Patent Description:
A technique of mass-producing board products by executing board work on a board on which printed wiring is applied has become widespread. Further, in general, multiple types of board work machines that execute board work are provided side by side to constitute a board work line. A component mounter among the board work machines uses a component supply unit loaded with a component container that accommodates multiple components. In many cases, the component container and the component supply unit are stored in a warehouse. Then, a preparation for use is completed by a loading work that loads the component container into the component supply unit. Technical examples related to storage and preparation for use of the component container and the component supply unit are disclosed in Patent Literatures <NUM> and <NUM>.

Patent Literature <NUM> discloses a manufacturing management system that manufactures a printed circuit board (a board product) by controlling an SMT line (a board work line). The manufacturing management system includes a reel stocker, a cartridge stocker, and a control personal computer that manages both stockers. The control personal computer includes a database that stores various data files related to the manufacture of the printed circuit board, a setup support section that instructs a setup work, and a mounting data creating section that creates mounting data for mounting a component on the printed circuit board. With this, even for SMT lines having different facility specifications and configurations, it is regarded that the setup work can be efficiently performed, and the mounting data according to the setup information can be created.

In addition, a component mounting system disclosed in Patent Literature <NUM> includes a component storage container that stores multiple feeder instruments (one form of a component supply unit) accommodating multiple components, a replenishing device that replenishes a feeder instrument to the component mounter and collects a feeder instrument from the component mounter, and a conveyance means that conveys the replenishing device between the component storage container and multiple component mounters. With this, it is regarded that necessary components can be automatically and efficiently replenished, so that labor saving and automation are possible.

Incidentally, Patent Literatures <NUM> and <NUM> realize a function of supplying by delivering a component container and a component supply unit stored in a warehouse (a stocker, a component storage container) according to an instruction. However, the loading work that loads the component container into the component supply unit is executed by an operator. In addition, although a device that automates the loading work is put into practical use, the carry-in to the devices of the component container and the component supply unit is executed by an operator. Therefore, it cannot be said that a sufficient labor saving has been achieved.

It is an object of the present specification to provide a warehouse system which is used for supporting a component mounter and achieves further labor saving than before in the loading work that loads a component container into a component supply unit.

The present specification discloses a warehouse system which is defined in appended claim <NUM>.

In the warehouse system disclosed in the present specification, the conveyance robot conveys the component container stored in the component container warehouse to the component container loader, and conveys the component supply unit stored in the component supply unit warehouse to the component container loader. In addition, the component container loader loads the component container into the component supply unit. As a result, the preparation for using the component supply unit in the component mounter is automatically completed. Therefore, an operator is not involved in the loading work, so that further labor saving is achieved than before.

A configuration of warehouse system <NUM> according to a first embodiment will be described with reference to <FIG>. Warehouse system <NUM> is used for supporting one or multiple component mounters <NUM> that constitutes board work line <NUM>. In addition, multiple component mounters <NUM> of board work line <NUM> can be regarded as support targets in warehouse system <NUM>. Component mounter <NUM> executes a mounting work that mounts a component on a board using a component supply unit in which a component container is loaded. Warehouse system <NUM> is in charge of work which relates to store and support the component container and the component supply unit.

The component container accommodates multiple components. The component supply unit is used when supplying a component accommodated in the component container to component mounter <NUM>. The component supply unit does not need to be an integral type, and may be configured as a separate type. In the present specification, a combination of at least a part of the component container and the component supply unit, or any one of them is referred to as "instrumentation".

Tape reel <NUM> can be exemplified as a component container and a feeder device can be exemplified as a component supply unit (indicated by dashed lines in <FIG>). A carrier tape in which multiple components are sealed at a predetermined pitch is wound and held on tape reel <NUM>. The feeder device supplies components to the component mounting tool of component mounter <NUM> by pulling out the carrier tape from tape reel <NUM> and sending the carrier tape to the component unloading position. There are roughly two types of feeder devices, one of the integral type and the other of the separate type.

Integral type feeder device <NUM> (indicated by dashed lines in <FIG>) is equipped on component mounter <NUM> in the form of prepared feeder device <NUM> loaded with tape reel <NUM>. When the components of tape reel <NUM> are completely consumed, the entire prepared feeder device <NUM> is exchanged. There may be a case that only tape reel <NUM> is exchanged. On the other hand, the separate type feeder device includes a feeder main body that has a built-in feeding mechanism of a carrier tape, and a reel cassette in which tape reel <NUM> is loaded. The feeder main body is permanently installed in component mounter <NUM>, and a separate reel cassette is disposed in the vicinity of the feeder main body. When the components of tape reel <NUM> are completely consumed, the reel cassette is exchanged.

