Patent Description:
The conventional art has proposed a component mounting system including a component mounter on which a cassette-type feeder (component supply unit) for supplying a component is detachably mounted, and which performs a mounting process of mounting the component on a board by causing a collection member to collect the component from the component supply unit, based on a production job; and a unit exchange device such as a robot for automatically exchanging the feeder (for example, refer to Patent Literature <NUM>). In this system, during the mounting process of the board, the component supply units are subsequently replaced at a position where an operation distance of the collection member is shortened as much as possible when the component is collected and mounted on the board, thereby improving efficiency of the mounting process.

Patent Application <CIT> relates to a system for mounting components on a board by component mounters, and in particular to production job optimization of component mounting.

Patent Application <CIT> relates to a component mounting system for mounting components picked up from feeder component on a board by component mounters.

Patent Application <CIT> relates to a mounting system for mounting components on a circuit board, and in particular to determining arrangement positions of tape feeders on a pallet, so that the production time required for processing the reference job is reduced based on a reference job.

Patent Application <CIT> relates to a component mounting system for mounting components on a board by component mounters, ad in particular to determining feeder arrangement positions.

Incidentally, without being limited to the configuration in which the component supply units are subsequently replaced at the above-described position during the mounting process of the board, another configuration is known in which the mounting process is performed while multiple component supply units are in a mounted state in a predetermined alignment disposition suitable for the mounting process. In this case, each time production jobs are changed, the multiple component supply units required for mounting process need to be mounted to have a predetermined disposition suitable for mounting process based on a new production job. Therefore, when a large number of component supply units are used for the mounting process, it takes time to realign the component supply units, thereby causing a possibility that starting the mounting process may be delayed.

A main object of the present disclosure is to suppress a decrease in efficiency of a mounting process while quickly starting the mounting process when production jobs are changed.

The present disclosure adopts the following means to achieve the main object described above.

In this manner, when the production jobs are changed, compared to a case where the mounting process starts after all of the required component supply units are mounted in the predetermined disposition, it is possible to quickly start the mounting process by shortening a time required for mounting the component supply unit. In addition, since the component supply units are re-mounted in the predetermined disposition after the mounting process starts so that the component supply units are in an alignment suitable for the mounting process, it is possible to suppress a significant decrease in efficiency of the mounting process. Therefore, it is possible to suppress a decrease in the efficiency of the mounting process while quickly starting the mounting process when the production jobs are changed.

Next, an embodiment of the present disclosure will be described with reference to the drawings.

<FIG> is a configuration diagram illustrating a schematic configuration of component mounting system <NUM> of the present embodiment, <FIG> is a configuration diagram illustrating a schematic configuration of component mounter <NUM>, and <FIG> is a configuration diagram illustrating a schematic configuration of feeder <NUM>. In addition, <FIG> is a configuration diagram illustrating a schematic configuration of loader <NUM>, and <FIG> is a configuration diagram relating to controlling of component mounting system <NUM>. A right-left direction of <FIG> is an X-direction, a front-rear direction is a Y-direction, and an up-down direction is a Z-direction.

As illustrated in <FIG>, component mounting system <NUM> includes printer <NUM>, printing inspection machine <NUM>, multiple component mounters <NUM>, mounting inspection machine (not illustrated), loader <NUM>, feeder storage <NUM>, and management device <NUM> (refer to <FIG>). Printer <NUM> prints a solder on board S. Printing inspection machine <NUM> inspects a state of the solder printed by printer <NUM>. Multiple component mounter <NUM> are aligned and installed along a conveyance direction (X-direction) of board S, mount a component supplied from feeder <NUM> on board S. The mounting inspection machine inspects a mounting state of the component mounted on component mounter <NUM>. Loader <NUM> supplies required feeder <NUM> to multiple component mounters <NUM>, or collects used feeder <NUM> from component mounter <NUM>. Feeder storage <NUM> stores feeder <NUM> scheduled to be used in component mounter <NUM> or used feeder <NUM>. Management device <NUM> manages the whole system. Printer <NUM>, printing inspection machine <NUM>, multiple component mounter <NUM>, and the mounting inspection machine are aligned and installed in the conveyance direction of board S in this order, thereby configuring a production line. Feeder storage <NUM> is incorporated into the production line of component mounting system <NUM>, and is installed between component mounter <NUM> on a most upstream side in the conveyance direction of board S out of multiple component mounters <NUM> and printing inspection machine <NUM>. In the present embodiment, a worker supplies feeder <NUM> to feeder storage <NUM>, or collects feeder <NUM> from feeder storage <NUM>. In addition to the above-described devices, component mounting system <NUM> may include a reflow device for performing a reflow process of board S having the component mounted thereon.

