JP7599142B2 - Substrate transport method and transport management device - Google Patents

Description

This disclosure relates to a method for transporting a magazine containing multiple substrates and a transport management device.

Conventionally, a board storage device and a board supply device have been proposed (see, for example, Patent Document 1). This board storage device sequentially receives a plurality of boards, each of which has components mounted by an electronic component mounting device, from the electronic component mounting device and stores them in a magazine. Then, when the magazine becomes full of boards, the board storage device stores boards in the next empty magazine. The board storage device repeatedly stores boards in this manner in the magazine. Meanwhile, the board supply device sequentially removes each of the plurality of boards from a magazine that is full of boards, and supplies the board to, for example, another electronic component mounting device. Then, when the magazine becomes empty, the board supply device removes a board from the next full magazine. The board supply device repeatedly removes boards from this manner in the magazine.

Here, each of the substrate storage device and the substrate supply device outputs a warning signal when the number of substrates stored in the magazine reaches a predetermined number. For example, when substrates are being stored in the magazine in sequence, the substrate storage device outputs a full warning signal when the number of substrates reaches a predetermined number and the magazine approaches a full state. When substrates are being removed from the magazine in sequence, the substrate supply device outputs an empty warning signal when the number of substrates reaches a predetermined number and the magazine approaches an empty state. By outputting such a full warning signal, an empty magazine can be transported to the substrate storage device before the magazine becomes full, and by outputting the empty warning signal, a full magazine can be transported to the substrate supply device before the magazine becomes empty. This makes it possible to prevent the mounting work of the electronic component mounting device from being stopped.

Japanese Patent Application Publication No. 4-364097

However, the magazine transport method using the substrate storage device and substrate supply device in Patent Document 1 has the problem that the efficiency of the magazine transport work is insufficient.

Therefore, this disclosure provides a transportation method that can improve the efficiency of transportation operations.

A method of transporting a board according to one aspect of the present disclosure includes storing multiple boards discharged from a first component mounting device that performs a mounting operation of mounting components on one of the two sides of the board that has been delivered into a magazine placed on an unloader, transporting the magazine containing the multiple boards from the unloader to a loader by a transport device that transports the magazine, and the loader removes the multiple boards from the magazine transported from the unloader and supplies the multiple boards to a second component mounting device that performs the mounting operation on the other of the two sides of the board, (a) acquiring unloader information regarding the storage status of the boards in the unloader and loader information regarding the removal status of the boards in the loader, and (b) determining whether at least one magazine, each containing multiple boards, needs to be transported from the unloader to the loader based on the unloader information and the loader information.

A transport method according to one aspect of the present disclosure is a transport method for transporting a magazine from an unloader to a loader, in which the unloader sequentially acquires each of a plurality of substrates from a first device for each of a plurality of magazines and stores them in the magazine, and the loader sequentially removes each of the plurality of substrates from the magazine in which the plurality of substrates are stored and sends them to a second device, and the transport method includes (a) acquiring unloader information regarding the storage status of the substrates in the unloader and loader information regarding the removal status of the substrates in the loader, and (b) determining whether at least one magazine, each of which stores the plurality of substrates, needs to be transported from the unloader to the loader based on the unloader information and the loader information.

These comprehensive or specific aspects may be realized by a system, a method, an integrated circuit, a computer program, or a recording medium such as a computer-readable CD-ROM, or may be realized by any combination of a system, a method, an integrated circuit, a computer program, and a recording medium. The recording medium may also be a non-transitory recording medium.

The transport method disclosed herein can improve the efficiency of transport operations.

Further advantages and benefits of certain aspects of the present disclosure will become apparent from the specification and drawings. Such advantages and/or benefits may be provided by some of the embodiments and features described in the specification and drawings, respectively, but not necessarily all of them need be provided to obtain one or more identical features.

FIG. 1 is a diagram showing a configuration of a transport system according to an embodiment. FIG. 2A is a perspective view of a magazine according to an embodiment. FIG. 2B is a diagram showing a state in which substrates are stored in the magazine in the embodiment. FIG. 3 is a diagram showing a magazine to be transported in the embodiment. FIG. 4 is a diagram showing an unloader mechanism in the embodiment. FIG. 5 is a diagram showing a mechanism of a loader according to the embodiment. FIG. 6 is a block diagram showing the functional configurations of the unloader, the loader, and the transport management device according to the embodiment. FIG. 7 is a diagram illustrating an example of information stored in an information storage unit according to the embodiment. FIG. 8 is a flowchart showing a schematic processing operation of the transport management device according to the embodiment. FIG. 9 is a flowchart showing a detailed processing operation of the transport management device according to the embodiment. FIG. 10 is a flowchart showing a more detailed processing operation of the transport management device according to the embodiment. FIG. 11 is a flowchart showing a processing operation of the transport management device in the first modification of the embodiment. FIG. 12 is a diagram showing work type information according to the second modification of the embodiment. FIG. 13 is a flowchart showing a processing operation of the transport management device in the second modification of the embodiment. FIG. 14 is a diagram showing a configuration of a transport system according to the third modification of the embodiment. FIG. 15 is a flowchart showing a processing operation of the transport management device in the third modification of the embodiment. FIG. 16 is a flowchart showing a processing operation of the transport management device in the fourth modified example of the embodiment. FIG. 17 is a diagram showing the results of a simulation of production time according to the number of mounted boards produced and the number of retained boards in the embodiment.

A transport method according to one aspect of the present disclosure is a transport method for transporting a magazine from an unloader to a loader, in which the unloader sequentially acquires each of a plurality of substrates from a first device for each of a plurality of magazines and stores them in the magazine, and the loader sequentially removes each of the plurality of substrates from the magazine in which the plurality of substrates are stored and sends them to a second device, and the transport method includes (a) acquiring unloader information regarding the storage status of the substrates in the unloader and loader information regarding the removal status of the substrates in the loader, and (b) determining whether at least one magazine, each of which stores the plurality of substrates, needs to be transported from the unloader to the loader based on the unloader information and the loader information.

As a result, the need for magazine transport is determined based on the storage status of the boards in the unloader and the removal status of the boards in the loader, thereby improving the efficiency of the transport work. In other words, in the above patent document, the need for magazine transport is determined based on the status of only one of the unloader and the loader, but in the transport method according to one aspect of the present disclosure, the determination is made based on the status of both the unloader and the loader. Therefore, it is possible to prevent the first device and the second device from stopping their respective operations due to the lack of boards to be used in those operations, and it is possible to shorten the production time required for the production of multiple mounted boards through those operations. Furthermore, it is possible to reduce the number of times at least one magazine, each of which stores multiple boards, is transported from the unloader to the loader. As a result, it is possible to improve the efficiency of the transport work.

For example, the transport method may further include (c) outputting a first instruction signal to a third device to instruct the third device to transport the at least one magazine from the unloader to the loader when it is determined in (b) that transportation is necessary.

As a result, for example, if the third device is a display device, the contents of the first instruction signal are displayed on the display device. Therefore, an operator operating the first device and the second device can transport at least one magazine to the loader at the appropriate time according to the contents displayed on the display device. Also, if the third device is a magazine transport robot, at least one magazine can be automatically transported to the loader at the appropriate time.

The unloader information includes first magazine information relating to the storage status of substrates in a first magazine handled by the unloader, and second magazine information relating to the storage status of substrates in a second magazine handled next by the unloader, and the loader information includes third magazine information relating to the removal status of substrates in a third magazine handled by the loader, and (a) further includes first work information relating to the work time for substrates in the first device, second work information relating to the work time for substrates in the second device, and transport information relating to the transport time required to transport the magazine from the unloader to the loader. and in (b), it is determined whether at least the first magazine needs to be transported from the unloader to the loader at a specified time based on the first magazine information, the second magazine information, the third magazine information, the first work information, the second work information, and the transport information, and in (c), if it is determined in (b) that at least the first magazine does not need to be transported to the loader, a second instruction signal may be output to the third device to instruct the third device to transport at least the first magazine and the second magazine together from the unloader to the loader at a timing after the specified time.

This allows appropriate determination based on various information as to whether at least the first magazine needs to be transported to the loader at a specified time. Furthermore, if it is determined that transport is not necessary, a second instruction signal is output at a timing after the specified time to instruct the first and second magazines to be transported together. This eliminates the need to transport only the first magazine at the specified time, making the transport operation more efficient.

Further, the first magazine information includes information regarding a first magazine full time, which is the time when the first magazine is filled with the plurality of substrates, and the specified time is the first magazine full time, the second magazine information includes substrate number information regarding the number of substrates stored in the second magazine, and the third magazine information includes substrate number information regarding the number of substrates remaining in the third magazine, and in (b), a second magazine full time, which is the time when the second magazine is filled with the plurality of substrates, is calculated based on the substrate number information of the second magazine and the first work information, and the second magazine filled with the plurality of substrates is calculated based on the second magazine full time and the transport time. The method (c) may calculate an arrival time when the gin arrives at the loader, calculate a third magazine empty time when the number of boards remaining in the third magazine will be zero based on the board number information of the third magazine and the second work information, and determine at the specified time whether the third magazine empty time is earlier than the arrival time of the second magazine, thereby determining whether at least the first magazine needs to be transported from the unloader to the loader at the specified time, and if it is determined in (b) that the third magazine empty time is not earlier than the arrival time of the second magazine, the second instruction signal may be output to the third device at a timing after the specified time.

