Patent Description:
In the related art, in a component mounting line, a malfunction detecting system for detecting a malfunction of a device during manufacturing of a mounting board is known (refer to Patent Literature <NUM>, for example). The system includes a data collection section, a determining section, and a notification processing section. The data collection section collects operation status data from a component mounting line including multiple component mounting machines. The determining section determines whether the tendency of one or more feature amount data included in the operation status data collected by the data collection section deviates from the tendency of the feature amount data at the time of normal operation. When the determining section determines that the tendency of the feature amount data deviates from the tendency at the time of normal processing, the notification processing section causes a display section to notify that the device corresponding to the feature amount data is malfunctioning. <CIT> relates to image recognition for picking up a side image of a component sucked by a suction nozzle of a component mounting machine with a camera to measure the height (i.e. the thickness) of the component. The measured height of the component is corrected by a tilt angle of the suction nozzle and an inclination of the component. <CIT> relates to a component mounting system and a component mounting method for transferring a component supplied from a component supply unit to a predetermined pickup position by a component transfer unit and then picking up the component by a component mounting unit and mounting the component on a substrate. <CIT> relates to recognizing an electronic component mounted on a substrate for inspection and measuring the position of the electronic component.

Incidentally, as one of the methods for inspecting the malfunction of a device, it is conceivable to inspect whether the mounting accuracy is good or bad by measuring the deviation of a mounting location after a mounting operation for picking up a component and mounting the component on a board is performed. In this case, even if the inspection result indicates that there is a malfunction, if it is not known where the malfunction location is, an operator will require a long work time to investigate the malfunction location, and the work load will be excessive.

It is a main object of the present disclosure to provide a malfunction determining device capable of determining the malfunction location of a component mounting machine including a head and a moving device for mounting a component on a board when it is determined that the component mounting machine is malfunctioning.

The present disclosure employs the following means in order to achieve the above-mentioned main object.

The scope of the invention is defined by the features of the independent claims.

In the first inspection, data is measured in association with an operation of the parts constituting the head and an operation of the parts constituting the moving device. On the other hand, in the second inspection, data is measured in association with the operation of the parts constituting the head. Therefore, according to the malfunction and a malfunction location in the head and the moving device based on a combination of a result of the first inspection and a result of the second inspection.

Next, an embodiment of the present disclosure will be described with reference to drawings. <FIG> is a schematic configuration diagram of a component mounting system. <FIG> is a top view of a component mounting machine. <FIG> is a schematic configuration diagram of a mounting head. <FIG> is a schematic configuration diagram of a ZS-axis driving device. <FIG> is a block diagram illustrating an electrical connection relationship between a control device and a management device of the component mounting machine. In <FIG> and <FIG>, a left-right direction is set as an X-axis direction, a front-rear direction is set as a Y-axis direction, and an up-down direction is set as a Z-axis direction.

As illustrated in <FIG>, component mounting system <NUM> includes printer <NUM>, print inspection device <NUM>, multiple component mounting machines <NUM>, mounting inspection device (not illustrated), and management device <NUM> (refer to <FIG>) that manages the entire system. Printer <NUM> is a device for printing solder on board S. Print inspection device <NUM> is a device for inspecting a state of solder printed by printer <NUM>. Component mounting machine <NUM> is a device for mounting a component on board S. The mounting inspection device is a device for inspecting a mounting state of a component mounted on component mounting machine <NUM>. Printer <NUM>, print inspection device <NUM>, multiple component mounting machines <NUM>, and the mounting inspection device are arranged and installed in this order in the conveyance direction of board S to constitute a production line.

As illustrated in <FIG>, component mounting machine <NUM> includes housing <NUM> mounted on base <NUM>, feeder <NUM>, board conveyance device <NUM>, head moving device <NUM>, mounting head <NUM>, and control device <NUM> (refer to <FIG>). In addition to these, component mounting machine <NUM> also includes part camera <NUM>, mark camera <NUM>, nozzle station <NUM>, and the like. Part camera <NUM> is provided between feeder <NUM> and board conveyance device <NUM> for imaging component P picked up by suction nozzle <NUM> of mounting head <NUM> from the bottom side. Mark camera <NUM> is provided on mounting head <NUM> for imaging and reading a reference mark affixed to board S from the top side. In addition, nozzle station <NUM> accommodates multiple types of suction nozzles for replacement, as well as jig nozzle IN used for calibration measurement of mounting head <NUM> described later.