As illustrated in <FIG>, component mounter <NUM> includes board conveyance device <NUM> for conveying board S in the X-direction, head <NUM> having a suction nozzle for picking up the component fed by feeder <NUM>, head moving mechanism <NUM> for moving head <NUM> in an XY-direction, and part camera <NUM> for imaging the component picked up by the suction nozzle from below. In addition, component mounter <NUM> includes mounting control device <NUM> (refer to <FIG>) configured to include a well-known CPU, ROM, or RAM for controlling the whole device. Mounting control device <NUM> inputs an image captured by part camera <NUM>, or outputs a drive signal to board conveyance device <NUM>, head <NUM>, and head moving mechanism <NUM>. In addition, a front side of component mounter <NUM> has two upper and lower areas where feeder <NUM> can be attached. The upper area is supply area 20A where feeder <NUM> can supply the component, and the lower area is stock area 20B where feeder <NUM> can be stocked. Supply area 20A and stock area 20B have feeder base <NUM> which is formed in an L-shape in a side view and to which multiple feeders <NUM> are respectively attached. Component mounter <NUM> may not include stock area 20B.

As illustrated in <FIG>, feeder <NUM> is configured to serve as a tape feeder for feeding a tape for accommodating the component at a predetermined pitch. Feeder <NUM> includes tape reel <NUM> around which the tape is wound, tape feeding mechanism <NUM> for feeding the tape from tape reel <NUM>, connector <NUM> having two positioning pins <NUM>, rail member <NUM> provided in a lower end, and feeder control device <NUM> (refer to <FIG>). As illustrated in <FIG>, feeder base <NUM> includes multiple slots <NUM> arrayed in the X-direction at an interval through which rail member <NUM> of feeder <NUM> is enabled to be inserted, two positioning holes <NUM>, and connector <NUM> provided between two positioning holes <NUM>. Rail member <NUM> of feeder <NUM> is inserted into slot <NUM> of feeder base <NUM>, and when two positioning pins <NUM> of feeder <NUM> are inserted into two positioning holes <NUM>, connector <NUM> and connector <NUM> are connected to each other. Feeder control device <NUM> is configured to include a well-known CPU, ROM, or RAM, and outputs a drive signal to tape feeding mechanism <NUM>. In addition, feeder control device <NUM> can communicate with a control section (mounting control device <NUM> or management device <NUM>) of an attachment destination of feeder <NUM> via connection of connectors <NUM> and <NUM>.

As illustrated in <FIG>, loader <NUM> is movable along X-axis rail <NUM> provided parallel to the conveyance direction (X-direction) of the board on a front surface of multiple component mounters <NUM> and a front surface of feeder storage <NUM>. In <FIG>, X-axis rail <NUM> is omitted in the illustration. As illustrated in <FIG> and <FIG>, loader <NUM> includes loader moving mechanism <NUM>, feeder transfer mechanism <NUM>, encoder <NUM>, and loader control device <NUM>. Loader moving mechanism <NUM> moves loader <NUM> along X-axis rail <NUM>, and includes X-axis motor 52a such as a servo motor for driving a driving belt, and guide roller 52b for guiding a movement of loader <NUM> along X-axis rail <NUM>. Feeder transfer mechanism <NUM> transfers feeder <NUM> to component mounter <NUM> or feeder storage <NUM>. Feeder transfer mechanism <NUM> includes clamp section <NUM> for clamping feeder <NUM>, and Y-axis slider <NUM> for moving clamp section <NUM> in the front-rear direction (Y-direction) along Y-axis guide rail 55b by driving Y-axis motor 55a. Feeder transfer mechanism <NUM> includes two Y-axis sliders <NUM>, and multiple feeders <NUM> can be simultaneously transferred by multiple clamp sections <NUM>. In addition, feeder transfer mechanism <NUM> includes slide base <NUM> to which clamp section <NUM> and Y-axis slider <NUM> are attached to be slidable, and Z-axis motor 56a for moving in the up-down direction (Z-direction) along Z-axis guide rail 56b. Encoder <NUM> detects a movement position of loader <NUM> in the X-direction. Loader control device <NUM> is configured to include a well-known CPU, ROM, or RAM. Loader control device <NUM> inputs a detection signal transmitted from encoder <NUM> or monitoring sensors 58a and 58b, and outputs a drive signal to loader moving mechanism <NUM> (X-axis motor 52a) or feeder transfer mechanism <NUM> (clamp section <NUM>, Y-axis motor 55a, or Z-axis motor 56a).

