Patent Description:
As described in <CIT>, some component feeding devices supply components in such a state that components are scattered on a stage. <CIT> discloses a flexible parts feeder that includes a flexible membrane for supporting parts and defining a selection zone where the positional state of parts is analyzed by a machine vision system. The output of the sensor is used to control a transformer that selectively applies impulse energy to the flexible membrane so as to change the positional states of at least some parts in the selection zone to a desired positional state. Those parts having the desired positional state are selected and removed from the membrane by a robot. <CIT> discloses a component feeding device according to the preamble of independent claim <NUM>. <CIT> discloses a loose component supply device including: component support member configured to support multiple components in a scattered state; component collection container configured to collect the components supported on the component support member via an opening in the component collection container; and a container oscillating device configured to scatter the components collected inside the component collection container onto the component support surface by swinging the component collection container such that the opening of the collection container faces the component support member.

The above mentioned patent literature describes the components being supplied on a single stage but does not describe that of being supplied on multiple stages. Then, a technical problem that the invention is to solve is how to supply components on each of multiple stages in a preferred manner.

With a view to solving the problem, according to the description of the invention, there is disclosed a component feeding device including multiple component replenishing devices configured to replenish with components having different shapes, multiple stages on which the components replenished from the multiple replenishing devices are scattered, and a control section configured to cause the multiple replenishing devices to replenish the components to the respective stages at an arbitrary timing.

With a view to solving the problem, according to the description, there is disclosed a component feeding method for supplying components, having different shapes and being respectively replenished onto multiple stages from multiple replenishing devices, to a component mounting device with the components being respectively scattered on the multiple stages, wherein amounts of the components can be respectively changed for each of the multiple stages.

According to the disclosure, the components can be replenished from the multiple replenishing devices onto the respective stages at the arbitrary timings. Also, according to the disclosure, the amounts of components replenished from the replenishing devices onto the respective stages can be changed for each of the multiple stages.

Hereinafter, with referring to drawings, an embodiment of the invention will be described as exemplary embodiments of the present invention.

<FIG> shows component mounting machine <NUM>. Component mounting machine <NUM> constitutes a device for executing mounting work of mounting components on circuit substrate <NUM>. Component mounting machine <NUM> includes device main body <NUM>, substrate conveyance and holding device <NUM>, component mounting device <NUM>, imaging devices <NUM>, <NUM>, component feeding device <NUM>, bulk component feeding device <NUM>, and control device (refer to <FIG>) <NUM>. A circuit board, a substrate having a three-dimensional structure, and the like are raised as circuit substrate <NUM>, and a printed wiring board, a printed circuit board, and the like are raised as a circuit board.

Device main body <NUM> is made up of frame section <NUM> and beam section <NUM> mounted on frame section <NUM>. Substrate conveyance and holding device <NUM> is disposed at a center of frame section <NUM> in a front-rear direction thereof and includes conveyance device <NUM> and clamping device <NUM>. Conveyance device <NUM> constitutes a device for conveying circuit substrate <NUM>, and clamping device <NUM> constitutes a device for holding circuit substrate <NUM>. As a result, substrate conveyance and holding device22 not only conveys circuit substrate <NUM> but also fixedly holds circuit substrate <NUM> in a predetermined position. In the following description, the conveyance direction of circuit substrate <NUM> is referred to as an X direction, a horizontal direction orthogonal to the conveyance or X direction is referred to a Y direction, and a vertical direction is referred to as a Z direction. That is,the X direction constitutes a width direction of component mounting machine <NUM>, and the Y direction constitutes the front-rear direction thereof.

Component mounting device <NUM> is disposed in beam section <NUM> and includes two work heads <NUM>, <NUM> and work head moving device <NUM>. Each of work heads <NUM>, <NUM> has suction nozzle (refer to <FIG>) <NUM> and holds a component using suction nozzle <NUM>. Further, working head moving device <NUM> includes X-direction moving device <NUM>, Y-direction moving device70, and Z-direction moving devices <NUM>. Then, two working heads <NUM>, <NUM> are caused to move together to an arbitrary position over frame section <NUM> by X-direction moving device <NUM> and Y-direction moving device <NUM>. As shown in <FIG>, work heads <NUM>, <NUM> are detachably attached to sliders <NUM>, <NUM>, respectively, and Z-direction moving devices <NUM> move individually respective sliders <NUM>, <NUM> in an up-down direction. That is, working heads <NUM>, <NUM> are caused to move individually in the up-down direction by respective Z-direction moving devices <NUM>.

Imaging device <NUM> is attached to slider <NUM> in such a state that imaging device <NUM> is directed downwards and is caused to move in the X direction, Y direction, and Z direction together with working head <NUM>. As a result, imaging device <NUM> images an arbitrary position over frame section <NUM>. As shown in <FIG>, imaging device <NUM> is disposed between substrate conveyance and holding device <NUM> and component feeding device <NUM> over frame section <NUM> in such a state that imaging device <NUM> is directed upwards. As a result, imaging device <NUM> images components held by suction nozzles <NUM> of work heads <NUM>, <NUM>.

Component feeding device <NUM> is disposed at one end portion of frame section <NUM> in the front-rear direction thereof. Component feeding device <NUM> includes tray-type component feeding device <NUM> and feeder-type component feeding device (not shown). Tray-type component feeding device <NUM> constitutes a device for supplying components which are rested on a tray. Feeder-type component feeding device constitutes a device for supply components by tape feeders (not shown) and stick feeders (not shown).

Bulk component feeding device <NUM> is disposed at the other end portion of frame section <NUM> in the front-rear direction thereof. Bulk component feeding device <NUM> constitutes a device for aligning multiple components, which are scattered in bulk, to have a proper orientation for supply and then supplying the components in the aligned state. That is, bulk component feeding device <NUM> constitutes the device for aligning multiple components with arbitrary postures to have a predetermined posture for supply, and then supplying the components with the predetermined posture. Hereinafter, the configuration of bulk component feeding device <NUM> will be described in detail. In high level, components supplied by component feeding device <NUM> and bulk component feeding device <NUM> are variant components, and more specifically, components supplied by these component feeding devices are, for example, electronic circuit components, solar cell constituent components, power module constituent components, and the like. Such electronic circuit components include a component with leads, a component without leads, and the like.

