Patent Description:
A technique of mass-producing board products by performing board work on a board on which printed wiring is performed has become widespread. Further, it is common to provide multiple types of board work machines for performing the board work side by side so as to configure a board work line. A component mounter among the board work machines uses a component supply unit loaded with the component container that contains multiple components. The loading operation for loading the component supply unit with the component container, in other words, a set-up operation for preparing the component supply unit for use, is often performed in a set-up area distant from the component mounter being operated (external set-up). The set-up component supply unit is conveyed to and installed in a component mounter (internal set-up).

The loading operation and the installing operation on the component mounter described above have been conventionally performed by human hand and require a lot of labor. Further, the loading operation is performed ahead of schedule to ensure that the production plan is achieved, which increases the number of work-in-process component supply units that cannot be diverted to other uses. Therefore, the management is complicated and further labor is required. In recent years, for the purpose of labor saving, a container loader that automates at least a part of the loading operation has been put into practical use. One example of a technique related to the automation of the loading operation and the installing operation disclosed in Patent Literature <NUM>.

A second embodiment of Patent Literature <NUM> describes a configuration including a storage shed for storing a reel (one example of the component container), a storage shed for storing a feeder (one example of the component supply unit), a reel set device, a conveyance device, and a management section. The reel set device performs the set-up work for setting a reel to a feeder. The conveyance device conveys the set-up feeder to the component mounter. The management section controls the retrieval, the set-up work, the conveyance operation, or the like of the reels and the feeders, and manages the production of the component mounter. According to this configuration, it is said that the combination and the location of the reel and the feeder can be easily recognized so that the real and the feeder can be easily managed. Further prior art is disclosed in <CIT>, <CIT> and <CIT>.

Incidentally, in the reel set device of Patent Literature <NUM>, it is preferable that the loading operation is automated. However, since the loading operation is performed one by one in order, which is not necessarily efficient.

In the present specification, it is an object to be solved to provide a component supply unit storage and retrieval system that improves the efficiency of a set-up work involving retrieval of a component supply unit from a warehouse.

The present specification discloses a component supply unit storage and retrieval system according to claim <NUM>.

In a component supply unit storage and retrieval system of the present specification, a storage and retrieval robot automatically performs an operation of retrieving multiple component supply units from a unit warehouse and storing the same in a unit storage. The multiple component supply units stored in the unit storage are collectively utilized in a subsequent set-up work or are collectively installed in a component mounter. Therefore, it is possible to improve the efficiency of the set-up work as compared with the conventional technique in which the component supply units are set-up one by one.

A configuration of component supply unit storage and retrieval system <NUM> of a first embodiment will be described with reference to the configuration diagrams of <FIG> and <FIG>, and the functional block diagram of <FIG>. Storage and retrieval system <NUM> corresponds to a loading operation for loading component supply unit <NUM> with component container <NUM> and related operations before and after the loading operation. Storage and retrieval system <NUM> is configured to include unit warehouse <NUM>, storage holding base <NUM>, unit storages (<NUM>, <NUM>), and storage and retrieval robot <NUM>.

Component container <NUM> is loaded in component supply unit <NUM> while containing multiple components. Component supply unit <NUM> is used when supplying the components contained in component container <NUM> in a mounting operation performed by component mounter <NUM>. Identification codes indicating each type or individual are attached to component container <NUM> and component supply unit <NUM>. The identification code of component container <NUM> includes information indicating the type of the component contained in component container <NUM>. As the identification code, a barcode, a two-dimensional code, or the like is used. When component supply unit <NUM> is loaded with component container <NUM>, the identification codes of both are read by the code reader. As a result, load information V (see <FIG>) associating an individual of component container <NUM> with an individual of component supply unit <NUM>, which is loaded with component container <NUM>, is created.

As component container <NUM>, a tape reel can be exemplified, and as component supply unit <NUM>, an integral type feeder device in which the tape reel is directly loaded can be exemplified. A carrier tape in which multiple components are sealed at a predetermined pitch is wound and held on the tape reel. The feeder device is installed on component mounter <NUM> in a form to which the tape reel is loaded. The feeder device supplies the component to a component mounting tool of component mounter <NUM> by pulling out the carrier tape from the tape reel and sending the carrier tape to a component pick up position. When the mounting operation of the component proceeds and the component of the tape reel is consumed, the entire feeder device is exchanged.

