Patent Description:
Conventionally, there has been known a component mounting system in which a storage container is provided at an upstream side of a component mounting machine group, which is made up by aligning multiple component mounting machines along a board conveyance direction, and a loader automatically detaches and/or attaches a feeder from and/or to the component mounting machines and the storage container (refer to Patent Literature <NUM>). There has also been known a component mounting machine fitted with a feeder stocking area in which a used feeder collection area is disposed adjacent to the feeder stock area (refer to Patent Literature <NUM>). In this component mounting machine, a component run-out feeder, from which all the components have been used up, is collected into the used feeder collection area, while a still-usable feeder, which still holds remaining usable components, is collected in the feeder stocking area.

Patent Literature <NUM> discloses a component mounting system according to the preamble of claim <NUM>.

However, with Patent Literature <NUM>, since feeders are stored in the storage container without considering their applications, there have been cases in which feeders that are used for production and feeders that are not used for production are stored in a mixed fashion. Due to this, when a feeder detaching or attaching operation is performed by the loader or an operator in which a feeder is detached from or attached to the storage container by the loader or the operator, there have been cases in which the movement distance gets long or the operation time gets long. On the other hand, with Patent Literature <NUM>, feeders from which components are used up and feeders which still hold usable components are stored not in the storage container but in the component mounting machine while being separated from each other. Even in a case that the feeders from which the components are used up and the feeders which still hold the usable components are stored while being separated in a similar fashion to that described above in the storage container, when both the feeders from which the components are used up and the feeders which still hold the usable components are not planned to be used for production, the operator is required to remove both the feeders from the storage container, and hence, there is no point in separating them from each other for storage.

The present disclosure has been made in view of the problems described heretofore, and a main object thereof is to improve convenience in performing detaching and attaching operations of detaching and attaching a component supply device that is not used for production and a component supply device that is used for production from and to a storage container.

According to the present disclosure, there is provided a component mounting system according to claim <NUM>.

With this component mounting system, the storage area is divided by the boundary into the collection area configured to detachably support the component supply device for collection that is not used for production and the supply area configured to detachably support the component supply device for supply that is used for production. As a result, the component supply device that is not used for production and the component supply device that is used for production are never stored in the storage area in a mixed fashion. This improves the convenience when the loader or the operator performs the detaching and attaching operations of detaching and attaching the component supply devices from and to the storage container.

Next, embodiments of the present disclosure will be described by referring to drawings. <FIG> is a perspective view schematically showing component mounting system <NUM> according to an embodiment of the present disclosure, <FIG> is a perspective view schematically showing component mounting machine <NUM>, and <FIG> is a block diagram showing a configuration related to a control of component mounting system <NUM>. In <FIG>, a left-right direction constitutes an X-direction, a front-rear direction constitutes a Y-direction, and an up-down direction constitutes a Z-direction.

As shown in <FIG>, component mounting system <NUM> includes component mounting line <NUM>, loader <NUM>, and management computer <NUM>. Component mounting machine group <NUM> and feeder storage <NUM> are aligned in the X-direction in component mounting line <NUM>. Multiple component mounting machines <NUM> are aligned in the X-direction in component mounting machine group <NUM>. Component mounting machine <NUM> mounts a component supplied from feeder <NUM> onto board S (refer to <FIG>). Board S is conveyed from a left-hand side (an upstream side) to a right-hand side (a downstream side) of component mounting line <NUM> along the X-direction. Feeder storage <NUM> is disposed at an upstream side of component mounting machine group <NUM> and stores feeder <NUM> (feeder <NUM> for collection or collection feeder <NUM>) that is not scheduled to be used for production and feeder <NUM> (feeder <NUM> for supply or supply feeder <NUM>) that is scheduled to be used for production. Loader <NUM> can automatically exchange feeders <NUM> between component mounting machine <NUM> or feeder storage <NUM> and itself. Management computer <NUM> manages a whole of component mounting system <NUM>.