As shown in <FIG>, bulk component feeding device <NUM> includes main body <NUM>, component supply units <NUM>, imaging device <NUM>, and component delivery device <NUM>.

Component supply unit <NUM> includes component supplier <NUM>, component scattering device (refer to <FIG>) <NUM>, and component return device (refer to <FIG>) <NUM>, and component supplier <NUM>, component scattering device <NUM>, and component return device <NUM> are integrated into component supply unit <NUM>. Component supply unit <NUM> is detachably assembled to base <NUM> of main body <NUM>, and bulk component feeding device <NUM> has five component supply units <NUM> which are aligned in a row in the X direction.

In general, component supplier <NUM> has a rectangular parallelepiped box shape and is disposed in such a manner as to extend in the Y direction as shown in <FIG> and <FIG>. The Y direction is referred to as a front-rear direction of component supplier <NUM>, and in component supply unit <NUM>, a direction towards an end where component return device <NUM> is disposed is referred to as a front, while a direction towards an end where component supplier <NUM> is disposed is referred to as a rear.

Component supplier <NUM> is opened at an upper surface and a front surface, and an opening in the upper surface constitutes a component supply port <NUM>, while an opening in the front surface constitutes a component discharge port <NUM>. In component supplier <NUM>, an inclined plate <NUM> is disposed below supply port <NUM>. Inclined plate <NUM> is disposed in such a manner as to be inclined downwards from a rear end face of component supplier <NUM> towards a center thereof.

As shown in <FIG>, a conveyor device <NUM> is disposed at a front side of inclined plate <NUM>. Conveyor device <NUM> is disposed in such a manner as to be inclined upwards from a front end portion of inclined plate <NUM> towards the front of component supplier <NUM>. Conveyor belt <NUM> of conveyor device <NUM> turns counterclockwise as seen in <FIG>. That is, a conveyance direction of components by conveyor device <NUM> is an obliquely upward direction starting from the front end portion of inclined plate <NUM> towards the front. In addition, multiple protruding sections <NUM> are formed on a front surface, that is, a conveyance surface of conveyor belt <NUM> in such a manner as to extend in a width direction of conveyor belt <NUM>. Multiple protruding sections <NUM> are formed at constant intervals in the turning direction of conveyor belt <NUM>, and the interval is made longer than a lengthwise direction of a component supplied by component supplier <NUM>.

Inclined plate <NUM> is disposed below a front end portion of conveyor device <NUM>. Inclined plate <NUM> is disposed to extend from a front end face of component supplier <NUM> towards below conveyor device <NUM>, and a rear end portion thereof is inclined downwards. Further, inclined plate <NUM> is also disposed below inclined plate <NUM>. Inclined plate <NUM> is inclined downwards from a central portion of conveyor device <NUM> towards discharge port <NUM> of component supplier <NUM> in such a manner that a front end portion thereof is positioned lower or downwards.

Additionally, as shown in <FIG>, a pair of side frame sections <NUM> are assembled to base <NUM>. A pair of side frame sections <NUM> are erected so as to face parallel to each other while extending in the Y direction. A distance defined between the pair of side frame sections <NUM> is made slightly greater than a widthwise dimension of component supplier <NUM>, so that component supplier <NUM> is removably installed between the pair of side frame sections <NUM>.

Component scattering device <NUM> includes component support member <NUM> and component support member moving device <NUM>. Component support member <NUM> is made up of stage <NUM> and a pair of side wall sections <NUM>. In general, stage <NUM> has a long plate-like shape and is disposed in such a manner as to extend forwards from below component supplier <NUM> installed between a pair of side frame sections <NUM>. Incidentally, an upper surface of stage <NUM> is generally horizontal and is disposed in such a manner as to define a slight clearance between a front end portion of inclined plate <NUM> of component supplier <NUM> and itself, as shown in <FIG>. As shown in <FIG>, a pair of side wall sections <NUM> are fixed to respective longitudinal side sections of stage <NUM> in such a manner as to be erected therefrom, and respective upper ends of side wall sections <NUM> extend further upwards than the upper surface of stage <NUM>.

Component support member moving device <NUM> slides component support member <NUM> in the Y direction as a result of the operation of air cylinder (refer to <FIG>) <NUM>. As this occurs, component support member <NUM> moves between a retracted state (refer to <FIG>) in which component support member <NUM> is retracted underneath component supplier <NUM> and an exposed state (refer to <FIG>) in which component support member <NUM> is exposed from underneath component supplier <NUM>.

As shown in <FIG>, component return device <NUM> includes component storage container <NUM> and container swing device <NUM>. In general, component storage container <NUM> has a box-like shape, and a bottom surface thereof is curved into an arc shape in an end view. Component storage container <NUM> is held in a swingable manner at a front end portion of stage <NUM> of component support member <NUM> and swings as a result of the operation of container swing device <NUM>. As this occurs, component storage container <NUM> swings between a storing posture (refer to <FIG>) in which an opening thereof is directed upwards and a return posture (refer to <FIG>) in which the opening is directed towards the upper surface of stage <NUM> of component support member <NUM>.

As shown in <FIG>, imaging device <NUM> includes camera <NUM> and camera moving device <NUM>. Camera moving device <NUM> includes guide rail <NUM> and slider <NUM>. Guide rail <NUM> is fixed to main body <NUM> in such a manner as to extend in a widthwise direction (the X direction) of bulk component feeding device <NUM> above component supplier <NUM>. Slider <NUM> is attached to guide rail <NUM> in such a manner as to slide thereon and slides to an arbitrary position as a result of the operation of electromagnetic motor (refer to <FIG>) <NUM>. In addition, camera <NUM> is mounted on slider <NUM> in such a state that camera <NUM> is directed downwards.