As illustrated in <FIG>, feeders <NUM> are arranged on a front face portion of component mounting machine <NUM> along an X-axis direction (left-right direction). Although not illustrated, feeder <NUM> includes a tape reel around which a tape is wound, and a tape feeding mechanism that pulls the tape from the tape reel and feeds the tape to a component supply position. Cavities are formed in the tape at predetermined intervals along the longitudinal direction of the tape. Component P is accommodated in the cavity. Feeder <NUM> feeds the tape by a predetermined amount by a feeder feeding mechanism (motor), thereby sequentially supplying components P accommodated in the tape to the component supply position. Component P housed in the tape is protected by a film covering the surface of the tape, and when the film is peeled off before the component supply position, component P is exposed at the component supply position, and component P can be picked up by suction nozzle <NUM>.

Board conveyance device <NUM> includes a pair of conveyor belts that are provided at intervals in the front-rear direction of <FIG> and spanned in the X-axis direction (the left-right direction). Board S is conveyed from the left to the right in the drawing by the conveyor belt of board conveyance device <NUM>.

Head moving device <NUM> moves mounting head <NUM> in the XY-axis direction (front-rear left-right direction), and includes X-axis slider <NUM> and Y-axis slider <NUM>, as illustrated in <FIG>. X-axis slider <NUM> is supported by a pair of upper and lower X-axis guide rails <NUM> provided on the bottom face of Y-axis slider <NUM> so as to extend in the X-axis direction (the left-right direction), and is movable in the X-axis direction by the driving of X-axis motor <NUM> (refer to <FIG>). Y-axis slider <NUM> is supported by a pair of left and right Y-axis guide rails <NUM> provided on the upper stage portion of housing <NUM> so as to extend in the Y-axis direction (the front-rear direction), and is movable in the Y-axis direction by the driving of Y-axis motor <NUM> (refer to <FIG>). The position of X-axis slider <NUM> in the X-axis direction is detected by X-axis position sensor <NUM> (refer to <FIG>), and the position of Y-axis slider <NUM> in the Y-axis direction is detected by Y-axis position sensor <NUM> (refer to <FIG>). Mounting head <NUM> is attached to X-axis slider <NUM>. Therefore, mounting head <NUM> is movable along an XY plane (horizontal plane) by driving and controlling head moving device <NUM> (X-axis motor <NUM> and Y-axis motor <NUM>).

Mounting head <NUM> is configured as a rotary head, and as illustrated in <FIG>, includes head main body <NUM>, rotation body <NUM>, multiple nozzle holders <NUM> (eight in the embodiment), multiple suction nozzles <NUM> (eight in the embodiment), R-axis driving device <NUM>, Q-axis driving device <NUM>, two Z-axis driving devices <NUM>, and ZS-axis driving device <NUM> (refer to <FIG>).

Rotation body <NUM> is rotatably supported by head main body <NUM> via rotation axis <NUM> coaxially coupled. Mark forming member <NUM> on which a reference mark (head reference mark HM) detected by a camera (part camera <NUM>) is formed is provided at an axial center of the lower surface of rotation body <NUM>.

Nozzle holders <NUM> are arranged at predetermined angular intervals (in the embodiment, at intervals of <NUM> degrees) on the same circumference about the axial center of rotation body <NUM>, and are supported so as to be freely lifted and lowered by rotation body <NUM>. Suction nozzle <NUM> is mounted on the distal end portion of nozzle holder <NUM>. Suction nozzle <NUM> includes a suction port at the distal end, and picks up component P by a negative pressure supplied from a negative pressure source (not illustrated) to the suction port via pressure adjustment valve <NUM> (refer to <FIG>). Suction nozzle <NUM> is detachable from nozzle holder <NUM>, and is replaced with a nozzle suitable for picking up component P according to the type of component P to be picked up.

R-axis driving device <NUM> rotates rotation body <NUM> to pivot (revolve) multiple nozzle holders <NUM> (multiple suction nozzles <NUM>) circumferentially around the center axis of rotation body <NUM>. As illustrated in <FIG>, R-axis driving device <NUM> includes R-axis motor <NUM>, driving gear <NUM> provided on the rotation axis of R-axis motor <NUM>, and R-axis gear <NUM> coaxially provided on the outer circumferential surface of rotation body <NUM> and having external teeth meshing with driving gear <NUM>. R-axis driving device <NUM> rotates rotation body <NUM> by rotationally driving R-axis gear <NUM> by R-axis motor <NUM>. Each nozzle holder <NUM> pivots (revolves) in the circumferential direction integrally with suction nozzle <NUM> by the rotation of the rotation body <NUM>. In addition, R-axis driving device <NUM> includes R-axis position sensor <NUM> (refer to <FIG>) for detecting the rotational position of R-axis gear <NUM>, that is, the pivoting position of each nozzle holder <NUM> (suction nozzle <NUM>).