When automatic exchange of feeder <NUM> is performed, loader control device <NUM> first moves loader <NUM> to reach a position facing Y-axis slider <NUM> of loader <NUM>, in slot <NUM> of component mounter <NUM> which performs the automatic exchange by controlling X-axis motor 52a. In addition, when the automatic exchange is performed with supply area 20A of component mounter <NUM>, loader control device <NUM> moves slide base <NUM> (Y-axis slider <NUM>) to upper transfer area 50A facing supply area 20A by controlling Z-axis motor 56a. On the other hand, when the automatic exchange is performed with stock area 20B of component mounter <NUM>, loader control device <NUM> moves slide base <NUM> to lower transfer area 50B facing stock area 20B by controlling Z-axis motor 56a. When feeder <NUM> inside loader <NUM> is attached to component mounter <NUM>, in a state where feeder <NUM> is clamped by clamp section <NUM>, loader control device <NUM> moves Y-axis slider <NUM> to component mounter <NUM> side (rearward) by controlling Y-axis motor 55a. In this manner, rail member <NUM> of feeder <NUM> is inserted into slot <NUM> of feeder base <NUM>. Subsequently, loader control device <NUM> releases feeder <NUM> clamped by clamp section <NUM>, thereby attaching feeder <NUM> to feeder base <NUM> of component mounter <NUM>. In addition, when feeder <NUM> is detached from component mounter <NUM> and is collected into loader <NUM>, loader control device <NUM> moves Y-axis slider <NUM> to component mounter <NUM> side (rearward) by controlling Y-axis motor 55a. Subsequently, after feeder <NUM> attached to feeder base <NUM> is clamped by clamp section <NUM>, loader control device <NUM> moves Y-axis slider <NUM> forward by controlling Y-axis motor 55a. In this manner, feeder <NUM> is detached from feeder base <NUM>, and is collected into loader <NUM>.

In order to accommodate multiple feeders <NUM>, feeder storage <NUM> has feeder base <NUM> having a configuration the same as that of feeder base <NUM> provided in component mounter <NUM>. Loader <NUM> can attach and detach feeder <NUM> to and from feeder base <NUM> of feeder storage <NUM> by performing the same operation in attaching and detaching feeder <NUM> to and from feeder base <NUM> of component mounter <NUM>. In addition, board conveyance device <NUM> for conveying board S in the X-direction is provided behind feeder storage <NUM>. Board conveyance device <NUM> can convey board S received from a board conveyance device of printing inspection machine <NUM>, and can transfer board S to board conveyance device <NUM> of adjacent component mounter <NUM>.

As illustrated in <FIG>, management device <NUM> is configured to include well-known CPU 80a, ROM80b, HDD80c, or RAM80d, and includes display <NUM> such as an LCD or input device <NUM> such as a keyboard and a mouse. Management device <NUM> stores a production job of board S or feeder management information. As the production job, it is determined that each of component mounters <NUM> mounts any component type of the component on board S in any sequence, or it is determined to produce how many boards S for mounting the component in this way. In addition, as the production job, when multiple feeders <NUM> corresponding to the component type to be mounted by each of component mounters <NUM> are mounted on feeder base <NUM> of supply area 20A, an optimum disposition indicating the alignment of feeder <NUM> which is suitable for mounting process is determined. For example, scheduled mounting time Ts per one board using the component supplied from multiple feeders <NUM> is obtained by simulation (desktop calculation), and the optimum disposition of feeder <NUM> is determined as efficient disposition in which scheduled mounting time Ts is shortest. In the simulation, a collection position or a collection order when the suction nozzle of head <NUM> collects the component from feeder <NUM>, a movement distance or a movement speed to a mounting position after the component is collected, and scheduled mounting time Ts corresponding to the number of mounting times for each component type can be obtained. The feeder management information relates to feeder <NUM> possessed by each component mounter <NUM> and feeder storage <NUM>. <FIG> is view for describing an example of feeder management information. As illustrated, the feeder management information includes a slot number (position information) of feeder base <NUM> on which each feeder <NUM> is mounted, a feeder ID (identification information) of feeder <NUM> mounted on each slot <NUM>, a component type possessed by each feeder <NUM>, and a remaining amount of the components. Each mounting control device <NUM> similarly manages the feeder management information of the host device.