The feeder device is not limited to an integral type and may be a separate type. The separate type feeder device is configured to include a feeder main body portion having a feeding mechanism of the carrier tape and a reel cassette to which the tape reel is loaded. The feeder main body portion is permanently provided in component mounter <NUM>, and the separate reel cassette is disposed in the vicinity of the feeder main body portion. When the mounting operation of the component proceeds and the component of the tape reel is consumed, the reel cassette is exchanged. The reel cassette corresponds to component supply unit <NUM> to which component container <NUM> is loaded.

Hereinafter, a case where component supply unit <NUM> is an integral type feeder device and a tape reel serving as component container <NUM> is already loaded will be described. A tray may be used as component container <NUM>, and a tray loading unit may be used as component supply unit <NUM>.

Unit warehouse <NUM> stores component supply units <NUM> more than component supply units <NUM> stored in unit storages <NUM> and <NUM> described later. As illustrated in <FIG> and <FIG>, unit warehouse <NUM> is formed in a large vertical rectangular parallelepiped shape. Unit warehouse <NUM> includes a storage and retrieval port <NUM> on a front face thereof. However, the configuration is not limited to this, a storage port and a retrieval port may be provided separately. Component supply unit <NUM>, which is loaded with component container <NUM>, is stored from storage and retrieval port <NUM> by an operator.

Upper section guide <NUM> extending in the left-right direction is provided on a lower portion of storage and retrieval port <NUM> on the front face of unit warehouse <NUM>. Lower section guide <NUM> extending in the left-right direction is provided on a lowermost portion of the front face of unit warehouse <NUM>. Upper section guide <NUM> and lower section guide <NUM> are formed in, for example, a protrusion shape protruding ahead or a groove shape opened upward.

As illustrated in <FIG>, multiple storing positions, actuator <NUM>, and code reader <NUM> are provided in unit warehouse <NUM>. The actuator <NUM> transfers component container <NUM> stored in storage and retrieval port <NUM> to a storing position, or transfers the component container <NUM> in the storing position to storage and retrieval port <NUM>. Actuator <NUM> is controlled by warehouse control section <NUM>.

Code reader <NUM> reads the identification code attached to stored component supply unit <NUM> and delivers the read result to warehouse control section <NUM>. Therefore, warehouse control section <NUM> can recognize the individuals of all stored component supply units <NUM> in association with the storing positions. Further, warehouse control section <NUM> can recognize component container <NUM> loaded in each of the component supply units <NUM> with reference to load information V. Warning lamp <NUM> is provided on the right front side of the upper portion of unit warehouse <NUM>. Warehouse control section <NUM> controls the lighting of warning lamp <NUM> when an abnormality occurs or a failure occurs and notifies an operator of the same.

As illustrated in <FIG> and <FIG>, storage holding base <NUM> is disposed on the left side of unit warehouse <NUM> adjacent to each other. However, the configuration is not limited to this, storage holding base <NUM> may be disposed on the right side of unit warehouse <NUM>. Storage holding base <NUM> holds unit storages <NUM> and <NUM> on the upper side. Storage holding base <NUM> is formed in a rectangular parallelepiped frame shape. Upper section guide <NUM> extending in the left-right direction is provided on an upper portion of the front face of storage holding base <NUM>. Lower section guide <NUM> extending in the left-right direction is provided on a lower portion of the front face of storage holding base <NUM>. Upper section guide <NUM> and Lower section guide <NUM> are disposed at the same height as upper section guide <NUM> and lower section guide <NUM> of unit warehouse <NUM>, and are formed in the same shape.

Storage holding base <NUM> is capable of being additionally installed. When storage holding base <NUM> is additionally installed, multiple storage holding bases <NUM> are disposed adjacent to each other in the left-right direction. Further, multiple storage holding bases <NUM> may be disposed so as to be dispersed on both the left and right sides of unit warehouse <NUM>. As a result, multiple upper section guides <NUM> are connected in the left-right direction and are further connected to upper section guide <NUM> of unit warehouse <NUM> to form a long movement guide. Similarly, multiple lower section guides <NUM> are connected in the left-right direction and are further connected to lower section guide <NUM> of unit warehouse <NUM> to form a long movement guide.