As a result, a transport decision is made at the first magazine full time when the first magazine of the unloader is full. In this decision, it is determined whether or not the third magazine of the loader will become empty before the magazines arrive at the loader if the first and second magazines, which are both full, are transported together after the second magazine next to the unloader becomes full. If it is determined that the third magazine will not become empty, a second instruction signal is output at a timing after the specified time, which is the first magazine full time. In other words, an instruction is given to transport the first and second magazines together. Therefore, the first and second magazines can be transported efficiently to the loader without stopping the work of the second device using the loader.

In addition, in (b), if it is determined that the third magazine empty time is not earlier than the arrival time of the second magazine, it is further determined whether the number of at least one magazine, including the first magazine, loaded on the unloader and each filled with the plurality of substrates is equal to or greater than a predetermined number, and in (c), if it is determined in (b) that the number of the at least one magazine is equal to or greater than the predetermined number, the first instruction signal may be output to the third device to instruct the transport of the at least one magazine from the unloader to the loader.

As a result, even if it is possible to transport the first and second magazines together without stopping the operation of the second device using the loader, if the number of full magazines in the unloader is equal to or exceeds a predetermined number, the first magazine is transported to the loader. This makes it possible to prevent full magazines from spilling out of the unloader.

In addition, in (c), if it is determined in (b) that the number of the at least one magazine is not equal to or greater than the predetermined number, the second instruction signal may be output to the third device at a timing after the predetermined time.

As a result, when the number of full magazines in the unloader is less than a predetermined number, the full magazines do not overflow from the unloader, and the second instruction signal can be output appropriately. In other words, the full magazines do not overflow from the unloader, and after waiting for the next second magazine to become full in the unloader, the first and second magazines, both of which are full, can be transported to the loader together.

In addition, in (b), if it is determined that the third magazine empty time is not earlier than the arrival time of the second magazine, it is further determined whether the number of at least one magazine, including the first magazine, loaded on the unloader and each filled with the plurality of substrates is equal to or greater than a predetermined number, and the transport method may further include (d) acquiring task type information indicating the priority of each of a plurality of tasks including magazine transport work if it is determined in (b) that the number of the at least one magazine is equal to or greater than the predetermined number, (e) determining whether there is a high priority task that is a task higher in priority than the magazine transport work based on the priority of each of the plurality of tasks, and (f) outputting information regarding an instruction to perform the high priority task if it is determined in (e) that there is a high priority task.

As a result, even if the number of full magazines in the unloader is equal to or greater than a predetermined number, if there is high priority work that has a higher priority than the magazine transport work, the execution of the high priority work is instructed to take precedence over the magazine transport work. For example, if there is sufficient time until the second magazine becomes full and there is a high priority work to be performed before the second magazine becomes full, the execution of the high priority work is given priority. This makes it possible to prevent the efficiency of other work from being reduced in order to improve the efficiency of the transport work.

The transport method may further include (g) outputting the first instruction signal to the third device when it is determined in (e) that there is no high priority work, the first instruction signal instructing the third device to transport at least one magazine including the first magazine from the unloader to the loader.

As a result, when there is no high priority task that has a higher priority than the magazine transport task, the magazine transport task is instructed as a priority. In other words, the transport of at least the first magazine to the loader is instructed. For example, when there is not enough time until the second magazine becomes full, the magazine transport task is given top priority. In such a case, the first magazine is transported to the loader without waiting for the second magazine to become full. This makes it possible to prevent full magazines from spilling out of the unloader.

The transport method may further include (g) determining whether the magazine filled with the plurality of substrates placed on the unloader can be loaded onto the loader if it is determined in (e) that there is no high priority task, and (h) outputting a third instruction signal to the third device to instruct the third device to transport the magazine to a temporary storage location if it is determined in (g) that the magazine cannot be loaded.

This allows a full magazine to be transported to a temporary storage location if it cannot be placed on the loader.

The transport method may further include (i) outputting a fourth instruction signal to the third device instructing the third device to transport the magazine to the loader if it is determined in (g) that the magazine can be placed.

This reduces the occurrence of a situation where a full magazine is transported to the loader but cannot be placed on the loader.

The transport method may further include (j) determining whether transport request information has been acquired that requests the transport of a magazine containing the plurality of substrates to the loader if it is determined in (b) that no transport is required, and (k) outputting the first instruction signal to the third device if it is determined in (j) that the transport request information has been acquired.

This allows, for example, a full magazine to be transported to the loader when transport request information is acquired, increasing the flexibility of transport.

The transport method may further determine the predetermined number based on (l) the production volume of mounting boards, each mounting board having one or more components mounted thereon, produced by the operations of the first device and the second device. For example, in (l), the predetermined number may be determined to be a smaller number as the production volume of the mounting boards decreases.

This makes it possible to improve the efficiency of transport operations while shortening the production time of multiple mounting boards produced by the work of the first and second devices.

The transport method may further include (m) determining the number of boards to be stored in the magazine by the unloader based on the production volume of mounted boards, each board having one or more components mounted thereon, produced by the operations of the first device and the second device. For example, in (m), the number of boards to be stored in the magazine by the unloader may be determined to be smaller the fewer the number of mounted boards produced.

This makes it possible to improve the efficiency of transport operations while shortening the production time of multiple mounting boards produced by the work of the first and second devices.

These comprehensive or specific aspects may be realized as a system, a method, an integrated circuit, a computer program, or a recording medium such as a computer-readable CD-ROM, or may be realized as any combination of a system, a method, an integrated circuit, a computer program, or a recording medium. The recording medium may also be a non-transitory recording medium.

The following describes the embodiment in detail with reference to the drawings.

The embodiments described below are all comprehensive or specific examples. The numerical values, shapes, materials, components, component placement and connection forms, steps, and order of steps shown in the following embodiments are merely examples and are not intended to limit the present disclosure. Furthermore, among the components in the following embodiments, components that are not described in an independent claim that indicates a superordinate concept are described as optional components.

The figures are schematic diagrams and are not necessarily drawn precisely. In each figure, the same components are given the same reference numerals. In the following embodiments, expressions such as "approximately parallel" are used. For example, "approximately parallel" does not only mean completely parallel, but also means substantially parallel, that is, including an error of, for example, about a few percent. Furthermore, "approximately parallel" means parallel within the range in which the effects of the present disclosure can be achieved. The same applies to other expressions using "approximately."

(Embodiment)
FIG. 1 is a diagram showing a configuration of a transport system according to an embodiment.

The conveying system 100 in this embodiment includes a conveying management device 10, a display device 20, loaders 30a and 30b, unloaders 40a and 40b, a conveying device 50, a number of magazines 60, a first component mounting device 91, and a second component mounting device 92.

The transport management device 10 manages the transport of the magazine 60 from the unloader 40a to the loader 30b. The transport management device 10 also communicates wirelessly or via wires with the loaders 30a and 30b, the unloaders 40a and 40b, the first component mounting device 91, and the second component mounting device 92. The wireless communication may be Wi-Fi (registered trademark), Bluetooth (registered trademark), ZigBee, or a specific low-power radio.

The display device 20 is connected to the transport management device 10 and displays images or characters under the control of the transport management device 10. For example, the display device 20 is a liquid crystal display, a plasma display, an organic EL (Electro-Luminescence) display, etc.

The first component mounting device 91 performs a mounting operation to mount components on a board supplied from the loader 30a, and conveys the board on which the components have been mounted to the unloader 40a. For example, the first component mounting device 91 performs mounting operation on one of the two sides of the board. Note that the first component mounting device 91 in this embodiment is an example of a first device.

The second component mounting device 92 mounts components onto the board supplied from the loader 30b, and transports the board onto which the components have been mounted to the unloader 40b. For example, the second component mounting device 92 mounts components onto the other of the two sides of the board. The second component mounting device 92 in this embodiment is an example of a second device.

By performing the mounting operation using the first component mounting device 91 and the second component mounting device 92, components are mounted on both sides of the board, resulting in the production of a mounted board.

One or more magazines 60, each filled with multiple circuit boards, are placed on the loader 30a. The loader 30a then sequentially removes each of the multiple circuit boards stored in one of the one or more magazines 60 from that one magazine 60, and supplies the removed circuit boards to the first component mounting device 91. Then, when the magazine 60 becomes empty, the loader 30a sequentially removes each of the multiple circuit boards from the next magazine 60 from the one or more magazines 60, and supplies the removed circuit boards to the first component mounting device 91.

The loader 30b has the same function as the loader 30a, but supplies boards to the second component mounting device 92 instead of the first component mounting device 91. That is, the loader 30b has one or more magazines 60, each filled with multiple boards. The loader 30b then sequentially removes each of the multiple boards stored in one of the one or more magazines 60, and supplies the removed boards to the second component mounting device 92. Then, when the magazine 60 becomes empty, the loader 30b sequentially removes each of the multiple boards from the next magazine 60 of the one or more magazines 60, and supplies the removed boards to the second component mounting device 92.

One or more empty magazines 60 are placed on the unloader 40a. Then, each time a board is discharged from the first component mounting device 91, the unloader 40a stores the board in one of the one or more magazines 60. Then, when a magazine 60 becomes full with multiple boards, the unloader 40a stores the board discharged from the first component mounting device 91 in the next magazine 60 of the one or more magazines 60.