In addition, management device <NUM> is connected in a wired manner to be capable of communicating with mounting control device <NUM>, is connected in a wireless manner to be capable of communicating with loader control device <NUM>, and is also connected to be capable of communicating with each control device of printer <NUM>, printing inspection machine <NUM>, and the mounting inspection machine. Management device <NUM> receives information relating to a mounting state of component mounter <NUM>, or information relating to attached and detached feeder <NUM>, from mounting control device <NUM>, or receives information relating to a driving state of loader <NUM> from loader control device <NUM>. When management device <NUM> receives information relating to feeder <NUM> attached to feeder base <NUM> of component mounter <NUM> or feeder <NUM> detached from feeder base <NUM> from mounting control device <NUM>, management device <NUM> updates the feeder management information of component mounter <NUM>. In addition, management device <NUM> outputs a drive signal to board conveyance device <NUM> of feeder storage <NUM>, and conveys board S to board conveyance device <NUM>. In addition, management device <NUM> is connected via connectors <NUM> and <NUM> to be capable of communicating with feeder control device <NUM> of feeder <NUM> attached to feeder base <NUM> of feeder storage <NUM>, and can acquire information of feeder <NUM>. When management device <NUM> acquires the information relating to feeder <NUM> attached to feeder base <NUM> of feeder storage <NUM> or feeder <NUM> detached from feeder base <NUM>, management device <NUM> updates the feeder management information of feeder storage <NUM>.

An operation of component mounting system <NUM> configured in this way, particularly an operation when loader <NUM> is instructed to dispose feeder <NUM> will be described. <FIG> is a flowchart illustrating an example of a feeder disposition instruction process. The process is performed by CPU 80a of management device <NUM>. In the feeder disposition instruction process, CPU 80a determines whether it is a changing timing of the production job (S100), and when CPU 80a determines that it is not the changing timing, the process proceeds to S110. When CPU 80a determines that it is the changing timing, CPU 80a performs a disposition instruction process before the mounting process starts for disposing feeder <NUM> required for the mounting process based on a new production jobs in component mounter <NUM> (S105), and the process proceeds to S110. At the changing timing of the production job, a preparation work such as exchange of feeder <NUM> or exchange of a nozzle based on the instruction in S105 is performed. When the preparation work is completed, CPU 80a instructs each component mounter <NUM> to start performing the mounting process based on the production job. Next, CPU 80a determines whether the mounting process based on the production job has started in component mounter <NUM> (S110), and when CPU 80a determines that the mounting process has not started, the process returns to S100. In addition, when CPU 80a determines that the mounting process has started, CPU 80a performs the disposition instruction process after the mounting process starts (S115), the process returns to S100. In the feeder disposition instruction process, a process of instructing automatic exchange of feeder <NUM> is performed in a case where there is no more remaining amount of the components of feeder <NUM> in use; however, description thereof will be omitted since this case does not constitute the gist of the present disclosure. Hereinafter, a process in S105 and a process in S115 will be subsequently described in detail.

The disposition instruction process before the mounting process starts in S105 is performed, based on a flowchart in <FIG>. In the process, CPU 80a acquires feeder <NUM> and optimum disposition which correspond to the component type required in each component mounter <NUM> from a new production job (S200). <FIG> is a view for describing an example of the optimum disposition of feeder <NUM>, illustrates the optimum disposition in component mounter <NUM> in <FIG>, and numerals in the drawing indicate slot positions (numbers). The optimum disposition is configured so that feeders <NUM> of component types a to i are aligned at slot positions <NUM> to <NUM> in this order, and feeders <NUM> are not mounted at slot positions <NUM> and <NUM>. When the nozzle picks up the component from feeder <NUM>, head <NUM> moves on board S via part camera <NUM>. Therefore, the optimum disposition of feeder <NUM> is usually disposed around slot position <NUM> close to part camera <NUM>.

Next, CPU 80a acquires a disposition status of feeder <NUM> in process target component mounter <NUM> from feeder management information (S205). Since the disposition instruction process before the mounting process starts is performed during the preparation work, feeder <NUM> used in the mounting process based on the previous production job is mounted on each slot <NUM> of supply area 20A of component mounter <NUM>. Therefore, in S205, the feeder ID or the slot position of feeder <NUM> mounted in the previous production jobs is acquired. Subsequently, CPU 80a selects a remainder excluding previously mounted feeder <NUM> in supply area 20A of component mounter <NUM> out of feeders <NUM> required for the mounting process, as attaching target feeder <NUM> (S210), and specifies a slot position corresponding to the optimum disposition of attaching target feeder <NUM> (S215).

<FIG> is a view for describing a disposition status of feeder <NUM> when the mounting process based on the previous production job is completed. In <FIG>, feeders <NUM> of component type e, d, a, b, c, and i are disposed at slot positions <NUM> to <NUM>, and slot positions <NUM>, <NUM>, and <NUM> to <NUM> are vacant slots. When feeders <NUM> of component types a to i are required for the mounting process, feeder <NUM> of remaining component types f, g, and h excluding mounted feeders <NUM> of component types a to e and i are selected as the attaching target. In S215, CPU 80a specifies slot positions <NUM>, <NUM>, and <NUM> as the slot positions corresponding to the optimum disposition of feeders <NUM> of component types f, g, and h. Although the slot positions of feeders <NUM> of previously mounted component types a to e and i are all different from those in the optimum disposition illustrated in <FIG>, switching to the optimum disposition is not performed before the mounting process starts in the present embodiment. Therefore, while mounted feeders <NUM> of component types a to e and i remain located at the temporary positions different from those in the optimum disposition, the mounting process starts.

