JP7620705B2 - Component mounting machine and abnormality judgment method - Google Patents

Description

The technology disclosed in this specification relates to a component mounting machine and an abnormality determination method.

There is a known component mounter that uses an imaging device to capture images of components in a tray before the components stored in the tray are picked up by the nozzle of a mounting head, to inspect the orientation of the components in the tray. For example, in the component mounter disclosed in JP 2019-114743 A, events that trigger component orientation inspection (e.g., setup change or replacement of a component supply device) are registered in advance, and orientation inspection is performed when the event occurs.

In JP 2019-114743 A, each time an abnormality is detected in a direction inspection, the abnormality is notified to the worker. For example, even if an abnormality occurs only in the posture of a specific part that was the subject of a direction inspection for multiple parts stored in a certain tray, and the postures of the other parts are normal, the worker is notified that an abnormality has occurred. For this reason, with the technology of JP 2019-114743 A, the worker may be required to take unnecessary action, which may reduce production efficiency. This specification provides a technology that can appropriately determine abnormalities in the supply of parts supplied from a part supply device.

The component mounter disclosed in this specification mounts components on a board. The component mounter includes a component supply device that supplies the components using a tray that stores a plurality of the components on its upper surface, an imaging device that sequentially images the plurality of components supplied from the component supply device, a determination unit that determines whether the posture of the components supplied from the component supply device is normal or not based on the images captured by the imaging device, and a determination unit that determines that an abnormality has occurred in the component mounter when the proportion of the images of the plurality of components captured consecutively a first number of times by the imaging device that are determined by the determination unit to be abnormal is equal to or greater than a predetermined proportion.

In the above component mounting machine, first, it is determined whether the posture of the multiple components supplied from the component supply device is normal or not based on the images captured by the imaging device. Then, when the proportion of the images of the multiple components captured consecutively the first number of times that are determined to be abnormal is equal to or greater than a predetermined proportion, it is determined that an abnormality has occurred in the component mounting machine. In this way, when it is determined that the posture of a certain component is abnormal, the component mounting machine does not determine whether an abnormality has occurred in the supply of the components, but determines whether the abnormality has occurred according to the proportion of the images captured consecutively that are determined to be abnormal. That is, in this component mounting machine, after determining whether the postures of the multiple components are normal or not, it determines whether an abnormality has actually occurred. Therefore, if an abnormality occurs only in the posture of a specific component, it is not determined to be abnormal, and an abnormality in the supply of components can be appropriately determined.

This specification also discloses an abnormality determination method for a component mounter equipped with a component supply device that supplies a plurality of components by a tray that stores the components on its upper surface. The abnormality determination method includes an imaging step of sequentially capturing images of the plurality of components supplied from the component supply device, a determination step of determining whether or not the posture of the components supplied from the component supply device is normal based on the images captured in the imaging step, and a determination step of determining that an abnormality has occurred in the component mounter when a proportion of the images of the plurality of components captured a first number of times consecutively in the imaging step that are determined to be abnormal in the determination step is equal to or greater than a predetermined proportion.

FIG. 1 is a diagram showing a schematic configuration of a component mounter according to an embodiment. FIG. 2 is a block diagram showing the configuration of a control system of the component mounter. FIG. 13 is a diagram showing an example of a count table. FIG. 4 is a flowchart showing an abnormality determination process. FIG. 13 is a diagram showing an example of a reference mark provided on the top surface of a component. FIG. 13 is a diagram showing another example of the count table.

In one embodiment of the present technology, when the judgment unit determines that an abnormality has occurred in the component mounting machine and detects a second consecutive number of times that the posture of the component determined to be abnormal is a specific posture, the judgment unit may determine that an abnormality has occurred in the supply direction of the component supply device or in the job settings input to the component mounting machine.

If the posture of the detected part is not normal, but that posture is detected continuously across multiple parts, it is highly likely that the posture of each part stored in the tray is correct. In this case, the judgment unit can determine that there is an abnormality (i.e., an error) in the settings of the command (i.e., job) including the supply direction of the part supply device installed by the worker or the production conditions of the board to be produced.