As shown in <FIG>, component delivery device <NUM> includes component holding head moving device <NUM>, component holding head <NUM>, and two shuttle devices <NUM>.

Component holding head moving device <NUM> includes X-direction moving device <NUM>, Y-direction moving device <NUM>, and Z-direction moving device <NUM>. Y-direction moving device <NUM> includes Y slider <NUM> which is disposed in such a manner as to extend in the X direction above component supply units <NUM>, and Y slider <NUM> moves to an arbitrary position in the Y direction as a result of electromagnetic motor (refer to <FIG>) <NUM> being driven accordingly. X-direction moving device <NUM> includes X slider <NUM> disposed on a side surface of Y slider <NUM>, and X slider <NUM> moves to an arbitrary position in the X direction as a result of electromagnetic motor (refer to <FIG>) <NUM> being driven accordingly. Z-direction moving device <NUM> includes Z slider <NUM> disposed on a side surface of X slider <NUM>, and Z slider <NUM> moves to an arbitrary position in the Z direction as a result of electromagnetic motor (refer to <FIG>) <NUM> being driven accordingly.

As shown in <FIG>, component holding head <NUM> includes head main body <NUM>, suction nozzle <NUM>, nozzle turning device <NUM>, and nozzle rotation device <NUM>. Head main body <NUM> is formed integrally with Z slider <NUM>. Suction nozzle <NUM> holds a component through suction and is detachably attached to a lower end portion of holder <NUM>. Holder <NUM> is allowed to be bent on support shaft <NUM>, whereby holder <NUM> is bent upwards through <NUM> degrees as a result of nozzle turning device <NUM> operating accordingly. As a result, suction nozzle <NUM>, which is attached to the lower end portion of holder <NUM>, turns through <NUM> degrees to be positioned in a turned position. That is, suction nozzle <NUM> turns between a non-turned position and the turned position as a result of nozzle turning device <NUM> operating accordingly. Suction nozzle <NUM> can, of course, be stopped to be positioned at an angle between the non-turned position and the turned position. Additionally, nozzle rotation device <NUM> rotates suction nozzle <NUM> around it own axis.

As shown in <FIG>, two shuttle devices <NUM> each include component carrier <NUM> and component carrier moving device <NUM> and are fixed to main body <NUM> in such a manner as to be aligned side by side in a lateral direction ahead of component supply units <NUM>. Component carrier <NUM> includes five component receiving members <NUM> which are arranged side by side in a row in the lateral direction, and components are placed individually in component receiving members <NUM>.

Bulk component feeding device <NUM> can supply various types of components, and, hence, various types of component receiving members <NUM> are prepared so as to receive components of various configurations. Here, component receiving member <NUM> will be described which is configured to receive electric component <NUM> with leads as shown in <FIG>, as an electronic circuit component supplied by bulk component feeding device <NUM>. Lead component <NUM> is made up of component main body <NUM> having a block-like shape and two leads <NUM> which project from a bottom surface of component main body <NUM>.

Component receiving member <NUM> has formed therein component receiving recess section <NUM> having a shape corresponding to the configuration of lead component <NUM>. Component receiving recess section <NUM> constitutes a recess section having a step-like shape, and is made up of main body receiving recess section <NUM>, which is opened in an upper surface of component receiving member <NUM>, and lead receiving recess section <NUM> which is opened in a bottom surface of main body receiving recess section <NUM>. Then, lead component <NUM> is inserted into an interior of component receiving recess section <NUM> with leads <NUM> adopting a posture in which they are directed downwards. As a result, lead component <NUM> is placed in the interior of component receiving recess section <NUM> with leads <NUM> inserted in lead receiving recess section <NUM> and component main body <NUM> inserted in main body receiving recess section <NUM>.

Component carrier moving device <NUM> is a plate-like longitudinal member and is disposed at a front side of component supply unit <NUM> in such a manner as to extend in the front-rear direction, as shown in <FIG>. Component carrier <NUM> is disposed on an upper surface of component carrier moving device <NUM> in such a manner as to slide in the front-rear direction, whereby component carrier <NUM> slides to an arbitrary position in the front-rear direction as a result of electromagnetic motor (refer to <FIG>) <NUM> being driven accordingly. Incidentally, when component carrier <NUM> slides in a direction in which component carrier <NUM> moves close to component supply unit <NUM>, component carrier <NUM> slides to a component receiving position which is situated within a moving range of component holding head <NUM> within which component holding head <NUM> is moved by component holding head moving device <NUM>. On the other hand, when component carrier <NUM> slides away from component supply unit <NUM>, component carrier <NUM> slides to a component supply position which is situated within a moving range of working heads <NUM>, <NUM> within which working heads <NUM>, <NUM> are moved by work head moving device <NUM>.

As shown in <FIG>, control device <NUM> includes integrated control device <NUM>, multiple individual control devices (only one control device is shown in <FIG>) <NUM>, and image processing device <NUM>. Integrated control device <NUM> is made up mainly of a computer and is connected to substrate conveyance and holding device <NUM>, component mounting device <NUM>, imaging device <NUM>, imaging device <NUM>, component feeding device <NUM>, and bulk component feeding device <NUM>. As a result, integrated control device <NUM> supervises and control substrate conveyance and holding device <NUM>, component mounting device <NUM>, imaging device <NUM>, imaging device <NUM>, component feeding device <NUM>, and bulk component feeding device <NUM>. Multiple individual control devices <NUM> are each made up mainly of a computer and are provided separately for substrate conveyance and holding device <NUM>, component mounting device <NUM>, imaging device <NUM>, imaging device <NUM>, component feeding device <NUM>, and bulk component feeding device <NUM> (in the figure, only individual control device <NUM> for bulk component feeding device <NUM> is shown).

