut is delivered from first chuck140to second chuck142, similarly to radial lead component80having no bad lead cut. Then, radial lead component80having a bad lead cut gripped by second chuck142is moved down toward the delivery position of third chuck144as described above. Then, radial lead component80having a bad lead cut gripped by second chuck142stops before extending in the vertical direction, and flange188is rotated by 180° by electromagnetic motor192. Accordingly, as illustrated inFIG.14, radial lead component80having a bad lead cut gripped by second chuck142is conveyed to a position where radial lead component80is easily taken out by the operator.

In the present embodiment, as described above with reference toFIGS.11and12, it is determined whether radial lead component80has a bad lead cut before radial lead component80is delivered from first chuck140to second chuck142. When it is determined that radial lead component80has a bad lead cut, control device28immediately stops the operation of component mounter10. That is, as illustrated inFIG.12, radial lead component80having a bad lead cut is stopped in the middle of being conveyed by first chuck140, and the subsequent conveyance to a position where the operator can easily take out radial lead component80is performed by control device28executing a component discarding command. However, the present disclosure is not limited thereto, and control device28may stop the operation of component mounter10after first chuck140delivers radial lead component80having a bad lead cut to second chuck142when it is determined that radial lead component80has a bad lead cut. In this case, an operation in which second chuck142receives radial lead component80having a bad lead cut and then conveys radial lead component80to a position where the operator can easily take out radial lead component80is performed by control device28executing a component discarding command. Further, in the present embodiment, when it is determined that radial lead component80has a bad lead cut, the operation of entire component mounter10is stopped, but the operation is not limited thereto, and the operation of a part of component mounter10, for example, component supply device24and component mounting device26, may be stopped.

In the present embodiment, when a component discarding command is executed, second chuck142receives and grips radial lead component80having a bad lead cut from first chuck140, and conveys gripped radial lead component80having a bad lead cut to a position where the operator can easily take out radial lead component80. At this time, as described above, the 180° rotation operation of flange188by electromagnetic motor192is performed after radial lead component80having a bad lead cut is moved down toward the delivery position of third chuck144and stopped before extending in the vertical direction. However, the present disclosure is not limited thereto, and the 180° rotation operation of flange188by electromagnetic motor192may be performed immediately from a state in which second chuck142receives and grips radial lead component80having a bad lead cut from first chuck140(seeFIG.13). In this case, the operation of moving radial lead component80having a bad lead cut down toward the delivery position of third chuck144is performed after the 180° rotation operation of flange188. Alternatively, the rotation operation of flange188and the moving-down operation of radial lead component80having a bad lead cut may be performed in parallel.

Further, in the present embodiment, when it is determined that radial lead component80has a bad lead cut, a component discarding command is executed at the same time as component mounter10is stopped, the present disclosure is not limited thereto, and it is also possible to only stop component mounter10and not execute the component discarding command. In this case, whether to execute the component discarding command need only be left to the operator's selection.

As described above, component mounter10of the present embodiment includes cutting device64that cuts leads88of taped component78in which radial lead component80is taped on carrier tape82to separate radial lead component80from carrier tape82, and bad lead cut detection sensor124that detects that cutting device64has failed to separate radial lead component80from carrier tape82.

As described above, in component mounter10of the present embodiment, since bad lead cut detection sensor124detects that cutting device64has failed to separate radial lead component80from carrier tape82, failure of cutting device64to separate radial lead component80from carrier tape82can be detected before radial lead component80is inserted into circuit base material12. In the present embodiment, component mounter10is an example of a “board work machine”. Radial lead component80is an example of a “lead component”. Taped component78is an example of a “taped lead component”. Bad lead cut detection sensor124is an example of a “detection device”.

Further, bad lead cut detection sensor124detects that cutting device64has failed to separate radial lead component from carrier tape82by detecting that carrier tape82remains uncut on radial lead component80after the cutting operation by cutting device64.

Further bad lead cut detection sensor124detects that carrier tape82remains uncut on radial lead component80while radial lead component80after the cutting operation by cutting device64is conveyed to a predetermined conveyance position.

Component mounter10further includes control device28that causes the conveyance of radial lead component80to stop when bad lead cut detection sensor124detects that cutting device64has failed to separate radial lead component from carrier tape82. This makes it possible to prevent the device from being damaged due to radial lead component80having a bad lead cut.

Further, control device28performs control such that radial lead component80is conveyed to a predetermined takeout position, after stopping the conveyance of radial lead component80. Accordingly, the operator can easily take out radial lead component80having a bad lead cut.

Component mounter10further includes component detection sensor122that detects whether taped component78is conveyed to a position where cutting device64performs a cutting operation. Bad lead cut detection sensor124detects that cutting device64has failed to separate radial lead component80from carrier tape82when component detection sensor122detects that taped component78has been conveyed to the position where cutting device64performs the cutting operation.

Accordingly, it is possible to prevent bad lead cut detection sensor124from erroneously detecting that cutting device64has failed to separate the radial lead component that has not been conveyed from carrier tape82. In addition, component detection sensor122is an example of a “component detection device”.

The present disclosure is not limited to the above embodiment, and various modifications can be made within the scope without departing from the concept of the present disclosure.

(1) In the above embodiment, the radial lead component includes a pair of leads, but the number of leads may be one or three or more. The method of the present disclosure can also be applied to a taped axial lead component that is taped with an axial lead component on a carrier tape.

(2) In the above embodiment, transmission type optical sensors are used as component detection sensor122and bad lead cut detection sensor124, but the present disclosure is not limited thereto, and other types of optical sensors such as a reflection type may be used. Other types of sensors such as an infrared sensor, an ultrasonic sensor, and a contact sensor may be used.

REFERENCE SIGNS LIST