In one embodiment of the present technology, when the judgment unit determines that an abnormality has occurred in the component mounting machine, if the judgment unit detects a third consecutive time that the posture of the component that has been determined to be abnormal is not the same as the posture of the component that was previously determined to be abnormal, the judgment unit may determine that an abnormality has occurred in the component supply device, the tray, or the component contained in the tray.

If the detected posture of a part is not normal and the postures of consecutive parts differ across multiple parts, it may be possible that a mistake was made when placing the parts in the tray or that an abnormality has occurred in the parts themselves. In this case, the judgment unit can judge that an abnormality has occurred, such as a poor quality of the part supply device or tray, or a poor quality of the parts placed in the tray.

In one embodiment of the present technology, the determination unit may determine whether or not the posture of a first part is normal when a plurality of first parts are contained in the tray, and may not need to determine whether or not the posture of a second part different from the first parts is normal when a plurality of second parts different from the first parts are contained in the tray.

Some of the components mounted on the board may be prone to change position on the tray. For this reason, for example, by setting the first component as a component whose position is prone to change on the tray and the second component as the other component, it is possible to selectively determine whether the position of the component is normal or not only for the component whose position is prone to change. As it is not determined whether the position of the second component is normal or not, production efficiency can be improved. Note that the second component may be a component different from the first component, and the second component may include multiple types of components.

In one embodiment of the present technology, the first part may be a part smaller than a predetermined size.

Relatively small parts are prone to change position on the tray. For this reason, it is useful to determine whether the position of parts smaller than a certain size is normal.

(Example)
Hereinafter, a component mounter 10 according to an embodiment will be described with reference to the drawings. The component mounter 10 is a device that mounts components 4 onto a board 2. The component mounter 10 is also called a component mounting device or a chip mounter. Typically, the component mounter 10 is installed alongside other board work machines such as a solder printer and a board inspection machine to form a series of mounting lines.

As shown in FIG. 1, the component mounter 10 includes a plurality of component trays 12, a tray supply device 14, a mounting head 16, a moving device 18, a board conveyor 20, an imaging camera 22, a control device 40, and a touch panel 42.

Each component tray 12 has a plurality of recesses (not shown) formed on its upper surface, for example in a matrix pattern, and each recess accommodates a plurality of components 4. The component tray 12 is removably attached to a tray supply device 14, and supplies the components 4 to the mounting head 16.

The tray supply device 14 has multiple magazines stacked vertically, and a component tray 12 can be removably installed in each of the multiple magazines. The tray supply device 14 supplies components 4 by sending out the component tray 12 into the component mounter 10. The tray supply device 14 may be fixed to the component mounter 10, or may be removably attached to the component mounter 10.

The moving device 18 moves the mounting head 16 and the imaging camera 22 between the component tray 12 sent into the component mounter 10 and the board 2. As an example, the moving device 18 in this embodiment is an XY robot that moves a moving base 18a in the X and Y directions, and the mounting head 16 and the imaging camera 22 are fixed to the moving base 18a. Note that the mounting head 16 is not limited to being fixed to the moving base 18a, and may be detachably attached to the moving base 18a.

The mounting head 16 has a nozzle 6 that picks up the component 4. The nozzle 6 is detachably attached to the mounting head 16. The mounting head 16 can move the nozzle 6 in the Z direction, and moves the nozzle 6 toward and away from the component tray 12 and the board 2. The nozzle 6 is configured to pick up the component 4. To mount the component 4 on the board 2 by the mounting head 16, the tray supply device 14 first moves the magazine in which the component tray 12 is installed in the vertical direction, and sends the component tray 12 into the component mounter 10 at the component supply height. Then, the mounting head 16 is positioned at a position to pick up the component 4 contained in the component tray 12, and the nozzle 6 is moved downward until the suction surface of the nozzle 6 abuts against the component 4. Next, the nozzle 6 picks up the component 4, and the mounting head 16 is positioned at a position to mount the component 4 on the board 2. After that, the nozzle 6 is lowered toward the board 2 to mount the component 4 on the board 2.

The imaging camera 22 is fixed to the movable base 18a and moves integrally with the movable base 18a. The imaging camera 22 is positioned so that its imaging direction faces downward (Z direction) and images the top surface of the board 2. The camera may be, for example, a CCD camera. The imaging camera 22 is also moved above the parts tray 12 by the movable base 18a and images the top surfaces of the multiple parts 4 contained on the parts tray 12. Image data of the image captured by the imaging camera 22 is transmitted to the control device 40.

