Patent Description:
A feeder operation inspection device is used to inspect the operation of a feeder. As illustrated in Patent Literature <NUM>, a feeder is set in a component mounter for use in supplying a component. The feeder is loaded with a carrier tape which accommodates components and conveys this carrier tape to thereby supply the components so as to be picked up. Whether the carrier tape is installed normally in the feeder is confirmed visually by, for example, an operator.

<CIT> is also from FUJI and relates to recognizing whether peeling is correctly performed in a process of peeling a top tape from a bottom tape in a tape feeder.

<CIT> relates to component conveyance in a component mounting machine. It is described that images of holes in the tape are used to determine the position of the tape and correct the conveyance position of the tape based thereon.

<CIT> relates to improving the pickup accuracy in a component mounting machine by ensuring that the feeder tape has stopped by the time the component is picked up. This is achieved with a delay time between the stop command and the pickup operation. Furthermore, two consecutive images are taken at the end of the delay time, and if the tape still moves, the delay time is prolonged.

<CIT> relates to providing a tape feeder set to a component mounting unit capable of automatically switching a component suction height of an suction nozzle in response to the tape type before and after a tape joint part when using a tape-spliced component-feeding tape.

<CIT> relates to a component feeder maintenance device being capable of predicting consumables required for maintenance based on a maintenance history.

<CIT> relates to providing a component packaging system capable of improving productivity by speedily performing switching from production of a preceding board type to production of a next board type.

Here, in the event that the carrier tape fails to be installed normally, there is a possibility that the feeder is caused to operate abnormally or malfunctions. Since there is a possibility that the production efficiency of the component mounter is badly affected when the feeder operates abnormally, such an abnormal operation of the feeder is desirably detected as early as possible. In addition, the abnormal operation of the feeder is sometimes attributed to a failure of a drive system or a control system which is different from the installation failure of the carrier tape. In such a case, it is not easy for the operator to detect an abnormal operation of the feeder.

The present description has been made in view of the situations described above, and an object thereof is to provide an operation inspection device for detecting an abnormal operation of a feeder which is loaded with a carrier tape.

According to the present description, there is provided a feeder operation inspection device for a feeder for conveying a carrier tape, the feeder executing a conveyance process for conveying the carrier tape by a designated conveyance amount, the feeder operation inspection device including a storage device configured to store multiple image data obtained by causing the carrier tape to be imaged by a camera at multiple different timings during execution of the conveyance process, an image processing section configured to deduce a position of a brightness change point group, which is a set of brightness change points in which an amount of change in brightness relative to a periphery in the image data is equal to or larger than a specified value, for each of the multiple image data, a calculating section configured to calculate an actual conveyance amount of the carrier tape which is actually conveyed through the conveyance process based on the position of the brightness change point group of each of the multiple image data, and a determination section configured to determine whether the feeder operates normally in the conveyance process based on the designated conveyance amount and the actual conveyance amount in the conveyance process.

With such a configuration, an abnormal operation of the feeder, which is loaded with the carrier tape, can be detected. In addition, the feeder operation inspection device extracts a brightness change point group and deduces a position of the brightness change point group in the image processing. As a result, for example, even if a feeding hole, which corresponds to the brightness change point group, is deformed or the apparent shape of the feeding hole is changed as a result of a change in the type of the carrier tape or imaging environment, the feeding hole can be recognized as a brightness change point group, whereby an actual conveyance amount of the carrier tape can be calculated.

Hereinafter, referring to drawings, an embodiment embodying a feeder operation inspection device will be described. In the present embodiment, operation inspection device <NUM> for feeder <NUM> will be described as being applied to tape installation device <NUM> as shown in <FIG>. Feeder <NUM> is set in component mounter <NUM> for use for supplying a component (refer to <FIG>).

Tape installation device <NUM> assists in installing or automatically installs carrier tape <NUM> in feeder <NUM>. In the present embodiment, tape installation device <NUM> assists an operator to install carrier tape <NUM> in feeder <NUM>. As shown in <FIG>, tape installation device <NUM> holds feeder <NUM> by feeder holding section <NUM> provided on base <NUM>. Feeder <NUM>, which is held by tape installation device <NUM>, is supplied with electric power and is then allowed to communicate with operation inspection device <NUM>, which will be described later.

Tape installation device <NUM> includes an exclusive camera <NUM>. Camera <NUM> is a digital imaging device having an imaging element such as CMOS. Camera <NUM> captures images which fall within camera's visual field Fc1 (refer to <FIG>) based on a control signal which is connected for communication therewith. Camera <NUM> transmits image data which camera <NUM> obtains through imaging. Camera <NUM> is provided in such a manner that its optical axis follows a vertical direction and is configured to image carrier tape <NUM> from above feeder <NUM> which is held by feeder holding section <NUM>. Specifically speaking, camera <NUM> is configured to image at least part of tape guide <NUM> of feeder <NUM>.