Thereafter, CPU 80a determines whether there is a feeder <NUM> whose slot position specified by S215 corresponds to a vacant slot (S220). When CPU 80a determines that there is corresponding feeder <NUM>, CPU 80a outputs an instruction to attach corresponding feeder <NUM> to the vacant slot to loader <NUM> (S225), and the process returns to S220. In <FIG>, slot position <NUM> corresponds to the optimum disposition of feeder <NUM> of component type h, and in <FIG>, slot position <NUM> is the vacant slot. Therefore, CPU 80a designates the vacant slot at slot position <NUM>, and outputs an instruction to attach feeder <NUM> of component type h to the vacant slot in S225. The instruction in S225 includes whether slot <NUM> from which attaching target feeder <NUM> is detached is feeder storage <NUM>, supply area 20A of component mounter <NUM>, or stock area 20B. Based on the instruction in S225, loader <NUM> performs the automatic exchange by detaching attaching target feeder <NUM> from slot <NUM> and attaching feeder <NUM> to the vacant slot corresponding to the optimum disposition.

On the other hand, when CPU 80a determines that there is no feeder <NUM> whose slot position corresponds to the vacant slot in S220, CPU 80a determines whether there are other vacant slots (S230). In <FIG>, CPU 80a determines that there are vacant slots, such as slot positions <NUM>, <NUM>, <NUM>, and <NUM>. When CPU 80a determines that there is the vacant slot, CPU 80a outputs an instruction to attach any of attaching target feeders <NUM> to the vacant slot as the temporary position, to loader <NUM> (S235), and the process proceeds to S240. CPU 80a designates a position having best work efficiency in the vacant slots, for example, the vacant slot close to the part camera <NUM>, as the temporary position. Based on the instruction in S235, loader <NUM> performs the automatic exchange by detaching attaching target feeder <NUM> from designated slot <NUM> and attaching feeder <NUM> to the vacant slot as the temporary position. In this way, even when the slot position corresponding to the optimum disposition of attaching target feeder <NUM> is not the vacant slot, feeder <NUM> is attached at the temporary position, and accordingly, feeder <NUM> can be quickly attached.

Next, CPU 80a determines whether all attaching target feeders <NUM> are attached (S240), and when CPU 80a determines that all are not attached, the process returns to S230. In addition, when CPU 80a determines that there is no vacant slot in S230, CPU 80a outputs an instruction to loader <NUM> to detach feeder <NUM> which is not scheduled to be used in the mounting process based on the new production job out of mounted feeders <NUM> (S245), and the process returns to S230. The instruction in S245 also includes designation of an attachment destination of detached feeder <NUM>. When feeder <NUM> is detached by loader <NUM> to have the vacant slot, CPU 80a determines that there is the vacant slot in S230, and performs a process in S235. Through the processes, feeder <NUM> required for the mounting process based on the new production job is attached to supply area 20A of component mounter <NUM>. <FIG> is a view for describing a disposition status of feeder <NUM> by the disposition instruction before the mounting process start. As described above, feeder <NUM> of component type h is attached to slot position <NUM>, and feeders <NUM> of component types f and g are attached to slot positions <NUM> and <NUM> as the temporary position. Thereafter, when CPU 80a determines that all attaching target feeders <NUM> are attached in S240, CPU 80a determines whether the disposition instruction is completed in all component mounters <NUM> (S250). When CPU 80a determines that the disposition instruction is not completed in all component mounters <NUM>, CPU 80a returns to S205 to repeat the processes, and when CPU 80a determines that the disposition instruction is completed in all component mounters <NUM>, CPU 80a completes the disposition instruction process before the mounting process starts.