Unloader 40b has the same function as unloader 40a, but stores boards discharged from second component mounting device 92 instead of first component mounting device 91 in magazine 60. In other words, one or more empty magazines 60 are placed on unloader 40b. Then, each time a board is discharged from second component mounting device 92, unloader 40b stores the board in one of the one or more magazines 60. Then, when a magazine 60 becomes full with multiple boards, unloader 40b stores the board discharged from second component mounting device 92 in the next magazine 60 of the one or more magazines 60.

The transport device 50 is a cart that transports multiple magazines 60 from the unloader 40a to the loader 30b. The transport device 50 has a mounting table on which multiple magazines 60 are mounted. In this embodiment, the transport device 50 transports the multiple magazines 60 by being pushed by an operator of the transport system 100. The transport device 50 may be a self-propelled transport robot.

Figure 2A is a perspective view of the magazine 60. Figure 2B is a diagram showing a state in which substrates are stored in the magazine 60. In this disclosure, the vertical direction is referred to as the Z-axis direction or up-down direction, one direction in a plane perpendicular to the vertical direction is referred to as the Y-axis direction or depth direction, and a direction perpendicular to the Y-axis direction in the perpendicular plane is referred to as the X-axis direction, left-right direction or lateral direction. In this disclosure, the positive side in the Z-axis direction is upward or up, and the negative side in the Z-axis direction is downward or down. In this disclosure, the positive side in the Y-axis direction is the back side or back, and the negative side in the Y-axis direction is the front side or front. In this disclosure, the positive side in the X-axis direction is the right side or right, and the negative side in the X-axis direction is the left side or left.

The magazine 60 comprises a top plate 61, a bottom plate 62, a first side plate 63a, a second side plate 63b, and two supports 64.

The top plate 61 and bottom plate 62 are each substantially rectangular and are arranged to face each other in the Z-axis direction.

The first side plate 63a and the second side plate 63b are each substantially rectangular and are arranged to face each other in the X-axis direction. In addition, a plurality of grooves 65 are formed along the Y-axis direction on the opposing surfaces of the first side plate 63a and the second side plate 63b. The plurality of grooves 65 are arranged in the Z-axis direction. The first side plate 63a is arranged between the top plate 61 and the bottom plate 62 and is fixed to the top plate 61 and the bottom plate 62. The second side plate 63b is arranged between the top plate 61 and the bottom plate 62 and is attached to each of the top plate 61 and the bottom plate 62 so as to be slidable in the X-axis direction.

The two pillars 64 are arranged to face the first side plate 63a and the second side plate 63b in the X-axis direction, and are fixed so as to be sandwiched between the top plate 61 and the bottom plate 62.

As shown in FIG. 2B, multiple substrates 1 are stored in the magazine 60. Here, when a substrate 1 is stored in the magazine 60, the second side plate 63b is slid in advance along the X-axis direction, and the distance between the first side plate 63a and the second side plate 63b is adjusted to the width of the substrate 1.

The unloader 40a then makes the substrate 1 approximately parallel to the XY plane and inserts the substrate 1 between the first side plate 63a and the second side plate 63b. This causes the substrate 1 to be stored in the magazine 60. At this time, both edges of the substrate 1 in the X-axis direction are fitted into the grooves 65 of the first side plate 63a and the second side plate 63b. Therefore, when multiple substrates 1 are stored in the magazine 60, each of the multiple substrates 1 is stacked in the Z-axis direction with a distance equal to the pitch between adjacent grooves 65 in the Z-axis direction. The loader 30b also removes the substrate 1 from the magazine 60 shown in FIG. 2B. At this time, the loader 30b slides the substrate 1 in the Y-axis direction to remove the substrate 1 from the magazine 60.

Figure 3 shows the magazine 60 being transported.

As described above, the transport device 50 has a mounting table capable of mounting multiple magazines 60. Therefore, the transport device 50 can transport multiple magazines 60, each filled with multiple substrates 1, from the unloader 40a to the loader 30b in a batch. Here, the maximum number of magazines 60 transported in a batch by the transport device 50 may be three. Note that the maximum number is not limited to three, and may be any number equal to or greater than two.

Figure 4 shows the mechanism of the unloader 40a.

The unloader 40a sequentially acquires each of the multiple circuit boards 1 from the first component mounting device 91 for each of the multiple magazines 60 and stores them in the magazine 60. Such an unloader 40a includes a lifting device 41, an unloading conveyor 44, and an inlet conveyor 45.

The carry-in conveyor 45 is configured so that multiple empty magazines 60 can be placed on the carry-in conveyor 45 when the empty magazines 60 are arranged along the X-axis direction. The carry-in conveyor 45 moves the placed empty magazines 60 towards the lifting device 41 and hands them over to the lifting device 41. The maximum number of magazines 60 that can be placed on the carry-in conveyor 45 is, for example, three. However, the maximum number is not limited to three and may be any number equal to or greater than two.

The lifting device 41 includes a transfer conveyor 43 and a lifter 42. The lifter 42 raises and lowers the transfer conveyor 43. The lifter 42 raises the transfer conveyor 43 to the height of the carry-in conveyor 45 (hereinafter referred to as the carry-in height). At this time, the transfer conveyor 43 receives an empty magazine 60 from the carry-in conveyor 45 and moves the empty magazine 60 to the first component mounting device 91 side. The lifter 42 then rises or lowers to a predetermined first reference height. Next, when the board 1 to be carried out from the first component mounting device 91 is stored in the magazine 60 on the transfer conveyor 43, the lifter 42 lowers by the pitch interval of the grooves 65 of the magazine 60.

By repeatedly storing the substrates 1 in the magazine 60 and lowering the lifter 42 at pitch intervals, the magazine 60 becomes full with multiple substrates 1. When the magazine 60 becomes full, the lifter 42 descends until the transfer conveyor 43 reaches the height of the discharge conveyor 44 (hereinafter referred to as the discharge height). The transfer conveyor 43, which has descended to the discharge height, moves the full magazine 60 to the discharge conveyor 44 and passes it to the discharge conveyor 44. When the transfer of the magazine 60 from the transfer conveyor 43 to the discharge conveyor 44 is completed, the lifter 42 again raises the transfer conveyor 43 to the carry-in height. By raising and lowering the lifter 42 in this way, multiple empty magazines 60 are filled in turn and passed to the discharge conveyor 44.

The discharge conveyor 44 is configured so that a plurality of full magazines 60 can be placed on the discharge conveyor 44 in a state where the full magazines 60 are arranged along the X-axis direction. The discharge conveyor 44 receives the full magazines 60 from the delivery conveyor 43 that has been lowered to the discharge height. At this time, when a full magazine 60 is already placed on the discharge conveyor 44, the discharge conveyor 44 receives a new full magazine 60 from the delivery conveyor 43 while moving the existing magazine 60 to the opposite side of the lifting device 41. By repeatedly receiving the magazines 60 in this manner, a plurality of full magazines 60 are placed on the discharge conveyor 44 in a state where they are arranged along the X-axis direction. The maximum number of magazines 60 that can be placed on the discharge conveyor 44 is, for example, three. However, the maximum number is not limited to three, and may be any number equal to or greater than two.

The conveying device 50 conveys at least one full magazine 60 placed on its discharge conveyor 44 from the unloader 40a to the loader 30b.

Figure 5 shows the mechanism of the loader 30b.

The loader 30b sequentially removes each of the multiple boards 1 from the magazine 60 in which the multiple boards 1 are stored, and sends them to the second component mounting device 92. Such a loader 30b includes a lifting device 31, an unloading conveyor 34, and an inloading conveyor 35.

The carry-in conveyor 35 is configured so that multiple full magazines 60 can be placed on the carry-in conveyor 35 when the full magazines 60 are arranged along the X-axis direction. The carry-in conveyor 35 moves the loaded full magazines 60 towards the lifting device 31 and hands them over to the lifting device 31. The maximum number of magazines 60 that can be loaded on the carry-in conveyor 35 is, for example, three. However, the maximum number is not limited to three and may be any number equal to or greater than two.

The lifting device 31 includes a transfer conveyor 33 and a lifter 32. The lifter 32 raises and lowers the transfer conveyor 33. The lifter 32 lowers the transfer conveyor 33 to the height of the carry-in conveyor 35 (hereinafter referred to as the carry-in height). At this time, the transfer conveyor 33 receives the full magazine 60 from the carry-in conveyor 35 and moves the full magazine 60 to the second component mounting device 92 side. The lifter 32 then rises or lowers to a predetermined second reference height. Next, when the board 1 is removed from the magazine 60 on the transfer conveyor 33 to the second component mounting device 92 side, the lifter 32 rises by the pitch interval of the grooves 65 of the magazine 60.

By repeatedly removing the substrates 1 from the magazine 60 and raising the pitch interval of the lifter 32 in this manner, the magazine 60 becomes empty. When the magazine 60 becomes empty, the lifter 32 rises until the transfer conveyor 33 reaches the height of the discharge conveyor 34 (hereinafter referred to as the discharge height). The transfer conveyor 33, which has risen to the discharge height, then moves the empty magazine 60 to the discharge conveyor 34 and passes it to the discharge conveyor 34. When the transfer of the magazine 60 from the transfer conveyor 33 to the discharge conveyor 34 is complete, the lifter 32 again lowers the transfer conveyor 33 to the carry-in height. By this raising and lowering of the lifter 32, the multiple full magazines 60 are emptied in turn and passed to the discharge conveyor 34.

