Abstract:
An electronic-circuit-component pick-up instruction data generating device is provided that generates pick-up instruction data for automatically picking up an electronic circuit component from a nonmatrix tray defined to have nonmatrix arrangement in which arrangeable positions of the electronic circuit components are arranged in a nonmatrix pattern, other than a matrix tray defined to have matrix arrangement in which arrangeable positions of a plurality of the electronic circuit components are regularly arranged in a matrix pattern in a state of being positioned at all the intersection points made by two groups of straight lines that are parallel to two directions orthogonal to each other, respectively, and that are separated at regular intervals for each direction. An electronic-circuit-component mounting machine is provided that picks up an electronic circuit component from the nonmatrix tray based on generated pick-up instruction data, and automatically mounts the component on a circuit board.

Description:
TECHNICAL FIELD 
       [0001]    The present disclosure relates to an electronic-circuit-component mounting machine that automatically mounts an electronic circuit component on a circuit substrate, and to an electronic-circuit-component pick-up instruction data generating device that generates pick-up instruction data for causing the electronic-circuit-component mounting machine to automatically pick up an electronic circuit component from a tray which supports a plurality of electronic circuit components arranged in a planar manner. 
       BACKGROUND ART 
       [0002]    A tray which supports a plurality of electronic circuit components arranged in a planar manner, and an electronic-circuit-component mounting machine that automatically picks up the electronic circuit component from the tray and mounts the component on a circuit substrate such as a circuit board, both are disclosed in the following PTLS 1 and 2, or the like, and have been widely used. However, in the related art, the tray used in the electronic-circuit-component mounting machine is a matrix tray in which a plurality of cavities are formed to be regularly arranged in a state in which the centers of the respective cavities are positioned at all the intersection points made by two groups of straight lines that are parallel to two directions orthogonal to each other, respectively, and that are separated at regular intervals for each direction. Here, it is not possible to use and to set another type of tray in the electronic-circuit-component mounting machine. 
       CITATION LIST 
     Patent Literature 
       [0003]    PTL 1: JP-A-2000-208990 
         [0004]    PTL 2: JP-A-2008-010594 
       SUMMARY 
     Problem to be Solved 
       [0005]    In comparison, some electronic circuit components are supplied and held by a nonmatrix tray that does not have the matrix arrangement of arrangeable positions of the electronic circuit components. Thus, in the related art, normally, the electronic circuit components held and supplied by such a nonmatrix tray are manually mounted on the circuit substrate, and thus, there is a need to rearrange the electronic circuit components on a separately prepared matrix tray such that the electronic-circuit-component mounting machine performs the automatic mounting of the components. 
         [0006]    The present disclosure is made to achieve an object of causing an electronic-circuit-component mounting machine to perform automatic mounting from a nonmatrix tray that holds electronic circuit components arranged in a planar manner, but that does not have matrix arrangement of the electronic circuit components. 
       Means for Solving the Problem 
       [0007]    The above described object is achieved by providing an electronic-circuit-component pick-up instruction data generating device that generates pick-up instruction data for automatically picking up an electronic circuit component from a tray set to have nonmatrix arrangement different from matrix arrangement in which arrangeable positions of a plurality of electronic circuit components are regularly arranged in a state of being positioned at all the intersection points made by two groups of straight lines that are parallel to two directions orthogonal to each other, respectively, and that are separated at regular intervals for each direction. 
         [0008]    When the pick-up instruction data of the electronic circuit components from the tray on which the arrangeable positions of the electronic circuit component are arranged in a nonmatrix arrangement is generated, it is easy to generate the data. However, it is possible to generate the data by other means different, from the means above. For example, it is also possible to generate the data by inputting individual coordinate data of respective positions in the nonmatrix arrangement from an input device. In addition, the electronic-circuit-component pick-up instruction data generating device may be configured as a data generation-dedicated device, may be configured as a part of a control device of an electronic circuit component supply device, may be configured as a part of a control device of an electronic-circuit-component mounting machine, or may be configured as a part of a control device of an electronic-circuit-component mounting line including a plurality of electronic-circuit-component mounting machines. 