The disposition instruction process after starting the mounting process in S115 is performed, based on a flowchart in <FIG>. In the process, CPU 80a acquires scheduled mounting time Ts per one board S in each component mounter <NUM> from the production job (S300). Next, CPU 80a acquires actual mounting times Tr actually required for the mounting process per one board S in each component mounter <NUM> (S305). For example, actual mounting time Tr is configured so that a time measured by mounting control device <NUM> of each component mounter <NUM> is acquired by CPU 80a through communication. Subsequently, CPU 80a calculates delay time ΔT by subtracting scheduled mounting time Ts from actual mounting time Tr (S310). Here, when feeder <NUM> is in the optimum disposition, actual mounting time Tr is acquired to have almost no difference from scheduled mounting time Ts. However, in component mounting system <NUM>, since feeder <NUM> is disposed at the temporary position to start the mounting process, it may take a longer time to collect the component than scheduled, or it may take a longer time to mount the collected component than scheduled. In this case, actual mounting time Tr is longer than scheduled mounting time Ts, and thus, delay time ΔT occurs. Delay time ΔT varies depending on a separated degree between the slot position corresponding to the optimum disposition and the temporary position, the number of feeders <NUM> mounted at the temporary position, or the number of components collected from feeders <NUM> mounted at the temporary position.

Thereafter, CPU 80a specifies component mounter <NUM> having long delay time ΔT out of respective component mounters <NUM>, as a process target (S315). In S315, component mounter <NUM> having longest delay time ΔT, that is, component mounter <NUM> which is a bottleneck is specified as the process target. Here, <FIG> is a view for describing delay time ΔT and a disposition change in feeder <NUM>. <FIG> illustrates scheduled mounting time Ts, actual mounting time Tr, and delay time ΔT in five component mounters <NUM>(<NUM>) to <NUM>(<NUM>) as an example. Although scheduled mounting time Ts varies depending on the component type, the number of components mounted by component mounter <NUM>, and the mounting position on board S, the same time is applied herein. As illustrated in <FIG>, since delay time ΔT increases in the order of component mounters <NUM>(<NUM>), <NUM>(<NUM>), <NUM>(<NUM>), <NUM>(<NUM>), and <NUM>(<NUM>), CPU 80a specifies component mounter <NUM>(<NUM>) as the process target in S315. In component mounter <NUM>(<NUM>), feeder <NUM> is in the optimum disposition before the mounting process starts, and delay time ΔT is zero seconds. Since each component mounter <NUM> performs the mounting process while subsequently conveying boards S from an upstream side, depending on a timing for performing the disposition instruction process after the mounting process starts, the mounting process may not yet be performed on board S, and there may be component mounter <NUM> for which actual mounting time Tr is not acquired. In this case, as the process target, CPU 80a may specify component mounter <NUM> having longer delay time ΔT out of component mounters <NUM> for which actual mounting time Tr is acquired.

Next, CPU 80a outputs an instruction to re-mount feeder <NUM> located at the temporary position at the slot position corresponding to the optimum disposition, to loader <NUM>, based on the optimum disposition and the disposition status of process target component mounter <NUM> (S320). When receiving the instruction in S320, loader <NUM> performs the automatic exchange by unloading feeder <NUM> from the temporary position and attaching feeder <NUM> to the slot position corresponding to the optimum disposition. CPU 80a acquires a mounting state from mounting control device <NUM>, and outputs the instruction in S330, by determining a timing at which the component is not supplied from re-mounted feeder <NUM>, such as a timing at which board S is conveyed into or conveyed out from feeder <NUM>. In this case, feeder <NUM> can be re-mounted without hindering the mounting process.

Thereafter, CPU 80a determines whether the disposition status of feeder <NUM> coincides with the optimum disposition (S325), when CPU 80a determines that the disposition status does not coincide with the optimum disposition, the process in S320 is repeated. In this manner, feeder <NUM> disposed as illustrated in <FIG> before the mounting process starts is changed to the optimum disposition as illustrated in <FIG> during the mounting process. When CPU 80a determines that the disposition status coincides with the optimum disposition, CPU 80a determines whether the process is completely performed in all component mounters <NUM> (S330). When CPU 80a determines that the process is not completely performed in all component mounters <NUM>, the process returns to S315 to perform the process. Therefore, feeders <NUM> are subsequently re-mounted from component mounter <NUM> having long delay time ΔT. For example, in <FIG>, when feeder <NUM> of component mounter <NUM>(<NUM>) is re-mounted, feeder <NUM> of component mounter <NUM>(<NUM>) is next re-mounted (<FIG>), feeder <NUM> of component mounter <NUM>(<NUM>) is subsequently re-mounted (<FIG>), and feeder <NUM> of component mounter <NUM>(<NUM>) is further re-mounted. Thereafter, when CPU 80a determines that the process is completely performed in all component mounters <NUM> in S330, CPU 80a completes the disposition instruction process after the mounting process starts.

Here, a correspondence relationship between the configuration elements of the present embodiment and configuration elements of the present invention will be clarified. Feeder <NUM> of the present embodiment corresponds to a component supply unit, component mounter <NUM> corresponds to a component mounter, loader <NUM> corresponds to a unit exchange device, and management device <NUM> and a loader control device <NUM> for performing a feeder exchange instruction process in <FIG> (disposition instruction process before the mounting process starts in <FIG>, and the disposition instruction process after the mounting process start s in <FIG>) corresponds to an exchange control device. In the present embodiment, an example of a disposition instruction method of the component supply unit of the present disclosure is also clarified by describing the process of management device <NUM>.