Feeder <NUM> includes main body section <NUM>. Main body section <NUM> is formed into a flat box shape. Main body section <NUM> includes supply section <NUM> for supplying a component to component mounter <NUM>. Supply section <NUM> is formed at a front upper portion of main body section <NUM>. In addition, main body section <NUM> holds reel <NUM>, around which carrier tape <NUM> is wound, detachably (in an exchangeable fashion). Reel <NUM> is supported rotatably with respect to main body section <NUM>.

Here, carrier tape <NUM> is made up of base tape <NUM> and cover tape <NUM> as shown in <FIG>. Base tape <NUM> has multiple feeding holes <NUM> and multiple component accommodating cavities <NUM>, which are both formed at equal intervals in a conveyance direction (a longitudinal direction of the carrier tape). Feeding holes <NUM> and cavities <NUM>, which are described above, can constitute apparent characteristic sections of carrier tape <NUM>. Cover tape <NUM> is bonded to an upper surface of base tape <NUM> so as to close opening portions of cavities <NUM>. Hereinafter, the carrier tape will also be referred to, simply, as a "tape".

As shown in <FIG>, feeder <NUM> includes sprocket <NUM>, which is rotatably supported on main body section <NUM>. Sprocket <NUM> has engagement projections which are disposed thereon at equal intervals in a circumferential direction in such a manner as to be brought into engagement with feeding holes <NUM> of tape <NUM>. Feeder <NUM> has motor <NUM>, which functions as a driving source for rotating sprocket <NUM>. For motor <NUM>, for example, a stepping motor is adopted which is configured to rotate sprocket <NUM> by a predetermined amount in accordance with a pulse power supplied.

Feeder <NUM> has feeder control section <NUM> for controlling the operation of motor <NUM>. Feeder control section <NUM> executes a conveyance processing for conveying tape <NUM> by a designated conveyance amount Ns. In the conveyance processing, feeder control section <NUM> causes motor <NUM> to rotate sprocket <NUM> by supplying electric power to motor <NUM> to thereby convey tape <NUM> to a predetermined position.

When feeder <NUM> is set in an external device such as tape installation device <NUM> or component mounter <NUM>, feeder <NUM> is supplied with electric power from the external device via a connector. As a result, feeder control section <NUM> is allowed to communicate with the external device. Feeder control section <NUM> controls the operation of motor <NUM> and a rotation amount of sprocket <NUM> based on a control command or the like given by the external device. In addition, feeder control section <NUM> transmits a feeder ID inherent to feeder <NUM> to the external device in response to a request from the external device.

Feeder <NUM> includes tape guide <NUM>. Tape guide <NUM> is detachably attached to an upper portion of feeder <NUM> in the vicinity of supply section <NUM>. Tape guide <NUM> restrains tape <NUM> from moving upwards and in a widthwise direction to guide tape <NUM> for engagement with sprocket <NUM>. As shown in <FIG> and <FIG>, tape guide <NUM> includes guide main body <NUM>, peeling device <NUM>, and folding device <NUM>.

Guide main body <NUM> is formed into a U-shape in section as an overall shape and is opened at a bottom thereof. Multiple opening sections <NUM>, <NUM> are formed in an upper wall of guide main body <NUM> within a range positioned above feeding holes <NUM> of tape <NUM> being conveyed. As a result, the operator can see to know whether tape <NUM> is being conveyed underneath tape guide <NUM>. Cutout portion <NUM> is formed in the upper wall of guide main body <NUM> in a range including supply section <NUM>. As a result, tape guide <NUM> enables a component to be picked up from cavity <NUM> of tape <NUM> which is positioned at supply section <NUM>.

Peeling device <NUM> is provided on guide main body <NUM>. Peeling device <NUM> has peeling blade <NUM> that cuts into an adhesive portion between base tape <NUM> and cover tape <NUM>. Peeling blade <NUM> peels off a part of cover tape <NUM> from base tape <NUM> as tape <NUM> is conveyed. Cover tape <NUM> is left adhering to base tape <NUM> along a longitudinal edge portion thereof on a side which lies to face feeding holes <NUM> in base tape <NUM>.

Folding device <NUM> is provided on guide main body <NUM> and is positioned closer to supply section <NUM> than a tip of peeling blade <NUM> of peeling device <NUM>. Folding device <NUM> lifts up a part of cover tape <NUM>, which is peeled off by peeling device <NUM> from base tape <NUM> while being partly left adhering thereto, and folds the part of cover tape <NUM> so lifted up towards feeding holes <NUM>. As a result, a state results in which an opening portion of cavity <NUM> on base tape <NUM> is not closed by cover tape <NUM>. To describe this in details, as shown in <FIG>, folding device <NUM> lifts up and folds cover tape <NUM> (a visible part of cover tape <NUM> is shown as hatched in <FIG>) which is peeled off from base tape <NUM>.