Q-axis driving device <NUM> rotates (spins) each nozzle holder <NUM> (each suction nozzle <NUM>) about the center axis thereof. As illustrated in <FIG>, Q-axis driving device <NUM> includes Q-axis motor <NUM>, driving gear <NUM> provided on the rotation axis of Q-axis motor <NUM>, pinion gear <NUM> provided coaxially with each nozzle holder <NUM>, and Q-axis gear <NUM> meshing with driving gear <NUM> and meshing with each pinion gear <NUM>. Pinion gear <NUM> is provided on the upper portion of each nozzle holder <NUM> and slidably meshes with Q-axis gear <NUM> in the Z-axis direction (up-down direction). Q-axis gear <NUM> is configured as a cylindrical member inserted so as to be coaxial with and relatively rotatable with rotation axis <NUM>. Q-axis driving device <NUM> rotationally drives Q-axis gear <NUM> by Q-axis motor <NUM>, thereby collectively rotating each pinion gear <NUM> meshing with Q-axis gear <NUM> in the same direction. Each nozzle holder <NUM> rotates (spins) about the center axis thereof integrally with suction nozzle <NUM> by the rotation of pinion gear <NUM>. In addition, Q-axis driving device <NUM> includes Q-axis position sensor <NUM> (refer to <FIG>) for detecting the rotational position of Q-axis gear <NUM>, that is, the rotational position of each nozzle holder <NUM> (suction nozzle <NUM>).

Each Z-axis driving device <NUM> is configured to individually lift and lower nozzle holder <NUM> at two locations on the pivot (revolving) trajectory of nozzle holder <NUM>. Suction nozzle <NUM> attached to nozzle holder <NUM> moves up and down together with nozzle holder <NUM>. Any of Z-axis driving devices <NUM> includes Z-axis slider <NUM> and Z-axis motor <NUM> for lifting and lowering Z-axis slider <NUM>, as illustrated in <FIG>. In addition, each Z-axis driving device <NUM> also includes Z-axis position sensor <NUM> (refer to <FIG>) for detecting the lifting and lowering position of corresponding Z-axis slider <NUM>, that is, the lifting and lowering position of corresponding nozzle holder <NUM> (suction nozzle <NUM>). Each Z-axis driving device <NUM> drives Z-axis motor <NUM> to lift and lower corresponding Z-axis slider <NUM>, thereby contacting nozzle holder <NUM> located below Z-axis slider <NUM> to lift and lower nozzle holder <NUM> integrally with suction nozzle <NUM>. Each Z-axis driving device <NUM> may be configured by using a linear motor, or may be configured by using a rotation motor and a feeding screw mechanism.

ZS-axis driving device <NUM> is a device for lifting and lowering mounting head <NUM> (head main body <NUM>) in the up-down direction (ZS-axis direction). As illustrated in <FIG>, ZS-axis driving device <NUM> includes guide rail <NUM> extending in the ZS-axis direction, and ZS-axis motor <NUM> for lifting and lowering head main body <NUM> along guide rail <NUM>. In addition, ZS-axis driving device <NUM> includes ZS-axis position sensor <NUM> (refer to <FIG>) for detecting the up-down position of head main body <NUM>. ZS-axis driving device <NUM> may be configured by using a linear motor, or may be configured by using a rotation motor and a feeding screw mechanism. In a case where, for example, component P having a low height is picked up and mounted, since component mounting machine <NUM> can shorten the up-down stroke of suction nozzle <NUM> by lowering mounting head <NUM> in advance, the operation time can be shortened. On the other hand, in a case where component P having a high height is picked up and mounted, component mounting machine <NUM> can prevent suction nozzle <NUM> from interfering with component P when performing the suction operation by lifting mounting head <NUM> in advance. As a result, component mounting machine <NUM> can handle multiple types of components P having different heights without replacing mounting head <NUM>.