         [0009]    The above object is also achieved by providing an electronic-circuit-component mounting machine including: (A) a circuit substrate holding device that holds a circuit substrate; (B) a tray that holds a plurality of electronic circuit components arranged in a planar manner; (C) a mounting device that includes a component holding tool and a movement applying device that applies a predetermined movement to the component holding tool, and that causes the component holding tool to pick up the electronic circuit component from the tray and to mount the component on the circuit substrate held in the circuit substrate holding device; and (D) a control device. The control device includes (a) a memory section that stores at least automatic mounting data containing the pick-up instruction data generated by the electronic-circuit-component pick-up instruction data generating device, and (b) a mounting device control section that controls the mounting device in response to the automatic mounting data stored in the memory section. The electronic circuit components in the nonmatrix arrangement can be automatically mounted on the circuit substrate. 
       Effects 
       [0010]    The electronic-circuit-component pick-up instruction data generating device according to the present disclosure makes it possible to generate pick-up instruction data for automatically picking up electronic circuit components from a tray having arrangeable positions of a plurality of electronic circuit components in nonmatrix arrangement. 
         [0011]    In addition, an electronic-circuit-component mounting machine according to the present disclosure makes it possible to perform automatic mounting of electronic circuit components held by a tray having arrangeable positions of the electronic circuit components in nonmatrix arrangement, to a circuit substrate, by causing a mounting control section to control mounting device based on automatic mounting data that is stored in a memory section and that contains pick-up instruction data generated by the electronic-circuit-component pick-up instruction data generating device. For example, it is possible to set multiple components which are freely arranged as available in the market, to an automatic mounting machine. 
     
    
     
       BRIEF DESCRIPTION OF DRAWINGS 
         [0012]      FIG. 1  is perspective view illustrating an electronic-circuit-component mounting line as Example of the present disclosure. 
           [0013]      FIG. 2  is a plan view illustrating a circuit board conveyance device in one electronic-circuit-component mounting machine configuring the electronic-circuit-component mounting line. 
           [0014]      FIG. 3  is a sectional view taken along line  3 - 3  in  FIG. 2 . 
           [0015]      FIG. 4  is a perspective view illustrating a mounting device in one electronic-circuit-component mounting machine configuring the electronic-circuit-component mounting line illustrated in  FIG. 1 . 
           [0016]      FIG. 5  illustrates plan views of a plurality of types of trays:  FIG. 5A  illustrates an example of a matrix tray;  FIG. 5B  illustrates an example of a nonmatrix tray; and  FIG. 5C  illustrates another example of the nonmatrix tray. 
           [0017]      FIG. 6  is a plan view illustrating an example of a tray holding table. 
           [0018]      FIG. 7  is a view illustrating a procedure of generating cavity arrangement data of the nonmatrix tray illustrated in  FIG. 5B  from cavity arrangement data of the matrix tray illustrated in  FIG. 5A . 
           [0019]      FIG. 8  is a view illustrating a procedure of generating cavity arrangement data of the nonmatrix tray illustrated in  FIG. 5C . 
           [0020]      FIG. 9  is a view depicting an example of pick-up instruction data of electronic circuit components from the matrix tray illustrated in  FIG. 5A . 
           [0021]      FIG. 10  is a view depicting an example of pick-up instruction data of electronic circuit components from the nonmatrix tray illustrated in  FIG. 5B . 
           [0022]      FIG. 11  is a view depicting an example of pick-up instruction data of electronic circuit components from the nonmatrix tray illustrated in  FIG. 5C . 
       
    
    
     DESCRIPTION OF EMBODIMENTS 
       [0023]    Hereinafter, Example as an embodiment of the present disclosure will be described with reference to the drawings. Further, the present disclosure can be altered and modified in various manners into other embodiments based on knowledge of those skilled in the art, in addition to above Example. 