As shown in <FIG>, component mounting machine <NUM> includes board conveyance device <NUM> for conveying board S in the X-direction, head <NUM> having a nozzle for picking up a component supplied by feeder <NUM>, head moving mechanism <NUM> for moving head <NUM> in XY-directions, and touch panel display <NUM> (refer to <FIG>). In addition, component mounting machine <NUM> includes mounting control device <NUM> (refer to <FIG>) made up of known CPU, ROM, RAM, and the like. Mounting control device <NUM> controls a whole of component mounting machine <NUM>. Mounting control device <NUM> can receive signals inputted from and output signals to board conveyance device <NUM>, head <NUM>, head moving mechanism <NUM>, touch panel display <NUM>, and the like. In addition, component mounting machine <NUM> has two upper and lower areas to which feeders <NUM> can be attached at a front portion thereof. The upper area is supply area 20A where feeder <NUM> can supply components, while the lower area is stock area 20B where feeder <NUM> can be stocked. Feeder base <NUM>, having an L-shape in a side view, is provided in supply area 20A and stock area 20B. Multiple feeders <NUM> are detachably attached to each feeder base <NUM>.

As shown in <FIG>, feeder <NUM> is configured as a tape feeder for feeding a tape that accommodates components at predetermined pitches. Feeder <NUM> includes tape reel <NUM> around which a tape is wound, tape feeding mechanism <NUM> for feeding the tape from tape reel <NUM>, and feeder control device <NUM> (refer to <FIG>). In addition, as shown in <FIG>, feeder base <NUM> includes multiple slots <NUM> which are arranged at predetermined intervals in the X-direction for feeder <NUM> to be inserted individually. When feeder <NUM> is inserted into slot <NUM> of feeder base <NUM>, a connector, not shown, of feeder <NUM> is connected to connector <NUM> of feeder base <NUM>. As a result, feeder control device <NUM> can communicate with a control section (mounting control device <NUM>, management computer <NUM>, and the like) of a feeder destination part where feeder <NUM> is attached. Feeder control device <NUM> causes tape feeding mechanism <NUM> to feed out a component accommodated in the tape to a predetermined component supply position, and causes again tape feeding mechanism <NUM> to feed out a component accommodated in the tape to the predetermined component supply position when the component in the component supply position is picked up by the nozzle of head <NUM>.

As shown in <FIG>, loader <NUM> can move along X-axis rail <NUM> provided to run on front surfaces of multiple component mounting machines <NUM> and a front surface of feeder storage <NUM> in parallel to the conveyance direction (X-direction) of a board, whereby loader <NUM> automatically detaches and/or attaches feeder <NUM> from and/or to component mounting machines <NUM> and feeder storage <NUM>. As shown in <FIG> and <FIG>, loader <NUM> includes loader moving mechanism <NUM> and feeder transfer mechanism <NUM>. Loader moving mechanism <NUM> moves loader <NUM> along X-axis rail <NUM>. Feeder transfer mechanism <NUM> attaches feeder <NUM> from loader <NUM> to component mounting machine <NUM> and feeder storage <NUM>, detaches feeder <NUM> from component mounting machine <NUM> and feeder storage <NUM> to house it in loader <NUM>, and moves feeder <NUM> between upper transfer area 50A and lower transfer area 50B. As shown in <FIG>, loader <NUM> also includes encoder <NUM> and loader control device <NUM>. Encoder <NUM> detects a movement position of loader <NUM> in the X-direction. Loader control device <NUM> is made up of known CPU, ROM, RAM, and the like. Loader control device <NUM> receives a detection signal inputted from encoder <NUM> and outputs a drive signal to loader moving mechanism <NUM> and feeder transfer mechanism <NUM>.

Feeder storage <NUM> has feeder base <NUM> (refer to <FIG>) having almost the same configuration as that of feeder base <NUM> provided in component mounting machine <NUM> for accommodation of multiple feeders <NUM>. Feeder base <NUM> includes multiple slots <NUM> which are arranged at predetermined intervals in the X-direction for feeder <NUM> to be inserted individually. Slots <NUM> each support corresponding feeder <NUM> removably. Multiple slots <NUM> so arranged are divided by boundary <NUM> in such a way as to constitute collection area a1 and supply area a2. Collection area a1 is an area where to store feeder <NUM> for collection or collection feeder <NUM> that is not used for production, and supply area a2 is an area where to store feeder <NUM> for supply or supply feeder <NUM> that is used for production. Collection feeder <NUM> is feeder <NUM> that is not used for production, for example, feeder <NUM> whose components have all been used up, feeder <NUM> that is not scheduled to be used for future production although it still holds components remaining therein, and the like. Supply feeder <NUM> is feeder <NUM> that is used for production, for example, new feeder <NUM> or feeder <NUM> that still holds components remaining therein that is to be exchanged with feeder <NUM> whose components have all been used up, feeder <NUM> that is scheduled to be used for a subsequent production job, and the like. Collection area a1 is provided on a side closer to component mounting machine group <NUM>, while supply area a2 is provided on a side farther from component mounting machine group <NUM>. Indicators <NUM>, each made up of an LED, are provided on a front surface of feeder base <NUM> in such a manner as to be positioned individually to face corresponding slots <NUM>. When indicator <NUM> is illuminated in red, it indicates that slot <NUM> facing that indicator <NUM> belongs to collection area a1, whereas when indicator <NUM> is illuminated in green, it indicates that slot <NUM> facing that indicator <NUM> belongs to supply area a2. As a result, boundary <NUM> is formed between that red indicator <NUM> and that green indicator <NUM>. It should be noted that indicators <NUM> may be illuminated in other different colors from red and green. In addition, indicators <NUM> may be so divided based not on colors but on illuminated states (turn-on / turn-off) instead of coloring. The illumination control of indicators <NUM> is executed by management computer <NUM>. When feeder <NUM> is inserted into slot <NUM> of feeder base <NUM>, a connector, not shown, of feeder <NUM> is connected to connector <NUM> of feeder base <NUM>. As a result, feeder control device <NUM> can communicate with a control section (mounting control device <NUM>, management computer <NUM>, and the like) of a feeder destination part where feeder <NUM> is attached.