As illustrated in <FIG>, control device <NUM> is configured as a microprocessor centered on CPU <NUM>, and includes ROM <NUM>, HDD <NUM>, RAM <NUM>, an input/output interface (not illustrated), and the like in addition to CPU <NUM>. Various detection signals from X-axis position sensor <NUM>, Y-axis position sensor <NUM>, R-axis position sensor <NUM>, Q-axis position sensor <NUM>, Z-axis position sensor <NUM>, ZS-axis position sensor <NUM>, and the like are input to control device <NUM> via the input/output interface. In addition, image signals and the like from part camera <NUM> and mark camera <NUM> are also input to control device <NUM> via the input/output interface. On the other hand, control device <NUM> outputs various control signals to feeder <NUM>, board conveyance device <NUM>, X-axis motor <NUM>, Y-axis motor <NUM>, R-axis motor <NUM>, Q-axis motor <NUM>, Z-axis motor <NUM>, ZS-axis motor <NUM>, pressure adjustment valve <NUM>, mark camera <NUM>, part camera <NUM>, and the like via the input/output interface.

As illustrated in <FIG>, management device <NUM> is a general-purpose computer including CPU <NUM>, ROM <NUM>, HDD <NUM> (storage device), RAM <NUM>, and the like. Input signals from input device <NUM> including a mouse and a keyboard are input to management device <NUM>. Management device <NUM> outputs a display signal to display <NUM>.

Next, the operation of component mounting machine <NUM> according to the embodiment configured as described above will be described. First, CPU <NUM> of control device <NUM> controls head moving device <NUM> so that suction nozzle <NUM> moves above the component supply position of feeder <NUM> that supplies component P to be picked up. CPU <NUM> controls corresponding Z-axis driving device <NUM> so that suction nozzle <NUM> moves down, and controls pressure adjustment valve <NUM> so that the negative pressure is supplied to the suction port of suction nozzle <NUM>. As a result, component P is picked up by suction nozzle <NUM>.

When component P is picked up by suction nozzle <NUM>, CPU <NUM> controls head moving device <NUM> so that mounting head <NUM> moves above part camera <NUM>, and images component P picked up by suction nozzle <NUM> by part camera <NUM> from the bottom side. Subsequently, CPU <NUM> processes the captured image, measures the suction deviation amount of component P picked up by suction nozzle <NUM> (each suction deviation amount in the X-axis direction and the Y-axis direction) (suction inspection), and corrects the mounting position of board S based on the measured suction deviation amount. Next, CPU <NUM> controls head moving device <NUM> so that component P picked up by suction nozzle <NUM> is located above the corrected mounting position. Then, CPU <NUM> controls corresponding Z-axis driving device <NUM> so that suction nozzle <NUM> moves down, and controls pressure adjustment valve <NUM> so that the supply of the negative pressure to the suction port of suction nozzle <NUM> is canceled. As a result, component P is mounted on the mounting position of board S.

Next, inspection processing for inspecting component mounting machine <NUM> and malfunction determination processing for determining presence or absence of a malfunction and a malfunction location based on an inspection result will be described. <FIG> is a flowchart illustrating an example of inspection processing executed by CPU <NUM> of control device <NUM>.

In the inspection processing, CPU <NUM> of control device <NUM> first determines whether a command to execute an inspection has been received from management device <NUM> (S100). The command to execute an inspection may be transmitted from management device <NUM> to control device <NUM> of each component mounting machine <NUM>, for example, when a predetermined operation is performed by an operator via input device <NUM>. In addition, the command to execute an inspection may be transmitted from management device <NUM> to control device <NUM> of each component mounting machine <NUM> (timer setting), for example, when the setting time registered in advance by an operation of the operator is reached.

When receiving the execution command, CPU <NUM> next determines whether inspection board IS for performing a mounting accuracy inspection, which is one of the inspections, is set in board conveyance device <NUM> (S110). Inspection board IS is, for example, a rectangular plate-shaped member having an identification mark detectable by a camera on the surface thereof, and is held by carrier <NUM> together with inspection component IP. <FIG> is an appearance perspective view of carrier <NUM>. As illustrated in the drawing, carrier <NUM> includes rectangular carrier main body <NUM> on which inspection board IS is disposed at the center portion of the surface thereof, and elongated component accommodation tray <NUM> attached to the outer circumferential portion of the surface of carrier main body <NUM>. Inspection board IS is accommodated in a rectangular recess formed in the center portion of the surface of carrier main body <NUM>, and is held by carrier main body <NUM> by fastener <NUM>. Multiple inspection components IP are accommodated in multiple component accommodation pockets 205a formed so as to line up in the longitudinal direction on the surface of component accommodation tray <NUM> in a state of being overlapped respectively. The determination in S110 is performed, for example, by performing an operation of transporting inspection board IS (carrier <NUM>) into the machine by board conveyance device <NUM>, imaging the conveyance position with mark camera <NUM>, processing the captured image, and determining whether an identification mark affixed to inspection board IS can be recognized in the captured image.