According to the configuration described above, tape guide <NUM> holds tape <NUM> between main body section <NUM> and guide main body <NUM> as tape <NUM> is conveyed towards supply section <NUM>. Further, as tape <NUM> is conveyed, tape guide <NUM> folds tape <NUM> while peeling off cover tape <NUM> from base tape <NUM> and exposes a component accommodated in cavity <NUM> for pickup in supply section <NUM>. A part of tape <NUM> which has passed supply section <NUM> is discharged from a tape discharge section (not shown) formed in a front portion of main body section <NUM> to the outside of feeder <NUM>.

Feeder <NUM>, which is configured as described above, is set in tape installation device <NUM> for exchange of reel <NUM>. At this time, a barcode affixed to reel <NUM> is read by a code reader (not shown) of tape installation device <NUM>, and a component ID that the barcode shows is stored in association with a feeder ID of feeder <NUM>. Further, feeding holes <NUM> of tape <NUM> are brought into engagement with sprocket <NUM> in such a manner that tape <NUM> can be conveyed, whereby tape <NUM> is installed in feeder <NUM>.

Feeder <NUM>, which is loaded with tape <NUM>, is set in component mounter <NUM>. Feeder <NUM> executes a conveyance process for conveying tape <NUM> when component mounter <NUM> executes a mounting process for mounting a component on board <NUM>. In the conveyance process, feeder <NUM> conveys tape <NUM> by a designated conveyance amount Ns in such a manner that multiple cavities <NUM> on tape <NUM> are sequentially positioned in supply section <NUM>. Here, the designated conveyance amount Ns corresponds to an interval defined between adjacent cavities <NUM>. In an operation inspection of feeder <NUM> by operation inspection device <NUM>, which will be described later, the designated conveyance amount Ns is set to an amount shorter than an interval defined between adjacent feeding holes <NUM>.

Feeder <NUM> is loaded with tape <NUM> in advance as a setup for a mounting process by component mounter <NUM>. Then, when an installation process of tape <NUM> in feeder <NUM> is not executed appropriately, this is referred to as an installation failure. A case is assumed as a cause for the installation failure in which engagement projections of sprocket <NUM> are not in engagement with feeding holes <NUM> of tape <NUM>, for example. As described above, an occurrence of the installation failure of tape <NUM> can cause feeder <NUM> to operate abnormally.

In addition, the abnormal operation of feeder <NUM> may be attributed to a failure of a drive system or a control system of feeder <NUM> in addition to the installation failure of tape <NUM>. Specifically speaking, it is assumed that a shortage or excess of a rotation amount of sprocket <NUM> which does not reach or exceeds a permissible range is generated irrespective of the fact that motor <NUM> is fed. This is attributed to the fact that feeder <NUM> is not maintained sufficiently or setting of a calibration value for a feeding amount of motor <NUM> fails when rotating sprocket <NUM>, or the like.

Here, for example, the operator visually verifies whether tape <NUM> is normally installed in feeder <NUM>. However, depending on various causes such as the state of engagement of sprocket <NUM> with feeding holes <NUM> of feeder <NUM>, an abnormal operation of feeder <NUM> fails to be noticed at the time of a setup change. Since an abnormal operation of feeder <NUM> possibly affects the production efficiency at component mounter <NUM>, the abnormal operation of feeder <NUM> is desirably detected as early as possible.

Then, operation inspection device <NUM> inspects the operation of feeder <NUM>, which is now loaded with tape <NUM>. In the present embodiment, operation inspection device <NUM> is incorporated in tape installation device <NUM> to execute an operation inspection on feeder <NUM>, in which reels <NUM> are exchanged and tape <NUM> is installed, as an inspection target object at the time of a setup change. Specifically speaking, operation inspection device <NUM> causes feeder <NUM> to perform a predetermined operation and camera <NUM> to image an operation state of feeder <NUM>, and determines whether feeder <NUM> operates normally through image processing.

Operation inspection device <NUM> is made up mainly of CPU, various types of memories, and a control circuit. Operation inspection device <NUM> can obtain a feeder ID for specifying feeder <NUM> and correction information for use for a conveyance operation of tape <NUM> by communication with feeder <NUM>. In addition, operation inspection device <NUM> can obtain a component ID associated with a feeder ID which is managed by a host computer connected therewith for communication.