As described below, prepared feeder device <NUM> is prepared by warehouse system <NUM>. Similarly, a prepared reel cassette loaded with tape reel <NUM> is prepared by warehouse system <NUM>. In <FIG>, a case where integral type feeder device <NUM> is used is illustrated, and an illustration of a separate type feeder device is omitted.

In addition, tray <NUM> can be exemplified as a component container, and tray loading unit <NUM> can be exemplified as a component supply unit (indicated by dashed lines in <FIG>). Tray <NUM> has multiple component accommodation sections that accommodate components respectively. Generally, multiple component accommodation sections are arranged in a two-dimensional lattice. Tray loading unit <NUM> is equipped on component mounter <NUM> in the form of prepared tray loading unit <NUM> in which tray <NUM> is loaded. When the components of tray <NUM> are completely consumed, the entire prepared tray loading unit <NUM> is exchanged. There may be a case that only tray <NUM> is exchanged. As described below, prepared tray loading unit <NUM> is prepared by warehouse system <NUM>. In addition, tray loading unit <NUM> is stacked and loaded by multiple trays <NUM>, and may have a mechanism in which trays <NUM> whose components have been consumed are removed in order from the top.

Warehouse system <NUM> according to the first embodiment is configured of multiple warehouse modules and conveyance robot <NUM>. As illustrated in <FIG>, seven warehouse modules are provided in parallel. That is, in order from the left side to the right side, a carry-in and information providing section <NUM>, first component container warehouse <NUM>, second component container warehouse <NUM>, component supply unit warehouse <NUM>, reel loader <NUM>, tray loader <NUM>, and conveyance vehicle stopping section <NUM> are provided side by side.

Each of the warehouse modules has a delivery port (not illustrated) on the front side for delivering conveyance robot <NUM> and the instrumentation. The arrangement and shape of the delivery port in each of the warehouse modules are commonized. In <FIG>, each of the warehouse modules is illustrated as a rectangular parallelepiped having a different size, but the actual shape may differ from the rectangular parallelepiped. In addition, an arrangement in which multiple warehouse modules are not arranged in line and an arrangement in which multiple warehouse modules are separated from each other are allowed.

Conveyance robot <NUM> includes robot main body <NUM> and moving path <NUM>. Moving path <NUM> is laid so as to pass through the front side of all the warehouse modules. Robot main body <NUM> has a moving mechanism such as a linear motor and a traveling wheel, and moves along moving path <NUM>. Therefore, robot main body <NUM> moves between each of the warehouse modules, and the movement range thereof extends from the carry-in and information providing section <NUM> at the left end to conveyance vehicle stopping section <NUM> at the right end.

Multiple robot main bodies <NUM> may be provided. In addition, moving path <NUM> may be double-lined or circularized, or may have a more complicated movement path. Multiple robot main bodies <NUM> are controlled by warehouse control section <NUM> (refer to <FIG>), which will be described below, to move while avoiding collisions.

Non-contact power transmitting sections <NUM> are provided near the upper surface of moving path <NUM> at regular intervals. On the other hand, non-contact power receiving section <NUM> is provided at a lower part of robot main body <NUM>. Robot main body <NUM> is supplied with power by a configuration of the non-contact power supply section consisting of non-contact power transmitting section <NUM> and non-contact power receiving section <NUM>. As a non-contact power supply section, a configuration of an electromagnetic coupling type using a coil can be exemplified, and the present invention is not limited to this.

Robot main body <NUM> has an arm (not illustrated) that grips the instrumentation, and performs a delivery operation of the instrumentation at the delivery port of the warehouse module. In more detail, at the front side of a certain warehouse module, robot main body <NUM> grips the instrumentation placed on the delivery port by using the arm. Next, robot main body <NUM> conveys the instrumentation by moving to another target warehouse module. Finally, at the front side of another warehouse module, robot main body <NUM> releases the arm and places the instrumentation on the delivery port. Each of the warehouse modules may have an arm, and robot main body <NUM> may only include a conveyance function that conveys the instrumentation.