Individual control device <NUM> for bulk component feeding device <NUM> is connected to component scattering devices <NUM>, component return devices <NUM>, camera moving device <NUM>, component holding head moving device <NUM>, component holding head <NUM>, and shuttle devices <NUM>. As a result, individual control device <NUM> for bulk component feeding device <NUM> controls component scattering devices <NUM>, component return devices <NUM>, camera moving device <NUM>, component holding head moving device <NUM>, component holding head <NUM>, and shuttle devices <NUM>. Image processing device <NUM> is connected to imaging device <NUM> for processing captured image data that is captured by imaging device <NUM>. Image processing device <NUM> is connected to individual control device <NUM> for bulk component feeding device <NUM>. As a result, individual control device <NUM> for bulk component feeding device <NUM> acquires captured image data that is captured by imaging device <NUM>.

Having the configuration that has been described heretofore, component mounting machine <NUM> performs mounting work of mounting components on circuit substrate <NUM> held by substrate conveyance and holding device <NUM>. Specifically, circuit substrate <NUM> is conveyed to a working position and is fixedly held by clamping device <NUM> in the working position. Next, imaging device <NUM> moves to a position lying above circuit substrate <NUM> and images circuit substrate <NUM>. As a result, information on an error in holding position of circuit substrate <NUM> is obtained. Component feeding device <NUM> or bulk component feeding device <NUM> supplies components in a predetermined supply position. A component supply operation by bulk component feeding device <NUM> will be described in detail later. Then, either of working heads <NUM>, <NUM> moves to a position lying above the component supply position and holds a component by suction nozzle <NUM> thereof through suction. Subsequently, working head <NUM> or <NUM> that holds the component moves to a position lying above imaging device <NUM>, whereby the component held by suction nozzle <NUM> is imaged by imaging device <NUM>. As a result, information on an error in holding position of the component is obtained. Then, working head <NUM> or <NUM> that holds the component moves to a position lying above circuit substrate <NUM> and mounts the component held thereby on circuit substrate <NUM> by correcting the error in holding position of circuit substrate <NUM> and the error in holding position of the component.

The operator supplies lead components <NUM> into bulk component feeding device <NUM> from supply ports <NUM> of component suppliers <NUM>, and lead components <NUM> so supplied are supplied while being placed on component receiving members <NUM> of component carriers <NUM> as a result operation of component supply units <NUM> and component delivery device <NUM>.

To describe this in detail, the operator supplies lead components <NUM> from supply port <NUM> in the upper surface of component supplier <NUM>. At this time, component support member <NUM> is moved to lie below component supplier <NUM> as a result of operation of component support member moving device <NUM>, whereby component support member <NUM> is pulled in the retracted state (refer to <FIG>). With component support member <NUM> staying in the retracted state, component storage container <NUM> disposed at the front end of component support member <NUM> is situated at the front of component supplier <NUM>, adopting a posture (a storing posture) in which the opening of component storage container <NUM> is directed upwards.

Lead components <NUM> supplied from supply port <NUM> of component supplier <NUM> fall on inclined plate <NUM> of component supplier <NUM> and roll down to a front lower end of inclined plate <NUM>. As this occurs, lead components <NUM>, which have rolled down to the front lower end of inclined plate <NUM>, are accumulated between the front lower end of inclined plate <NUM> and a rear lower end of conveyor device <NUM>. Then, as a result of conveyor device <NUM> being activated to operate, conveyor belt <NUM> of conveyor device <NUM> turns counterclockwise as seen in <FIG>. At this time, in lead components <NUM> accumulated between inclined plate <NUM> and conveyor belt <NUM>, a predetermined number of lead components <NUM> enter between adjacent protruding sections <NUM> on conveyor belt <NUM>, whereby multiple lead components <NUM>, which are now staying between adjacent protruding sections <NUM>, are conveyed obliquely upwards by conveyor belt <NUM>.

Then, lead components <NUM>, which have been so conveyed by conveyor belt <NUM>, fall on inclined plate <NUM> from a front upper end of conveyor device <NUM>. Lead components <NUM>, which have so fallen on inclined plate <NUM>, roll down to the rear on inclined plate <NUM> to fall on inclined plate <NUM>. Lead components <NUM>, which have so fallen on inclined plate <NUM>, roll down to the front and are then discharged from discharge port <NUM> at the front side of component supplier <NUM>.

As a result, lead components <NUM>, which are discharged from discharge port <NUM> of component supplier <NUM>, are stored in an interior of component storage container <NUM>. Then, when the predetermined amount of lead components <NUM> are discharged from component supplier <NUM>, that is, when conveyor device <NUM> operates a certain amount, conveyor device <NUM> stops. Next, component support member <NUM> moves to the front from the retracted state as a result of operation of component support member moving device <NUM>.

Then, container swing device <NUM> of component return device <NUM> is activated to operate at a timing at which component support member <NUM> moves a predetermined amount from the retracted state to the front towards the exposed state, whereby component storage container <NUM> swings. As a result, the posture of component storage container <NUM> changes forcibly from the posture in which the opening is directed upwards (the storing posture) to a posture in which the opening is directed towards stage <NUM> (a returning posture). As this occurs, lead components <NUM> stored in component storage container <NUM> are discarded forcibly onto stage <NUM>. As a result, lead components <NUM>, which have been so discarded onto stage <NUM> from component storage container <NUM>, are then scattered on stage <NUM>. In addition, the swing action of the component storage container is set so as to be completed before component support member <NUM> is completely exposed so as not to extend a cycle time.