In component mounting system <NUM> described above, feeder <NUM> is mounted on component mounter <NUM> by allowing the temporary position different from that of the optimum disposition (predetermined disposition) before the mounting process starts based on the new production job. In addition, after the mounting process starts, feeder <NUM> mounted at the temporary position is re-mounted, based on the optimum disposition. In this manner, compared to a case where the mounting process starts after feeder <NUM> is in the optimum disposition when the production jobs are changed, the mounting process can more quickly start. In addition, feeder <NUM> is re-mounted in the optimum disposition after the mounting process starts, it is possible to suppress a significant decrease in efficiency of the mounting process.

In addition, since feeder <NUM> is preferentially mounted at the vacant position having not feeder <NUM> mounted thereon, as the temporary position, it is possible to further shorten a time required for mounting feeder <NUM>.

In addition, since component mounter <NUM> having long delay time ΔT is specified after the mounting process starts and feeder <NUM> is re-mounted from component mounter <NUM>, it is possible to suppress influence on the decrease in the efficiency of the mounting process when the mounting process starts in a disposition state different from the optimum disposition. In addition, the delay location of the mounting process can be properly specified, based on delay time ΔT calculated from scheduled mounting time Ts and actual mounting time Tr per one board. In addition, since component mounter <NUM> is re-mounted in units, feeder <NUM> can be quickly re-mounted in the optimum disposition by suppressing a movement loss of loader <NUM> frequently moving between component mounters <NUM>.

For example, in the above-described embodiment, in the disposition instruction process before the mounting process starts, feeder <NUM> whose slot position corresponding to the optimum disposition is the vacant slot is mounted on the vacant slot; however, the configuration is not limited to this. For example, in the disposition instruction process before the mounting process starts, the feeder <NUM> may be attached to any vacant slot, regardless of whether the slot position corresponds to the optimum disposition. In addition, feeder <NUM> whose slot position corresponding to the optimum disposition is not the vacant slot is attached to any the other vacant slot; however, the configuration is not limited to this. For example, a vacant slot on which feeder <NUM> can be easily re-mounted at the slot position corresponding to the optimum disposition may be selected from other vacant slots, and feeder <NUM> may be attached to the selected vacant slot. For example, a vacant slot having a smallest movement amount of loader <NUM> when feeder <NUM> is re-mounted at the slot position corresponding to the optimum disposition may be selected.

In the above-described embodiment described, in the disposition instruction process after the mounting process starts, the process targets are subsequently specified from component mounters <NUM> having longest delay time ΔT, and feeder <NUM> is re-mounted; however, the configuration is not limited to this. For example, when there are multiple component mounters <NUM> having no great difference in delay time ΔT, the process target may be specified from component mounters <NUM> close to a current position of loader <NUM> to further suppress the movement loss of loader <NUM> frequently moving between component mounters <NUM>. That is, process target component mounter <NUM> may be specified, based on delay time T and the movement distance of loader <NUM>.

In the above-described embodiment, in the disposition instruction process after the mounting process start, the location for re-mounting feeder <NUM> is specified in units of component mounter <NUM>; however, without being limited to this, the location may be specified in units of feeder <NUM>. For example, for all feeders <NUM> disposed at the temporary position, the delay time is derived, based on a difference between the time required from the collection to the mounting of the component in a case of the optimum disposition and the time required from the collection to the mounting of the component in a case of the temporary position. Thereafter, feeders <NUM> having the long delay time may be re-mounted as the delay location in the longest order, or multiple feeders <NUM> including feeder <NUM> having the long delay time and feeder <NUM> at the surrounding temporary position may be re-mounted as the delay locations.

In the above-described embodiment, in the disposition instruction process after the mounting process starts, feeder <NUM> is re-mounted from the location (component mounter <NUM>) having long delay time ΔT; however, the configuration is not limited to this. For example, without calculating delay time ΔT, feeders <NUM> may be subsequently re-mounted from the locations where feeder <NUM> is not in the optimum disposition. In this case, feeders <NUM> may be subsequently re-mounted from the upstream side or downstream side out of component mounters <NUM> which are not in the optimum disposition so that a movement direction of loader <NUM> is one direction. Alternatively, without calculating delay time ΔT, feeder <NUM> may be re-mounted from component mounter <NUM> having longest actual mounting time Tr per one board S. In this case, scheduled mounting time Ts may be used instead of actual mounting time Tr with regard to component mounter <NUM> on which the mounting process is not yet performed on board S and for which actual mounting time Tr is not acquired.