When determining that inspection board IS is not set in board conveyance device <NUM>, CPU <NUM> transmits a predetermined warning signal to management device <NUM> (S120), and returns to S110. Management device <NUM> that has received a warning signal displays a message on display <NUM> prompting the operator to set inspection board IS. When determining that inspection board IS is set in board conveyance device <NUM>, CPU <NUM> initiates the mounting accuracy inspection (S130).

The mounting accuracy inspection is performed in the following manner. CPU <NUM> controls head moving device <NUM> and mounting head <NUM> so that suction nozzle <NUM> moves above inspection component IP accommodated in component accommodation pocket 205a and inspection component IP is picked up by suction nozzle <NUM>. Subsequently, CPU <NUM> controls head moving device <NUM> and mounting head <NUM> so that inspection component IP that is picked up moves above a target mounting position of inspection board IS and inspection component IP is mounted on the target mounting position. The mounting operation of inspection component IP with respect to inspection board IS is performed for each suction nozzle <NUM> provided in mounting head <NUM>. Next, CPU <NUM> controls head moving device <NUM> and mark camera <NUM> so that mark camera <NUM> moves above inspection board IS and mark camera <NUM> images inspection component IP mounted on inspection board IS. Then, CPU <NUM> measures the mounting deviation amount of inspection component IP (mounting deviation amount ΔXp in the X-axis direction, mounting deviation amount ΔYp in the Y-axis direction, and angle deviation amount Δθp) with respect to the target mounting position of inspection board IS for each suction nozzle <NUM> used in the mounting operation by performing the image processing on the captured image. When the measurement is completed, CPU <NUM> controls head moving device <NUM> and mounting head <NUM> so that suction nozzle <NUM> moves above inspection component IP mounted on inspection board IS and inspection component IP is picked up by suction nozzle <NUM>. Next, CPU <NUM> controls head moving device <NUM> and mounting head <NUM> so that inspection component IP picked up by suction nozzle <NUM> is accommodated (returned) in a vacant pocket among component accommodation pockets 205a. CPU <NUM> controls board conveyance device <NUM> so that carrier <NUM> accommodating inspection board IS and inspection component IP is transported to downstream component mounting machine <NUM>. As a result, carrier <NUM> accommodating inspection board IS and inspection component IP is delivered to next component mounting machine <NUM>, and a similar mounting accuracy inspection is executed in next component mounting machine <NUM>. As described above, by sequentially executing the mounting accuracy inspection from the upstream side to the downstream side by multiple component mounting machines <NUM> constituting the production line, the mounting accuracy inspection of all component mounting machines <NUM> can be efficiently performed.

<FIG> is an explanatory diagram illustrating an example of mounting accuracy data. As illustrated in the drawing, the mounting accuracy data includes mounting deviation amount ΔXp in the X-axis direction, mounting deviation amount ΔYp in the Y-axis direction, and angle deviation amount Δθp as measured values. This mounting accuracy data is generated for each suction nozzle <NUM> used in the mounting operation.

When determining that the mounting accuracy inspection is completed, CPU <NUM> next determines whether jig nozzle IN used for head calibration measurement is accommodated in nozzle station <NUM> (S150). <FIG> is a schematic configuration diagram of a jig nozzle. Jig nozzle IN has substantially the same outer shape as suction nozzle <NUM>. A reference mark (nozzle reference mark NM) detected by a camera (part camera <NUM>) is formed on the end surface of jig nozzle IN. The processing of S150 is performed, for example, by imaging nozzle station <NUM> with mark camera <NUM>, processing the captured image, and determining whether the identification mark affixed to jig nozzle IN can be recognized in the captured image. When determining that jig nozzle IN is not accommodated in nozzle station <NUM>, CPU <NUM> transmits a predetermined warning signal to management device <NUM> (S160), and returns to S150. Management device <NUM> that has received a warning signal displays a message on display <NUM> prompting the operator to accommodate jig nozzle IN. In step S170, when determining that jig nozzle IN is accommodated in nozzle station <NUM>, CPU <NUM> initiates the head calibration measurement.

The head calibration measurement includes ZS-axis inclination measurement for measuring the inclination of a ZS axis, nozzle mounting position measurement for measuring the mounting position of suction nozzle <NUM> for each nozzle holder <NUM> (bending of nozzle holder <NUM>, and the like).