When lead components <NUM> are scattered from component supplier <NUM> onto stage <NUM> of component support member <NUM> by following the procedure that has been described heretofore, camera <NUM> of imaging device <NUM> moves to a position lying above component support member <NUM>, as a result of operation of camera moving device <NUM>, and images lead components <NUM>. Then, based on the captured image data, multiple lead components <NUM> scattered on the upper surface of component support member <NUM> are divided into lead components that can be picked up by suction nozzle <NUM>, and lead components that cannot be picked up by suction nozzle <NUM>. The lead component that can be picked up by suction nozzle <NUM> is referred to as a pickup target component, while the lead component that cannot be picked up by suction nozzle <NUM> is referred to as a non-pickup target component.

Since a classifying method for classifying components into pickup target components and non-pickup target components has nothing to do with the invention, the method will be described briefly in which lead component <NUM> an upwardly directed surface of which constitutes an irregular surface or the like which makes it difficult for lead component <NUM> to be picked up, lead component <NUM> which is partly covered by another lead component <NUM>, lead component <NUM> which lies too close to side wall section <NUM> to be picked up, and the like are classified into non-pickup target components, while remaining lead components <NUM> are classified into pickup target components. Further, pieces of information about lead components 410on, such as the positions on component support member <NUM>, postures thereof and the like, are acquired based on the captured image data for lead components <NUM> classified into pickup target components.

Then, component holding head <NUM> moves to a position lying above the pickup target component based on the acquired information on the pickup target components, and as a result of operation of component holding head moving device <NUM>, the relevant pickup target component is picked up and held through suction by suction nozzle <NUM>. When the pickup target component is picked up and held through suction by suction nozzle <NUM>, suction nozzle <NUM> is situated in the non-turned position.

Next,component holding head <NUM> moves to a position lying above component carrier <NUM> after lead component <NUM> has been held by suction nozzle <NUM>. As this occurs, component carrier <NUM> moves to the component receiving position as a result of operation of component carrier moving device390. When component holding head <NUM> moves to the position lying above component carrier <NUM>, suction nozzle <NUM> is turned to the turned position. Suction nozzle <NUM> turns so that leads <NUM> of lead component <NUM> held by suction nozzle <NUM> in the turned position are directed downwards in the vertical direction as a result of operation of nozzle turning device <NUM>.

When component holding head <NUM> moves to the position lying above component carrier <NUM>, lead component <NUM>, whose leads <NUM> are directed downwards in the vertical direction, is inserted into component receiving recess section <NUM> of component receiving member <NUM>. As a result, as shown in <FIG>, lead component <NUM> is placed in component receiving member <NUM> with leads <NUM> kept directed downwards in the vertical direction.

Then, when lead component <NUM> is so placed in component receiving member <NUM>, component carrier <NUM> moves to the component supply position as a result of operation of component carrier moving device <NUM>. Since component carrier <NUM>, which has so moved to the component supply position, is then situated within the moving range of working heads <NUM>, <NUM>, in bulk component feeding device <NUM>, lead component <NUM> is supplied to component mounting machine <NUM> in the component supply position. In this way, in bulk component feeding device <NUM>, lead components <NUM> are supplied with leads <NUM> directed to face downwards and upper surfaces opposite to bottom surfaces to which leads <NUM> are connected directed to face upwards. Due to this, suction nozzles <NUM> of work heads <NUM>, <NUM> can hold lead components <NUM> properly.

In bulk component feeding device <NUM>, as pickup target components are kept scattered on stage <NUM> of component support member <NUM>, the scattered pickup target components are repeatedly picked up, and then, the pickup target components so picked up are placed in component receiving members <NUM> accordingly. Then, component carrier <NUM> including component receiving members <NUM> mounted thereon is moved to the component supply position, whereby lead components <NUM> are supplied as set. However, with no pickup target components scattered on stage <NUM> of component support member <NUM>, no lead component <NUM> can be picked up from stage <NUM>. That is, with all lead components <NUM> determined as pickup acceptable components having been picked up, leaving lead components <NUM> determined as pickup unacceptable components or lead components <NUM> determined to be unavailable for determination on stage <NUM>, no lead component <NUM> can be picked up from stage <NUM>.

To deal with such a case, in bulk component feeding device <NUM>, lead components <NUM> left unpicked on stage <NUM> are recovered into component storage container <NUM>. Then, lead components <NUM>, which have been recovered into component storage container <NUM>, are scattered again on stage <NUM> in such a manner that lead components <NUM> adopt different postures, whereby picking up of lead components <NUM> from stage <NUM> is resumed.

Specifically, when all pickup target components on stage <NUM> are picked up, component support member <NUM> moves towards the retracted position underneath component carrier <NUM> as a result of operation of component support member moving device <NUM>. That is, component support member <NUM> moves from the exposed state (refer to <FIG>) towards the retracted state (refer to <FIG>). As this occurs, component storage container <NUM>, which is disposed at the front end portion of component support member <NUM>, is adopting the posture (a recovery posture) in which the opening is directed upwards. When component support member <NUM> moves from the exposed state towards the retracted state, lead components <NUM> on stage <NUM> of component support member <NUM> are held back by a front end portion of inclined plate <NUM> of component carrier <NUM>.

Further, as shown in <FIG>, when component support member <NUM> has moved to reach the retracted state, lead components <NUM> on stage <NUM> are swept off to fall into an interior of component storage container <NUM>. As a result, lead components <NUM> on stage <NUM> are recovered into component storage container <NUM>. When lead components <NUM> on stage <NUM> are recovered into component storage container <NUM> in the way described above, lead components <NUM> so recovered are replenished onto stage <NUM>.

To describe this in detail, when the recovery of lead components <NUM> into component storage container <NUM> is completed, component support member <NUM> is then in the retracted state as shown in <FIG>. Due to this, component support member <NUM> moves from the retracted state to the front as a result of operation of component support member moving device <NUM>. Then, container swing device <NUM> of component return device <NUM> is activated to operate at a timing at which component support member <NUM> moves a predetermined amount from the retracted state to the front towards the exposed state, whereby component storage container <NUM> swings. As a result, the posture of component storage container <NUM> changes forcibly from the posture in which the opening is directed upwards (the storing posture) to a posture in which the opening is directed towards stage <NUM> (a returning posture).