In the above-described embodiment, loader <NUM> that performs the automatic exchange of feeder <NUM> has been described so that the instruction of disposing feeder <NUM> is output to loader <NUM>; however, without being limited to this, an instruction to dispose feeder <NUM> may be output to a worker. In this case, for example, the instruction may be output to the worker by displaying the instruction to dispose feeder <NUM> on a screen of a portable terminal possessed by the worker.

In the component mounting system of the present disclosure, the exchange control device may control the unit exchange device so that the remaining component supply unit excluding the component supply unit mounted during the previously performed production job, out of the component supply units required for the mounting process, is preferentially mounted at the vacant position where the component supply unit is not mounted, as the temporary position, before the mounting process starts. In this case, since the component supply unit required for the mounting process can be quickly mounted, a time required for the mounting can be further shortened, and the mounting process can more quickly start.

In the component mounting system of the present disclosure, the exchange control device may specify the delay location where the longer delay occurs in the mounting process, out of the locations including the temporary position where the component supply unit is mounted, after the mounting process starts, and may control the unit exchange device to re-mount the component supply unit from the delay location. In this case, it is possible to suppress influence on the decrease in the efficiency of the mounting process when the mounting process starts in a state different from that of the predetermined disposition.

In the component mounting system of the present disclosure, the exchange control device may specify the delay location, based on a difference between the scheduled time scheduled for the mounting process per one board when the component supply unit is in a state of the predetermined disposition and the actual time required for the mounting process per one board when the component supply unit is in a state different from that of the predetermined disposition. In this case, since the delay location of the mounting process can be properly specified, it is possible to properly suppress the influence on decrease in the efficiency of the mounting process.

In the component mounting system of the present disclosure, the unit exchange device may move along the alignment direction of the multiple component mounters to perform the automatic exchange, and the exchange control device may specify the delay location in units of the component mounter. In this case, the component supply unit can be quickly re-mounted in the predetermined disposition by suppressing the movement loss of the component supply unit frequently moving between the component mounters when the unit exchange device re-mounts component supply unit.

According to the present disclosure, there is provided the method for instructing disposition of the component supply unit in the component mounter on which multiple component supply units are aligned and detachably mounted, and which is configured to perform the mounting process of mounting the component on the board by collecting the component from the component supply units, based on the production job. The disposition instruction method includes (a) a step of outputting an instruction so that the component supply unit required for the mounting process is mounted on the component mounter by allowing a temporary position different from a predetermined alignment disposition suitable for the mounting process, before the mounting process starts based on a new production job; and
(b) a step of outputting an instruction so that the component supply unit mounted at the temporary position is re-mounted on the component mounter, based on the predetermined disposition, after the mounting process starts.

In the method for instructing disposition of the component supply unit of the present disclosure, before the mounting process starts based on the new production job, the required component supply unit is instructed to be mounted on the component mounter by allowing the temporary position different from the predetermined alignment disposition suitable for the mounting process. In addition, after the mounting process starts, the component supply unit mounted at the temporary position is instructed to be re-mounted, based on the predetermined disposition. Therefore, since the component supply units are disposed as instructed, it is possible to suppress the decrease in the efficiency of the mounting process while the mounting process quickly starts when the production jobs are changed, as in the above-described component mounting system. In the method for instructing disposition of the component supply unit, various aspects of the above-described component mounting system may be adopted, or a step for realizing each function of the above-described component mounting system may be added.

The present invention is applicable to a manufacturing industry of the component mounting system.

Claim 1:
A component mounting system (<NUM>) including a component mounter (<NUM>) on which multiple component supply units (<NUM>) are aligned and detachably mounted, and which is configured to perform a mounting process of mounting a component on a board (S) by collecting the component from the component supply units, based on a production job, the system comprising:
a unit exchange device (<NUM>) configured to automatically exchange the component supply units within the component mounter; and
an exchange control device (<NUM>, <NUM>);
characterized by
the exchange control device configured to control the unit exchange device so that:
- the component supply unit required for the mounting process is mounted on the component mounter by allowing a temporary position within a supply area (20A) of the component mounter different from a predetermined alignment disposition within the supply area suitable for the mounting process, before the mounting process starts based on a new production job;
- the remaining component supply unit excluding the component supply unit mounted during the previously performed production job, out of the component supply units required for the mounting process, is preferentially mounted at a vacant position where the component supply unit is not mounted, as the temporary position, before the mounting process starts; and
- the component supply unit mounted at the temporary position is re-mounted within the supply area, based on the predetermined disposition, after the mounting process starts.