As shown in <FIG>, management computer <NUM> is made up of known CPU 80a, ROM 80b, RAM 80c, HDD 80d, and the like and is connected to display <NUM> such as LCD, input device <NUM> such as a keyboard and a mouse, and the like. HDD 80d of management computer <NUM> stores a production program (a program related to a plan that specifies types of components to be mounted on board S, the number of boards with such components to be fabricated, and the like), a production job (a job that specifies types and orders of feeders <NUM> to be set on feeder base <NUM>, types and orders of components to be mounted on board S, and the like for each component mounting machine <NUM>), and the like. The production program is stored in HDD 80d of management computer <NUM> by an operator operating input device <NUM>. The production job is set based on the production program by CPU 80a of management computer <NUM> and is stored in HDD 80d. In setting the production job, management computer <NUM> sets a mounting sequence based on the production program, distributes the mounting sequence to each component mounting machine <NUM>, sets a mounting order of components distributed to each component mounting machine <NUM>, sets how to arrange feeders <NUM> for each component mounting machine <NUM>, and sets the production jobs for all those component mounting machines <NUM> so that the production efficiency of component mounting line <NUM> is increased as high as possible. As a result, when production programs are switched, production jobs for each component mounting machine <NUM> are also switched. Management computer <NUM> is connected with mounting control device <NUM> and loader control device <NUM> so as to enable a bidirectional communication therebetween. Management computer <NUM> receives information on a mounting status of component mounting machine <NUM> from mounting control device <NUM> and receives information on a driving status of loader <NUM> from loader control device <NUM>. Management computer <NUM> is communicably connected to feeder control device <NUM> of feeder <NUM> so as to be able to obtain information on stored feeder <NUM>.

Next, an operation (a component mounting action) will be described in which mounting control device <NUM> of component mounting machine <NUM> causes component mounting machine <NUM> to mount a component on board S based on a production job that mounting control device <NUM> receives from management computer <NUM>. First, mounting control device <NUM> causes the nozzle of head <NUM> to pick up a component supplied from feeder <NUM>. Specifically, mounting control device <NUM> causes head moving mechanism <NUM> to move the nozzle of head <NUM> to a position lying directly above a desired component supply position. Next, mounting control device <NUM> causes the nozzle to be lowered and then causes a negative pressure to be supplied to the nozzle. As a result, the desired component is picked up at a distal end of the nozzle. Thereafter, mounting control device <NUM> causes the nozzle to be lifted up and then causes head moving mechanism <NUM> to move the nozzle, which has picked up the desired component, to a position lying above a predetermined position on board S. Then, mounting control device <NUM> causes the nozzle to be lowered at the predetermined position and then causes the atmospheric pressure to be supplied to the nozzle. As a result, the component picked up and held to the nozzle is allowed to leave from the nozzle to be mounted on board S in the predetermined position. Other components to be mounted on board S are also mounted on board S in a similar manner, and when all the components to be mounted are mounted completely on board S in question, mounting control device <NUM> causes that board S to be fed to component mounting machine <NUM> residing on a downstream side.