The discharge conveyor 34 is configured so that a plurality of empty magazines 60 can be placed on the discharge conveyor 34 in a state where the empty magazines 60 are arranged along the X-axis direction. The discharge conveyor 34 receives the empty magazines 60 from the delivery conveyor 33 that has been raised to the discharge height. At this time, when an empty magazine 60 is already placed on the discharge conveyor 34, the discharge conveyor 34 receives a new empty magazine 60 from the delivery conveyor 33 while moving the existing magazine 60 to the opposite side of the lifting device 31. By repeatedly receiving the magazines 60 in this manner, a plurality of empty magazines 60 are placed on the discharge conveyor 34 in a state where they are arranged along the X-axis direction. The maximum number of magazines 60 that can be placed on the discharge conveyor 34 is, for example, three. However, the maximum number is not limited to three, and may be any number equal to or greater than two.

Figure 6 is a block diagram showing the functional configuration of each of the unloader 40a, the loader 30b, and the transport management device 10.

The unloader 40a includes a first board number detection unit 411, a first magazine number detection unit 412, a first drive mechanism 413, a first control unit 414, and a first communication unit 415.

The first substrate number detection unit 411 detects the number of substrates 1 stored in the magazine 60 in the lifting device 41 of the unloader 40a. For example, the first substrate number detection unit 411 may be equipped with a weight sensor and detect the number of substrates 1 stored in the magazine 60 from the weight obtained by the weight sensor, i.e., the weight on the transfer conveyor 43. In other words, the first substrate number detection unit 411 may calculate the number of substrates 1 stored in the magazine 60 by subtracting the weight of the magazine 60 only from the weight on the transfer conveyor 43 and dividing the subtraction result by the weight of the substrates 1. The first substrate number detection unit 411 may also be equipped with an infrared sensor and detect the number of substrates 1 stored in the magazine 60 by infrared rays.

The first magazine number detection unit 412 detects the number of full magazines 60 placed on the discharge conveyor 44 of the unloader 40a. For example, the first magazine number detection unit 412 may be equipped with a weight sensor and detect the number of full magazines 60 placed on the discharge conveyor 44 from the weight obtained by the weight sensor, i.e., the weight on the discharge conveyor 44. In other words, the first magazine number detection unit 412 may calculate the number of full magazines 60 placed on the discharge conveyor 44 by dividing the weight on the discharge conveyor 44 by the weight of the full magazines 60. The first magazine number detection unit 412 may also be equipped with an infrared sensor and detect the number of magazines 60 by infrared light.

The first drive mechanism 413 is a mechanism consisting of a lifter 42, a delivery conveyor 43, an output conveyor 44, and an input conveyor 45.

The first communication unit 415 communicates with the transport management device 10.

The first control unit 414 controls the first drive mechanism 413 and the first communication unit 415.

The loader 30b includes a second board number detection unit 311, a second magazine number detection unit 312, a second drive mechanism 313, a second control unit 314, and a second communication unit 315.

The second board number detection unit 311 detects the number of boards 1 remaining in the magazine 60 in the lifting device 31 of the loader 30b. This second board number detection unit 311, like the first board number detection unit 411, detects the number of boards 1 using a weight sensor or an infrared sensor.

The second magazine number detection unit 312 detects the number of full magazines 60 placed on the input conveyor 35 of the loader 30b. Like the first magazine number detection unit 412, the second magazine number detection unit 312 detects the number of full magazines 60 using a weight sensor or an infrared sensor.

The second drive mechanism 313 is a mechanism consisting of a lifter 32, a delivery conveyor 33, an output conveyor 34, and an input conveyor 35.

The second communication unit 315 communicates with the transport management device 10.

The second control unit 314 controls the second drive mechanism 313 and the second communication unit 315.

The transport management device 10 includes a time calculation unit 11, a judgment unit 12, a third communication unit 13, a third control unit 14, an acquisition unit 15, an information storage unit 16, and an instruction unit 17.

The third communication unit 13 communicates with the first communication unit 415 of the unloader 40a and the second communication unit 315 of the loader 30b. This communication is performed via wired or wireless communication. Note that the wireless communication may be Wi-Fi (registered trademark), Bluetooth (registered trademark), ZigBee, or a specific low-power radio.

The acquisition unit 15 acquires various information from the unloader 40a and the loader 30b via the third communication unit 13. The acquisition unit 15 also acquires various information stored in the information storage unit 16.

The time calculation unit 11 uses various information acquired by the acquisition unit 15 to calculate each time related to the transportation of the magazine 60 from the unloader 40a to the loader 30b.

The judgment unit 12 uses each time calculated by the time calculation unit 11 to judge whether at least one magazine 60 containing multiple substrates 1 needs to be transported from the unloader 40a to the loader 30b.

The instruction unit 17 outputs an instruction signal according to the result of the judgment by the judgment unit 12 to the display device 20. This instruction signal is, for example, a signal instructing to transport at least one magazine 60 from the unloader 40a to the loader 30b. When the display device 20 acquires the instruction signal, it displays the content indicated by the instruction signal. Thus, a message instructing to transport at least one magazine 60 from the unloader 40a to the loader 30b is displayed on the display device 20. Upon seeing such a message, the operator uses the transport device 50 to transport at least one magazine 60 from the unloader 40a to the loader 30b.

The information storage unit 16 is a recording medium that holds various information used by the time calculation unit 11 to calculate the time. For example, the information storage unit 16 is a hard disk, a RAM (Read Only Memory), a ROM (Random Access Memory), or a semiconductor memory. Note that such an information storage unit 16 may be either volatile or non-volatile.

Figure 7 shows an example of information stored in the information storage unit 16.

The information storage unit 16 stores first work information, second work information, and transport information.

The first work information indicates a first work time ta1 as the time required for the first component mounting device 91 to perform the mounting work on the board 1. This mounting work is the work in which the first component mounting device 91 mounts at least one predetermined component on the supplied board 1 and carries it away.

The second work information indicates a second work time ta2 as the time required for the second component mounting device 92 to perform the mounting work on the board 1. This mounting work is the work in which the second component mounting device 92 mounts at least one predetermined component on the supplied board 1 and carries it away.

The transport information indicates the transport time T that it takes for the transport device 50 to transport the magazine 60 from the unloader 40a to the loader 30b.

Figure 8 is a flowchart showing the general processing operation of the transport management device 10.

The acquisition unit 15 of the transport management device 10 acquires unloader information regarding the storage status of the substrate 1 in the unloader 40a and loader information regarding the removal status of the substrate 1 in the loader 30b (step S1).

Based on the unloader information and the loader information, the judgment unit 12 judges whether or not it is necessary to transport the magazine 60 to the loader 30b (step S2). In other words, the judgment unit 12 judges whether it is necessary to transport at least one magazine 60, each of which contains multiple substrates 1, from the unloader 40a to the loader 30b.

If the judgment unit 12 determines that transportation is not necessary (No in step S2), the transportation management device 10 repeats the process from step S1.

On the other hand, when the judgment unit 12 judges that transportation is necessary (Yes in step S2), the instruction unit 17 outputs a first instruction signal to the third device instructing the transport of at least one magazine 60 from the unloader 40a to the loader 30b (step S3). This third device is, for example, the display device 20. When the display device 20 receives the first instruction signal, it displays the content indicated by the first instruction signal. In other words, the display device 20 displays a message encouraging the transport of at least one magazine 60 from the unloader 40a to the loader 30b.

If the transport device 50 is a transport robot, the third device may be the transport device 50. In this case, when the transport device 50 receives the first instruction signal, it transports at least one magazine 60 from the unloader 40a to the loader 30b by self-propelling.

As a result, whether the magazine 60 needs to be transported is determined based on the storage status of the board 1 in the unloader 40a and the removal status of the board 1 in the loader 30b, so that the efficiency of the transport work can be improved. In other words, in the past, whether the magazine needs to be transported was determined based on the status of only one of the unloader and the loader, but in this embodiment, it is determined based on the status of both the unloader 40a and the loader 30b. Therefore, it is possible to prevent the first component mounting device 91 and the second component mounting device 92 from stopping their work because there is no board 1 to be used for that work, and it is possible to shorten the production time required for the production of multiple mounted boards by that work. Furthermore, it is possible to reduce the number of times that at least one magazine 60, each of which stores multiple boards 1, is transported from the unloader 40a to the loader 30b. As a result, it is possible to improve the efficiency of the transport work.

Figure 9 is a flowchart showing the detailed processing operations of the transport management device 10.

The third control unit 14 of the transport management device 10 first initializes the variable i to 1 (step S4). Then, the acquisition unit 15 acquires the magazine information i and the magazine information (i+1) as unloader information (step S11). This magazine information i is information about the storage status of the substrate 1 in the magazine i of the unloader 40a. The magazine information (i+1) is information about the storage status of the substrate 1 in the magazine (i+1) next to the magazine i. The acquisition unit 15 acquires the magazine information i and the magazine information (i+1) from the unloader 40a via the third communication unit 13.

Note that magazine i is the magazine 60 identified by variable i, and more specifically, the magazine 60 handled by the unloader 40a for the i-th time. When i=1, magazine information i is information about the storage status of the first magazine 60 handled first by the unloader 40a, and magazine information (i+1) is information about the storage status of the second magazine 60 handled next by the unloader 40a. Magazine i and magazine information i are also referred to as the first magazine and first magazine information, and magazine (i+1) and magazine information (i+1) are also referred to as the second magazine and second magazine information.

