Patent ID: 12246869

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

In the configuration illustrated in International Publication No. 2015/045018, it is necessary that each component mounting device has a waste tape transport device embedded therein. Therefore, when an attempt is made to construct a scraps collecting mechanism that collects scraps of carrier tape generated from a tape feeder of each component mounting device in one place, there is a problem that it may take a large amount of costs including the design change of the existing component mounting device.

An object of the present disclosure is to provide a component mounting system that can inexpensively construct a scraps collecting mechanism that collects scraps of carrier tape generated from a tape feeder of each component mounting device in one place.

Hereinafter, embodiments of the present disclosure will be described with reference to the drawings.FIG.1illustrates component mounting system1according to an embodiment of the present disclosure. Component mounting system1is an apparatus that mounts components on board KB to manufacture mount board JKB, and is installed on the floor surface. Component mounting system1includes board supply device11, screen printing device12, slide conveyor13, first relay conveyor14, solder inspection device15, component mounting device16, second relay conveyor17, post-mounting inspection device18, reflow device19, and mount board collecting device20, and these devices are arranged in series in this order from the left side when viewed from operator OP. In the present embodiment, the left-right direction (the direction of conveying board KB) viewed from operator OP is the X-axis direction, and the front-rear direction viewed from operator OP is the Y-axis direction. In addition, the up-down direction is the Z-axis direction.

InFIG.1, component mounting system1has two board conveying paths1L extending in the X-axis direction at the front and rear when viewed from operator OP, and the component mounting work on board KB can be performed at the same time in parallel in these two board conveying paths1L. Therefore, in the present embodiment, two board supply devices11, two screen printing devices12, and two mount board collecting devices20are arranged in the front-rear direction, and slide conveyor13, first relay conveyor14, solder inspection device15, four component mounting devices16, second relay conveyor17, post-mounting inspection device18, and reflow device19respectively have two board conveyors at the front and rear.

Board supply device11stocks a plurality of boards KB and supplies boards KB one by one to the downstream side. Screen printing device12screen-prints solder on board KB supplied from board supply device11and conveys the board to the downstream side. Slide conveyor13distributes and conveys board KB conveyed from screen printing device12to two board conveying paths1L. First relay conveyor14receives board KB conveyed from slide conveyor13and conveys the board to the downstream side.

Solder inspection device15performs a solder inspection of board KB received from first relay conveyor14. In the solder inspection, it is inspected whether or not a predetermined amount of solder is printed at a predetermined position on board KB. Component mounting device16mounts components on board KB that has been sent from the upstream side and conveys the board to the downstream side. In the present embodiment, four component mounting devices16are connected to each other in series on floor surface FL to configure component mounting device group16G (refer to alsoFIG.2). The configuration of component mounting device16that configures component mounting device group16G will be described later.

Second relay conveyor17receives board KB conveyed from component mounting device16positioned on the most downstream side of component mounting device group16G by conveyor mechanism17C (FIG.2) and conveys the board to the downstream side. Post-mounting inspection device18performs component mounting inspection on board KB received from second relay conveyor17. In the component mounting inspection, it is inspected whether or not the component is attached at a predetermined position on board KB in a predetermined direction. Post-mounting inspection device18conveys board KB to which the component mounting inspection has been completed to the downstream side.

Reflow device19performs solder reflow while conveying board KB after the component mounting inspection, which is conveyed from post-mounting inspection device18. Accordingly, after the solder on board KB is melted, the solder is cooled and solidified, and each component mounted on board KB by component mounting device group16G is fixed to board KB. Reflow device19conveys mount board JKB generated in this manner to the downstream side. Mount board collecting device20receives, collects, and stocks mount board JKB conveyed from reflow device19.

As illustrated inFIG.3, component mounting device16includes two board conveyors23and two mounting heads24in a space between base21and cover member22. Two board conveyors23are arranged at the front and rear, and each extends in the X-axis direction (the direction perpendicular to the paper surface ofFIG.3). These two board conveyors23configure a part of two board conveying paths1L of component mounting system1.