The ZS-axis inclination measurement is performed in the following manner. First, CPU <NUM> controls ZS-axis driving device <NUM> so that mounting head <NUM> moves up to the lifting end in the ZS axis. Subsequently, CPU <NUM> controls head moving device <NUM> and part camera <NUM> so that mark forming member <NUM> of mounting head <NUM> moves above part camera <NUM> and head reference mark HM formed on mark forming member <NUM> is imaged. Next, CPU <NUM> controls ZS-axis driving device <NUM> so that mounting head <NUM> moves down to the lowering end in the ZS axis, and then controls part camera <NUM> so that head reference mark HM is imaged in the same manner. That is, CPU <NUM> images head reference mark HM of mounting head <NUM> at each position of the lifting end and lowering end in the ZS axis. Then, CPU <NUM> recognizes each of head reference marks HM by performing image processing on the obtained two captured images, measures the positional deviation amount between the recognized head reference marks HM in the X-axis direction as inclination amount ΔXzs in the X-axis direction, and measures the positional deviation amount in the Y-axis direction as inclination amount ΔYzs in the Y-axis direction.

The nozzle mounting position is measured in the following manner. First, CPU <NUM> controls head moving device <NUM> and mounting head <NUM> so that mounting head <NUM> moves above nozzle station <NUM> and jig nozzle IN is mounted on each nozzle holder <NUM> of mounting head <NUM>. Subsequently, CPU <NUM> controls head moving device <NUM> and part camera <NUM> so that nozzle reference mark NM formed at the distal end of jig nozzle IN is imaged in a state in which jig nozzle IN moves above part camera <NUM> and jig nozzle IN is located at the lifting end in the Z-axis direction. Next, CPU <NUM> controls Z-axis driving device <NUM> so that jig nozzle IN moves down to the lowering end in the Z-axis, and then controls part camera <NUM> so that nozzle reference mark NM is imaged in the same manner. That is, CPU <NUM> images nozzle reference mark NM of jig nozzle IN at each position of the lifting end and the lowering end in the Z axis. Then, CPU <NUM> recognizes each of nozzle reference marks NM by performing image processing on the two obtained captured images, measures the positional deviation amount between recognized nozzle reference marks NM in the X-axis direction as inclination amount ΔXn in the X-axis direction, and measures the positional deviation amount in the Y-axis direction as inclination amount ΔYn in the Y-axis direction.

<FIG> is an explanatory diagram illustrating an example of calibration data. As illustrated in the drawing, the calibration data includes, as measured values, a ZS axis inclination, a nozzle mounting position for each nozzle, and the like. The ZS-axis inclination includes inclination amount ΔXzs in the X-axis direction and inclination amount ΔYzs in the Y-axis direction. The nozzle mounting position includes inclination amount ΔXn in the X-axis direction and inclination amount ΔYn in the Y-axis direction.

When determining that the head calibration measurement is completed, CPU <NUM> transmits the obtained measured values (mounting accuracy data and calibration data) to management device <NUM> (S190). In step S200, CPU <NUM> determines whether a shutdown has been instructed. If it is determined that there is no instruction of the shutdown, CPU <NUM> ends the malfunction inspection processing as it is, whereas if it is determined that there is a instruction of the shutdown, CPU <NUM> shuts down (S210) and ends the malfunction inspection processing. The shutdown is instructed by the operator inputting in advance to management device <NUM> via input device <NUM>. In a case where the operator has set the inspection processing to be executed after the day's work is completed, by instructing in advance the shutdown after the inspection is completed, the operator can leave without waiting for the inspection to complete.

Next, the malfunction determination processing performed by using the result of the malfunction inspection processing will be described. <FIG> is a flowchart illustrating an example of the malfunction determination processing executed by CPU <NUM> of management device <NUM>.

In the malfunction determination processing, CPU <NUM> of management device <NUM> first waits to receive measured values from component mounting machine <NUM> (S300). When receiving the measured values, CPU <NUM> stores the received measured values in HDD <NUM> (storage device) and analyzes the received measured values (S310). <FIG> is an explanatory diagram illustrating an example of the measured values stored in the storage device. As illustrated in the drawing, HDD <NUM> (storage device) stores the mounting accuracy data and the calibration data as measured values in association with the execution date of the inspection.