Next, the acquisition unit 15 acquires the last magazine information as the loader information (step S12). This last magazine information is information regarding the removal status of the board 1 from the magazine 60 that is last handled by the loader 30b. For example, the second control unit 314 of the loader 30b determines whether the number of full magazines 60 placed on the carry-in conveyor 35 detected by the second magazine number detection unit 312 is 0. If the second control unit 314 determines that the number of full magazines 60 is 0, it determines that the magazine 60 in the lifting device 31 is the magazine 60 that is last handled. Then, the second control unit 314 of the loader 30b transmits the above-mentioned last magazine information as information on the magazine 60 that is last handled to the transport management device 10 via the second communication unit 315. The acquisition unit 15 of the transport management device 10 acquires the last magazine information from the loader 30b via the third communication unit 13.

This final magazine information is also called the third magazine information, and the magazine handled last by the loader 30b is also called the last magazine or the third magazine.

Furthermore, the acquisition unit 15 acquires first work information regarding the first work time ta1 of the first component mounting device 91 (step S13). Specifically, the acquisition unit 15 acquires the first work information from the information storage unit 16. Note that the first time information is information regarding the work time for the board 1 in the first device, which is the first component mounting device 91.

Furthermore, the acquisition unit 15 acquires second work information regarding the second work time ta2 of the second component mounting device 92 (step S14). Specifically, the acquisition unit 15 acquires the second work information from the information storage unit 16. Note that the second time information is information regarding the work time for the board 1 in the second device, which is the second component mounting device 92.

Furthermore, the acquisition unit 15 acquires transport information regarding the transport time T required to transport the magazine 60 from the unloader 40a to the loader 30b (step S15). Specifically, the acquisition unit 15 acquires the transport information from the information storage unit 16.

The determination unit 12 determines whether or not it is necessary to transport the magazine 60 to the loader 30b based on the information acquired in steps S11 to S15 (step S2a). That is, the determination unit 12 determines whether or not it is necessary to transport at least magazine i from the unloader 40a to the loader 30b at a specified time based on the magazine information i, magazine information (i+1), last magazine information, first work information, second work information, and transport information. The specified time is, for example, the time when magazine i becomes full and at which it is determined whether magazine i needs to be transported.

Here, when the judgment unit 12 judges that transportation is necessary (Yes in step S2a), the instruction unit 17 outputs a first instruction signal to the third device instructing the third device to transport at least magazine i from the unloader 40a to the loader 30b (step S3a). At this time, the instruction unit 17 may obtain information indicating the number of magazines 60 detected by the first magazine number detection unit 412 of the unloader 40a from the unloader 40a via the third communication unit 13. Specifically, the information indicates the number of full magazines 60 placed on the discharge conveyor 44 of the unloader 40a. Therefore, the instruction unit 17 may output a first instruction signal to the third device instructing the third device to transport the number of magazines 60 indicated by the information to the loader 30b.

On the other hand, if the judgment unit 12 judges that at least magazine i does not need to be transported to the loader 30b (No in step S2a), the third control unit 14 increments the variable i (step S5). Then, the third control unit 14 causes the acquisition unit 15 and the judgment unit 12 to repeatedly execute the processes from step S11. Therefore, in this case, the instruction unit 17 executes the process of step S3a at a timing later than the above-mentioned predetermined time. In other words, the instruction unit 17 outputs a second instruction signal to the third device at a timing later than the above-mentioned predetermined time, instructing the third device to transport at least magazine i and magazine (i+1) together from the unloader 40a to the loader 30b.

The magazine i and magazine (i+1) whose transport is instructed by the second instruction signal are the magazines 60 before the variable i was incremented. For example, in the first step S2a, it is determined that transport of magazine (i=1) is not necessary, and in the second step S2a, it is determined that transport of magazine (i=2) is necessary. At this time, a second instruction signal is output that instructs to transport magazines (i=1) and (i=2) before the increment of the variable i together, rather than magazine (i=2) and magazine (i=3). This second instruction signal is output when magazine (i=2) becomes full after the specified time when magazine (i=1) becomes full.

The third device to which the second instruction signal is output is, for example, the display device 20, which is the same as the output destination of the first instruction signal. When the display device 20 receives the second instruction signal, it displays the content indicated by the second instruction signal. In other words, the display device 20 displays a message encouraging the transport of at least magazine i and magazine (i+1) together from the unloader 40a to the loader 30b.

If the transport device 50 is a transport robot, the third device may be the transport device 50. In this case, when the transport device 50 receives the second instruction signal, it travels on its own to transport at least magazine i and magazine (i+1) together from the unloader 40a to the loader 30b.

In this manner, in this embodiment, it is possible to appropriately determine whether at least magazine i needs to be transported to loader 30b at a specified time based on various information. Furthermore, if it is determined that transport is not necessary, a second instruction signal is output at a timing after the specified time to instruct magazine i and magazine (i+1) to be transported together. This eliminates the need to transport only magazine i at the specified time, and makes the transport operation more efficient.

Figure 10 is a flowchart showing more detailed processing operations of the transport management device 10.

The third control unit 14 of the transport management device 10 first initializes a variable i to 1 (step S4). Then, as part of the processing of step S11 in FIG. 9, the acquisition unit 15 acquires magazine information i indicating the full time t1(i) when magazine i of the unloader 40a becomes full (step S11a). The full time t1(i) is also called the first magazine full time. In other words, the magazine information i includes information regarding the first magazine full time, which is the full time t1(i) when that magazine i is filled with multiple substrates 1. Also, the above-mentioned predetermined time in the example of FIG. 9 is that full time t1(i).

For example, as described above, the first board number detection unit 411 of the unloader 40a detects the number of boards 1 stored in the magazine 60 in the lifting device 41. That magazine 60 is the i-th magazine 60 to be handled, that is, magazine i. The number of boards 1 detected by that first board number detection unit 411 reaches the maximum number of boards 1 that can be stored in the magazine 60. At this time, it is detected that the magazine i is full. As a result, the first control unit 414 of the unloader 40a transmits magazine information i indicating the full time t1(i) at which the magazine i became full to the transport management device 10 via the first communication unit 415. The acquisition unit 15 of the transport management device 10 acquires that magazine information i, that is, the full time t1(i), from the unloader 40a via the third communication unit 13.

Furthermore, as part of the processing of step S11 in FIG. 9, the acquisition unit 15 acquires magazine information (i+1) indicating the number of boards in the magazine (i+1) of the unloader 40a (step S11b). In other words, the magazine information (i+1) includes board number information regarding the number of boards 1 stored in the magazine (i+1).

For example, the first board number detection unit 411 of the unloader 40a detects the number of boards 1 stored in the magazine (i+1) that will be placed next on the lifting device 41 after magazine i becomes full. As a result, the first control unit 414 of the unloader 40a transmits board number information indicating the number of boards 1 stored in the magazine (i+1) detected by the first board number detection unit 411 to the transport management device 10 via the first communication unit 415. The acquisition unit 15 of the transport management device 10 acquires the board number information from the unloader 40a via the third communication unit 13 as magazine information (i+1).

Next, the acquisition unit 15 acquires final magazine information indicating the number of boards in the final magazine 60 of the loader 30b (step S12). In other words, the final magazine information includes board number information regarding the number of boards 1 remaining in the final magazine 60.

For example, as described above, the second control unit 314 of the loader 30b determines that the magazine 60 in the lifting device 31 is the last magazine 60. At this time, the second board number detection unit 311 of the loader 30b detects the number of boards 1 remaining in that magazine 60. As a result, the second control unit 314 of the loader 30b transmits board number information indicating the number of boards 1 remaining in the last magazine detected by the second board number detection unit 311 to the transport management device 10 via the second communication unit 315. The acquisition unit 15 of the transport management device 10 acquires the board number information from the loader 30b via the third communication unit 13 as final magazine information.

Next, the acquisition unit 15 acquires the first work information, the second work information, and the transport information by performing the processes of steps S13 to S15 shown in FIG. 10 (step S15).

Then, the time calculation unit 11 calculates the full time t1(i+1) when the magazine (i+1) of the unloader 40a becomes full (step S16). That is, the time calculation unit 11 calculates the second magazine full time, which is the time when the magazine (i+1) is filled with multiple boards 1, based on the board number information of the magazine (i+1) and the first work information. Specifically, the time calculation unit 11 calculates the remaining number of storage by subtracting the number of boards in the magazine (i+1) indicated by the magazine information (i+1) from the maximum number of boards 1 that can be stored in the magazine 60. Then, the time calculation unit 11 multiplies the remaining number of storage by the first work time ta1 indicated by the first work information, and adds the multiplication result to the current time. In this way, the full time t1(i+1), which is the second magazine full time, is calculated.

Next, the time calculation unit 11 calculates the arrival time (t1(i+1)+T) when the magazine (i+1) of the unloader 40a arrives at the loader 30b (step S17). That is, the time calculation unit 11 calculates the arrival time (t1(i+1)+T) when the magazine (i+1) filled with multiple substrates 1 arrives at the loader 30b based on the full time t1(i+1), which is the second magazine full time, and the transport time T. Specifically, the time calculation unit 11 calculates the arrival time (t1(i+1)+T) by adding the transport time T to the full time t1(i+1).

Furthermore, the time calculation unit 11 calculates the empty time t2 when the last magazine 60 of the loader 30b becomes empty (step S18). That is, based on the board number information of the last magazine 60 and the second work information, the time calculation unit 11 calculates the empty time when the number of boards 1 remaining in the last magazine 60 becomes 0. This empty time is also called the third magazine empty time. Specifically, the time calculation unit 11 multiplies the number of boards in the last magazine 60 by the second work time ta2 indicated by the second work information, and adds the multiplication result to the current time. This calculates the empty time t2, which is the third magazine empty time.