Each board conveyor23receives and conveys board KB that has been sent from the upstream side, and positions the board at a predetermined working position. Two mounting heads24are arranged at the front and rear, and each has suction nozzle25extending downward. These two mounting heads24are moved in the horizontal plane by head moving mechanism24K.

InFIGS.2and3, a plurality of tape feeders26are provided while being arranged in the X-axis direction respectively at the front and rear of base21. Each tape feeder26is supported by feeder cart27connected to each of the front and rear of base21. By connecting feeder cart27to base21, the plurality of tape feeders26are collectively attached to base21.

InFIG.3, feeder cart27is provided with a plurality of tape reels28corresponding to each tape feeder26. Carrier tape29that accommodates the components therein is wound around each tape reel28. Tape feeder26supplies component PT to component supply port26K by pulling out carrier tape29from corresponding tape reel28and pitch-feeding the carrier tape. By suctioning component PT supplied to component supply port26K by each tape feeder26and moving the component by head moving mechanism24K, mounting head24mounts the component onto board KB positioned at the working position by board conveyor23. Board KB on which component PT is mounted is conveyed by board conveyor23to the downstream side. The operation of each part of component mounting device16is controlled by control device16CT included in component mounting device16.

In this manner, each component mounting device16performs a series of component mounting operations in which component PT supplied by tape feeder26is mounted on board KB conveyed from the upstream side and is conveyed to the downstream side. By performing the component mounting operation while four component mounting devices16that configure component mounting device group16G are adjacent to each other and deliver board KB, board KB on which components PT in component mounting device group16G have been mounted is conveyed from component mounting device16positioned on the most downstream side.

InFIG.3, cutter device31and duct32are provided on each feeder cart27at the front and rear in each component mounting device16. Cutter device31cuts carrier tape29after supplying components PT in each tape feeder26. Duct32is provided below cutter device31, and guides scraps KZ of carrier tape29, which is cut by cutter device31and drops by the own weight, to duct opening32K opened at the lower portion of feeder cart27(FIG.4).

In this manner, scraps KZ of carrier tape29are generated from each component mounting device16that configures component mounting device group16G, and the amount of scraps KZ of carrier tape29generated in the entire component mounting device group16G is enormous. Component mounting system1in the present embodiment includes scraps collecting mechanism40(tape scraps collecting device) for automatically collecting and discarding a large amount of scraps KZ of carrier tape29generated from component mounting device group16G in one place without manual labor (FIGS.2,5, and6). Scraps collecting mechanism40will be described below.

InFIGS.5and6, scraps collecting mechanism40includes main conveyor41, sub-conveyor42, disposing conveyor43, and storage box44. Main conveyor41is installed in region FA covered with component mounting device group16G on floor surface FL. Main conveyor41is installed such that the conveying direction is oriented in the arrangement direction (X-axis direction) of four component mounting devices16. At the end portion (the end portion on the right side when viewed from operator OP) on the downstream side of main conveyor41in the conveying direction (X-axis direction), component mounting device16positioned on the most downstream side is positioned in the vicinity of the right end portion.

In the present embodiment, component mounting system1has two board conveying paths1L at the front and rear, and two feeder carts27at the front and rear are connected to each other in each component mounting device16corresponding to two board conveying paths1L. Therefore, in the present embodiment, two main conveyors41are installed while being arranged in the Y-axis direction corresponding to two board conveying paths1L provided in component mounting system1(that is, corresponding to the rows of feeder carts27). Two main conveyors41are installed in region FA of floor surface FL under component mounting device group16G at a step before component mounting system1is installed on floor surface FL or in a process in which component mounting system1is installed on floor surface FL.

Each main conveyor41may be one long conveyor extending in the X-axis direction, but in the present embodiment, a plurality of conveyor devices41B are connected to each other in series (FIG.6). As illustrated inFIG.7, one conveyor device41B has a configuration in which motor41M drives belt41C supported by two side walls41H that are provided to face each other (here, face each other in the Y-axis direction) in the horizontal direction. The operation of motor41M is controlled by a host control system (not illustrated) that controls the overall operation of component mounting system1.