         [0024]      FIG. 1  illustrates an example of an electronic-circuit-component mounting line. Such an electronic-circuit-component mounting line  10  is configured to include a plurality of mounting modules  12  and  14 , each of which is an electronic-circuit-component mounting machine, and which are arranged in one line. The mounting module  12  includes a tape feeder  16  and a tray feeder  18  as a component supply device  15 , and the mounting module  14  includes only the tape feeder  16 . The tape feeder  16  feeds, pitch by pitch, a component holding tape on which electronic circuit components (hereinafter, abbreviated to a component) are held at an equal pitch, and supplies the components in a preset supply section; however, the tape feeder is well known and thus, detailed description thereof is omitted. 
         [0025]    The tray feeder  18  includes a tray holding table  26  that positions and holds a matrix tray  20  illustrated in  FIG. 5A , or a nonmatrix tray  22  or  24  illustrated in  FIG. 5B or 5C  on a level support surface. Each of the trays  20 ,  22 , and  24  has a rectangular shape, a fixed positioning member  28  and a detachable positioning member  29  are provided in the tray holding table  26  as illustrated in  FIG. 6 , and each of the trays  20 ,  22 , and  24 , is selectively positioned by the positioning member  28  or  29  and is held in an orientation in which two sides of the rectangular tray are parallel to an X axis and a Y axis, respectively. 
         [0026]    In the nonmatrix trays  22  and  24 , there are both a case where arrangeable positions of a plurality of components are set in a condition in which one component is disposed at one cavity (accommodating recessed portion), and a case where the arrangeable positions are set in a condition in which a plurality of components are disposed at one cavity  30 . It is possible to consider the cavity  30  in the former case as a real cavity, and an arrangeable position for one component in the latter case as a virtual cavity, and, in this description and claims of the present application, the term, “cavity” means both the real cavity and the virtual cavity. 
         [0027]    On the nonmatrix tray  22  illustrated in  FIG. 5B , the cavity  30  is illustrated as the real cavity, for easy understanding; however, the cavity often means the virtual cavity and a plurality of (two in the case in  FIG. 6 ) components are arranged in a state of being in contact with each other at one accommodating recessed portion. It is advantageous to use this type of tray in that multiple simple-shaped components can be held on a relatively small tray. 
         [0028]    It is advantageous to use the nonmatrix tray  24  illustrated in  FIG. 5C  in that a pitch between columns of components having a circular or similar shape is decreased and thereby, multiple components can be held on a relatively small tray. 
         [0029]    Each of the mounting modules  12  and  14  further includes a board conveying and holding device  40  illustrated in  FIGS. 2 and 3 . The board conveying and holding device  40  includes a fixed guide rail  42  and a movable guide rail  44  which extend parallel to each other. The movable guide rail  44  can approach and can be separated from the fixed guide rail  42  following along guiding by a pair of guide members  46  provided between both the guide rails  42  and  44 . The movable guide rail  44  includes a pair of nuts  50  screwed to a pair of lead screws  48  and approaches and is separated from the fixed guide rail  42  by the pair of lead screws  48  synchronized with each other to be rotated by a servomotor  52  and a rotation transmitting device  54 . In this manner, a distance between both the guide rails  42  and  44  is adjusted to equal a width of a circuit board  56  which is to be conveyed. 
         [0030]    Conveyance belts  60  are held in a circling-movement manner by both the guide rails  42  and  44 , respectively, and a pair of the conveyance belts  60  are synchronized with each other to move in a circle by a servomotor  62 , a rotation transmitting device  64 , and a spline shaft  66 , support both sides of the circuit board  56 , and convey the circuit board by conveyance sections  68  which extend parallel to each other. At that time, the pair of guide rails  42  and  44  guide both side end surfaces of the circuit board  56 . In addition, a lifting and lowering base omitted in the drawings is provided at a position between both the guide rails  42  and  44  and the circuit board  56  is lifted by being supported by support members such as a plurality of support pins or the like, which are attached to the lifting and lowering base. Here, both side end portions of the circuit board  56  are raised from the conveyance sections  68  and the circuit board is pressed and fixed to a lower surface of a reception member  70 . 