Then, as the process of step S2a in FIG. 9, the judgment unit 12 judges whether the empty time t2 is earlier than the arrival time (t1(i+1)+T) (step S2b). In other words, the judgment unit 12 judges at the full time t1(i) whether the empty time t2 is earlier than the arrival time (t1(i+1)+T) of magazine (i+1). This determines whether at least magazine i needs to be transported from the unloader 40a to the loader 30b at the specified time, which is the full time t1(i).

Here, if the judgment unit 12 judges that the empty time t2 is earlier than the arrival time (t1(i+1)+T) (Yes in step S2b), the instruction unit 17 outputs a first instruction signal to the third device (step S3a), as in the example shown in FIG. 9.

On the other hand, if the judgment unit 12 judges that the empty time t2 is not earlier than the arrival time (t1(i+1)+T) (No in step S2b), the third control unit 14 increments the variable i (step S5). Then, the third control unit 14 causes the acquisition unit 15, the time calculation unit 11, and the judgment unit 12 to repeatedly execute the processes from step S11a. Therefore, in this case, the instruction unit 17 executes the process of step S3a at a timing later than the specified time, which is the full time t1(i). That is, the instruction unit 17 outputs a second instruction signal to the third device at a timing later than the specified time, instructing the third device to transport at least magazine i and magazine (i+1) collectively from the unloader 40a to the loader 30b. Note that the magazines i and magazines (i+1) instructed to be transported by the second instruction signal are the magazines 60 before the variable i is incremented, as in the example shown in FIG. 9.

In this manner, in this embodiment, the transport decision is made at the full time t1(i) when the magazine i of the unloader 40a becomes full. In this decision, it is determined whether the last magazine 60 of the loader 30b will be emptied before the magazines arrive at the loader 30b if the next magazine (i+1) of the unloader 40a becomes full and the full magazines i and (i+1) are transported together to the loader 30b. If it is determined that the last magazine 60 will not be emptied, the second instruction signal is output at a timing after the predetermined time, which is the full time t1(i). In other words, it is instructed to transport magazines i and (i+1) together. Therefore, magazines i and (i+1) can be transported efficiently to the loader 30b without stopping the operation of the second component mounting device 92 using the loader 30b.

(Variation 1)
In this modified example, the transportation of the magazine 60 is instructed based not only on the empty time t2 and the arrival time (t1(i+1)+T) but also on the number of full magazines 60 placed on the unloader 40a.

Figure 11 is a flowchart showing the processing operation of the transport management device 10 in variant example 1.

The third control unit 14 of the transport management device 10 first initializes the variable i to 1 (step S4). Then, the acquisition unit 15 executes an information acquisition process including the processes of steps S11a to S15 in FIG. 10 (step S21). Next, the time calculation unit 11 executes a time calculation process including the processes of steps S16 to S18 in FIG. 10 (step S22).

Then, based on the empty time t2 calculated in step S22 and the arrival time (t1(i+1)+T), the judgment unit 12 judges whether the empty time t2 is earlier than the arrival time (t1(i+1)+T) (step S2b).

Here, if the judgment unit 12 judges that the empty time t2 is earlier than the arrival time (t1(i+1)+T) (Yes in step S2b), the instruction unit 17 outputs a first instruction signal to the third device (step S3a), as in the example shown in FIG. 9.

On the other hand, in this modified example, when the judgment unit 12 judges that the empty time t2 is not earlier than the arrival time (t1(i+1)+T) (No in step S2b), the judgment unit 12 further judges whether the number of magazines on the unloader 40a is equal to or greater than a predetermined number (step S31). In other words, the judgment unit 12 judges whether the number of at least one magazine 60, including magazine i, placed on the unloader 40a and each filled with multiple substrates 1, is equal to or greater than a predetermined number.

For example, the acquisition unit 15 of the transport management device 10 acquires information indicating the number of magazines 60 detected by the first magazine number detection unit 412 of the unloader 40a from the unloader 40a via the third communication unit 13. Then, in step S31, the judgment unit 12 judges whether the number of at least one magazine 60 indicated by the acquired information is equal to or greater than a predetermined number.

Here, when the determination unit 12 determines that the number of the at least one magazine 60 is equal to or greater than the predetermined number (Yes in step S31), the instruction unit 17 outputs a first instruction signal to the third device (step S3a). In other words, the instruction unit 17 outputs a first instruction signal to the third device to instruct the third device to transport at least one magazine 60 including magazine i from the unloader 40a to the loader 30b.

On the other hand, if the judgment unit 12 judges that the number of at least one magazine 60 is not equal to or greater than the predetermined number (No in step S31), the third control unit 14 increments the variable i (step S5). Then, the third control unit 14 causes the acquisition unit 15, the time calculation unit 11, and the judgment unit 12 to repeatedly execute the processes from step S21. Therefore, in this case, the instruction unit 17 executes the process of step S3a at a timing after the predetermined time, which is the full time t1(i). In other words, the instruction unit 17 outputs a second instruction signal to the third device at a timing after the predetermined time to instruct the third device to transport at least magazine i and magazine (i+1) collectively from the unloader 40a to the loader 30b. Note that the magazines i and magazines (i+1) instructed to be transported by the second instruction signal are the magazines 60 before the variable i was incremented.

In this manner, in this modified example, even in a situation where magazine i and magazine (i+1) can be transported together without stopping the operation of the second component mounting device 92 using the loader 30b, if the number of full magazines 60 in the unloader 40a is equal to or greater than a predetermined number, magazine i is transported to the loader 30b. Therefore, it is possible to prevent full magazines 60 from spilling out of the unloader 40a.

In addition, when the number of full magazines 60 in the unloader 40a is less than a predetermined number, the full magazines 60 do not overflow from the unloader 40a, and the second instruction signal can be output appropriately. In other words, the full magazines 60 do not overflow from the unloader 40a, and after waiting for the next magazine (i+1) to become full in the unloader 40a, the full magazines i and (i+1) can be transported together to the loader 30b.

(Variation 2)
In this modified example, the transportation of the magazine 60 is instructed based on the work type information as well.

Figure 12 shows the work type information in variant example 2.

As shown in FIG. 12, the work type information d1 indicates multiple work types, the priority of each of the multiple work types, and the scheduled work completion time.

For example, the multiple work types include pallet supply work, reel supply work, magazine transport work, nozzle preparation work, pin preparation work, and adhesive replenishment work.

The pallet supply work is, for example, the work of supplying pallets to devices such as the first component mounting device 91 and the second component mounting device 92. The pallet is a plate or stand, and is supplied with multiple components to be mounted on the board 1 placed on the pallet.

The reel supply work is, for example, the work of supplying reels to devices such as the first component mounting device 91 and the second component mounting device 92. Note that the reels are supplied with component tape wound around them, which holds multiple components to be mounted on the board 1.

The magazine transport operation is the operation of transporting at least one magazine 60 from the unloader 40a to the loader 30b.

The nozzle preparation work is, for example, the work of placing nozzles for sucking and holding components and mounting them on the board 1 on devices such as the first component mounting device 91 and the second component mounting device 92.

The pin preparation work involves setting up pins provided on devices such as the first component mounting device 91 and the second component mounting device 92 to support from below the board 1 on which the components are to be mounted.

The adhesive refilling operation involves refilling devices such as the first component mounting device 91 and the second component mounting device 92 with adhesive for adhering components to the board 1.

The scheduled work completion time for each of the multiple work types indicated by the work type information d1 is the time when the work of that work type should be completed. Therefore, if the work is not completed by the scheduled work completion time, the work of the first component mounting device 91 and the second component mounting device 92 will be stopped or interrupted, and the production time of the mounted board will be extended.

The priority of each of the multiple work types indicated by the work type information d1 is a numerical value set according to the scheduled completion time of that work type, with the higher the priority being the smaller the numerical value. For example, in the work type information d1, the earlier the scheduled completion time of a work type is, the higher the priority, i.e., the smaller the numerical value, associated with that work type. For example, in the example shown in FIG. 12, the work with the highest priority is the work type "pallet supply work," and the work with the third highest priority is the work type "magazine transport work."

Such work type information d1 may be generated, for example, by the third control unit 14 of the transport management device 10 and stored in the information storage unit 16. In addition, the work type information d1 may be periodically updated according to the status of the component mounting work on the board 1.

Figure 13 is a flowchart showing the processing operation of the transport management device 10 in variant example 2.

The third control unit 14 of the transport management device 10 first initializes the variable i to 1 (step S4). Then, the acquisition unit 15 executes an information acquisition process including the processes of steps S11a to S15 in FIG. 10 (step S21). Next, the time calculation unit 11 executes a time calculation process including the processes of steps S16 to S18 in FIG. 10 (step S22).

Then, based on the empty time t2 calculated in step S22 and the arrival time (t1(i+1)+T), the judgment unit 12 judges whether the empty time t2 is earlier than the arrival time (t1(i+1)+T) (step S2b).

Here, if the judgment unit 12 judges that the empty time t2 is earlier than the arrival time (t1(i+1)+T) (Yes in step S2b), the instruction unit 17 outputs a first instruction signal to the third device (step S3a), as in the example shown in FIG. 9.