Next, a processing operation will be described in which management computer <NUM> sets boundary <NUM>. CPU 80a of management computer <NUM> predicts the number of collection feeders <NUM>, sets boundary <NUM> of feeder base <NUM> of feeder storage <NUM> based on the predicted number of collection feeders <NUM>, and performs an illumination control of indicators <NUM> of feeder base <NUM> in accordance with boundary <NUM> so set.

An example of a boundary setting routine executed by management computer <NUM> will be described below by use of a flowchart shown in <FIG>. The boundary setting routine shown in <FIG> is a routine that is executed within a time period from a start of processing of a certain production program to an end of the processing in component mounting line <NUM>. In this case, component mounting machines <NUM> involved in a production in component mounting line <NUM> repeatedly execute production jobs set individually for those component mounting machines <NUM> until the production program is completed.

When starting the boundary setting routine shown in <FIG>, CPU 80a of management computer <NUM> first determines whether it is a timing right now at which the boundary is to be set (S110). The boundary setting timing is a timing that occurs at predetermined time intervals (for example, every <NUM> minutes or every <NUM> minutes) after the production program is started to be processed. If it is determined in step S110 that it is not the boundary setting timing right now, CPU 80a returns to step S110 again. On the other hand, if it is determined in step S110 that it is the boundary setting timing right now, CPU 80a predicts the number of collection feeders <NUM> that will be resulting by the occurrence of a subsequent boundary setting timing (S120). This prediction is made based on the operating conditions (the number of remaining components or the like) of feeders <NUM> that are set in each component mounting machine <NUM> and the production job of that component mounting machine <NUM>. For example, if in certain component mounting machine <NUM>, the production job can be executed n times by the occurrence of a subsequent boundary setting timing, and the number of remaining components of certain feeder <NUM> set in that component mounting machine <NUM> is smaller than a total number of components to be used in the production jobs that are carried out n times, that particular feeder <NUM> is counted as collection feeder <NUM>. Subsequently, CPU 80a sets boundary <NUM> based on the predicted number of collection feeders <NUM> (S130). CPU 80a sets correction area a1 so that the number of free slots <NUM> in collection area a1 becomes equal to the predicted number of collection feeders <NUM>. In association with this, not only is boundary <NUM> set, but also supply area a2 is set. Subsequently, CPU 80a causes the position of boundary <NUM> so set to be indicated by controlling illumination of indicators <NUM> based on that boundary <NUM> (S140). Subsequently, CPU 80a determines whether the processing of the production program ends at a subsequent boundary setting timing (S150). If the determination made in S150 is negative, CPU 80a returns to S110 again, whereas if the determination made in S150 is affirmative, CPU 80a ends this routine since no more prediction of the number of collection feeders <NUM> is required. <FIG> is a perspective view of feeder base <NUM> in feeder storage <NUM>. The position of boundary <NUM> of feeder base <NUM> is changed as shown in <FIG>, for example.

Another example of the boundary setting routine executed by management computer <NUM> will be described below by use of a flowchart shown in <FIG>. A boundary setting routine shown in <FIG> is a routine that is executed before production programs, which are processed in component mounting line <NUM>, are switched over. Since component mounting machines <NUM> involved in a production in component mounting line <NUM> execute different production jobs before and after production programs are switched over, feeders <NUM> for use for production are also exchanged as required as the different production jobs are so executed.

When starting the boundary setting routine shown in <FIG>, CPU 80a of management computer <NUM> first predicts the number of collection feeders <NUM> based on the present and subsequent production jobs (S210). Specifically, CPU 80a determines feeder <NUM> that is used in the present production job but is not used in a subsequent production job as collection feeder <NUM> and regards a total number of feeders <NUM> so determined as the number of collection feeders for each of component mounting machines <NUM> involved in a production in component mounting line <NUM>. Subsequently, CPU 80a sets boundary <NUM> based on the predicted number of collection feeders <NUM> (S220). This step S220 is the same as that step S130 described above. Subsequently, CPU 80a causes the position of boundary <NUM> so set to be indicated by controlling illumination of indicators <NUM> based on that boundary <NUM> (S230) and ends this routine.