The substrate conveyor 20 is a device that loads, positions, and unloads the substrate 2. As an example, the substrate conveyor 20 in this embodiment has a pair of belt conveyors and a support device (not shown) that supports the substrate 2 from below.

The touch panel 42 is a display device that provides various information to the worker and is also a user interface that accepts instructions and information from the worker.

The control device 40 is configured using a computer including a memory 50 and a CPU 60. As shown in Figure 2, the control device 40 is communicatively connected to the component tray 12, the tray supply device 14, the mounting head 16, the moving device 18, the board conveyor 20, the imaging camera 22, and the touch panel 42. The control device 40 controls each of these parts to perform processes such as mounting the components 4 onto the board 2.

The memory 50 is provided with job data 52, a production program 54, and a count table 56. The job data 52 is data describing the production item and production quantity. The job data 52 also describes the supply direction of the parts tray 12. The production program 54 is data describing a number of components 4 to be mounted on the board 2 and the position on the board 2 at which each component 4 is to be mounted. The production program 54 can be prepared, for example, for each production item.

As shown in FIG. 3, the count table 56 registers the imaging count, the image processing result, the consecutive abnormality count, the consecutive same posture abnormality count, and the total abnormality count in association with each other. The imaging count is information indicating the number of times the part 4 has been imaged by the imaging camera 22 (i.e., the number of parts imaged). The image processing result is information indicating the result of image processing of the image data of the part 4 imaged by the imaging camera 22. Specifically, the image processing result indicates the supply angle of the part 4 that has actually been imaged. The consecutive abnormality count is information indicating the number of times that abnormalities in these postures have been detected consecutively in the parts 4 imaged in sequence by the imaging camera 22. The consecutive same posture abnormality count is information indicating the number of times that abnormalities in the same posture have been detected consecutively when abnormalities in the posture of the part 4 have been detected consecutively. The total abnormality count is information indicating the total number of times that abnormalities in the posture of the part 4 have been detected.

In addition, a calculation program (not shown) is stored in the memory 50, and when the CPU 60 executes the calculation program, the CPU 60 functions as a judgment unit 62 and a determination unit 64.

The judgment unit 62 judges whether the posture of the components 4 accommodated in the component tray 12 is normal or not based on the job data 52 and the image processing results registered in the count table 56. The judgment unit 64 judges whether an abnormality has occurred regarding the supply of components 4 (e.g., the posture of the components 4, etc.) by the component mounter 10 based on the judgment results by the judgment unit 62 (specifically, each count registered in the count table 56). Details of the processes executed by the judgment unit 62 and the judgment unit 64 will be described later.

Next, a process for determining whether or not an abnormality has occurred regarding the supply of components 4 (hereinafter referred to as abnormality determination process) will be described. FIG. 4 is a flowchart showing the abnormality determination process. In the following, the description will be continued assuming that the supply angle of components 4 described in the job data 52 (job supply angle in FIG. 3) is 0 degrees, as shown in FIG. 3. The process in FIG. 4 is executed when production by the component mounter 10 is started. Note that the process in FIG. 4 is executed for a specific component tray 12, and in a component mounter 10 on which multiple component trays 12 are installed, the process in FIG. 4 may be executed individually for each of the multiple component trays 12.

First, in S10, the CPU 60 moves the imaging camera 22 to capture an image of the top surface of the component 4 on the component tray 12. Here, the image is captured of the top surface of the component 4 that is to be mounted next.