Carry-in and information providing section <NUM> is a form of a work execution section that executes a predetermined work on the component container. In addition, carry-in and information providing section <NUM> also serves as a carry-in section into which the component container is carried. Carry-in and information providing section <NUM> has carry-in port <NUM> of the component container on the left surface. Carry-in and information providing section <NUM> moves the component container carried into carry-in port <NUM> to a work execution section therein (not illustrated). The work execution section executes an information providing work that provides individual identification information to the component container.

The individual identification information is provided to each of the component containers such as tape reel <NUM> and tray <NUM> described above. Examples of the work contents of the information providing work may include printing of an individual identification number and attaching of an individual identification barcode. Carry-in and information providing section <NUM> places the component container to which the individual identification information is provided on the delivery port, so that the component container is in a conveyable state. As a result, the information providing work and the conveyed-out to the component container are automatically executed, so that labor saving is achieved.

First component container warehouse <NUM> is a warehouse with a desiccator, and stores multiple component containers. First component container warehouse <NUM> preferentially stocks, stores, and delivers component containers of components that are averse to moisture. Examples of the moisture-averse components include an IC component and an LSI component, which are stored in the form of tape reel <NUM> and tray <NUM>, respectively. First component container warehouse <NUM> may store other non-priority components, feeder device <NUM>, and tray loading unit <NUM> in a case where there is enough storage space.

Second component container warehouse <NUM> is a general-purpose warehouse, and there are no particular constraints on multiple component containers which are stored. Second component container warehouse <NUM> stocks, stores, and delivers component containers such as tape reel <NUM> and tray <NUM>. These component containers are conveyed from carry-in and information providing section <NUM> by conveyance robot <NUM>.

Component supply unit warehouse <NUM> stocks, stores, and delivers multiple component supply units such as integral type feeder device <NUM>, a reel cassette, and tray loading unit <NUM>. These component supply units are carried into the delivery port of component supply unit warehouse <NUM> by an operator. Alternatively, these component supply units are conveyed by conveyance robot <NUM>.

The internal configurations of first component container warehouse <NUM>, second component container warehouse <NUM>, and component supply unit warehouse <NUM> are similar to each other. For example, these warehouses include storage shelves and in-warehouse conveyance sections. The storage shelf has multiple storage positions two-dimensionally arranged in the width direction and the height direction, and stores the instrumentation at each storage position. The in-warehouse conveyance section conveys the instrumentation between the storage position and the delivery port. Not limited to this, in these warehouses, for example, multiple storage shelves may be provided in a front-rear direction.

Each of reel loader <NUM> and tray loader <NUM> is a form of a component container loader that loads a component container into a component supply unit. Reel loader <NUM> executes a loading work that loads tape reel <NUM> into feeder device <NUM> or the reel cassette. Specifically, reel loader <NUM> moves tape reel <NUM>, and feeder device <NUM> or the reel cassette which are placed on the delivery port by conveyance robot <NUM> to the work execution section therein (not illustrated). The work execution section loads tape reel <NUM> in a predetermined posture at a predetermined position of feeder device <NUM> or the reel cassette. As a result, the loading work of tape reel <NUM> is completed, and tape reel <NUM> is prepared to be used in component mounter <NUM>. Prepared feeder device <NUM> that the preparation to be used is completed or the prepared reel cassette is placed on the delivery port or temporarily stored therein.

Reel loader <NUM> may have a function of a separation work that removes tape reel <NUM> from prepared feeder device <NUM> or the prepared reel cassette. Tape reel <NUM> which is separated is returned to second component container warehouse <NUM> and stored. In addition, feeder device <NUM> or the reel cassette from which tape reel <NUM> is removed is returned to component supply unit warehouse <NUM> and stored.

Tray loader <NUM> executes the loading work that loads tray <NUM> into tray loading unit <NUM>. Specifically, tray loader <NUM> moves a predetermined number of trays <NUM> and tray loading unit <NUM> placed on the delivery port by conveyance robot <NUM> to the work execution section therein (not illustrated). The work execution section loads tray <NUM> at a predetermined position of tray loading unit <NUM> in a predetermined posture. As a result, the loading work of tray <NUM> is completed, and tray <NUM> is prepared to be used in component mounter <NUM>. Prepared tray loading unit <NUM> that the preparation to be used is completed (tray loading unit <NUM> loaded with tray <NUM>) is placed on the delivery port or temporarily stored therein.