Next, an operation will be described which is performed when loader control device <NUM> causes loader <NUM> to execute an automatic exchange of feeders <NUM> based on an instruction from management computer <NUM>. When receiving an instruction to transfer collection feeder <NUM> to feeder storage <NUM> from management computer <NUM>, loader control device <NUM> causes loader moving mechanism <NUM> to move loader <NUM> to the front of feeder base <NUM> of component mounting machine <NUM> to which collection feeder <NUM> is attached. Subsequently, loader control device <NUM> causes feeder transfer mechanism <NUM> to detach collection feeder <NUM> from feeder base <NUM> in question and house collection feeder <NUM> so detached in loader <NUM> and then causes loader moving mechanism <NUM> to move loader <NUM> to the front of feeder base <NUM> of feeder storage <NUM>. Subsequently, loader control device <NUM> causes feeder transfer mechanism <NUM> to attach collection feeder <NUM> in question to a free slot of collection area a1 of feeder base <NUM>. In addition, when receiving a replenishment instruction of supply feeder <NUM> from management computer <NUM>, loader control device <NUM> causes loader moving mechanism <NUM> to move loader <NUM> to the front of feeder base <NUM> of feeder storage <NUM>. Subsequently, loader control device <NUM> causes feeder transfer mechanism <NUM> to detach supply feeder <NUM> that is attached to supply area a2 of feeder base <NUM> and house supply feeder <NUM> so detached into loader <NUM> and then causes loader moving mechanism <NUM> to move loader <NUM> to the front of feeder base <NUM> of component mounting machine <NUM> of a replenishing target. Subsequently, loader control device <NUM> causes feeder transfer mechanism <NUM> to attach supply feeder <NUM> in question to feeder base <NUM>.

Here, the correspondence between the constituent elements of component mounting system <NUM> of the present embodiment and constituent elements of a component mounting system of the present disclosure will be clarified. Component mounting machine group <NUM> of the present embodiment corresponds to a component mounting machine group of the present disclosure, feeder storage <NUM> of the former corresponds to a storage of the latter, loader <NUM> of the former corresponds to a loader of the latter, and feeder base <NUM> of the former corresponds to a storage area of the latter. In addition, feeder <NUM> corresponds to a component supply device, board S corresponds to a mounting target, component mounting machine <NUM> corresponds to a component mounting machine, CPU 80a of management computer <NUM> corresponds to a control section, and indicator <NUM> corresponds to a boundary position indicator.

In component mounting system <NUM> that has been described heretofore, feeder base <NUM> of feeder storage <NUM> is divided into collection area a1 where to detachably support collection feeder <NUM> that is not used for production and supply area a2 where to detachably support supply feeder <NUM> that is used for production by boundary <NUM>. As a result, there never occurs a case in which collection feeder <NUM> and supply feeder <NUM> are stored in a mixed fashion in feeder base <NUM>. This improves the convenience of work in which loader <NUM> and the operator detach and attach feeder <NUM> from and to feeder storage <NUM>.

In addition, collection area a1 is provided on the side of feeder base <NUM> that lies closer to component mounting machine group <NUM>. Loader <NUM> moves forwards and backwards along component mounting machine group <NUM>. As a result, a movement distance of loader <NUM> over which loader <NUM> moves when loader <NUM> places collection feeder <NUM> in collection area a1 becomes shorter when collection area a1 is provided on the side closer to component mounting machine group <NUM> than when collection area a1 is provided on a side farther from component mounting machine group <NUM>, which then serves to make the operation time shorter.

Further, management computer <NUM> predicts the number of collection feeders <NUM> and sets boundary <NUM> based on the number of collection feeders <NUM> so predicted. As a result, the occurrence of a case in which collection feeder <NUM> cannot be stored in feeder base <NUM> of feeder storage <NUM> can be prevented. Incidentally, when a situation arises in which collection feeder <NUM> cannot be stored in feeder base <NUM> of feeder storage <NUM>, loader <NUM> is placed in a state in which loader <NUM> has to hold collection feeder <NUM> housed therein, whereby the operation of loader <NUM> may be obstructed. On the other hand, since supply feeder <NUM> is normally stored in feeder storage <NUM> by the operator, such obstruction is prevented from arising. That is, even if a situation arises in which supply feeder <NUM> cannot be stored in feeder base <NUM> of feeder storage <NUM>, free slot <NUM> is generated if only the operator removes or detaches collection feeder <NUM> remaining in feeder base <NUM> from feeder base <NUM> in question. Then, in the boundary setting routine shown in <FIG>, when the routine is performed subsequently, collection area a1 is narrowed, while supply area a2 is widened. As a result, the operator can store supply feeder <NUM> in supply area a2 so widened. Accordingly, boundary <NUM> is designed to be set based on the number of collection feeders <NUM> in preference to the number of supply feeders <NUM>.