As this occurs, lead components <NUM> stored in component storage container <NUM> are discarded forcibly onto stage <NUM>. As a result, lead components <NUM>, which have been so discarded onto stage <NUM> from component storage container <NUM>, are then scattered on stage <NUM>. That is, lead components <NUM> recovered into component storage container <NUM> are replenished onto stage <NUM>. As a result, the postures of lead components <NUM> so replenished are changed, enabling lead components <NUM> to be picked up again from the upper surface of stage <NUM>.

Further, when lead components <NUM> are repeatedly stored from stage <NUM> into component storage container <NUM> and lead components <NUM> are repeatedly replenished from component storage container <NUM> onto stage <NUM>, the number of lead components <NUM> scattered on stage <NUM> is reduced. Thus, when the number of lead components <NUM> scattered on stage <NUM> is reduced, lead components <NUM> are replenished from component supplier <NUM>.

Specifically speaking, in order to replenish lead components <NUM> from component supplier <NUM>, the number of lead components <NUM> left scattered on stage <NUM> needs to be recognized. Then, an occupation ratio of stage <NUM> by lead components <NUM> is used as an index value for estimating the number of lead components <NUM> scattered on stage <NUM>.

To describe this in detail, stage <NUM> is imaged by camera <NUM> before lead components <NUM> are stored from stage <NUM> into component storage container <NUM>. Then, in the area of stage <NUM> on which lead components <NUM> are scattered, an area of portions where lead components <NUM> are not placed is calculated based on captured image data. That is, an area of portions where stage <NUM> is exposed (hereinafter, referred to as an "exposed area") is calculated. Specifically speaking, for example, when stage <NUM> is white color while lead components <NUM> are black color, the portions recognized as white are extracted based on the captured image data acquired by camera <NUM>, and an area of the portions so extracted is calculated as the exposed area.

Stage <NUM> is imaged by camera <NUM> before lead components <NUM> are scattered on stage <NUM>, that is, in such a state that nothing is placed on stage <NUM>. Then, an area of stage <NUM> (hereinafter, referred to as a "stage area") is calculated based on the acquired captured image data. That is, for example, when stage <NUM> is white color, white portions are extracted based on the captured image data, and an area of the portions so extracted is calculated as the stage area.

Then, an area occupied by lead components <NUM> scattered on stage <NUM> (hereinafter, referred to as a "component occupation area") is calculated by subtracting the exposed area from the stage area. Next, a ratio of an area occupied by lead components <NUM> to a total area of stage <NUM>, that is, an occupation ratio of stage <NUM> by lead components <NUM> (hereinafter, referred to as a "component occupation ratio) is calculated by calculating a ratio of the component occupation area to the stage area. A higher component occupation ratio denotes that the number of lead components <NUM> scattered on stage <NUM> becomes greater, while a lower occupation ratio denotes that the number of lead components <NUM> scattered on stage <NUM> becomes smaller. As a result, the component occupation ratio can be used as an index value for estimating the number of lead components <NUM> scattered on stage <NUM>.

As a result, when a calculated component occupation ratio becomes a threshold or smaller, it is estimated that the number of lead components <NUM> scattered on stage <NUM> becomes a predetermined number or smaller, components are replenished onto stage <NUM> from component supplier <NUM>. Specifically speaking, when the calculated component occupation ratio becomes the threshold or smaller, component support member <NUM> moves from the exposed state towards the retracted state as a result of operation of component support member moving device <NUM>. As this occurs, lead components <NUM> are supplied from component supplier <NUM> at that timing. Since the supply work of supplying lead components <NUM> from component supplier <NUM> has already been described before, a detailed description thereof will be omitted here.

That is, when the calculated component occupation ratio becomes the threshold or smaller, lead components <NUM> are supplied onto stage <NUM> from component supplier <NUM> while stage <NUM> is moving from the exposed state towards the retracted state. As a result, lead components <NUM> supplied onto stage <NUM> from component supplier <NUM> and lead components <NUM> having been left on stage <NUM> since before lead components <NUM> are supplied from component supplier <NUM> are stored in component storage container <NUM>. Then, lead components <NUM> stores in component storage container <NUM> are then scattered on stage <NUM> according to the procedure described above. As a result, when the number of lead components <NUM> remaining on stage <NUM> is reduced, lead components <NUM> are replenished from component supplier <NUM> at that timing, whereby lead components <NUM> can continue to be picked up from stage <NUM>.

Lead components <NUM> having remained on stage <NUM> and components supplied from component supplier <NUM> are once stored in component storage container <NUM>, and then, the components so stored in component storage container <NUM> are scattered on the stage again. Thus, the components that are replenished onto stage <NUM> include the components that have been left on stage <NUM> since before the components are stored in component storage container <NUM>. Component supplier <NUM> and component storage container <NUM> function as a replenishing device.

As described above, when the component occupation ratio becomes the threshold or smaller, lead components <NUM> are supplied from component supplier <NUM> onto stage <NUM>, whereby lead components <NUM> are allowed to continue to be picked up from stage <NUM>. However, in the event that the threshold is set uniform irrespective of types of lead components <NUM>, there is a possibility that lead components <NUM> scattered on stage <NUM> come to overlap one another.

Specifically speaking, for example, as shown in <FIG>, when a component occupation ratio of lead components 410a of a small size becomes threshold A or smaller, a relatively large clearance is defined between adjacent lead components 410a. Due to this, when the component occupation ratio of lead components 410a of a small size becomes threshold A or smaller, even though lead components 410a are replenished from component supplier <NUM>, there still remains room where lead components 410a replenished newly can be scattered on stage <NUM>, whereby lead components 410a hardly overlap one another.