As shown in <FIG>, operation inspection device <NUM> includes storage device <NUM>. Storage device <NUM> is made up of an optical drive device such as a hard disk device or a flash memory, and the like. Storage device <NUM> stores multiple image data <NUM> captured through imaging by camera <NUM>. Here, in the present embodiment, camera visual field Fc1 of camera <NUM> is set in the vicinity of opening section <NUM> of tape guide <NUM>, as shown in <FIG>. Thus, image data <NUM> obtained through imaging by camera <NUM> includes opening section <NUM> and feeding holes <NUM> of tape <NUM>, as shown in <FIG> and <FIG>.

In addition to those stored as described above, storage device <NUM> can store times when camera <NUM> performs imaging and driving states of feeder <NUM> when an imaging process is performed by camera <NUM> in association with multiple individual image data <NUM>. The driving states of feeder <NUM> include an initial state when the conveyance process of tape <NUM> is initiated, an intermediate state when sprocket <NUM> rotates by a predetermined amount, a termination state when the conveyance process is terminated, and the like. When feeder <NUM> is loaded properly with tape <NUM> and no failure is found in the drive system or the control system, tape <NUM> is conveyed by the designated conveyance amount Ns. The designated conveyance amount Ns may include an allowable error that is set in advance.

Operation inspection device <NUM> includes image processing section <NUM>, as shown in <FIG>. As shown in <FIG> and <FIG>, image processing section <NUM> deduces brightness change point group <NUM> for each of multiple image data <NUM>. The "brightness change point group" is a set of brightness change points <NUM> at which an amount of change in brightness relative to a periphery is equal to or larger than a specified value in image data <NUM>. Each of multiple brightness change points <NUM> corresponds to, for example, a boundary between adjacent areas which differ from each other in lightness or hue (that is, brightness) over a predetermined threshold value in image data <NUM>, for example. Brightness change point <NUM> may take a pixel of an imaging element as a minimum unit (a single point) or may take a certain number of pixels or a range corresponding thereto as a minimum unit.

Brightness change point group <NUM> is a set of brightness change points <NUM> in which those brightness change points <NUM> continue, and as shown in <FIG>, brightness change point group <NUM> can form a closed figure of, for example, a circular shape. In addition, depending on the relationship among camera <NUM>, a light source, whose illustration is omitted, and tape <NUM>, brightness change point group <NUM> in image data <NUM> can form an open figure of, for example, an arc-like shape as shown in <FIG>.

In the present embodiment,brightness change point group <NUM> may be an occupied area of a predetermined surface area in image data <NUM> or may be an occupied area made up of a predetermined number of pixels in image data <NUM>. Which occupied area brightness change point group <NUM> adopts can be appropriately switched therebetween depending on the shape, color, and material of tape <NUM>, and a part of tape <NUM> that falls within camera visual field Fc1.

In the present embodiment, brightness change point group <NUM> corresponds to at least a part of a characteristic section of tape <NUM>. Specifically, as shown in <FIG>, <FIG>, brightness change point group <NUM> corresponds to at least a part of a circumferential edge of feeding hole <NUM> which constitutes an apparent characteristic section of tape <NUM>. When image processing section <NUM> extracts one or more brightness change point groups <NUM> in image data <NUM>, image processing section <NUM> deduces position Ps of brightness change point group <NUM> in the image data. That is, image processing section <NUM> deduces a center position or a centroid position of brightness change point group <NUM> as position Ps of that brightness change point group <NUM> using, for example, a defined position of image data <NUM> as an origin.

There may be a case in which three or more image data <NUM> which are obtained by causing tape <NUM> to be imaged at multiple different timings during execution of one conveyance process are stored in storage device <NUM>. In such a case, image processing section <NUM> extracts brightness change point group <NUM> for each of those three or more image data <NUM>. Further, image processing section <NUM> deduces position Ps of brightness change point group <NUM> for each of those three or more image data <NUM>.

Image processing section <NUM> does not calculate a degree of matching of shape or surface area for multiple brightness change point groups <NUM> which are extracted individually for multiple image data <NUM>, or even when image processing section <NUM> does such a calculation, image processing section <NUM> may restrict the use of the degree of matching of shape or surface area so calculated only to reference for recognition of movement of brightness change point group <NUM>. This is because a possibility that the apparent shape of the characteristic section of tape <NUM> changes as tape <NUM> moves relative to camera <NUM> or the light source should be taken into consideration.

Operation inspection device <NUM> includes calculating section <NUM> as shown in <FIG>. Calculating section <NUM> calculates actual conveyance amount Nr of tape <NUM> which is actually conveyed as a result of the conveyance process based on positions Ps of brightness change point groups <NUM> which are deduced individually for multiple image data <NUM> by image processing section <NUM> (refer to <FIG>). Actual conveyance amount Nr mentioned above corresponds to a moving distance in a conveyance direction of tape <NUM> when tape <NUM> is conveyed as a result of a conveyance process in which feeder <NUM> conveys tape <NUM> in the conveyance direction by expected designated conveyance amount Ns when the conveyance process is executed.