The analysis of the mounting accuracy data is performed in the following manner. First, CPU <NUM> calculates average value µ and standard deviation σ of the deviation amount received so far for each deviation amount among mounting deviation amounts ΔXp and ΔYp, and angular deviation amount Δθp. Subsequently, CPU <NUM> determines whether the deviation amount received this time falls within a range determined by a lower limit value (µ - 3σ) obtained by subtracting 3σ from average value µ and an upper limit value (µ + 3σ) obtained by adding 3σ to average value µ, for each deviation amount. The lower limit value and the upper limit value may be a value determined by using 2σ instead of 3σ, or may be a value determined by using σ, or may be a value selected by the operator. Then, when determining that any of the deviation amounts received this time falls within the range determined by the lower limit value and the upper limit value (refer to, for example, <FIG>, CPU <NUM> determines that there is no sign of a malfunction ('no malfunction'). On the other hand, when determining that any of the deviation amounts received this time does not fall within the range determined by the lower limit value and the upper limit value (refer to, for example, <FIG>), CPU <NUM> determines that there is a sign of a malfunction ('malfunction'). As described above, the mounting accuracy inspection is performed by using inspection component IP held by carrier <NUM> together with inspection board IS, instead of component P supplied from feeder <NUM>. Therefore, the analysis result of the mounting accuracy data is not affected by the malfunction of feeder <NUM>, and reflects the influence of the malfunction of head moving device <NUM> or mounting head <NUM>.

The analysis of the calibration data (the ZS-axis inclination and the nozzle mounting position) is performed in the following manner. When analyzing the ZS-axis inclination, CPU <NUM> first calculates average value µ and standard deviation σ of the inclination amount received so far for each inclination amount among inclination amounts ΔXzs and ΔYzs. Subsequently, CPU <NUM> determines whether the inclination amount received this time falls within a range determined by a lower limit value (µ - 3σ) obtained by subtracting 3σ from average value µ and an upper limit value (µ + 3σ) obtained by adding 3σ to average value µ, for each inclination amount. The lower limit value and the upper limit value may be a value determined by using 2σ instead of 3σ, or may be a value determined by using σ, or may be a value selected by the operator. Then, when determining that any of the indication amounts received this time falls within the range determined by the lower limit value and the upper limit value, CPU <NUM> determines that there is no sign of a malfunction ('no malfunction'), and determines that there is an indication of a malfunction ('malfunction') when determining that any of the inclination amounts received this time does not fall within the range determined by the lower limit value and the upper limit value. CUP <NUM> can also be similarly performed when analyzing the nozzle mounting position (inclination amount ΔXn in the X-axis direction and inclination amount ΔYn in the Y-axis direction). As described above, the head calibration measurement is performed by operating the parts constituting mounting head <NUM>. Therefore, only the influence of the malfunction of mounting head <NUM> is reflected in the analysis result of the calibration data.

As described above, in the present embodiment, CPU <NUM> analyzes the measured values by determining whether the measured value received this time falls within a predetermined range of the distribution centered on average value µ of the measured values received so far (in <FIG>, the area surrounded by the dashed line). Then, when determining that the measured value received this time falls within the predetermined range (refer to <FIG>), CPU <NUM> determines that there is no malfunction, and determines that there is a malfunction when determining that the measured value received this time does not fall within the predetermined range (refer to <FIG>).

In step S320, CPU <NUM> determines whether the result of the mounting accuracy inspection is a result of a malfunction as a result of the analysis of the mounting accuracy data. When determining that the result of the mounting accuracy inspection is a result of no malfunction, CPU <NUM> determines that neither head moving device <NUM> nor mounting head <NUM> is malfunctioning (S330).

On the other hand, when determining that the result of the mounting accuracy inspection is a result of a malfunction, CPU <NUM> further determines whether the result of the head calibration measurement is a result of a malfunction (S340). When determining that the result of the head calibration measurement is a result of no malfunction, CPU <NUM> determines that there is a malfunction in head moving device <NUM> (S350). On the other hand, when determining that the result of the head calibration measurement is the result of a malfunction, CPU <NUM> determines that mounting head <NUM> is malfunctioning (S360).

When determining the presence or absence of a malfunction and a malfunction location in this manner, CPU <NUM> displays the determination result on display <NUM> (S370) in order to notify the operator of the determination result, and ends the malfunction determination processing. <FIG> is an explanatory diagram illustrating an example of a notification screen of a malfunction determination result. The drawing is an example of a notification screen when there is a malfunction in mounting head <NUM>.

Here, a correspondence relationship between main elements of the embodiment and main elements of the present disclosure described in the scope of claims will be described. That is, mounting head <NUM> of the embodiment corresponds to the head of the present disclosure, head moving device <NUM> corresponds to a moving device, CPU <NUM> of control device <NUM> that executes the inspection processing corresponds to an inspection section, CPU <NUM> of management device <NUM> that executes the malfunction determination processing corresponds to a determining section, and display <NUM> corresponds to a notification section.