InFIG.7, belt41C of conveyor device41B is inclined such that the conveying direction is a direction of the slope from the upstream side to the downstream side in the direction of board KB. As illustrated inFIG.8, in the conveyor devices41B connected to each other, downstream side end portion41K of conveyor device41B positioned on the upstream side is positioned below upstream side end portion41J of conveyor device41B positioned on the downstream side. Therefore, the conveyed object that has been conveyed by conveyor device41B on the downstream side and has reached downstream side end portion41K drops from there and transfers to upstream side end portion41J of conveyor device41B on the upstream side. In this manner, on main conveyor41, scraps KZ of carrier tape29, which is the conveyed object, are conveyed from the upstream side to the downstream side.

It is preferable that the plurality of conveyor devices41B are the same type, and the length (dimension in the X-axis direction) of one conveyor device41B is the same as the lateral width (dimension in the X-axis direction) of one component mounting device16. In this case, the number of connected conveyor devices41B is the same as the number of component mounting devices16that configure component mounting device group16G.

InFIG.4, sub-conveyor42is installed on floor surface FL under feeder cart27included in each component mounting device16. Sub-conveyor42is installed for each feeder cart27included in each component mounting device16. In the present embodiment, since each component mounting device16has two feeder carts27at the front and rear, two sub-conveyors42are also installed at the front and rear of each component mounting device16.

As illustrated inFIG.7, each sub-conveyor42has a configuration in which motor42M drives belt42C supported by two side walls42H that are provided to face each other (here, face each other in the X-axis direction) in the horizontal direction. The operation of motor42M is controlled by control device16CT of component mounting device16positioned above sub-conveyor42.

InFIG.6, of two front and rear sub-conveyors42provided corresponding to each component mounting device16, the one positioned on the front side of component mounting device16is connected to main conveyor41positioned on the front side. Meanwhile, of the two front and rear sub-conveyors42provided corresponding to each component mounting device16, the one positioned on the rear side of component mounting device16is connected to main conveyor41positioned on the rear side.

InFIG.7, the conveying direction of belt42C of each sub-conveyor42installed on floor surface FL is a horizontal direction. When sub-conveyor42is connected to main conveyor41, downstream side end portion42K of sub-conveyor42in the conveying direction is positioned above main conveyor41(FIGS.4and7). Here, the conveying direction of belt42C of each sub-conveyor42is the horizontal direction, but as illustrated inFIG.9, the belt may be inclined such that the conveying direction is a direction of the slope from the upstream side (feeder cart27side) to the downstream side (main conveyor41side).

Each sub-conveyor42receives scraps KZ of carrier tape29discharged from tape feeder26of corresponding component mounting device16through duct32. Then, by conveying scraps KZ toward the center portion side of component mounting device16, and dropping scraps KZ of carrier tape29from downstream side end portion42K in the conveying direction, scraps KZ are delivered to main conveyor41.

As illustrated inFIG.10A, container27B for containing scraps KZ of carrier tape29discharged from duct32is usually installed in the lower portion of feeder cart27. In the present embodiment, container27B is removed from feeder cart27of each component mounting device16(FIG.10B), and sub-conveyor42is installed by using space27S above floor surface FL formed by removing container27B (FIG.10C). Therefore, each sub-conveyor42can be installed after component mounting device group16G is installed on floor surface FL, and can be connected to main conveyor41already installed on floor surface FL.

InFIG.6, disposing conveyor43is installed on an extension line of the arrangement of component mounting device group16G outside region FA (FIG.2). In detail, the disposing conveyor is installed on floor surface FL below second relay conveyor17at a position in the vicinity of the terminal end portion of main conveyor41. Each disposing conveyor43has a configuration in which motor43M drives belt43C supported by two side walls43H that are provided to face each other (here, face each other in the Y-axis direction) in the horizontal direction. The operation of motor43M is controlled by the above-described host control system that controls the overall operation of component mounting system1.