In addition, as shown in <FIG>, calculating section <NUM> calculates partial actual conveyance amounts nr1, nr2 of tape <NUM> at imaging intervals corresponding to three or more image data 60A to 60C, the calculation being made based on position Ps of brightness change point group <NUM> of each of three or more image data <NUM>, for example. Here, these three image data 60A to 60C are those which are obtained by imaging tape <NUM> at timings corresponding respectively to a starting timing when the conveyance process starts, an intermediate timing when tape <NUM> is conveyed on trial by a half of designated conveyance amount Ns, and an ending timing when the conveyance process ends.

As shown in <FIG>, operation inspection device <NUM> includes determination section <NUM>. Determination section <NUM> determines whether feeder <NUM> operates normally in the conveyance process based on designated conveyance amount Ns and actual conveyance amount Nr in the conveyance process. Specifically speaking, determination section <NUM> determines whether actual conveyance amount Nr of tape <NUM> falls within an allowable range which is something like a positioning error with respect to the designated conveyance amount Ns when feeder <NUM> conveys tape <NUM> on trial by designated conveyance amount Ns in the conveyance process.

If a difference between designated conveyance amount Ns and actual conveyance amount Nr is not within the allowable range, determination section <NUM> determines that feeder <NUM> is not operating normally. Even if actual conveyance amount Nr coincides with designated conveyance amount Ns (the difference is within the allowable range), there is an unapparent possibility that feeder <NUM> operates abnormally in reality; for example, partial movement distances of tape <NUM> are not constant over the whole of the execution period of the conveyance process or tape <NUM> moves in an opposite direction in reality.

Then, determination section <NUM> may determine whether feeder <NUM> operates normally based on partial designated conveyance amounts ns1, ns <NUM> of tape <NUM> by which tape <NUM> is conveyed at each of intervals of imaging carried out multiple times during execution of the conveyance process and partial actual conveyance amounts nr1, nr2 which are calculated by calculating section <NUM>. As a result, determination section <NUM> can determine whether tape <NUM> is conveyed normally by partial designated conveyance amount ns1 in the conveyance direction, for example, at the intermediate timing in the conveyance process.

In the present embodiment, in the case that the difference between designated conveyance amount Ns and actual conveyance amount Nr in the conveyance process is out of the allowable range, determination section <NUM> determines that feeder <NUM> operates abnormally due to at least one of an engagement failure between sprocket <NUM> and feeding holes <NUM> and a rotational operation failure of sprocket <NUM>. Additionally, determination section <NUM> may determine whether feeder <NUM> operates normally or identify a cause for an abnormal operation of feeder <NUM> based on the result of comparison of partial designated conveyance amounts ns1, ns2 with partial actual conveyance amounts nr1, nr2, respectively.

According to the configuration described above, an abnormal operation of feeder <NUM>, which is now loaded with tape <NUM>, can be detected. In addition, operation inspection device <NUM> of the present embodiment does not adopt a method of detecting, for example, the circular shape of feeding hole <NUM> of tape <NUM> but otherwise extracts brightness change point group <NUM> and deduces position Ps thereof in an image processing. As a result, even if, for example, the shape of feeding hole <NUM> is deformed, or the apparent shape thereof is changed due to a change in type of tape <NUM> or imaging environment, those deformation and change in apparent shape can be captured as brightness change point group <NUM>, thereby making it possible to calculate actual conveyance amount Nr of tape <NUM>.

Here, a calibration device is known which is used for setting a calibration value for use in a conveyance process by feeder <NUM>. As the calibration device described above, there is, for example, a calibration device for feeder <NUM> loaded with a metallic master tape formed highly accurately in place of tape <NUM> as a target object in which a conveyance amount of the master tape is imaged by an exclusive camera to measure an actual conveyance amount. In the calibration device configured as described above, however, since the calibration device is provided to calculate a calibration value, a high image processing precision is required thereon, which increases the processing load. In addition, a constituent device needs to be managed strictly in terms of imaging environment or the like.

In contrast with this, with operation inspection device <NUM> described in the present embodiment, whether tape <NUM> is actually conveyed can be determined by the device configuration which is simpler than that of the calibration device mentioned above. Further, in the image processing, the change in type of tape <NUM> or imaging environment can be dealt with by deducing position Ps of brightness change point group <NUM>. Furthermore, the processing load such as image processing can be mitigated.

An operation inspection process of feeder <NUM> carried out by operation inspection device <NUM>, which is configured as described above, will be described by reference to <FIG> and <FIG>. Operation inspection device <NUM> starts an operation inspection process after, for example, reels <NUM> are exchanged and tape <NUM> is installed in feeder <NUM> which is set in tape installation device <NUM>. Operation inspection device <NUM> may obtain a type (shape, color, material, or the like) of tape <NUM> based on a component ID of a component installed in feeder <NUM> and set a condition for imaging by camera <NUM>.