         [0031]    Each of the mounting modules  12  and  14  further includes a mounting device  80  illustrated in  FIG. 4 . The mounting device  80  is supported by an upper beam  78  of a module main body  76  and includes a mounting head  82  and a head moving device  84  that causes the mounting head  82  to move to any position in an X-axial direction and a Y-axial direction orthogonal to each other. The head moving device  84  includes an X-axial slider  86  and a Y-axial slider  88 . A Y-axis drive device  90  causes the Y-axial slider  88  to move to any position in the Y-axial direction and an X-axis drive device  92  causes the X-axial slider  86  to move to any position in the X-axial direction on the Y-axial slider  88 , thereby causing the mounting head  82  to move to any position in an X-Y plane. The mounting head  82  can be detachably attached to the X-axial slider  86 , and a multi-nozzle head, as a component holding tool, including a plurality of suction nozzles  100  is illustrated in  FIG. 4 . An imaging device  102  is further attached to the X-axial slider  86 . The imaging device  102  captures a plurality of fiducial marks  104  provided on the circuit board  56  or the tray  20 ,  22 , or  24 , thereby detecting a position of the circuit board  56  or the tray  20 ,  22 , or  24 . 
         [0032]    As illustrated in  FIG. 1 , a module control device  120  is provided in each of the mounting modules  12  and  14  described above, and an integrated control device  130 , which performs integrated control of the entire electronic--circuit-component mounting line  10 , is connected to the module control devices  120 . Each module control device  120  includes a display  122  and an input/operation device  124  which are provided on an upper front portion of each of the mounting modules  12  and  14 , and the integrated control device  130  also includes a display  134  and an input/operation device  132 . An operator can perform input or operation to individual mounting modules  12  and  14  by operating the input/operation device  124  while looking at a display on the display  122 ; however the operator can perform input or instruction to the mounting modules  12  and  14  and the entire electronic-circuit-component mounting line  10  by operating the input/operation device  132  while looking at a display on the display  134  of the integrated control device  130 . 
         [0033]    The input, operation, and instruction related to the matrix tray are well known and thus, description thereof is omitted. Hereinafter, the input, operation, and instruction related to the nonmatrix tray will be described as specific features in the present disclosure. Here, since a mounting motion of the component to the circuit board  56  is not changed whether the tray is the matrix tray or the nonmatrix tray, and there is a difference only in a pick-up motion of the component from the tray, hereinafter, the pick-up of the component from the nonmatrix tray and, particularly, the generation of the pick-up instruction data will be described in detail. 
         [0034]    The pick-up instruction data from the nonmatrix tray is generated based on the pick-up instruction data from the matrix tray; however, it is desirable that it is not essential to generate the data based on the pick-up instruction data from the matrix tray. For example, it is convenient to generate pick-up instruction data from the nonmatrix tray  22  illustrated in  FIG. 5B  based on pick-up instruction data from the matrix tray  20  illustrated in  FIG. 5A . 
         [0035]    As illustrated in  FIG. 9 , the pick-up instruction data from the matrix tray  20  is configured to contain a first suction coordinate (X 1 , Y 1 ) as a coordinate of the central position of the cavity  30  from which the component is first to be picked up, inter-cavity pitches Px and Py in the X-axial direction and the Y-axial direction, and the numbers of cavities Nx and Ny in the X-axial direction and in the Y-axial direction, respectively. The pick-up instruction data is stored in a memory section  126  (refer to  FIG. 1 ) of the module control device  120  of each of the mounting modules  12  and  14 , and each of the mounting modules  12  and  14  can pick up the components in order from the respective cavities  30  of the matrix tray  20  based on the data. The same is true of the mounting module in the related art; however, the mounting modules  12  and  14  of the present. Example can also pick up the components from the nonmatrix trays  22  and  24 . 
         [0036]    It is also possible to generate pick-up instruction data for picking up from the nonmatrix tray in the control device  120  of each of the mounting modules  12  and  14 ; however, in the present Example, the data is generated in the integrated control device  130 , then, is transmitted to the control device  120  of each of the mounting modules  12  and  14 , and is stored in the memory section  126 . Hereinafter, the generation of the pick-up instruction data in the integrated control device  130  will be described. 