For example, in the above embodiment, in the malfunction determination processing, CPU <NUM> determines the presence or absence of a malfunction by determining whether the measured value received this time falls within the predetermined range of the distribution centered on average value µ of the measured values received so far. However, CPU <NUM> may determine the presence or absence of a malfunction by determining whether the measured value received this time falls within a predetermined range centered on a value determined from the tendency of change in the measured values received so far. For example, when the current measured value is set to X0, CPU <NUM> determines the presence or absence of a malfunction by determining whether the value falls within a range determined by a lower limit value obtained by multiplying tendency Xa of the change in the measured values received so far by coefficient k1 smaller than value <NUM> and an upper limit value obtained by multiplying tendency Xa by coefficient k2 larger than value <NUM>. However, tendency Xa of the change in the measured values received so far is defined by the following equation (<NUM>) when X1 is a measured value received one time before, X2 is a measured value received two times before, Xi is a measured value received i times before, and a1, a2,. , ai are weighting parameters, respectively. Predetermined values may be used as coefficients k1 and k2, or values designated by the operator may be used.

In the above embodiment, CPU <NUM> determines the malfunction of head moving device <NUM> and mounting head <NUM> provided in component mounting machine <NUM>, but may additionally determine the malfunction of feeder <NUM>. The determination of a malfunction of feeder <NUM> is performed in the following manner. CPU <NUM> receives the above-described suction deviation amount (each suction deviation amount in the X-axis direction and the Y-axis direction) measured in the suction inspection executed after the suction operation is executed in each component mounting machine <NUM> from control device <NUM>, and analyzes the received suction deviation amounts. The analysis of the suction deviation amount can be performed in the same manner as the analysis of the mounting accuracy data and the calibration data described above. Then, when the result of the mounting accuracy inspection is a result of no malfunction and the result of the suction inspection is a result of a malfunction, CPU <NUM> determines that there is a malfunction in feeder <NUM>.

As described above, a malfunction determining device of a component mounting machine according to the present disclosure includes a head configured to include a pickup member for picking up a component, a moving device configured to move the head, an inspection section configured to execute multiple inspections including a first inspection for performing a mounting operation under control of the head and the moving device to inspect whether the mounting is good or bad and a second inspection for performing calibration measurement of the head to inspect whether the measurement is good or bad, and a determining section configured to determine presence or absence of a malfunction and a malfunction location in the head and the moving device based on a combination of results of the multiple inspections.

In such a malfunction determining device of a component mounting machine according to the present disclosure, when the result of the first inspection is a result of a malfunction, the determining section may determine that the moving device is malfunctioning if the result of the second inspection is a result of no malfunction, and may determine that the head is malfunctioning if the result of the second inspection is a result of a malfunction. By doing so, it is possible to more appropriately determine which of the head and the moving device has a malfunction.

In the malfunction determining device of the component mounting machine according to the present disclosure, the inspection section may shut down the component mounting machine after the first inspection and the second inspection are completed. As a result, the operator can leave the holding site after the work is completed without waiting for component mounting machine <NUM> to end the inspection.

Further, in the malfunction determining device of the component mounting machine according to the present disclosure, the first inspection is an inspection for determining whether the mounting operation is good or bad by sequentially mounting multiple components of the same type on an inspection board by sequentially picking up the multiple components by the pickup member by the pickup member and detecting a positional deviation of each mounted component, and the inspection section initiates the first inspection when the inspection board is set and a command to initiate an inspection is issued.

In the malfunction determining device of the component mounting machine according to the present disclosure, the inspection section may initiate the second inspection when a preset time is reached or when a command to initiate an inspection is issued.

In addition, in the malfunction determining device of the component mounting machine according to the present disclosure, a notification section for notifying of a result of the determination may be provided.

Claim 1:
A malfunction determining device of a component mounting machine (<NUM>), the component mounting machine comprising a head (<NUM>) including a pickup member for picking up a component and a moving device (<NUM>) configured to move the head (<NUM>) horizontally,
the malfunction determining device being characterized by:
an inspection section configured to execute multiple inspections including a first inspection for performing a mounting operation under control of the head (<NUM>) and the moving device (<NUM>) to inspect whether the mounting operation is good or bad and a second inspection for performing a calibration measurement of the head (<NUM>) to inspect whether the calibration measurement is good or bad, and
a determining section configured to determine presence or absence of a malfunction and a malfunction location in the head (<NUM>) and the moving device (<NUM>) based on a combination of results of the multiple inspections,
wherein the calibration measurement includes ZS-axis inclination measurement for measuring an inclination of a ZS axis, the ZS-axis being an axis in up-down direction along which the head (<NUM>) is lifted and lowered.