In S12, the CPU 60 performs image processing on the image data of the captured part 4 to determine whether the posture of the part 4 is normal. Here, as shown in FIG. 5(a), the part 4 in this embodiment has a reference mark Mr on its upper surface. For example, if the part 4 has a rectangular shape, the reference mark Mr is provided near a corner of the part 4. FIG. 5(a) shows image data of the part 4 in a state where the supply angle is 0 degrees, and the image data (hereinafter referred to as reference image data) is stored in the memory 50 together with the supply angle (i.e., 0 degrees). When the determination unit 62 determines whether the posture of the part 4 is normal, first, as shown in FIG. 5(b), the position of the reference mark Md is detected by image processing the image data captured by the imaging camera 22. Then, the actual supply angle is calculated by comparing the position of the detected reference mark Md with the position of the reference mark Mr in the reference image data. In the example shown in Fig. 5(b), since the reference mark Md is located at a position rotated 90 degrees from the position of the reference mark Mr in Fig. 5(a), it is possible to calculate that the actual supply angle is 90 degrees. Then, the determination unit 62 determines that the posture of the component 4 is not normal if the calculated supply angle differs from the supply direction of the component tray 12 described in the job data 52 (i.e., the supply angle at which the component 4 should be supplied). If the CPU 60 determines that the posture of the component 4 is not normal (NO in S12), it proceeds to S14, and if the CPU 60 determines that the posture of the component 4 is normal (YES in S12), it proceeds to S16.

When the CPU 60 determines that the posture of the part 4 is not normal (NO in S12), in S14, it counts up a predetermined count and updates the count table 56. With reference to FIG. 3, a case where the imaging count is registered up to "2" will be described. First, the CPU 60 counts up the imaging count by one and registers "3" in the region R1. Next, the CPU 60 registers the image processing result (i.e., the actual supply angle of the part 4) based on the result of the image processing of the image data. Here, the CPU 60 registers "90 degrees" in the region R2 as shown in FIG. 5(b). Next, the CPU 60 counts up the consecutive abnormal count by one and registers "3" in the region R3. Next, the CPU 60 counts up the consecutive same posture abnormal count by one and registers "3" in the region R5 based on the fact that the image processing results of the region R2 and the region R4 (i.e., the supply angle of the previous part 4) are the same. Furthermore, the CPU 60 increments the total abnormality count by one and registers "3" in the region R6. After registering each count and updating the count table 56 as described above, the CPU 60 proceeds to S18.

On the other hand, when the CPU 60 determines that the posture of the part 4 is normal, in S16, it resets the predetermined count and updates the count table 56. FIG. 6 shows an example of the count table 56 different from that in FIG. 3. With reference to FIG. 6, a case where the imaging count is registered up to "1" will be described. First, the CPU 60 counts up the imaging count by one and registers "2" in the region R7. Next, the CPU 60 registers the image processing result based on the result of the image processing of the image data. Here, since it is determined in S12 that the supply angle of the part 4 is normal (i.e., the same as the supply angle "0 degrees" of the part 4 described in the job data 52), the CPU 60 registers "0 degrees" in the region R8. Next, the CPU 60 resets the consecutive abnormality count and the consecutive same posture abnormality count (i.e., registers "0" in the regions R9 and R10). In addition, the CPU 60 registers "1" in the region R11 without changing the total abnormality count from the previous value. After registering each count and updating the count table 56 as described above, the CPU 60 proceeds to S18.

In S18, the CPU 60 judges whether an abnormality has occurred in the supply of the parts 4 by judging whether the predetermined count number in the count table 56 is equal to or greater than a predetermined threshold. Specifically, the CPU 60 judges whether the continuous abnormality count or the continuous same-position abnormality count is equal to or greater than a predetermined threshold. The predetermined threshold is not particularly limited, but may be, for example, three times. In the example of the count table 56 shown in FIG. 3, since both the continuous abnormality count (region R3) corresponding to the imaging count "3" updated in S14 and the continuous same-position abnormality count (region R5) are "3", the CPU 60 judges that the predetermined count number is equal to or greater than the threshold (YES in S18) and proceeds to S22. In the example of the count table 56 shown in FIG. 6, both the continuous abnormality count (region R9) corresponding to the imaging count "2" updated in S16 and the continuous same-position abnormality count (region R10) are "0", the CPU 60 judges that the predetermined count number is less than the threshold (NO in S18) and proceeds to S20.

In S20, the CPU 60 causes the nozzle 6 to pick up the component 4 that is the subject of the abnormality determination process and mounts it on the board 2. Once the CPU 60 has mounted the component 4, it returns to S10 and again executes the process of FIG. 4 for the next component 4 contained in the component tray 12.