Tray loader <NUM> may have a function of a separation work that removes tray <NUM> from prepared tray loading unit <NUM>. Tray <NUM> which is separated is returned to second component container warehouse <NUM> and stored. In addition, tray loading unit <NUM> from which tray <NUM> is removed is returned to component supply unit warehouse <NUM> and stored.

Here, a stand-alone type information providing device, a reel loading device, and a tray loading device have been conventionally used. However, in the stand-alone type, it is necessary for an operator to carry in and out the instrumentation. In the first embodiment, since the provision of conveyance robot <NUM> reduces a carry in and out work by an operator, further labor saving is achieved than before.

Conveyance vehicle stopping section <NUM> stops conveyance vehicle <NUM> which is movable between warehouse system <NUM> and component mounter <NUM>. Conveyance vehicle stopping section <NUM> executes the work of loading the instrumentation received from conveyance robot <NUM> onto conveyance vehicle <NUM>. As indicated by arrow M1 in <FIG>, conveyance vehicle <NUM> travels through conveyance path <NUM> that connects warehouse system <NUM> and board work line <NUM>, and conveys the loaded instrumentation to component mounter <NUM>. Therefore, conveyance vehicle stopping section <NUM> serves as a carry-out section from which at least one of the component container and the component supply unit is carried out.

In addition, conveyance vehicle <NUM> conveys idle instrumentation that has been used in component mounter <NUM> and has no use plan for the time being from component mounter <NUM> to conveyance vehicle stopping section <NUM> in a reverse direction. The instrumentation conveyed in the reverse direction is returned to any warehouse or any loader by conveyance robot <NUM>. Accordingly, conveyance vehicle stopping section <NUM> serves as a carry-in section into which at least one of the component container and the component supply unit is carried.

Multiple conveyance vehicles <NUM> may be provided. Further, in a configuration in which multiple board work lines <NUM> are regarded as support targets, conveyance path <NUM> may be branched or circularized in the middle thereof, and a more complicated conveyance path may be constituted. Multiple conveyance vehicles <NUM> are controlled by conveyance control section <NUM> (refer to <FIG>) described below, and travel while avoiding collision.

Here, seven warehouse modules have a common element that is common to each other. As a result, changing in increase and decrease and changing in arrangement of the warehouse modules can be easily performed. In general, the term "module" means a constituent unit that has a common element and is easy to change. The common element includes at least one of the following six items.

Hereinafter, descriptions will be given in order.

Next, the functional configuration of warehouse system <NUM> and the functional configuration of the upper-level production management system <NUM> according to the first embodiment will be described with reference to <FIG>. As illustrated in <FIG>, production management system <NUM> includes production management section <NUM>, warehouse control section <NUM>, conveyance control section <NUM>, and line control section <NUM>. Production management section <NUM> is positioned in an upper-level of the control. Warehouse control section <NUM>, conveyance control section <NUM>, and line control section <NUM> are wired and communicatively connected to production management section <NUM> and are positioned in the lower-level of production management section <NUM>.

Production management section <NUM> promotes a production plan of board product to be produced on board work line <NUM>, and manages the progress status of production. Specifically, production management section <NUM> issues an instruction to prepare necessary instrumentation to warehouse control section <NUM> when starting the production of the board product or switching the type of the board product being produced. In addition, production management section <NUM> issues an instruction to conveyance control section <NUM> to convey the prepared instrumentation from warehouse system <NUM> to board work line <NUM>.

When necessary instrumentation is conveyed to and mounted on component mounter <NUM> of board work line <NUM>, production management section <NUM> issues an instruction to start the production of the board product to line control section <NUM>. As a result, board work line <NUM> executes the board work to advance the production of the board product. The information of the production record of the board product is appropriately notified from line control section <NUM> to production management section <NUM>. In addition, when components are consumed and reduced by the progress of production, the information of the reduced components is notified from line control section <NUM> to production management section <NUM>. Production management section <NUM> issues an instruction for replenishing the components to warehouse control section <NUM> and conveyance control section <NUM>.

Warehouse system <NUM> includes warehouse control section <NUM>. Warehouse control section <NUM> is wired and communicatively connected to each of the warehouse modules. In addition, warehouse control section <NUM> is wirelessly communicatively connected to robot main body <NUM> (indicated by dashed lines). Warehouse control section <NUM> issues a command to each warehouse module and robot main body <NUM> based on the instruction received from production management section <NUM>. On the other hand, warehouse control section <NUM> acquires information which relates to the operation status from each warehouse module and robot main body <NUM>.