Firstly, operation inspection device <NUM> sets designated conveyance amount Ns of tape <NUM> by feeder <NUM> and the number of times of imaging in a conveyance process (S11). Here, designated conveyance amount Ns is set to an amount corresponding to a shorter interval than an interval defined between adjacent feeding holes <NUM> or an interval resulting from adding an integer multiple of the interval between these feeding holes to the shorter interval so that the positions of feeding holes <NUM> contained in image data <NUM> do not coincide at the starting timing, the intermediate timing, and the ending timing of the conveyance process. The number of times of imaging is a minimum of twice and three times in this case.

That is, operation inspection device <NUM> causes camera <NUM> to execute an imaging process three times in total which are timings corresponding to the starting timing of the conveyance process, the intermediate timing when tape <NUM> is conveyed on trial by a half of designated conveyance amount Ns (partial designated conveyance amount ns1), and the ending timing of the conveyance process. The intermediate timing of the conveyance process may be the timing when tape <NUM> is conveyed by a half of designated conveyance amount Ns as described above (ns1=ns2) or a timing when tape <NUM> is conveyed as far as a position deviating from the position where tape <NUM> is conveyed by a half of designated conveyance amount Ns as described above (ns <NUM> ≠ ns <NUM>).

As described above, operation inspection device <NUM> causes camera <NUM> to execute the imaging process at the starting timing of the conveyance process (S12). Subsequently, operation inspection device <NUM> determines whether tape <NUM> is conveyed on trial by designated conveyance amount Ns by feeder <NUM> (S13). Since a conveyance amount by which tape <NUM> is conveyed on trial is <NUM> at this starting timing (S13:No), operation inspection device <NUM> conveys tape <NUM> by partial designated conveyance amount ns1 (S14).

Operation inspection device <NUM> causes camera <NUM> to execute the imaging process again on tape <NUM>, as an imaging target, which has been conveyed on trial by a half of designated conveyance amount Ns in S14 (S12). In this way, operation inspection device <NUM> repeats the imaging process by camera <NUM> (S12) and the conveyance process of tape <NUM> (S14) by a specified number of times. As a result, storage device <NUM> stores image data 60A-60C which are captured at the starting timing, the intermediate timing, and the ending timing of the conveyance process.

Subsequently, image processing section <NUM> image processes multiple image data 60A to 60C which are obtained through the image processing (S12) executed multiple times (S21). Specifically speaking, image processing section <NUM> deduces position Ps of brightness change point group <NUM> for each of multiple image data 60A to 60C. Here, image processing section <NUM> knows that an area which can be brightness change point group <NUM> in image data 60A is an occupied area having a predetermined surface area which corresponds to feeding hole <NUM> of tape <NUM> and knows roughly a position where feeding hole <NUM> is located in image data 60A.

Image processing section <NUM> executes an image processing, for example, the type of tape <NUM>, extracts brightness change point group <NUM> corresponding to feeding hole <NUM> which constitutes an apparent characteristic section of tape <NUM>, and deduces position Ps of that brightness change point group <NUM>. In addition, in image processings from a second time on, image processing section <NUM> may be made to extract brightness change point group <NUM> and deduce position Ps from the respective corresponding areas based on conveyance information on how much feeding hole <NUM> is conveyed in an expected conveyance direction so as to increase the image processing efficiency.

Thereafter, calculating section <NUM> executes a calculation processing of actual conveyance amount Nr of tape <NUM> which is actually conveyed through the conveyance process (S22). Specifically speaking, calculating section <NUM> calculates actual conveyance amount Nr of tape <NUM> based on position Ps of brightness change point group <NUM> deduced for each of multiple image data 60A and 60C through the image processing (S21). Further, calculating section <NUM> calculates individually actual conveyance amounts nr1, nr2 of tape <NUM> based on brightness change point group <NUM> of image data 60B.

Subsequently, determination section <NUM> executes a determination processing for determining whether feeder <NUM> operates normally (S23). Specifically speaking, in the case that the difference between designated conveyance amount Ns and actual conveyance amount Nr is out of the allowable range, determination section <NUM> determines that feeder <NUM> operates abnormally. Further, determination section <NUM> determines from multiple points of view whether feeder <NUM> operates normally based on partial designated conveyance amounts ns1, ns2 and partial actual conveyance amounts nr1, nr2 which are calculated by calculating section <NUM>. If nothing abnormal is determined in both the determinations, determination section <NUM> determines that feeder <NUM> operates normally.