InFIG.7, in the present embodiment, belt43C of disposing conveyor43is configured to be inclined in the direction of the slope from the upstream side to the downstream side in the conveying direction. Upstream side end portion43J of disposing conveyor43is positioned below downstream side end portion41K of conveyor device41B positioned on the most downstream side of the plurality (four here) of conveyor devices41B that configure main conveyor41. (FIG.6). Disposing conveyor43receives scraps KZ of carrier tape29conveyed by main conveyor41to the terminal end portion thereof, and conveys received scraps KZ from downstream side end portion43K to upstream side end portion43J.

InFIG.7, storage box44is a box-shaped member that opens upward and is installed outside region FA and on the downstream side of disposing conveyor43. In a state where storage box44and disposing conveyor43are connected to each other, downstream side end portion43K of disposing conveyor43is positioned above storage box44. Scraps KZ of carrier tape29, which are received from main conveyor41by disposing conveyor43and conveyed from upstream side end portion43J toward downstream side end portion43K, drop from downstream side end portion43K of disposing conveyor43and are disposed of in storage box44. Storage box44stores scraps KZ of carrier tape29, which are disposed of from disposing conveyor43.

In this manner, in the present embodiment, disposing conveyor43serves as a scraps disposer that receives scraps KZ of carrier tape29conveyed by main conveyor41and disposes of scraps KZ into storage box44disposed outside region FA. Further, storage box44is a scraps storage that stores scraps KZ of carrier tape29discharged from each of the plurality of tape feeders26included in four component mounting devices16.

When component mounting system1is in an operating state and each component mounting device16that configures component mounting device group16G performs a component mounting operation, scraps KZ of carrier tape29are generated from component mounting device16, and scraps KZ are discharged by the own weight drop from duct32provided in feeder cart27. Scraps KZ discharged from duct32drop onto sub-conveyor42installed under feeder cart27, and are conveyed by sub-conveyor42toward the center portion side of component mounting device16. Then, scraps KZ drop from downstream side end portion42K of sub-conveyor42and are delivered to main conveyor41. Main conveyor41is always operating during the operation of component mounting device group16G, and conveys scraps KZ received from each of the plurality of sub-conveyors42in the same direction as the flow of board KB. Scraps KZ conveyed by main conveyor41are delivered to disposing conveyor43, and disposing conveyor43disposes of scraps KZ into storage box44.

Here, control device16CT provided in each component mounting device16operates each sub-conveyor42in accordance with the cutting operation of cutter device31that discharges scraps KZ of carrier tape29to sub-conveyors42. Specifically, when cutter device31of feeder cart27performs a cutting operation, control device16CT operates sub-conveyor42installed under feeder cart27for a predetermined period of time. Scraps KZ of carrier tape29discharged from cutter device31are delivered from sub-conveyor42to main conveyor41when sub-conveyor42operates for a predetermined period of time. In addition, control device16CT may operate sub-conveyor42every time when a plurality of times of cutting work are operated, instead of operating sub-conveyor42every time cutter device31performs the cutting work.

As described above, when scraps KZ of carrier tape29are stored in storage box44, and the appropriate time arrives when the amount of accommodated scraps KZ becomes a certain amount, storage box44is moved from floor surface FL. Then, scraps KZ are picked up from storage box44and discarded. In the present embodiment, as illustrated inFIG.7, caster44C is provided at the bottom portion of storage box44, and storage box44can be easily moved on floor surface FL.

As described above, in component mounting system1according to the present embodiment, main conveyor41is installed so as to extend in the arrangement direction of component mounting devices16in the region on floor surface FL under component mounting device group16G, and scraps KZ of carrier tape29discharged from each component mounting device16and delivered from sub-conveyor42installed under each feeder cart27are conveyed outward from underneath of component mounting device group16G. In addition, scraps KZ of carrier tape29conveyed by main conveyor41are stored in storage box44installed outside region FA. Since storage box44stores scraps KZ of carrier tape29discharged from all tape feeders26included in component mounting device group16G, by discarding scraps KZ of carrier tape29stored in storage box44, the operator who collects and discards scraps KZ can discard all scraps KZ discharged from four component mounting devices16without going around each component mounting device16.