However, warehouse control section <NUM> advances the control of the carry-in of the component container without receiving the instruction of production management section <NUM>. That is, warehouse control section <NUM> commands the execution of the information providing work when the component container is carried into carry-in port <NUM>. In addition, warehouse control section <NUM> selects a warehouse to be stored based on the type and quantity of the carried-in component container, and determines a storage position. Thereafter, warehouse control section <NUM> commands robot main body <NUM> to convey the component container, and commands the selected warehouse to stock and store the component container. In addition, warehouse control section <NUM> notifies production management section <NUM> of the stored information related to the component container.

In the control other than the carry-in of the component container, warehouse control section <NUM> commands first component container warehouse <NUM>, second component container warehouse <NUM>, and component supply unit warehouse <NUM> to stock, store, and deliver the instrumentation. In addition, warehouse control section <NUM> commands reel loader <NUM> and tray loader <NUM> to execute the loading work. In addition, warehouse control section <NUM> commands conveyance vehicle stopping section <NUM> to load and unload the instrumentation onto conveyance vehicle <NUM>. Each of the warehouse modules executes a commanded operation or work, and notifies warehouse control section <NUM> of the progress status.

In a case where the instruction from production management section <NUM> is a loading work, warehouse control section <NUM> first commands robot main body <NUM> to convey the component container and the component supply unit stored in any of warehouses. Next, warehouse control section <NUM> commands reel loader <NUM> or tray loader <NUM> to execute the loading work. Next, warehouse control section <NUM> commands robot main body <NUM> to convey the prepared instrumentation to conveyance vehicle stopping section <NUM>.

In a case where the instruction is a conveyance work of the instrumentation to component mounter <NUM>, warehouse control section <NUM> commands robot main body <NUM> to convey the instrumentation stored in any of the warehouses to conveyance vehicle stopping section <NUM>. In both the loading work and the conveyance work, warehouse control section <NUM> commands conveyance vehicle stopping section <NUM> to load the instrumentation onto conveyance vehicle <NUM>.

Conveyance control section <NUM> is wirelessly communicatively connected to conveyance vehicle <NUM> (indicated by dashed lines). Conveyance control section <NUM> controls the conveyance of the instrumentation by conveyance vehicle <NUM>. Conveyance control section <NUM> receives an instruction from production management section <NUM>, and causes conveyance vehicle stopping section <NUM> to stop conveyance vehicle <NUM>. When the instrumentation is loaded on conveyance vehicle <NUM>, conveyance control section <NUM> causes conveyance vehicle <NUM> to travel from warehouse system <NUM> to component mounter <NUM>. The instrumentation conveyed by conveyance vehicle <NUM> is mounted on component mounter <NUM> and used. A mounting work and a removal work of the instrumentation on and from component mounter <NUM> are automatically or manually performed.

Line control section <NUM> is wired and communicatively connected to each of board work machines constituting board work line <NUM>. Line control section <NUM> controls an operation of each of the board work machines. Line control section <NUM> receives an instruction from production management section <NUM>, and causes the board work machine to execute the board work. Line control section <NUM> notifies production management section <NUM> of the information of the production record of the board product and the information of the reduced components.

When the production of a certain type of board product is completed, idle instrumentation which is not used in the next production plan becomes apparent. Production management section <NUM> issues an instruction to return the idle instrumentation to warehouse system <NUM> to conveyance control section <NUM> and warehouse control section <NUM>. At this time, conveyance control section <NUM> controls the conveyance in the reverse direction from component mounter <NUM> to warehouse system <NUM>. In addition, warehouse control section <NUM> controls a stock operation in the reverse direction from conveyance vehicle stopping section <NUM> to the warehouse or the loader.

Next, the operation of warehouse system <NUM> according to the first embodiment will be described with reference to an operation flow illustrated in <FIG>. This operation flow is mainly performed under the control of warehouse control section <NUM>. In step S1 in <FIG>, warehouse control section <NUM> investigates whether the component container is carried into carry-in port <NUM>. In step S2 which is a case where the component container is carried into carry-in port <NUM>, carry-in and information providing section <NUM> executes an information providing work.