On the other hand, as shown in <FIG>, when a component occupation ratio of lead components 410b of a large size becomes the threshold A or smaller, there remains almost no clearance among adjacent lead components 410b. As a result, in the case that the component occupation ratio of lead components 410b of a large size becomes threshold A or smaller, when lead components 410b are replenished from component supplier <NUM>, there remains no roof for lead components 410b replenished newly to be scattered on stage <NUM>, whereby lead components 410b tend to overlap one another easily.

That is, in the case that the component occupation ratio of lead components 410b of a large size becomes threshold A or smaller, when lead components 410b are supplied from component supplier <NUM>, lead components 410b come to overlap one another on stage <NUM>, increasing the probability that lead components 410b so supplied become non-pickup target components. When the probability that lead components 410b become non-pickup target components is increased in this way, the number of times of performing the recovery work of recovering components into component storage container <NUM> is increased, reducing the work efficiency.

In addition, depending upon a shape of lead component <NUM> in addition to the size of lead component <NUM>, some lead components 410b overlap one another with ease, while other lead components <NUM> overlap one another only with great difficulty. As a result, when the component occupation ratio of lead component <NUM> tending to overlap another lead component <NUM> only with difficulty becomes threshold A or smaller, even though lead components 410b are replenished from component supplier <NUM>, lead components <NUM> overlap one another only with great difficulty. On the other hand, in the case that the component occupation ratio of lead component <NUM> tending to overlap another lead component <NUM> with ease becomes threshold A or smaller, when lead components <NUM> are replenished from component supplier <NUM>, lead components <NUM> come to overlap one another with ease. In other words, lead components of different sizes can also be considered to be lead components of different shapes.

In view of these situations, with bulk component feeding device <NUM>, thresholds are set for types of lead components <NUM>. For example, threshold A1 set for lead component 410b of a large size is set smaller than threshold A2 set for lead component 410a of a small size. That is, with lead components 410a of a large size scattered on stage <NUM>, lead components 410b of a large size are replenished from component supplier <NUM> in such a state that the number of components remaining on stage <NUM> is reduced compared with lead components 410a of a small size.

In addition, for example, threshold A3 set for lead component <NUM> of a shape making it overlap another lead component <NUM> with ease is set smaller than threshold A4 set for lead component <NUM> of a shape making it overlap another lead component <NUM> only with great difficulty. That is, when lead components <NUM> of a shape making them overlap one another with ease are scattered on stage <NUM>, lead components <NUM> are replenished from component supplier <NUM> in such a state that the number of components remaining on stage <NUM> is reduced compared with lead components <NUM> of a shape making them overlap one another only with great difficulty. Lead components can be restrained from overlapping one another when the components are replenished from component supplier <NUM> by setting the thresholds for the types of lead components <NUM> in the way described above.

However, since the numbers of components replenished from component supplier <NUM> differ according to types of lead components <NUM> when lead components <NUM> are replenished onto stage <NUM> from component supplier <NUM>, there is a possibility that an appropriate number of lead components <NUM> cannot be scattered on stage <NUM> after replenishment. To describe this in detail, component supplier <NUM> replenishes lead components <NUM> onto stage <NUM> as a result of conveyor belt <NUM> turning accordingly, and as this occurs, conveyor belt <NUM> turns, for example, a distance corresponding to a dimension defined between two adjacent protruding sections <NUM> of conveyor belt <NUM>. As a result, lead components <NUM> staying between two adjacent protruding sections <NUM> are supplied onto stage <NUM> from component supplier <NUM>.

Specifically speaking, for example, when lead components 410a of a small size are supplied from the component supply unit <NUM>, as shown in <FIG>, since nine lead components 410a are supplied to be placed between two adjacent protruding sections <NUM>, nine lead components 410a are supplied from component supplier <NUM> onto stage <NUM>. On the other hand, when lead components 410b of a large size are supplied from component supplier <NUM>, since two lead components 410b are supplied to be placed between two adjacent protruding sections <NUM> as shown in <FIG>, two lead components 410b are supplied from component supplier <NUM> onto stage <NUM>.

Additionally, since lead components <NUM> of a shape facilitating overlapping thereof tend to overlap one another with ease between two adjacent protruding sections <NUM>, a relatively large number of lead components <NUM> fall to be placed therebetween, and such a large number of lead components <NUM> are supplied from component supplier <NUM> onto stage <NUM>. On the other hand, since lead components <NUM> of a shape making them hardly overlap each other tend to overlap each other only with great difficulty between two adjacent protruding sections <NUM>. only a relatively small number of lead components <NUM> are allowed to fall to be placed therebetween, and such a small number of lead components <NUM> are supplied from component supplier <NUM> onto stage <NUM>.

In this manner, in replenishing lead components <NUM> from component supplier <NUM>, when the turning amount of conveyor belt <NUM> is set uniform irrespective of the types of components, the replenishing numbers of components replenished from component supplier <NUM> come to differ according to the types of components to be replenished, whereby an appropriate number of lead components <NUM> cannot be scattered on stage <NUM> after replenishment. In view of these situations, turning amounts of conveyor belt <NUM> for replenishment of components are set for the types of lead components <NUM> to be replenished.

For example, a turning amount of conveyor belt <NUM> for replenishment of lead components 410a of a small size is set at a distance corresponding to the dimension defined between two adjacent protruding sections <NUM> (hereinafter, referred to as a "set distance") in individual control device <NUM> or integrated control device <NUM>. On the other hand, a turning amount of conveyor belt <NUM> for replenishment of lead components <NUM> of a large size is set at a distance five times greater than the set distance. As a result, when components are replenished from component supplier <NUM> onto stage <NUM>, about nine lead components 410a of a small size are replenished, while about <NUM> lead components 410b of a large size are replenished. Additionally, the turning amount of conveyor belt <NUM> for replenishment of lead components <NUM> of a shape making them hardly overlap one another is set more than the turning amount of conveyor belt <NUM> for replenishment of lead components <NUM> of a shape making them overlap one another with ease.