Full width unit storages <NUM> are held on the right side and center on the upper side of storage holding bases <NUM> among three storage holding bases <NUM> illustrated in <FIG> and <FIG>. Further, two half width unit storages <NUM> are held on the upper side of storage holding base <NUM> on the left side. The width dimension of full width unit storage <NUM> is slightly smaller than the width dimension of component mounter <NUM>. The width dimension of half width unit storage <NUM> is substantially half the width dimension of full width unit storage <NUM>.

Unit storages (<NUM>, <NUM>) stores multiple component supply units <NUM>. Multiple storage slots set-up in the left-right direction are formed on the bottom face of the inner side of unit storages (<NUM>, <NUM>). Storage slot is formed with, for example, a groove extending in the front-rear direction, into which component supply unit <NUM> is inserted from the front side and stored. In <FIG> and <FIG>, one component supply unit <NUM> is illustrated in full width unit storage <NUM> on the right side, and in actuality, multiple component supply units <NUM> are stored side by side in the left-right direction. The number of storage slots of half width unit storage <NUM> is half of the number of storage slots of full width unit storage <NUM>.

Full width unit storage <NUM> is installed on component mounter <NUM> and serves as a main portion of a component supply device. Similarly, two half width unit storages <NUM> are installed on component mounter <NUM> to serve as a main portion of the component supply device. However, the configuration is not limited to this, unit storages (<NUM>, <NUM>) may not be installed on component mounter <NUM> but may collectively perform a set-up work, transportation, or the like of stored multiple component supply units <NUM> to improve efficiency.

Storage and retrieval robot <NUM> delivers set-up component supply unit <NUM> loaded with component container <NUM> between unit storages (<NUM>, <NUM>) and unit warehouse <NUM>. Storage and retrieval robot <NUM> is formed so as to be longitudinally long. Storage and retrieval robot <NUM> includes a guide member and a movement drive section on the rear side. The guide member engages with the movement guide including multiple section guides (<NUM>, <NUM>, <NUM>, <NUM>). As a result, the entire weight of storage and retrieval robot <NUM> is supported by the movement guide, and a movement direction is predefined. The movement drive section operates, for example, by using a non-contact power supply device or a battery (not illustrated) as a power source. The movement drive section is configured to include, for example, a combination of traveling wheels and a drive motor, or a movement mechanism to which a linear motor is applied. As a result, storage and retrieval robot <NUM> is moved on the front side of unit storages (<NUM>, <NUM>) and unit warehouse <NUM> along the movement guide.

Storage and retrieval robot <NUM> further includes a unit holding space and a unit operating mechanism. The unit holding space is a space defined in the inner portion of storage and retrieval robot <NUM> and opened rearward. The unit holding space temporarily holds component supply unit <NUM> to be conveyed. The unit operating mechanism delivers component supply unit <NUM> between the unit holding space and unit storages (<NUM>, <NUM>), and between the unit holding space and storage and retrieval port <NUM> of unit warehouse <NUM>. At this time, since the height of storage and retrieval robot <NUM> is appropriately maintained by the engagement of the guide member and the movement guide, the delivering operation is stabilized. Storage and retrieval robot <NUM> is controlled by storage and retrieval control section <NUM>.

Next, a configuration related to control of storage and retrieval system <NUM> will be described. As illustrated in <FIG>, storage and retrieval control section <NUM> is communicatively connected to streamlining processing section <NUM>. Streamlining processing section <NUM> is communicatively connected to line control section <NUM>. Further, line control section <NUM> is communicatively connected to each of multiple types of board work machines constituting board work line <NUM>. Board work line <NUM> is a production line for mounting components on a board to mass-produce a board product. Component mounter <NUM> constituting board work line <NUM> is installed with set-up unit storages (<NUM>, <NUM>) to enable the supply of the components.

Streamlining processing section <NUM> performs a streamlined process for improving the efficiency of the operation in board work line <NUM>. As part of the streamlined process, streamlining processing section <NUM> optimizes the storage positions of multiple component supply units <NUM> in unit storages (<NUM>, <NUM>) in order to improve the efficiency of the mounting operation of the components in component mounter <NUM>. This streamlined process is also referred to as an optimization process, and various well-known techniques can be applied. Line control section <NUM> controls the operation of board work line <NUM> based on the result of the streamlined process received from streamlining processing section <NUM>.