In the next step S3, warehouse control section <NUM> selects a warehouse that stores the component container to which the individual identification information is provided, and further determines a storage position. In the next step S4, conveyance robot <NUM> conveys the component container to the selected warehouse. The selected warehouse receives the component container and stocks the component container in the determined storage position. After step S4, and in a case where the component container is not carried into carry-in port <NUM> in step S1, the execution of the operation flow advances to step S5.

In step S5, warehouse control section <NUM> confirms whether an instruction is received from production management section <NUM>. In step S6 which is a case where the instruction is received from production management section <NUM>, warehouse control section <NUM> investigates the content of the instruction and determines the branch destination of the operation flow. That is, warehouse control section <NUM> designates step S11 when the instruction is a conveyance work, step S21 when the instruction is a loading work, and step S31 when the instruction is a separation work, as branch destinations, respectively.

In step S11 which is a case where the content of the instruction is a conveyance work, warehouse control section <NUM> commands the warehouse module that stores the instrumentation to be conveyed to deliver the instrumentation. The warehouse module that has received the command delivers the instrumentation to the delivery port. Next, warehouse control section <NUM> gives a conveyance command to robot main body <NUM>. Conveyance robot <NUM> receives the instrumentation from the delivery port of the warehouse module, and conveys the instrumentation to conveyance vehicle stopping section <NUM>.

Step S11 is executed when the remaining number of components is reduced and an exchange work of tape reel <NUM> or tray <NUM> is performed in component mounter <NUM>. In addition, step S11 is executed on prepared feeder device <NUM> or prepared reel cassette which is temporarily stored in reel loader <NUM>. Further, step S11 is executed on prepared tray loading unit <NUM> which is temporarily stored in tray loader <NUM>. After step S11, the execution of the operation flow is merged with step S24 (described later).

In step S21 which is a case where the content of the instruction in step S6 is a loading work, warehouse control section <NUM> commands robot main body <NUM> to convey the component container and the component supply unit, which are to be targets of the instructed loading work. Hereinafter, a case where tape reel <NUM> and tray <NUM> are stored in second component container warehouse <NUM> will be described. In a case where tape reel <NUM> and tray <NUM> are stored in first component container warehouse <NUM>, second component container warehouse <NUM> in the following description is replaced by first component container warehouse <NUM>.

When tape reel <NUM> is loaded into feeder device <NUM> or the reel cassette, warehouse control section <NUM> first commands second component container warehouse <NUM> to deliver tape reel <NUM>, and then gives a conveyance command to robot main body <NUM>. Second component container warehouse <NUM> delivers tape reel <NUM> to the delivery port in accordance with the command. Robot main body <NUM> receives tape reel <NUM> from second component container warehouse <NUM>, and conveys tape reel <NUM> to reel loader <NUM>.

Next, warehouse control section <NUM> commands component supply unit warehouse <NUM> to deliver feeder device <NUM> or the reel cassette, and then gives a conveyance command to robot main body <NUM>. Component supply unit warehouse <NUM> delivers feeder device <NUM> or the reel cassette to the delivery port in accordance with the command. Robot main body <NUM> receives feeder device <NUM> or the reel cassette from component supply unit warehouse <NUM>, and conveys feeder device <NUM> or the reel cassette to reel loader <NUM>. Robot main body <NUM> may convey tape reel <NUM>, and feeder device <NUM> or the reel cassette together.

In the next step S22, reel loader <NUM> executes the work of loading tape reel <NUM> into feeder device <NUM> or the reel cassette. Subsequently, reel loader <NUM> places prepared feeder device <NUM> or the prepared reel cassette on the delivery port. In addition, reel loader <NUM> notifies warehouse control section <NUM> that the loading work is completed. In the next step S23, warehouse control section <NUM> that has received the notification gives a conveyance command to robot main body <NUM>. Robot main body <NUM> receives prepared feeder device <NUM> or the prepared reel cassette from reel loader <NUM>, and conveys prepared feeder device <NUM> or the prepared reel cassette to conveyance vehicle stopping section <NUM>.

In the next step S24, warehouse control section <NUM> commands conveyance vehicle stopping section <NUM> to load prepared feeder device <NUM> or the prepared reel cassette into conveyance vehicle <NUM>. The subsequent conveyance to component mounter <NUM> is executed under the control of conveyance control section <NUM>. After step S24, the execution of the operation flow is returned to step S1. In addition, when tray <NUM> is loaded in tray loading unit <NUM>, the same operations as in steps S21 to S24 described above are executed except that tray loader <NUM> executes the loading work.