         [0037]    The pick-up instruction data of the components from the nonmatrix tray  22  is generated based on the pick-up instruction data from the matrix tray  20  described above. In other words, as illustrated as step  1  in  FIG. 7 , the pick-up instruction data of the matrix tray  20  is first input from the input/operation device  132  of the integrated control device  130  illustrated in  FIG. 1  and is stored in the memory section  136 . The arrangement of the cavities  30  of the matrix tray  20  is displayed on the display  134 , based on the pick-up instruction data. 
         [0038]    Subsequently, as illustrated as step  2 , the input/operation device  132  is operated so as to designate the uppermost two rows of cavities  30  surrounded in a two-dot chain line, of the cavities  30  displayed in the display  134  and a shift amount Sy of the cavities  30  in the Y-axial direction is input. As a result, the pick-up instruction data of the matrix tray  20  is modified and the display on the display  134  according to the modification is changed to a display in response to the modification (that is, input, shift amount) as illustrated on the right side of step  2 . In the present Example, ten rows of cavities  30  are divided into five sets with two rows grouped in one set, and a value of 4δ, which is four times a gap δ between the sets, is input as the shift amount. Similarly, from here on, the designation of two rows of cavities  30  from the top and the input of the shift amounts (3δ, 2δ, and δ) of the cavities  30  are repeated, thereby the display of the cavities  30  on the display  134  is sequentially changed, and, finally, the nonmatrix tray  22  having a cavity arrangement on the right end in  FIG. 7  is displayed on the display  134 . 
         [0039]    In other words, a generation procedure of the pick-up instruction data of the nonmatrix tray  22  is not limited to the procedure illustrated in  FIG. 7 , but, for example, instead of designating the uppermost two rows of cavities  30 , in step  1 , the uppermost eight rows of cavities  30  are designated and the shift amount δ between the sets is input, next, the uppermost six rows of cavities  30  are designated and the shift amount δ between the sets is input, and then, the same operation is repeated. Here, of the sets with one set made up of two rows, sets of upper rows are sequentially shifted from a set of lower rows, and, finally, it is possible to display the nonmatrix tray  22  having the cavity arrangement on the right end in  FIG. 7  on the display  134 . 
         [0040]    In comparison, as illustrated in  FIG. 8 , the generation of the pick-up instruction data of the nonmatrix tray  24  is performed, based on the pick-up instruction data of the matrix tray  20  on the left end in  FIG. 8 . The matrix tray  20  illustrated in  FIG. 8  looks different from the matrix tray  20  illustrated in  FIG. 7 ; however, the view only looks different for easy understanding. Actually, the pick-up instruction data of the matrix tray does not contain data of the shape of the cavities  30 , but includes the coordinates of the central positions of the cavities  30  as described above. Therefore, in the integrated control device  130  (also in the module control device  120 ) virtually, there is no difference between the matrix tray  20  illustrated in  FIG. 8  and the matrix tray  20  illustrated in  FIG. 7 . 
         [0041]    As illustrated as step  1  in  FIG. 8 , in the generation of the pick-up instruction data of the nonmatrix tray  24 , first, the pick-up instruction data of the matrix tray  20  is input and the arrangement of the cavities  30  in the matrix tray  20  is displayed on the display  134 . Then, as illustrated as step  2 , an operator designates the cavities belonging to the leftmost column surrounded in a two-dot chain line, of the displayed cavities  30 , and inputs δ as the shift amount Sy of the cavities  30  in the Y-axial direction. The display on the display  134  is changed to the view on the right side in step  2 , in response to the input. Similarly, odd-numbered cavity columns such as the third cavity column and the fifth cavity column from the end of the left side are sequentially designated, the shift amounts Sy of the columns in the Y-axial direction are input, the display on the display  134  is changed in response to the input, and, finally, the display of the cavity arrangement is changed to a state in a second view from the right in  FIG. 8 . Then, the operator designates the cavities  30  surrounded in a two-dot chain line in step  3  and instructs removal of data corresponding to the cavities  30 . The instruction is performed, thereby, the pick-up instruction data of the nonmatrix tray  24  is completed, and the cavity arrangement is modified to the rightmost view in  FIG. 8 . 