Furthermore, in predicting the number of collection feeders <NUM> in the boundary setting routine shown in <FIG>, management computer <NUM> calculates the number of feeders <NUM> that are not to be used in a subsequent production job in feeders <NUM> that are currently in use before the current production job is switched over to the subsequent production job and refers to the number so calculated as the number of collection feeders <NUM>. As a result, the position of boundary <NUM> can appropriately be changed before the production jobs are switched over so as to avoid the occurrence of a situation in which collection feeder <NUM> cannot be stored in feeder base <NUM> of feeder storage <NUM>.

In addition, in predicting the number of collection feeders <NUM> in the boundary setting routine shown in <FIG>, management computer <NUM> predicts the number (for example, a maximum number) of collection feeders <NUM> that would result by a subsequent passage of the predetermined time period every predetermined time while component mounting machine <NUM> is executing repeatedly the production job set individually for component mounting machine <NUM> in question. As a result, even in a case in which the same production job is repeatedly executed for a long time, the position of the boundary can appropriately be changed every predetermined time until the production job in question is completed.

Further, in setting boundary <NUM>, management computer <NUM> causes indicators <NUM> provided on feeder base <NUM> of feeder storage <NUM> to indicate boundary <NUM>. As a result, the operator can visually confirm the current setting position of boundary <NUM>.

Needless to say, the present disclosure is not limited to the embodiment that has been described heretofore in any way but can be carried out in various forms without departing from the technical scope of the present disclosure.

For example, in the embodiment that has been described heretofore, feeder storage <NUM> is described as including one feeder base <NUM>; however, as shown in <FIG>, a configuration may be adopted in which feeder storage <NUM> includes three feeder bases <NUM> (support tables), and collection area a1 and supply area a2 are set up of feeder base <NUM> as a unit. Indicator <NUM> for feeder base <NUM> is made up of a lamp that is long in the left-right direction. When this indicator <NUM> is illuminated in red, it indicates that feeder base <NUM> corresponding to this indicator <NUM> so illuminated is set to function as collection area a1, whereas when this indicator <NUM> is illuminated in green, it indicates that feeder base <NUM> corresponding to this indicator <NUM> so illuminated is set to function as supply area a2. In <FIG>, in those three feeder bases <NUM>, right-hand side or rightmost feeder base <NUM> (lying on a side closer to component mounting machine group <NUM>) is set to constitute collection area a1, and the remaining two feeder bases are set to constitute supply area a2. Boundary <NUM> is set between right-hand side feeder base <NUM> and central feeder base <NUM>. On the other hand, in <FIG>, in three feeder bases <NUM>, right-hand side and central feeder bases <NUM> (two on a side closer to component mounting machine group <NUM>) are set to constitute collection area a1, and left-hand side feeder base <NUM> is set to constitute supply area a2. Boundary <NUM> is set between left-hand side feeder base <NUM> and central feeder base <NUM>. If a sum of the predicted number of collection feeders <NUM> and the number of collection feeders <NUM> that have already been stored in feeder storage <NUM> is equal to or smaller than the number of slots of one feeder base <NUM>, CPU 80a of management computer <NUM> sets boundary <NUM> as shown in <FIG>, whereas the sum is greater than the number of slots of one feeder base <NUM> and equal to or smaller than the number of slots of two feeder bases <NUM>, CPU 80a sets boundary <NUM> as shown in <FIG>. As a result, since the operator can store feeder bases <NUM> one by one in feeder storage <NUM> or remove feeder bases <NUM> one by one from feeder storage <NUM>, the work efficiency is improved as compared with a case in which feeders <NUM> are stored or removed one by one.

In the embodiment that has been described heretofore, boundary <NUM> is set in collection area a1 so that the number of free slots <NUM> in collection area a1 becomes the same as the predicted number of collection feeders <NUM>; however, the present disclosure is not limited particularly to this. For example, boundary <NUM> may be set in collection area a1 so that the number of free slots <NUM> in collection area a1 is greater by a predetermined number (or greater by a predetermined ratio) than the predicted number of collection feeders <NUM>. As a result, even if the number of collection feeders <NUM> becomes greater than the predicted number of collection feeders <NUM> in contradiction to the prediction, collection feeders <NUM> can be stored in collection area a1.

In the embodiment that has been described heretofore, in setting boundary <NUM>, CPU 80a may set boundary <NUM> so that a minimum required number of slots remains in both collection area a1 and supply area a2. For example, when setting collection area a1 based on the predicted number of collection feeders <NUM>, collection area a1 may be set so that a number resulting from deducting the minimum required number of slots in supply area a2 from the total number of slots on feeder base <NUM> constitutes an upper limit of the number of slots in collection area a1.