Finally, operation inspection device <NUM> notifies the operator or the like of the result of the inspection process (S24). Specifically speaking, operation inspection device <NUM> may notify the operator or the like of a degree at which designated conveyance amount Ns coincides with actual conveyance amount Nr together with the results of the determination on whether feeder <NUM> operates normally. In addition, in the case that feeder <NUM> operates abnormally, operation inspection device <NUM> may also notify additionally of a cause for the abnormal operation such as an installation failure of tape <NUM>, a failure occurring possibly in the drive system or the control system, or the like.

In the embodiment, operation inspection device <NUM> for feeder <NUM> is described as being applied to tape installation device <NUM>. In contrast with this, operation inspection device <NUM> may be configured so as to be applied to component mounter <NUM> for mounting a component on board <NUM>.

Component mounter <NUM> includes, as shown in <FIG>, board conveyance device <NUM>, component supply device <NUM>, component transfer device <NUM>, part camera <NUM>, board camera <NUM>, and control device <NUM>. Board conveyance device <NUM> conveys sequentially board <NUM> in a conveyance direction and positions board <NUM> in a predetermined position inside component mounter <NUM>. Component supply device <NUM> supplies a component that is to be mounted on substrate <NUM>. In component supply device <NUM>, feeders <NUM> are individually set in multiple slots <NUM>.

Component transfer device <NUM> transfers the component supplied by component supply device <NUM> to a predetermined mounting position on board <NUM>. Component transfer device <NUM> includes moving table <NUM> and mounting head <NUM>. Moving table <NUM> is moved in a horizontal direction (an X-direction and a Y-direction) by a linear motion mechanism. Mounting head <NUM> is fixed to moving table <NUM> in an exchangeable fashion by a clamp member, not shown.

Mounting head <NUM> supports one or more holding members in such a manner as to allow them not only to be rotated but also to be lifted up and lowered. As a result of being configured as described above, mounting head <NUM> picks up a component supplied by feeder <NUM> and mounts the component so picked up on board <NUM>. A suction nozzle configured to pick up a component using negative pressure air or a chuck configured to hold a component can be adopted as the holding member mentioned above.

Part camera <NUM> and board camera <NUM> are a digital imaging device having an imaging element such as CMOS or the like. Part camera <NUM> and board camera <NUM> execute imaging based on a control signal and transmit image data captured through the imaging. Part camera <NUM> is configured so as to image a component held by the holding member of mounting head <NUM> from below. Board camera <NUM> is provided on moving table <NUM> in such a manner as to move in a horizontal direction together with mounting head <NUM>. Board camera <NUM> is configured so as to image board <NUM> from above.

Control device <NUM> is made up mainly of CPU, various types of memories, and a control circuit. Control device <NUM> controls a mounting process for mounting a component on board <NUM>. Various data including a control program used for controlling the mounting process and the like are stored in control device <NUM>. The mounting process includes a process for repeating multiple times a pick-and-place cycle (hereinafter, referred to as a "PP cycle") in which a component supplied by component supply device <NUM> is picked up by mounting head <NUM> and the component so picked up is mounted in a predetermined mounting position on board <NUM>.

In the mounting process, control device <NUM> controls the operation of component transfer device <NUM> based on information outputted from various types of sensors, the result of an image processing, the control program, and the like. As a result, the positions and angles of the multiple holding members supported by mounting head <NUM> are controlled. In the PP cycle, control device <NUM> causes part camera <NUM> to image a component held by the holding member and recognizes a holding state of the component using image data obtained through the imaging.

Further, control device <NUM> causes board camera <NUM> to image board <NUM> which is conveyed into component mounter <NUM> by board conveyance device <NUM> and recognizes a positioning state of board <NUM> using image data captured through the imaging. Then, operation inspection device <NUM> is incorporated in, for example, control device <NUM> of component mounter <NUM> and executes an operation inspection on feeder <NUM> as an inspection target at an appropriate timing. For example, a timing when feeder <NUM> is set in slot <NUM>, a timing when component mounter <NUM> is charged with a power supply, a timing when mounting head <NUM> fails to pick up a component, and the like are considered as the timing when the operation inspection is carried out.

In the configuration described above, multiple image data <NUM>, which are used for the operation inspection process, are obtained through imaging by board camera <NUM> which is moved so as to image tape <NUM> installed in feeder <NUM> for supplying components. That is, board camera <NUM> provided on moving table <NUM> has a movable range which enables board camera <NUM> to capture feeder <NUM> within a camera visual field and is shared for an imaging process of tape <NUM> during execution of the conveyance process by feeder <NUM>.