On the other hand, if the judgment unit 12 judges that the empty time t2 is not earlier than the arrival time (t1(i+1)+T) (No in step S2b), the judgment unit 12 further judges whether the number of magazines on the unloader 40a is equal to or greater than a predetermined number (step S31). In other words, the judgment unit 12 judges whether the number of at least one magazine 60, including magazine i, placed on the unloader 40a and each filled with multiple substrates 1, is equal to or greater than a predetermined number.

Here, in this modified example, when the judgment unit 12 judges that the number of at least one magazine 60 is equal to or greater than the predetermined number (Yes in step S31), the acquisition unit 15 acquires the work type information d1 stored in the information storage unit 16 (step S32). In other words, the acquisition unit 15 acquires the work type information d1 indicating the priority of each of the multiple tasks including the magazine transport task.

Then, the judgment unit 12 judges whether there is a high priority task, which is a task with a higher priority than the magazine transport task, based on the priority of each of the multiple tasks indicated in the task type information d1 (step S33). Here, if the judgment unit 12 judges that there is a high priority task (Yes in step S33), the instruction unit 17 outputs information regarding an instruction to perform the high priority task to a third device (step S34). The third device is, for example, the display device 20. When the display device 20 receives information regarding an instruction to perform the high priority task, it displays a message encouraging the user to perform the high priority task. Thereafter, the judgment unit 12 repeatedly executes the process of step S33.

On the other hand, if the judgment unit 12 judges that there is no high priority work (No in step S33), the instruction unit 17 outputs a first instruction signal (step S3a). That is, the instruction unit 17 outputs a first instruction signal to the third device to instruct the third device to transport at least one magazine 60 including magazine i from the unloader 40a to the loader 30b.

In this manner, in this modified example, even if the number of full magazines 60 in the unloader 40a is equal to or greater than a predetermined number, if there is a high priority task that has a higher priority than the magazine transport task, the execution of the high priority task is instructed to take precedence over the magazine transport task. For example, if there is sufficient time before the magazine (i+1) becomes full and there is a high priority task before the magazine (i+1) becomes full, the execution of the high priority task is prioritized. Therefore, it is possible to prevent the efficiency of other tasks from being reduced in order to improve the efficiency of the transport task. Furthermore, it is possible to reduce the possibility that the operations of the first component mounting device 91 and the second component mounting device 92 will be stopped or interrupted.

In addition, when there is no high priority task that has a higher priority than the magazine transport task, the magazine transport task is instructed as a priority. In other words, the transport of at least magazine i to loader 30b is instructed. For example, when there is not enough time until magazine (i+1) becomes full, the magazine transport task is given top priority. In such a case, magazine i is transported to loader 30b without waiting for magazine (i+1) to become full. This makes it possible to prevent a full magazine 60 from overflowing from unloader 40a.

(Variation 3)
In this modified example, a temporary storage location is used for transporting the magazine 60.

Figure 14 shows the configuration of the transport system in variant 3.

The transport system 101 in this third modified example has a temporary storage location 80. For example, there may be cases where a magazine 60 filled by an unloader 40a cannot be placed on either the unloader 40a or the loader 30b. In such a case, the transport device 50 transports the magazine 60 filled by the unloader 40a to the temporary storage location 80. Then, when the full magazine 60 can be placed on the loader 30b, the transport device 50 transports the full magazine 60 to the loader 30b.

In other words, the transport device 50 transports a full magazine 60 from the unloader 40a to the loader 30b, or transports a full magazine 60 from the unloader 40a to the loader 30b via the temporary storage location 80.

Figure 15 is a flowchart showing the processing operation of the transport management device 10 in variant example 3.

The third control unit 14 of the transport management device 10 first initializes the variable i to 1 (step S4). Then, the acquisition unit 15 executes an information acquisition process including the processes of steps S11a to S15 in FIG. 10 (step S21). Next, the time calculation unit 11 executes a time calculation process including the processes of steps S16 to S18 in FIG. 10 (step S22).

Then, based on the empty time t2 calculated in step S120 and the arrival time (t1(i+1)+T), the judgment unit 12 judges whether the empty time t2 is earlier than the arrival time (t1(i+1)+T) (step S2b).

Here, when the judgment unit 12 judges that the empty time t2 is earlier than the arrival time (t1(i+1)+T) (Yes in step S2b), the instruction unit 17 outputs an instruction signal to the third device to instruct the transport of at least one magazine 60 to the loader 30b (step S3b). The at least one magazine 60 may be a magazine 60 other than magazine i. The at least one magazine 60 may be placed on the unloader 40a or in the temporary storage location 80. The third device is, for example, the display device 20.

On the other hand, if the judgment unit 12 judges that the empty time t2 is not earlier than the arrival time (t1(i+1)+T) (No in step S2b), the transport management device 10 performs the processes of steps S31, S32, and S33, as in the example shown in FIG. 13.

Here, in this modified example, if the judgment unit 12 determines in step S33 that there is no high priority work (No in step S33), it judges whether the full magazine 60 placed on the unloader 40a can be placed on the loader 30b (step S35).

For example, the acquisition unit 15 of the transport management device 10 acquires information indicating the number of magazines 60 detected by the second magazine number detection unit 312 of the loader 30b from the loader 30b via the third communication unit 13. Then, in step S35, the judgment unit 12 judges that a full magazine 60 can be loaded onto the loader 30b if the number of magazines 60 indicated by the acquired information is less than the maximum number of magazines 60 that can be loaded onto the input conveyor 35 of the loader 30b. Conversely, the judgment unit 12 judges that a full magazine 60 cannot be loaded onto the loader 30b if the number of magazines 60 indicated by the information is equal to or greater than the maximum number.

If the judgment unit 12 judges that the full magazine 60 cannot be placed (No in step S35), the instruction unit 17 outputs a third instruction signal to the third device (step S37). This third instruction signal is a signal that instructs the third device to transport at least one magazine 60 placed on the unloader 40a to the temporary storage location 80.

After the processing of step S37, the judgment unit 12 again judges whether the magazine 60 filled with multiple substrates 1 can be placed on the loader 30b (step S38). If the judgment unit 12 judges that the magazine 60 can be placed on the loader 30b (Yes in step S38), the instruction unit 17 outputs an instruction signal to the third device to instruct the third device to transport at least one magazine 60 in the temporary storage location 80 to the loader 30b (step S39). If the judgment unit 12 judges that the magazine 60 cannot be placed on the loader 30b (No in step S38), it repeats the processing of step S38.

If it is determined in step S35 that the magazine 60 can be placed on the loader 30b, the instruction unit 17 outputs a fourth instruction signal to the third device (step S36). This fourth instruction signal is a signal that instructs the full magazine 60 placed on the unloader 40a to be transported to the loader 30b.

In steps S3b, S36, S37, and S39, instruction signals such as the third instruction signal are output to a third device, for example the display device 20. When the display device 20 receives the instruction signal, it displays the content indicated by the instruction signal. Furthermore, if the transport device 50 is a transport robot, the third device may be the transport device 50. In this case, when the transport device 50 receives the instruction signal, it transports the magazine 60 by self-propelling in response to the instruction signal.

In this manner, in this modified example, if a full magazine 60 cannot be placed on the loader 30b, the magazine 60 can be transported to the temporary storage location 80. In addition, even if a full magazine 60 is transported to the loader 30b, it is possible to prevent the magazine 60 from being unable to be placed on the loader 30b.

(Variation 4)
In this modification, the transportation of the magazine 60 is instructed in response to the transportation request information.

Figure 16 is a flowchart showing the processing operation of the transport management device 10 in variant example 4.

The acquisition unit 15 of the transport management device 10 acquires unloader information and loader information (step S1), similar to the example in Figure 8.

Based on the unloader information and the loader information, the judgment unit 12 judges whether or not it is necessary to transport the magazine 60 to the loader 30b (step S2). In other words, the judgment unit 12 judges whether it is necessary to transport at least one magazine 60, each of which contains multiple substrates 1, from the unloader 40a to the loader 30b.

Here, in this modified example, when the determination unit 12 determines that transportation is not necessary (No in step S2), it further determines whether the acquisition unit 15 has acquired transportation request information (step S41). The transportation request information is information requesting transportation of a magazine 60 containing multiple substrates 1 to the loader 30b. For example, the transportation request information is transmitted from the second communication unit 315 of the loader 30b, and is acquired by the acquisition unit 15 via the third communication unit 13 of the transportation management device 10. In other words, the transportation request information is information requesting a full magazine 60 from the loader 30b. Note that the transportation request information may be transmitted from a device other than the loader 30b.

Then, when the judgment unit 12 judges that the acquisition unit 15 has not acquired the transport request information (No in step S41), the transport management device 10 repeats the process from step S1.

On the other hand, when the judgment unit 12 judges that the acquisition unit 15 has acquired the transport request information (Yes in step S41), the instruction unit 17 outputs a first instruction signal to the third device instructing the third device to transport at least one magazine 60 from the unloader 40a to the loader 30b (step S3).

As a result, when transport request information is acquired, a full magazine 60 can be transported to the loader 30b, increasing the degree of freedom in transport.

(Variation 5)
The transport management device 10 in this modification determines the predetermined number of magazines 60 in the above modifications 1 to 4. This predetermined number is used for the judgment in step S31 in Figures 11, 13, and 15. The numerical value obtained by multiplying the maximum number of substrates 1 that can be stored in the magazine 60 by this predetermined number is also called the number of substrates 1 remaining.