On the other hand, storage and retrieval control section <NUM> is communicatively connected to warehouse control section <NUM> of unit warehouse <NUM>. Further, storage and retrieval control section <NUM> controls storage and retrieval robot <NUM>. Further, load information memory section <NUM> attached to storage and retrieval control section <NUM> stores load information V. Storage and retrieval control section <NUM> includes a man-machine interface (an input section, a display section, a wireless communication section, or the like) for exchanging information with the operator.

Load information V or other various information are appropriately transmitted and received between each of the control elements described above. Therefore, storage and retrieval control section <NUM> can enable unit warehouse <NUM> and component mounter <NUM> to share load information V. Further, all of each control element described above needs not to be independent hardware. For example, storage and retrieval control section <NUM> and warehouse control section <NUM> may be achieved by different software in one computer device. Further, for example, storage and retrieval control section <NUM> may be achieved as a partial function of streamlining processing section <NUM>. Further, the communication connection or the information transmission described above may be performed by using a wireless communication device. The control functions of storage and retrieval control section <NUM> and the like will be described in detail in the following description of operations.

Next, the operation of storage and retrieval system <NUM> will be described with reference to <FIG>. In step S1 in <FIG>, storage and retrieval control section <NUM> acquires the result of the streamlined process from streamlining processing section <NUM>. The result of the streamlined process includes an identification code of component supply unit <NUM> to be used and information about the storage position in unit storages (<NUM>, <NUM>). The information about the storage position is represented by, for example, a slot number indicating a position of the storage slot.

In the next step S2, storage and retrieval control section <NUM> provides the identification code of component supply unit <NUM> to be used to warehouse control section <NUM> through the command. Warehouse control section <NUM> controls actuator <NUM> in accordance with the command and transfers component supply unit <NUM> to storage and retrieval port <NUM>. In the next step S3, storage and retrieval control section <NUM> commands storage and retrieval robot <NUM> to convey component supply unit <NUM>. Storage and retrieval robot <NUM> conveys component supply unit <NUM> at storage and retrieval port <NUM> to unit storages (<NUM>, <NUM>) in accordance with the command.

In the next step S4, storage and retrieval control section <NUM> provides the storage positions in unit storages (<NUM>, <NUM>) to storage and retrieval robot <NUM> through the command. Storage and retrieval robot <NUM> stores component supply unit <NUM> in the commanded storage position. In the next step S5, storage and retrieval control section <NUM> determines whether all component supply units <NUM> included in the result of the streamlined process are aligned in unit storages (<NUM>, <NUM>). Thereafter, while all component supply units <NUM> are not aligned, storage and retrieval control section <NUM> repeatedly executes steps S2 to S5.

When all component supply units <NUM> are aligned by the repetition of the execution, the operation flow ends. At this point, unit storages (<NUM>, <NUM>) are ready for use. The operator transports and installs one full width unit storage <NUM> or two half width unit storages <NUM> to component mounter <NUM>. In one example of this installing operation, first, the operator connects a carriage (not illustrated) for transportation to the opposite side of storage and retrieval robot <NUM> at storage holding base <NUM>. Secondly, the operator pulls out unit storages (<NUM>, <NUM>) from storage holding base <NUM>, transfers unit storages (<NUM>, <NUM>) to the carriage, and transports unit storages (<NUM>, <NUM>) to component mounter <NUM>. Third, the operator connects the carriage to an installation position of component mounter <NUM>. Finally, the operator transfers unit storages (<NUM>, <NUM>) from the carriage to component mounter <NUM>. As a result, component mounter <NUM> is ready to supply the components. At this time, load information V is shared by component mounter <NUM> by the communication or the like.

In component supply unit storage and retrieval system <NUM> of the first embodiment, storage and retrieval robot <NUM> automatically performs an operation of retrieving multiple component supply units <NUM> from unit warehouse <NUM> and storing the same in unit storages (<NUM>, <NUM>). Thereafter, the multiple component supply units <NUM> stored in unit storages (<NUM>, <NUM>) are collectively utilized in a subsequent set-up work or are collectively installed in component mounter <NUM>. Therefore, it is possible to streamline the set-up work as compared with the conventional technique in which component supply units <NUM> are set-up one by one.