In the embodiment that has been described heretofore, CPU 80a of management computer <NUM> may display on display <NUM> a guidance screen for prompting a removal of collection feeder <NUM> from feeder storage <NUM> when the number of collection feeders <NUM> stored in feeder base <NUM> of feeder storage <NUM> reaches a predetermined ratio to the total number of slots of feeder base <NUM>. As a result, since the operator, who has viewed the guide screen, performs a removal operation of collection feeder <NUM> from feeder storage <NUM>, securing a free slot in feeder base <NUM> can be facilitated.

In the embodiment that has been described heretofore, a lamp may be provided on a front surface of feeder <NUM>. In this case, feeder control device <NUM> may be configured to receive information on feeder <NUM> set in feeder base <NUM> from management computer <NUM> to cause the lamp to be illuminate in red when feeder <NUM> in question is a collection feeder, whereas feeder control device <NUM> may cause the lamp to be illuminated in green when feeder <NUM> in question is a supply feeder. As a result, the operator can determine whether feeder <NUM> set in correction area a1 is collection feeder <NUM> or supply feeder <NUM> and whether feeder <NUM> set in supply area a2 is collection feeder <NUM> or supply feeder <NUM> based on the color of the illuminated lamp of feeder <NUM> in question. This enables the operator to determine easily whether collection feeder <NUM> is correctly set in collection area a1 and whether supply feeder <NUM> is correctly set in supply area a2.

In the embodiment that has been described heretofore, indicator <NUM> is provided on the front surface of feeder base <NUM>; however, instead of this configuration, an indicator similar to indicator <NUM> may be provided on a table of feeder storage <NUM> on which feeder base <NUM> is placed. In this case, the indicator only needs to be provided in a position lying ahead of feeder base <NUM> and corresponding to each slot <NUM>.

In the embodiment that has been described above, management computer <NUM> is described as changing boundary <NUM>; however, alternatively or in addition to this configuration, the operator may be made to change boundary <NUM> arbitrarily by operating input device <NUM>. In addition, in indicating boundary <NUM>, where to indicate boundary <NUM> is not limited to where the color of indicators <NUM> changes, and hence, for example, boundary <NUM> may be indicated by a lamp with a Δ mark, or a boundary position may be indicated by characters by use of liquid crystal or the like.

In the embodiment that has been described heretofore, boundary <NUM> provided on feeder base <NUM> of feeder storage <NUM> is described as being changeable in position; however, boundary <NUM> may be made unchangeable in position. For example, as shown in <FIG>, a configuration may be adopted in which two feeder bases <NUM> are disposed in feeder storage <NUM> in such a manner that feeder base <NUM> on a side closer to component mounting machine group <NUM> constitutes collection area a1, while feeder base <NUM> on a side farther from component mounting machine group <NUM> constitutes supply area a2, and boundary <NUM> is formed between those two feeder bases <NUM>. In this case, feeder base <NUM> without any indicator may be used in place of feeder base <NUM>. Alternatively, in a case that one feeder base <NUM> is disposed in feeder storage <NUM> as shown in <FIG>, the position of boundary <NUM> may be made unchangeable.

In the embodiment that has been described heretofore, feeder storage <NUM> is described as being disposed at the upstream side of component mounting machine group <NUM>; however, instead of or in addition to that configuration, feeder storage <NUM> may be disposed at a downstream side of component mounting machine group <NUM>. In addition, two or more feeder storages <NUM> may be disposed in series at the upstream side (or the downstream side) of component mounting machine group <NUM>.

In the embodiment that has been described heretofore, there may be added to component mounting line <NUM> a solder printing machine for printing solder on board S with no component mounted thereon yet or an inspection machine for inspecting board S with a component mounted already thereon to see whether the component is correctly mounted on board S. In addition, component mounting machine group <NUM> and feeder storage <NUM> may be adjacent to each other; however, a solder printing machine or the like may be disposed between component mounting machine group <NUM> and feeder storage <NUM>.

In the embodiment that has been described heretofore, loader <NUM> is described as executing the operation of exchanging feeders <NUM> for component mounting machine <NUM>; however, the operator may execute this operation. In this case, a guidance for how to exchange feeders <NUM> may be caused to be displayed on touch panel display <NUM> of component mounting machine <NUM> or display <NUM> of management computer <NUM>, so that the operator can exchange feeders <NUM> in accordance with the guidance so displayed.