In step S31 which is a case where the content of the instruction in step S6 is a separation work, warehouse control section <NUM> commands robot main body <NUM> to return the instrumentation returned from component mounter <NUM> to reel loader <NUM> or tray loader <NUM>. For example, in the case of the separation work that removes tape reel <NUM> from prepared feeder device <NUM> or the prepared reel cassette, warehouse control section <NUM> first commands conveyance vehicle stopping section <NUM> to unload prepared feeder device <NUM> or the prepared reel cassette from conveyance vehicle <NUM>, and then gives a conveyance command to robot main body <NUM>. Conveyance vehicle stopping section <NUM> unloads prepared feeder device <NUM> or the prepared reel cassette according to the command and places prepared feeder device <NUM> or the prepared reel cassette on the delivery port. Robot main body <NUM> receives prepared feeder device <NUM> or the prepared reel cassette from conveyance vehicle stopping section <NUM>, and conveys prepared feeder device <NUM> or the prepared reel cassette to reel loader <NUM>.

In the next step S32, reel loader <NUM> executes the separation work that removes tape reel <NUM> from prepared feeder device <NUM> or the prepared reel cassette. Subsequently, reel loader <NUM> places tape reel <NUM>, and feeder device <NUM> or the reel cassette that have been separated on the delivery port. In addition, reel loader <NUM> notifies warehouse control section <NUM> that the separation work is completed.

In the next step S33, warehouse control section <NUM> that has received the notification gives a conveyance command to robot main body <NUM>. Robot main body <NUM> receives tape reel <NUM>, and feeder device <NUM> or the reel cassette from reel loader <NUM>. Next, robot main body <NUM> returns tape reel <NUM> to second component container warehouse <NUM>, and returns feeder device <NUM> or the reel cassette to component supply unit warehouse <NUM>. After step S33, the execution of the operation flow is returned to step S1. In the case of the separation work that removes tray <NUM> from prepared tray loading unit <NUM>, the same operations as in steps S31 to S33 are executed except that tray loader <NUM> executes the separation work.

The separation work described above is not essential. In other words, prepared feeder device <NUM> or the prepared reel cassette returned from component mounter <NUM> may be stored in reel loader <NUM> or component supply unit warehouse <NUM> in a usable state. With this storage method, in a combination of tape reel <NUM> and feeder device <NUM> or the reel cassette that are intermittently used with the pause period interposed therebetween, it is possible to reduce the removal work and the reloading work of tape reel <NUM>. Similarly, prepared tray loading unit <NUM> returned from component mounter <NUM> may be stored in tray loader <NUM> or component supply unit warehouse <NUM> in a usable state.

In addition, there may be a case of multiple instructions from production management section <NUM>. For example, when the loading work to three feeder devices <NUM> or the reel cassettes is instructed, warehouse control section <NUM> repeatedly executes steps S21 to S24 three times. As a result, conveyance vehicle <NUM> can convey three prepared feeder devices <NUM> or three prepared reel cassettes together.

Further, in some cases, conveyance vehicle <NUM> returns the idle instrumentation from component mounter <NUM> to conveyance vehicle stopping section <NUM>, and then conveys prepared instrumentation to component mounter <NUM>. In this case, warehouse control section <NUM> executes steps S21 to S24 corresponding to the instrumentation to be prepared in advance, and executes steps S31 to S33 corresponding to the returned instrumentation later. With this, since the work of unloading of the returned instrumentation and the work of loading of the prepared instrumentation are continuously performed without delay after conveyance vehicle <NUM> stops on conveyance vehicle stopping section <NUM>, it is efficient.

In warehouse system <NUM> of the first embodiment, conveyance robot <NUM> conveys the component container (tape reel <NUM> and tray <NUM>) stored in second component container warehouse <NUM> to the component container loader (reel loader <NUM> and tray loader <NUM>), and conveys the component supply unit (feeder device <NUM>, reel cassette, and tray loading unit <NUM>) stored in component supply unit warehouse <NUM> to the component container loader. In addition, the component container loader loads the component container into the component supply unit. As a result, the preparation for using the component supply unit in the component mounter <NUM> is automatically completed. Therefore, an operator is not involved in the loading work, so that further labor saving is achieved than before.