In S22, the CPU 60 judges the type of abnormality occurring with respect to the supply of the parts 4. Specifically, in S18, the CPU 60 judges the type of abnormality depending on which count is equal to or greater than a predetermined threshold. In the example shown in FIG. 3, the continuous same-position abnormality count is equal to or greater than the threshold (i.e., 3 times). That is, in the example shown in FIG. 3, the supply angle of the detected parts 4 is not normal, but the supply angle (i.e., 90 degrees) is detected continuously across multiple parts 4. In this case, it is highly likely that the posture of each part 4 contained in the parts tray 12 is correct. For this reason, the CPU 60 judges that an error has occurred in the supply direction (i.e., the insertion direction) of the parts tray 12 to the magazine of the tray supply device 14 by the worker or the supply direction of the parts tray 12 described in the job data 52.

In the example shown in FIG. 6, the consecutive same-position abnormality count corresponding to the imaging count "5" is below the threshold, while the consecutive abnormality count is equal to or greater than the threshold (i.e., 3 times). That is, the supply angle of the detected components 4 is not normal, and the postures of consecutive previous and next components 4 are different across multiple components 4, as shown in region R11. This situation may occur when an operator places components 4 in the component tray 12 in the wrong orientation, or when there is a problem with the components 4 placed in the component tray 12 or the operation of the tray supply device 14. For this reason, the CPU 60 determines that there is a quality defect in the component tray 12 (e.g., distortion, chipping, etc.), a quality defect in the components 4 placed in the component tray 12, or an abnormality in the tray supply device 14.

Then, in S24, the CPU 60 notifies the content of the abnormality determined in S22. For example, the CPU 60 displays the content of the abnormality on the touch panel 42. Here, for example, the content of the abnormality may be notified to an external device (not shown) connected to the control device 40 of the component mounter 10. After executing S24, the CPU 60 ends the series of processes.

In the component mounter 10 of this embodiment, first, based on the image captured by the imaging camera 22, it is determined in sequence whether the supply angles of the multiple components 4 supplied from the component tray 12 are normal or not (S12). Then, when the continuous abnormal count or the continuous same posture abnormal count exceeds a predetermined threshold (YES in S18), it is determined that an abnormality has occurred in the supply of the components 4. In this way, when the component mounter 10 determines that the posture of a certain component 4 is not normal (YES in S12), it does not determine whether an abnormality has occurred in the supply of the components 4, but determines that the abnormality has occurred when a specific count exceeds a predetermined threshold. That is, in this component mounter 10, after determining whether the supply angles of the multiple components 4 are normal or not (S12), it is determined whether an abnormality has actually occurred in the supply of the components 4 (S18). Therefore, it is possible to appropriately determine an abnormality in the supply of the components 4 supplied from the component tray 12. Furthermore, in the component mounter 10 of this embodiment, it is possible to identify which part of the component mounter 10 is experiencing an abnormality, based on the posture (supply angle) of each of the components 4 that are successively detected.

(Correspondence)
The parts tray 12 and the tray supply device 14 are examples of a "tray" and a "parts supply device", respectively. The imaging camera 22 is an example of an "imaging device". 90 degrees is an example of a "specific posture". Three times are examples of a "second number of times" and a "third number of times".

Specific examples of the technology disclosed in this specification have been described in detail above, but these are merely examples and do not limit the scope of the claims. The technology described in the claims includes various modifications and variations of the specific examples exemplified above. Below, we list some variations of the above examples.

In the above-described embodiment, when the consecutive abnormality count or the consecutive same-position abnormality count is equal to or greater than a predetermined threshold (S18), it is determined that an abnormality has occurred in the supply of the component 4. However, it may be determined whether or not an abnormality has occurred in the supply of the component 4 based on the ratio of the imaging count to the total abnormality count. Specifically, it may be determined that an abnormality has occurred in the supply of the component 4 when the proportion of the image processing results of a predetermined number of consecutive times in which the supply angle is determined to be abnormal is equal to or greater than a predetermined proportion. The predetermined number and the predetermined proportion are not particularly limited, but may be, for example, four times and 50%. For example, in the example shown in FIG. 6, the total abnormality count increases by "3" between the four imaging counts "2" and "5". In other words, the proportion of the image processing results of four consecutive times in which the supply angle is determined to be abnormal is 75%. In such a case, it may be determined that an abnormality has occurred in the supply of the component 4. 4 may be read as "The imaging count and the total abnormality count are counted up and updated", S16 may be read as "The imaging count is counted up and updated", and S18 may be read as "Among the results of a predetermined number of consecutive image processing operations, the proportion of the supply angles that are not normal is a predetermined proportion or more?" In this example, the count table 56 does not need to store the image processing results, the consecutive abnormality count, and the consecutive same posture abnormality count in association with each other.