In the embodiment that has been described heretofore, feeder <NUM> is exemplified as a component supply device; however, the present disclosure is not particularly limited thereto, and hence, for example, a tray on which multiple components are placed may be adopted as a component supply device.

The component mounting system of the present disclosure may be configured as follows.

In the component mounting system of the present disclosure, the storage area may include multiple support tables configured to support detachably some of the multiple component supply devices that are arranged in an aligned fashion, and the collection area and the supply area may be set up of the support table as a unit. As a result, since the support tables each supporting some of the multiple component supply devices can be stored in and removed from the storage container one by one, the work efficiency is improved compared with a case in which the component supply devices are stored in and removed from the storage container one by one.

In the component mounting system of the present disclosure, the collection area may be provided at a side of the storage area that lies closer to the component mounting machine. The loader moves back and forth in the area where the multiple component mounting machines are arranged in the aligned fashion. Due to this, the movement distance of the loader over which the loader travels when the loader places the component supply device that is not used for production in the collection area gets shorter with the collection area provided at the side closer to the component mounting machine than with the collection area provided at the side farther from the component mounting machine, which then results in a reduction in the operation time.

The component mounting system of the present disclosure may include a control section configured to predict the number of the component supply devices for collection to set the boundary based on the number of the component supply devices for collection so predicted. As a result, the occurrence of a situation can be prevented in which the component supply device for collection cannot be stored in the storage area.

In this case, in predicting the number of the component supply devices for collection, the control section may calculate the number of component supply devices that are not to be used in a subsequent production job in the component supply devices that are currently in use before the current production job is switched over to the subsequent production job and refers to the number so calculated as the number of the component supply devices for collection. As a result, the position of the boundary can appropriately be changed before the production jobs are switched over so as to avoid the occurrence of a situation in which the component supply device for collection cannot be stored in the storage area.

Alternatively, in predicting the number of the component supply devices for collection, the control section may predict the number (for example, a maximum number) of the component supply devices for collection that would result by a subsequent passage of the predetermined time period every predetermined time while the component mounting machine is executing repeatedly a production job set individually for the component mounting machine in question. As a result, even in a case in which the same production job is repeatedly executed for a long time period, the position of the boundary can appropriately be changed every predetermined time until the production job is completed.

In addition, in setting the boundary, the control section may cause a boundary position indicator provided in the storage area to indicate the boundary. As a result, the operator can visually confirm the current setting position of the boundary.

The present disclosure can be applied to a technical field in which a component is mounted on a mounting target using a component mounting machine group.

Claim 1:
A component mounting system (<NUM>) comprising:
a component mounting machine group (<NUM>) made up by aligning multiple component mounting machines (<NUM>) along a conveyance direction of a mounting target object (S), the component mounting machines (<NUM>) each including multiple component supply devices (<NUM>; <NUM>, <NUM>) that are set detachably and configured to mount a component supplied by the component supply devices (<NUM>; <NUM>, <NUM>) onto the mounting target object (S);
a storage container (<NUM>) provided at an upstream side or a downstream side of the component mounting machine group (<NUM>) and having a storage area (<NUM>, <NUM>) configured to support detachably some of the multiple component supply devices (<NUM>; <NUM>, <NUM>) that are arranged in an aligned fashion;
a loader (<NUM>) configured to move along the conveyance direction to automatically detach and/or attach the component supply devices (<NUM>; <NUM>, <NUM>) from and/or to the component mounting machines (<NUM>) and the storage container (<NUM>); and
a control section (<NUM>)
the component mounting system (<NUM>) is characterized in that the control section (<NUM>) is configured to predict a number of the component supply devices (<NUM><NUM>) for collection to set a the- boundary (<NUM>) based on the number of the component supply devices (<NUM>; <NUM>) for collection so predicted, wherein the storage area (<NUM>, <NUM>) is divided by the boundary (<NUM>) into a collection area (a1) configured to detachably support the component supply device (<NUM>; <NUM>) for collection that is not used for production and a supply area (a2) configured to detachably support the component supply device (<NUM>; <NUM>) for supply that is used for production, and
wherein in setting the boundary (<NUM>), the control section (<NUM>) causes a boundary position indicator (<NUM>, <NUM>) provided in the storage area (<NUM>, <NUM>) to indicate the boundary (<NUM>).