Figure 17 shows the results of a simulation of production time according to the number of mounted boards produced and the number of boards 1 in the holdup. Here, the number in the holdup is the number of boards 1 transported in a batch from the unloader 40a to the loader 30b. In other words, when the unloader 40a stores the holdup number of boards 1 in one or more magazines, the one or more magazines are transported in a batch to the loader 30b. Also, when the production number of mounted boards is less than the holdup number, the same number of boards 1 as the production number are transported in a batch from the unloader 40a to the loader 30b. In other words, when the unloader 40a stores the same number of boards 1 as the production number in one or more magazines, the one or more magazines are transported in a batch to the loader 30b.

As shown in Figure 17, the production time when the production number of mounted boards is 25 is the same whether the number of boards in stock is 100 or 25. However, the production time when the production number of mounted boards is 50, 75, 100, 150, 200, 300, 400, 500, and 1000 is different for the number of boards in stock of 100 and 25.

Specifically, the production time when the number of mounted boards to be produced is 50 differs depending on whether the number of held up boards is 100 or 25. The production time when the number of mounted boards to be produced is 1 hour, 7 minutes, and 16 seconds when the number of held up boards is 100, and 59 minutes and 26 seconds when the number of held up boards is 25. In other words, the production time can be reduced by 12% when the number of held up boards is 25 compared to when the number of held up boards is 100.

Therefore, when the production volume of mounted boards is small, such as 50 to 100 boards, the production time can be shortened by reducing the number of boards in the queue.

However, when the production number of mounted boards is 150 or more, the difference in production time is small even when the number of backlogged boards is 100 and 25. For example, the production time when the production number of mounted boards is 150 is 2 hours 10 minutes 30 seconds when the number of backlogged boards is 100, and 2 hours 7 minutes 32 seconds when the number of backlogged boards is 25. In other words, the difference between the production time when the number of backlogged boards is 25 and the production time when the number of backlogged boards is 100 is only 2%.

Therefore, when the production volume of mounted boards is large, such as 150 or more, it is difficult to achieve the effect of shortening production time even if the number of boards in the waiting state is reduced. In addition, if the number of boards in the waiting state is reduced, one or more magazines 60 must be transported frequently, which reduces the efficiency of the transport work.

The transport management device 10 in this modified example therefore determines the number of sheets to be held in order to achieve both a reduction in production time and an increase in the efficiency of transport operations. In other words, the transport management device 10 determines the predetermined number of magazines 60 in the above modified examples 1 to 4.

Specifically, the third control unit 14 of the transport management device 10 determines the predetermined number based on the production number of mounted boards, each having one or more components mounted on a board 1, produced by the work of the first component mounting device 91 and the second component mounting device 92. For example, the third control unit 14 determines the predetermined number to be a smaller number the fewer the number of mounted boards produced.

Furthermore, the third control unit 14 determines the number of boards 1 to be stored in the magazine 60. In other words, the third control unit 14 determines the number of boards 1 to be stored in the magazine 60 by the unloader 40a based on the production number of mounted boards, each of which has one or more components mounted on it, produced by the work of the first component mounting device 91 and the second component mounting device 92. For example, the number of boards 1 determined is the maximum number of boards 1 that can be stored in the magazine 60 to fill it up.

This allows us to both shorten production time and improve the efficiency of transportation operations.

(Other Modifications)
Although the conveying method according to one or more aspects has been described based on the embodiment and each modified example thereof, the present disclosure is not limited to the embodiment and each modified example. As long as it does not deviate from the gist of the present disclosure, various modifications conceived by a person skilled in the art to the above embodiment and each modified example, or a form constructed by combining components in different modified examples may also be included within the scope of the present disclosure.

For example, in the example shown in FIG. 10 in the above embodiment, the full time t1(i) is the specified time, and steps S11a to S18 and S2b are performed at that specified time. However, these processes may be performed at a timing that is shifted from the full time t1(i).

The transport device 50 in the above embodiment and each modified example may be a cart that transports the magazine 60 by being pushed by an operator, or may be a self-propelled transport robot. The transport robot may be an AGV (Automated Guided Vehicle). In the present embodiment and modified examples, the efficiency of the transport work can be improved, and therefore the number of AGVs can be reduced.

In addition, in the above embodiment and each modified example, the third magazine is the magazine 60 handled last by the loader 30b, but it does not have to be limited to the magazine 60 handled last. For example, the third magazine may be the magazine 60 handled Nth from the end (N is an integer of 2 or more).

In the above embodiment and each modified example, each component may be configured with dedicated hardware, or may be realized by executing a software program suitable for each component. Each component may be realized by a program execution unit such as a CPU or processor reading and executing a software program recorded on a recording medium such as a hard disk or semiconductor memory. Here, the software that realizes the transport management device 10 of the above embodiment and each modified example is a program that causes a computer to execute the processing of the flowcharts shown in each of Figures 8 to 11, 13, 15, and 16.

The following cases are also included in this disclosure:

(1) The at least one device is specifically a computer system consisting of a microprocessor, a ROM (Read Only Memory), a RAM (Random Access Memory), a hard disk unit, a display unit, a keyboard, a mouse, etc. A computer program is stored in the RAM or hard disk unit. The at least one device achieves its functions by the microprocessor operating in accordance with the computer program. Here, the computer program is composed of a combination of multiple instruction codes that indicate commands for the computer to achieve a specified function.

(2) Some or all of the components constituting at least one of the above devices may be composed of a single system LSI (Large Scale Integration). A system LSI is an ultra-multifunctional LSI manufactured by integrating multiple components on a single chip, and specifically, is a computer system including a microprocessor, ROM, RAM, etc. A computer program is stored in the RAM. The system LSI achieves its functions when the microprocessor operates in accordance with the computer program.

(3) Some or all of the components constituting at least one of the above devices may be composed of an IC card or a standalone module that is detachable from the device. The IC card or module is a computer system composed of a microprocessor, ROM, RAM, etc. The IC card or module may include the above-mentioned ultra-multifunction LSI. The IC card or module achieves its functions when the microprocessor operates according to a computer program. This IC card or module may be tamper-resistant.

(4) The present disclosure may be the methods described above. It may also be a computer program that realizes these methods by a computer, or a digital signal that is a computer program.

The present disclosure may also be a computer program or a digital signal recorded on a computer-readable recording medium, such as a flexible disk, a hard disk, a CD (Compact Disc)-ROM, a DVD, a DVD-ROM, a DVD-RAM, a BD (Blu-ray (registered trademark) Disc), a semiconductor memory, or the like. It may also be a digital signal recorded on such a recording medium.

The present disclosure may also involve the transmission of computer programs or digital signals via telecommunications lines, wireless or wired communication lines, networks such as the Internet, data broadcasting, etc.

The program or digital signal may also be implemented by another independent computer system by recording it on a recording medium and transferring it, or by transferring the program or digital signal via a network, etc.

This disclosure can be used in systems that mount components on boards to produce mounted boards.

REFERENCE SIGNS LIST 1 Substrate 10 Transport management device 11 Time calculation unit 12 Determination unit 13 Third communication unit 14 Third control unit 15 Acquisition unit 16 Information storage unit 17 Instruction unit 20 Display device 30a, 30b Loader 31, 41 Lifting device 32, 42 Lifter 33, 43 Delivery conveyor 34, 44 Delivery conveyor 35, 45 Delivery conveyor 40a, 40b Unloader 50 Transport device 60 Magazine 100, 101 Transport system 311 Second substrate number detection unit 312 Second magazine number detection unit 313 Second drive mechanism 314 Second control unit 315 Second communication unit 411 First substrate number detection unit 412 First magazine number detection unit 413 First drive mechanism 414 First control unit 415 First communication unit

Claims (4)

storing a plurality of boards discharged from a first component mounting device that performs a mounting operation of mounting components on one of two sides of the board that has been carried in, in a magazine placed on an unloader;
a transport device for transporting the magazine transporting the magazine containing the plurality of substrates from the unloader to a loader;
the loader takes out the plurality of boards from the magazine conveyed by the unloader, and supplies the plurality of boards to a second component mounting device that performs the mounting operation on the other of the two surfaces of the boards;
(a) acquiring unloader information relating to a storage status of the substrate in the unloader and loader information relating to a removal status of the substrate in the loader;
(b) determining whether at least one magazine, each of which stores a plurality of substrates, needs to be transported from the unloader to the loader based on the unloader information and the loader information;
A method for transporting a substrate. When the number of the magazines placed on the unloader is equal to or greater than a predetermined number, the at least one magazine placed on the unloader with the plurality of substrates stored therein is transported from the unloader to the loader.
The method for transporting a substrate according to claim 1 . the predetermined number is determined based on the number of mounting boards produced by the first component mounting device and the second component mounting device.
The substrate transport method according to claim 2 . A transport management device that manages transport of a magazine from an unloader to a loader,
an acquisition unit that acquires unloader information relating to the storage status of a plurality of boards that are removed from a first component mounting device that performs a mounting operation of mounting components on one of two sides of a board that is carried in and stored in a magazine placed on the unloader, and loader information relating to the removal status of the plurality of boards in a second component mounting device that removes the plurality of boards from a magazine that is transported from the unloader to the loader by a transport device while containing the plurality of boards, and performs the mounting operation on the other of the two sides of the boards;
a determination unit that determines whether at least one magazine, each of which is placed on the unloader and stores a plurality of substrates, needs to be transported from the unloader to the loader based on the unloader information and the loader information;
A transport management device comprising:

Images