In addition, in the abnormality judgment process of FIG. 4, a process for judging whether the parts 4 supplied from the parts tray 12 are smaller than a predetermined size may be performed before S10. If the parts 4 are smaller than the predetermined size, the process proceeds to S10, and if the parts 4 are larger than the predetermined size, the process shown in FIG. 4 may not be performed. A relatively small part 4 is likely to change its posture (angle) on the parts tray 12. For this reason, it is highly necessary to perform the process of FIG. 4 for parts 4 smaller than the predetermined size. On the other hand, it is less necessary to perform the process of FIG. 4 for parts 4 larger than the predetermined size, and by not performing the process, it is possible to improve production efficiency. Furthermore, as in the above-mentioned embodiment, an abnormality judgment may be performed for all parts first, and after confirming that no continuous same posture abnormality has occurred (i.e., after confirming that there is no abnormality in the supply direction of the parts tray 12, etc.), an abnormality judgment may be performed only for parts smaller than the predetermined size.

In addition, in the above-described embodiment, an abnormality was detected regarding the supply of components 4 stored in the component trays 12 installed in the tray supply device 14, but the device that supplies the components 4 is not limited to this. For example, it may be a device that supplies components using a magazine with multiple component trays placed on a pallet, or a device that supplies multiple component trays using a belt.

In addition, the technical elements described in this specification or drawings exert technical utility alone or in various combinations, and are not limited to the combinations described in the claims at the time of filing. In addition, the technologies illustrated in this specification or drawings achieve multiple objectives simultaneously, and achieving one of those objectives is itself technically useful.

Claims (6)

A component mounter that mounts components on a board,
a component supplying device that supplies the components using a tray that accommodates a plurality of the components on an upper surface thereof;
an imaging device that sequentially images the plurality of components supplied from the component supply device;
a determination unit that determines whether or not the posture of the component supplied from the component supply device is normal based on the image captured by the imaging device;
a determination unit that determines that an abnormality has occurred in the component mounter when a rate of the images of the components that have been consecutively captured a first number of times by the imaging device that are determined by the determination unit to be abnormal is equal to or greater than a predetermined rate;
A component mounting machine comprising: The component mounting machine of claim 1, wherein when the judgment unit judges that an abnormality has occurred in the component mounting machine and detects that the posture of the component judged to be abnormal is a specific posture a second number of times in succession, it judges that an abnormality has occurred in the supply direction of the component supply device or in the job settings input to the component mounting machine. The component mounting machine according to claim 1 or 2, wherein when the judgment unit judges that an abnormality has occurred in the component mounting machine, if the judgment unit detects a third consecutive time that the posture of the component judged by the judgment unit to be abnormal is not the same as the posture of the component previously judged to be abnormal, the judgment unit judges that an abnormality has occurred in the component supply device, the tray, or the component contained in the tray. The determination unit is
When a plurality of first components are accommodated in the tray, determining whether or not the posture of the first components is normal;
The component mounter according to any one of claims 1 to 3, wherein when the tray contains a plurality of second components different from the first components, the mounter does not determine whether the posture of the second components is normal or not. The component mounting machine of claim 4, wherein the first component is a component smaller than a predetermined size. 1. A method for determining an abnormality in a component mounter that mounts components on a board, the component mounter including a component supply device that supplies the components by a tray that accommodates a plurality of the components on an upper surface thereof, the method comprising:
an imaging step of sequentially imaging the plurality of components supplied from the component supply device;
a determination step of determining whether or not the posture of the component supplied from the component supply device is normal based on the image captured in the imaging step;
a determination step of determining that an abnormality has occurred in the component mounter when a proportion of the images of the components captured a first number of times in the imaging step that are determined to be abnormal in the determination step is equal to or greater than a predetermined proportion;
The abnormality determination method includes:

Images