Further, storage and retrieval control section <NUM> controls for selecting multiple component supply units <NUM> which are retrieved from unit warehouse <NUM> and further controls the storage positions of retrieved multiple component supply units <NUM> in unit storages (<NUM>, <NUM>), based on the result of the streamlined process. According to this configuration, subsequent to the streamlined process, it is possible to timely perform the set-up of unit storages (<NUM>, <NUM>) to be installed in component mounter <NUM>. Further, since the storage positions of multiple component supply units <NUM> in the unit storages (<NUM>, <NUM>) are automatically controlled, there would be no possibility that the storage positions are erroneous. Further, since unit warehouse <NUM> for storing component supply unit <NUM> and storage holding base <NUM> for storing component supply unit <NUM> in unit storages (<NUM>, <NUM>) are disposed adjacent to each other, a space-saving system configuration is achieved.

Next, with reference to <FIG>, a description will be given of storage and retrieval system 1A of a second embodiment that differs from the first embodiment. As illustrated in <FIG>, in the second embodiment, traveling path <NUM> and conveyance vehicle <NUM> are added to the configuration of the first embodiment.

Traveling path <NUM> is laid from the rear side of storage holding base <NUM> on the left side to board work line <NUM>. Storage holding base <NUM> on the left side also serves as a carry-out station for carrying out component supply unit <NUM>, which is loaded with component container <NUM>, toward component mounter <NUM>, and a carry-in station for carrying in component supply unit <NUM> that has been used in component mounter <NUM>. Conveyance vehicle <NUM> travels on traveling path <NUM> in accordance with a wireless command from storage and retrieval control section <NUM> and also loads and unloads half width unit storage <NUM>. Conveyance vehicle <NUM> appropriately reports a progress status of the conveyance operation to storage and retrieval control section <NUM>. A standby position of conveyance vehicle <NUM> is set on the rear side of storage holding base <NUM> on the left side (illustrated in <FIG>). Traveling path <NUM> may be laid over multiple board work lines <NUM> so that multiple conveyance vehicles <NUM> may travel while avoiding collisions. Further, conveyance vehicle <NUM> may be an AGV of a type in which physical traveling path <NUM> is unnecessary and travels by referring to information about the traveling path on map data.

In the above configuration, conveyance vehicle <NUM> removes half width unit storage <NUM> ready to be used from storage holding base <NUM> and loads the same. Next, conveyance vehicle <NUM> travels to component mounter <NUM>, conveys half width unit storage <NUM>, and installs the same in component mounter <NUM>. Alternatively, conveyance vehicle <NUM> delivers half width unit storage <NUM> to the operator in the vicinity of component mounter <NUM>. Further, conveyance vehicle <NUM> conveys second half width unit storage <NUM> in the same manner. According to the second embodiment, in addition to the storage of component supply unit <NUM> in half width unit storage <NUM>, automation of the transporting operation of half width unit storage <NUM> is achieved.

Claim 1:
A component supply unit storage and retrieval system (<NUM>, 1A) comprising:
a unit storage (<NUM>, <NUM>) configured to store multiple component supply units (<NUM>) used when multiple components are supplied to a component mounter (<NUM>);
a storage holding base (<NUM>) configured to hold the unit storage (<NUM>, <NUM>);
a unit warehouse (<NUM>) configured to store more component supply units (<NUM>) than the unit storage (<NUM>, <NUM>);
a storage and retrieval robot (<NUM>) configured to deliver one or more of the multiple component supply units (<NUM>) between the unit storage (<NUM>, <NUM>) and the unit warehouse (<NUM>), and
a movement guide (<NUM>, <NUM>) provided from the storage holding base (<NUM>) to the unit warehouse (<NUM>),
wherein the storage and retrieval robot (<NUM>) is configured to move along the movement guide (<NUM>, <NUM>),
characterized in that
the unit storage (<NUM>, <NUM>) is configured to be attached to and detached from the storage holding base (<NUM>) so that the multiple component supply units (<NUM>) stored in the unit storage (<NUM>, <NUM>) can be collectively utilized in a subsequent set-up work or can be collectively installed in the component mounter (<NUM>).