The numbers of components replenished from component supplier <NUM> onto stage <NUM> can be made the same in general irrespective of the types of components replenished by setting the turning amounts of conveyor belt <NUM> according to the types of the components in the way described above. As a result, an appropriate amount of components can be scattered on stage <NUM> after the components have been replenished from component supplier <NUM> onto stage <NUM>. Further, the turning amount of the conveyor belt does not have to be limited to a multiple of an integer of the set distance.

For this reason, with bulk component feeding device <NUM>, the number of components scattered on stage <NUM> can be adjusted appropriately so as to ensure an appropriate component supply by setting the threshold for use in specifying the timing at which components are replenished from component supplier <NUM> and the turning amounts of conveyor belt <NUM> for replenishment of components in accordance with the types of components to be replenished.

Additionally, for bulk component feeding device <NUM>, five component supply units <NUM> are provided as described above. In each of the five component supply units <NUM>, one stage is associated with on component supplier <NUM>, and components are supplied from component supplier <NUM> which is associated with one stage. As a result, an amount of components on stage <NUM> can be adjusted for each of the five component supply units <NUM>. That is, in the case that the five component supply units <NUM> are each provided with different types of components, thresholds for use in specifying timings at which the different types of components are replenished from component suppliers <NUM> and turning amounts of conveyor belts <NUM> for replenishment of the different types of components come to differ from stage <NUM> to stage <NUM>. As a result, an amount of components scattered on stage <NUM> is adjusted for each of the five component supply units <NUM>. Thus, the amount of components on stage <NUM> can be adjusted according to the amount of components supplied from each of the five component supply units <NUM>, whereby bulk component feeding device <NUM> can supply various types of components in a well-balanced manner. That is, components can be supplied accurately in accordance with a required component supply speed.

Further, with bulk component feeding device <NUM>, since the thresholds for use in specifying the timings at which the different types of components are replenished and the turning amounts of conveyor belts <NUM> for replenishment of the different types of components differ from stage <NUM> to stage <NUM>, the specific types of components can be replenished from respective component suppliers <NUM> onto respective stages <NUM> at an arbitrary timing. A timing at which conveyor belt <NUM> starts operating for replenishment of components and a timing at which conveyor belt <NUM> in question stops operating can be adopted as the arbitrary timing. As a result, the component replenishing timing can be a timing based on the number of times of replenishment of components from conveyor belt <NUM> per unit time.

Incidentally, bulk component feeding device <NUM> constitutes an example of a component feeding device. Component supplier <NUM> constitutes an example of a replenishing device. Stage <NUM> constitutes an example of a stage. Component storing container <NUM> constitutes an example of the replenishing device. Individual control device <NUM> constitutes an example of a control device.

In the embodiment described above, the amount of components supplied onto stage <NUM> is adjusted by setting the threshold for use in specifying the timing at which components are replenished from component supplier <NUM> and the turning amount of conveyor belt <NUM> for replenishment of components in accordance with the types of components to be replenished. On the other hand, the amount of components supplied onto stage <NUM> may be adjusted by setting at least one of the threshold and the turning amount of conveyor belt <NUM> in accordance with the types of components to be replenished.

In the embodiment described above, while one stage is associated with one component supplier, for example, two stages may be associated with three component suppliers. In such a case, components are supplied from two component suppliers associated with a first stage, and components are supplied from a remaining component supplier associated with a second stage.

In the embodiment described above, while the number of components replenished from component supplier <NUM> is adjusted by setting the turning amount of conveyor belt <NUM> in accordance with the types of components to be replenished, the number of components replenished from component supplier <NUM> may be adjusted by setting an operation time of conveyor belt <NUM> in accordance with the types of components to be replenished. In addition, in the case that a bucket is used in place of conveyor device <NUM> as the device for supplying components from component supplier <NUM> onto stage <NUM>, the number of components replenished from component supplier <NUM> may be adjusted by setting the number of times of supply of components from the bucket in accordance with the types of components to be replenished.

In the embodiment described above, while the component occupation ratio is used as the index value for estimating the number of components scattered on stage <NUM>, in a modification that does not fall within the scope of the invention, the number of components scattered on stage <NUM> may be used instead. Specifically speaking, for example, outlines of components having various postures may be distinguished from one another based on the captured image data, so that the number of components scattered on stage <NUM> is calculated based on the distinguished outlines. In this case, when the number of components so calculated becomes a threshold or smaller, components are replenished from component supplier <NUM> onto stage <NUM>.

Further, in the embodiment described above, while the total components occupation area is calculated by subtracting the exposed area from the stage area, the total components occupation area may be calculated based on the captured image data. Specifically speaking, for example, when stage <NUM> is white or bright color, and lead components <NUM> are black or dark color, portions recognized as black or dark may be extracted based on the captured image data, so that an area of the portions so extracted is calculated as a component occupation area.

Additionally, in the embodiment described above, while the invention is applied to lead components <NUM>, the invention can be applied to various types of components. Roughly speaking, the invention can be applied to profile components, and specifically speaking, the invention can be applied to, for example, solar cell constituent components, power module constituent components, electronic circuit components with no lead, and the like.

Claim 1:
A component feeding device (<NUM>) comprising:
multiple component replenishing devices (<NUM>) configured to replenish with components (<NUM>) having different shapes and sizes;
multiple stages (<NUM>) on which the components (<NUM>) replenished from the multiple replenishing devices (<NUM>) are scattered; and
a control section (<NUM>) configured to, for each stage, calculate an occupation ratio of the stage (<NUM>) by calculating a ratio of a component occupation area to a stage area, based on captured image data, and to cause the multiple replenishing devices (<NUM>) to replenish the components (<NUM>) to the respective stages (<NUM>) when the respective calculated component occupation ratio becomes a threshold or smaller, the threshold being different for components (<NUM>) of different sizes,
characterized in that
the threshold set for a component (410b) of a large size is set smaller than the threshold set for a component (410a) of a small size.