Further, in component mounting system1according to the present embodiment, the controller (here, each control device16CT of four component mounting devices16) that controls each of the plurality of sub-conveyors operates each of the plurality of sub-conveyors42in accordance with the cutting operation of cutter device31that discharges scraps KZ to sub-conveyor42. Therefore, it is possible to reduce power consumption as compared with a case where the plurality of sub-conveyors42are always in the operating state.

In the first modification example illustrated inFIG.11, the scraps disposer that receives scraps KZ of carrier tape29conveyed by main conveyor41and disposes of scraps KZ to storage box44is changed from disposing conveyor43described above to scraps suction-up device50. Scraps suction-up device50receives scraps KZ of carrier tape29that has been conveyed by main conveyor41to the terminal end portion thereof by receiving tray51, and ejects the scraps to storage box44from ejection port53by suctioning up scraps KZ of carrier tape29received by receiving tray51from suction-up port52. Even with such a configuration, it is possible to obtain the same effect as the configuration using disposing conveyor43.

A second modification example illustrated inFIG.12is an example in which storage box44is installed at a position out of the arrangement of the plurality of component mounting devices16. In the second modification example, the terminal end portion of main conveyor41is connected to a direction changing conveyor41T that changes the conveying direction from main conveyor41side to operator OP side (or may be the side opposite to operator OP). Then, after connecting disposing conveyor43to the tip of the conveying direction changed by direction changing conveyor41T, the conveying direction of disposing conveyor43is made to coincide with the changed conveying direction. In the second modification example, scraps KZ of carrier tape29conveyed by main conveyor41can be stored in storage box44installed at a position deviated from operator OP side (or the side opposite to operator OP) from the region occupied by component mounting system1on floor surface FL. Therefore, the work of moving storage box44and discarding scraps KZ is easy, and the workability is improved.

As described above, in component mounting system1according to the present embodiment, main conveyor41is installed in region FA on floor surface FL under component mounting device group16G along the arrangement direction of component mounting devices16, and main conveyor41conveys scraps KZ of carrier tape29discharged from each of the plurality of component mounting devices16. In addition, scraps KZ of carrier tape29conveyed by main conveyor41are stored in storage box44installed outside region FA, and collected and discarded in one place. Since main conveyor41is installed on floor surface FL as a device separate from each component mounting device16, there is no need to change the design of the equipment on component mounting device16side and the layout can be freely laid out on floor surface FL for general use, and scraps collecting mechanism40can be constructed inexpensively.

Although the embodiments of the present disclosure have been described above, the present disclosure is not limited to the description above, and various modifications and the like are possible. For example, in the above-described embodiment, scraps collecting mechanism40is configured to include a scraps disposer that receives scraps KZ of carrier tape29conveyed by main conveyor41and disposes of scraps KZ into storage box44, but in a case where storage box44directly receives scraps KZ of carrier tape29conveyed to the terminal end portion by main conveyor41(for example, in a case where a recessed portion is provided on floor surface FL and storage box44is accommodated in the recessed portion) and the like, the scraps disposer becomes unnecessary. Further, in the above-described embodiment, main conveyor41conveys scraps KZ in the direction from the upstream side to the downstream side of the flow of board KB, but on the contrary, scraps KZ may be conveyed in the direction from the downstream side to the upstream side of the flow of board KB.

Further, in the above-described embodiment, scraps collecting mechanism40includes the plurality of sub-conveyors42, and the plurality of sub-conveyors42receive scraps KZ of carrier tape29discharged from each of the plurality of component mounting devices16and deliver the scraps to main conveyor41, but when main conveyor41directly receives scraps KZ discharged from each component mounting device16, sub-conveyor42becomes unnecessary. Further, in the above-described embodiment, each of the plurality of sub-conveyors42operates in accordance with the cutting operation of carrier tape29by cutter device31, but similar to main conveyor41, the sub-conveyor may be always operating during the operation of component mounting device group16G.

There is provided a component mounting system and a tape scraps collecting device that can inexpensively construct a scraps collecting mechanism that collects the scraps of carrier tape generated from the tape feeder of each component mounting device in one place.