In addition, since the seven warehouse modules have a common element, it is easy to additionally install the warehouse modules. Therefore, it is easy to respond to an increase in the storage amount of the instrumentation, and the cost required to respond is also low. In addition, since warehouse system <NUM> can be configured by freely combining multiple types of warehouse modules, it is possible to add a work execution function such as an information providing work in addition to the storage function, so that further labor saving is achieved than before.

Warehouse system 1A according to the second embodiment will be described with reference to <FIG>. As illustrated in <FIG>, in warehouse system 1A according to the second embodiment, multiple warehouse modules are divided into a lower stage and an upper stage in a height direction and arranged. The type and arrangement of the warehouse module in the lower stage coincide with those of the first embodiment. The type and the arrangement of the warehouse module in the upper stage are such that conveyance vehicle stopping section <NUM> is omitted from the configuration of the lower stage.

Conveyance robot 6A includes two sets of robot main body <NUM> and moving path <NUM>, each of which is in charge of a lower stage and an upper stage, and elevator <NUM>. Robot main body <NUM> in charge of the upper stage moves to moving path <NUM> in the lower stage using elevator <NUM>, and can move to conveyance vehicle stopping section <NUM> provided only in the lower stage. Two robot main bodies <NUM> are controlled by warehouse control section <NUM> to move while avoiding collisions.

In the second embodiment, the structure and function of each warehouse module, the operation of conveyance robot 6A, and the like are the same as those of the first embodiment. In warehouse system 1A of the second embodiment, since the warehouse modules are arranged in the upper and lower two stages, the storage amount of the instrumentation can be increased by about twice without increasing the installation space as compared with that of the first embodiment. In addition, the warehouse module can be arranged in three or more stages, so that multiple instrumentations are stored with higher space efficiency.

Conveyance vehicle stopping section <NUM>, conveyance vehicle <NUM>, and conveyance path <NUM> may be omitted, and an operator may convey the prepared instrumentation to component mounter <NUM>. In addition, the separation work executed by reel loader <NUM> may be executed by a separate reel unloader. Similarly, the separation work executed by tray loader <NUM> may be executed by a separate tray unloader.

In addition, first component container warehouse <NUM>, second component container warehouse <NUM>, and component supply unit warehouse <NUM> may store raw materials of board, incomplete board products in which some components are not mounted, board products determined to be defective by the board inspection machine and required to be repaired, and the like. In addition, warehouse system (<NUM>, 1A) may store solder used in the solder printing device, and instruments such as a screen and a squeegee, and may be conveyable from conveyance vehicle stopping section <NUM> to the solder printing device. In addition, the first and second embodiments are capable of various applications and modifications.

Claim 1:
A warehouse system (<NUM>, 1A) comprising:
a component container warehouse (<NUM>, <NUM>) configured to store multiple component containers (<NUM>, <NUM>) that accommodate multiple components;
a component supply unit warehouse (<NUM>) configured to store multiple component supply units (<NUM>, <NUM>) used when supplying the components accommodated in the component container (<NUM>, <NUM>) to a component mounter (<NUM>);
a component container loader (<NUM>, <NUM>) configured to load the component container (<NUM>, <NUM>) into the component supply unit (<NUM>, <NUM>);
a conveyance robot (<NUM>) configured to move between the component container warehouse (<NUM>, <NUM>), the component supply unit warehouse (<NUM>), and the component container loader (<NUM>, <NUM>) to convey the component container (<NUM>, <NUM>) and the component supply unit (<NUM>, <NUM>) to the component container loader (<NUM>, <NUM>), and
at least one of a carry-in section (<NUM>) into which at least one of the component container (<NUM>, <NUM>) and the component supply unit (<NUM>, <NUM>) is carried and a carry-out section (<NUM>) from which at least one of the component container (<NUM>, <NUM>) and the component supply unit (<NUM>, <NUM>) is carried out, within a movement range of the conveyance robot (<NUM>)
characterized in that:
at least one of the carry-in section (<NUM>) and the carry-out section (<NUM>) is a conveyance vehicle stopping section (<NUM>) wherein the conveyance vehicle (<NUM>) is configured to stop at the conveyance vehicle stopping section (<NUM>), the conveyance vehicle (<NUM>) loading at least one of the component container (<NUM>, <NUM>) and the component supply unit (<NUM>, <NUM>) and being movable between the warehouse system (<NUM>, 1A) and the component mounter (<NUM>).