With such a configuration, component mounter <NUM> executes an operation inspection process for inspecting the operation of feeder <NUM> at a timing when a pickup error of a component by mounting head <NUM> is detected or the like, for example, in the midst of execution of the mounting process. Specifically speaking, in the case that an abnormal operation of feeder <NUM> is considered as a cause for generating the pickup error described above, operation inspection device <NUM> causes board camera <NUM> to be moved as far as a position lying above feeder <NUM> in question. Then, operation inspection device <NUM> causes feeder <NUM> to execute a conveyance process of tape <NUM> and obtains multiple image data <NUM> through an imaging process which is repeated multiple times by board camera <NUM>.

As with the embodiment, operation inspection device <NUM> determines whether feeder <NUM> operates normally by use of multiple image data <NUM> so obtained. Control device <NUM> obtains an inspection result from operation inspection device <NUM>, and in the case that an abnormal operation of feeder <NUM> is detected, control device <NUM> can notify, for example, the operator to that effect or can switch the supply of a component from one by malfunctioning feeder <NUM> to another by separate compatible feeder <NUM> to thereby resume the mounting process.

In addition, in the case that no abnormal operation is detected in feeder <NUM>, control device <NUM> may notify, for example, the operator of a possibility that a cause for the pickup error resides in mounting head <NUM> or the holding member, or of a need for maintenance of these pieces of equipment. With such a configuration, an abnormal operation of feeder <NUM> or the like can be detected at an early timing, thereby making it possible to suppress a decrease in the production efficiency at component mounter <NUM>.

In the embodiment, camera <NUM> is set to camera visual field Fc1 so that a part of tape <NUM> can be imaged through, for example, opening portion <NUM> in tape guide <NUM>, as shown in <FIG>. In contrast with this, in camera <NUM> or board camera <NUM>, its camera visual field may be set in a position other than camera visual field Fc1 described above as long as camera <NUM> or board camera <NUM> can image tape <NUM> installed in feeder <NUM>.

Specifically speaking, in camera <NUM> and board camera <NUM>, camera visual field Fc2 may be set which enables tape <NUM> to be imaged through supply section <NUM> of feeder <NUM> as shown, for example, in <FIG> when imaging tape <NUM> during execution of the conveyance process. Cavity <NUM>, which constitutes an apparent characteristic section of tape <NUM>, is contained in image data <NUM> which are obtained through the imaging process configured as described above.

Then, in the image processing, image processing section <NUM> extracts brightness change point group <NUM>, which corresponds to at least a part of a circumference of cavity <NUM>, for each of multiple image data <NUM>. Further, image processing section <NUM> deduces position Ps of that brightness change point group <NUM> so extracted for each of multiple image data <NUM>. With such a configuration, the same advantage as that of the embodiment can be provided.

In addition, camera <NUM> and board camera <NUM> may image a portion of tape <NUM> other than feeding hole <NUM> and cavity <NUM> as a characteristic section of tape <NUM> in the imaging process. For example, in the case that a mark is affixed to tape <NUM> or a flaw happens to be caused on an upper surface of tape <NUM>, these may be imaged as a characteristic section of tape <NUM>. In addition, image processing section <NUM> may be configured to extract these characteristic sections and feeding hole <NUM> or cavity <NUM> as brightness change point groups <NUM> which correspond to each other in a combined fashion and to deduce positions Ps of those brightness change point groups <NUM>.

In the embodiment and the modified aspect, operation inspection device <NUM> is described as being applied to tape installation device <NUM> or component mounter <NUM>. In contrast with these examples, operation inspection device <NUM> may be an external device which is different from tape installation device <NUM> or component mounter <NUM>. In this case, operation inspection device <NUM> may be an exclusive device which mainly has a function of executing an operation inspection processing or may be configured to be applied to a pallet for use for an external setup of feeder <NUM>. With either of the configurations, the same advantage as that of the embodiment can be provided.

Claim 1:
A feeder operation inspection device (<NUM>) for a feeder (<NUM>) for conveying a carrier tape (<NUM>), the feeder (<NUM>) executing a conveyance process for conveying the carrier tape by a designated conveyance amount,
characterized by the feeder operation inspection device (<NUM>) comprising:
a storage device (<NUM>) configured to store multiple image data (<NUM>) obtained by causing the carrier tape to be imaged by a camera (<NUM>) at multiple different timings during execution of the conveyance process,
an image processing section (<NUM>) configured to deduce a position of a brightness change point group (<NUM>), which is a set of brightness change points (<NUM>) where an amount of change in brightness relative to a periphery in the image data is equal to or larger than a specified value, for each of the multiple image data;
a calculating section (<NUM>) configured to calculate an actual conveyance amount of the carrier tape which is actually conveyed through the conveyance process based on the position of the brightness change point group (<NUM>) of each of the multiple image data; and
a determination section (<NUM>) configured to determine whether the feeder (<NUM>) operates normally in the conveyance process based on the designated conveyance amount and the actual conveyance amount in the conveyance process.