         [0042]    The generation procedure of the pick-up instruction data of the nonmatrix tray  24  is not limited to the procedure described above. For example, it is possible to reverse the input order of the instruction of the shift and the instruction of the removal. In other words, in the matrix tray  20 , three cavities  30  corresponding to three cavities  30  designated in step  3  in  FIG. 8  may be first designated, and the shift of the odd-numbered columns may be instructed after the removal of the three cavities  30 . To be described in a generalized manner, the removing instruction of the arrangeable position may also mean that some of the plurality of arrangeable positions are removed from the matrix arrangement defined in the matrix arrangement data, or that some of the plurality of arrangeable positions after a change in the matrix arrangement (for example, the plurality of arrangeable positions shifted by an arrangeable position shifting section, as in an example illustrated in  FIG. 8 ) may be removed. 
         [0043]    During production of a real electronic circuit, the pick-up instruction data generated in such a manner is transmitted from the integrated control device  130  to the module control device  120  of each of the mounting modules  12  and  14  and is stored as automatic mounting data, along with other data, in the memory sections  126  of the module control devices  120 , and execution of the automatic mounting data causes the electronic circuit to be produced. 
         [0044]    As clearly described above, in the present Example, a portion, which generates the pick-up instruction data of the integrated control device  130 , configures an electronic-circuit-component pick-up instruction data generating device, and a portion, which generates the nonmatrix arrangement data by modifying a part of the matrix arrangement data, configures a matrix arrangement data modifying section as an example of a matrix arrangement data-dependent nonmatrix arrangement data generating section. Also, the arrangeable position shifting section or an arrangeable position removing section is an example of the matrix arrangement data modifying section. In addition, a portion of the display  134 , on which an image of the cavities  30  of the matrix tray  20  is displayed, configures a matrix arrangement cavity image displaying section, and a cavity image shifting section as a portion that shifts a part of a cavity image, and a cavity image deleting section as a portion that deletes a part of the cavity image are an example of a cavity image modifying section. 
         [0045]    In other words, in Example described above, designation of cavities  30 , of which the arrangement is to be modified, is performed by unit of a cavity group as one row or one column of the matrix tray  20 ; however, it is possible to perform the designation for each individual cavity  30 , and, in this manner, modification flexibility from the matrix arrangement to the nonmatrix arrangement is increased. 
         [0046]    In addition, in Example described above, since the change from the matrix tray to the nonmatrix tray is viewed as an actual change of the image of the cavities  30 , it is advantageous that it is easy to understand the change, and it is easy to check the validity of the pick-up instruction data of the generated nonmatrix tray, to check that there is no interference between the cavities or between the components. However, since only the data of the central positions of the cavities is required in order for the suction nozzle to hold the component, (display state changing section) the cavities, which are to be modified, may be shown by being surrounded in a two-dot line or in a dash line, or by being classified by color, and (difference displaying section) meaning of the change may be displayed by other means which a person can recognize, such as a character, a sign, or the like, and/or instead thereof, (difference notifying section) acoustic notification may be performed. 
         [0047]    Further, data for inputting the data of the matrix tray may exist in advance, or, when the data does not exist, a person may measure each portion of the real tray and may obtain data thereof. 
       REFERENCE SIGNS LIST 
       [0048]      10 : electronic-circuit-component mounting line,  12 ,  14 : mounting module,  15 : component supply device,  18 : tray feeder,  20 : matrix tray,  22 ,  24 : nonmatrix tray,  26 : tray holding table,  30 : cavity,  40 : board conveying and holding device,  76 : module main body,  80 : mounting device,  82 : mounting head,  84 : head moving device,  100 : suction nozzle,  102 : imaging device,  104 : fiducial mark,  120 : module control device,  126 : memory section,  130 : integrated control device,  132 : input/operation device,  134 : display,  136 : memory section