JP7657694B2 - Component Mounting System - Google Patents

Description

The present invention relates to a component mounting system that produces component-mounted boards by picking up components from a component supply area, transporting the components onto a board, and mounting (mounting) them.

Conventionally, component mounting systems including a mounting machine that produces component-mounted boards on which electronic components (hereinafter simply referred to as "components") are mounted on a board such as a printed circuit board have been known. As described in Patent Document 1, the mounting machine is usually equipped with a mounting head that adsorbs and holds components from a component supply area and transports them to the board, and a camera unit that captures the components adsorbed and held by the mounting head. After the components are taken out of the component supply area and before they are mounted on the board, the camera unit captures the components adsorbed and held by the mounting head. Based on the image, a component recognition process is performed to recognize the positional deviation (adsorption deviation) of the components relative to the mounting head. Then, when the components are mounted on the board, the position of the mounting head is corrected according to the recognition result, thereby ensuring the mounting position accuracy of the components relative to the board. On the other hand, if the components in the image cannot be recognized in the component recognition process or if there is an abnormality in the components in the image, the mounting machine stops with an error and the operator is notified of the component recognition abnormality. For example, if the mounting head fails to pick up a component due to a component pickup error, or if the posture of the picked-up component is extremely poor (if the component is misaligned beyond the tolerance), a component recognition error will occur.

JP 2015-130377 A

In the above mounting machine, the camera unit is equipped with a camera body equipped with an image sensor and a dedicated lighting device attached to it, and is usually able to capture component images without being affected by the lighting environment around the mounting machine (the lighting environment in the factory). However, if an abnormality occurs, such as a dirty lens on the camera body or a drop in the brightness level of the lighting device due to a malfunction, the quality of the captured image may decrease, which may cause component recognition errors.

In other words, even if a component is properly adsorbed and held by the mounting head, lens dirt or the like can hinder component recognition, which can lead to component recognition errors. Therefore, if it were possible to determine whether a component recognition error is due to lens dirt or other camera unit abnormalities when a component recognition error occurs, a quick response would be possible and the error stop period of the mounting machine could be shortened, but Patent Document 1 makes no mention of such technology.

The present invention was made in consideration of the above circumstances, and aims to provide a technology that can determine anomalies in the camera unit, such as lens dirt, when a component recognition anomaly occurs during component recognition processing in a mounting machine.

The component mounting system according to one aspect of the present invention comprises a mounting execution unit including a mounting head that performs a component mounting process of suction-holding and removing components from a feeder that supplies components and mounting the components on a board, and a camera unit that acquires an image related to the state of component suction-holding by the mounting head; a recognition unit that performs a component recognition process that recognizes the state of component suction by the mounting head based on the image captured by the camera unit; and a determination unit that determines whether or not there is an abnormality in the camera unit when a component recognition abnormality occurs in the component recognition process, and the determination unit acquires a normal state image that is a past image captured by the camera unit and is an image of a normal component recognition state, compares this normal state image with an abnormal state image that is an image in which the component recognition abnormality occurred, and determines whether or not there is an abnormality in the camera unit based on the differences between these images.

In this component mounting system, if a component recognition abnormality occurs during component recognition processing by the recognition unit, the determination unit acquires a previous normal state image (an image of a normal component recognition state) from the camera unit, compares this normal state image with an abnormal state image (an image in which a component recognition abnormality occurred), and determines whether or not there is an abnormality in the camera unit based on the differences between these images. If there is an abnormality in the camera unit, such as a dirty lens or poor lighting, there is often a clear difference between the normal state image and the abnormal state image. Therefore, with this component mounting system, it becomes possible to determine whether or not there is an abnormality in the camera unit during component recognition processing.

In the component mounting device, each of the abnormal state image and normal state image includes a component image made up of a group of pixels representing a component, and a background image made up of a group of pixels representing a peripheral area of the component image, and the determination unit determines whether or not there is an abnormality in the camera unit based on the difference between the background image in the abnormal state image and the background image in the normal state image.

If the lens of the camera unit is dirty and appears in the background image, the dirt may be recognized as part of a part, which may cause an abnormality in part recognition. With the above configuration, the presence or absence of an abnormality in the camera unit is determined based on the difference between the background image in the abnormal state image and the background image in the normal state image, so when an abnormality in part recognition occurs due to lens dirt as described above, it is possible to determine with a high degree of accuracy that there is an abnormality in the camera unit.

In this case, the determination unit determines that there is an abnormality in the camera unit if the brightness of the background image in the abnormal state image is lower than the brightness of the background image in the normal state image.

If the entire lens of the camera unit is dirty due to the adhesion of dust or the like, or if there is an abnormality in the lighting, the entire image becomes dark and the contrast difference between the part image and the background image becomes small, which may result in the part becoming unclear and causing an abnormality in part recognition. With the above configuration, the presence or absence of an abnormality in the camera unit is determined based on a comparison between the brightness of the background image in the abnormal state image and the brightness of the background image in the normal state image, so that in cases where the entire lens of the camera unit is dirty due to the adhesion of dust or the like, as described above, it is possible to determine with a high level of accuracy that there is an abnormality in the camera unit.

In this case, it is preferable that the determination unit further determines that there is an abnormality in the camera unit if the brightness of the background image in the abnormal state image is equal to or lower than a threshold value.

This configuration makes it possible to more accurately determine abnormalities in the camera unit, such as when the entire lens of the camera unit is dirty due to the adhesion of dust or the like.

In addition, in the above-mentioned component mounting device, it is preferable that the determination unit obtains, as the normal state image, an image in which a component of the same type as the component that is the subject of the abnormal state image is the subject.

With this configuration, the subject is the same, improving the reliability of determining whether or not there is an abnormality in the camera unit based on the differences between the abnormal state image and the normal state image.

The component mounting device preferably further includes a notification unit that notifies the user of an abnormality in the camera unit when the determination unit determines that the camera unit has an abnormality.

With this configuration, when a component recognition anomaly occurs, the operator can recognize that the cause is an anomaly in the camera unit. This saves the operator the trouble of investigating other causes, allowing subsequent measures to be taken promptly and ultimately shortening the period during which the mounting execution unit is stopped due to an error.

In the above-mentioned component mounting system, if the determination unit determines that there is no abnormality in the camera unit, it may determine that a pickup error by the mounting head and/or a component abnormality has occurred, and the notification unit may be configured to notify that a pickup error by the mounting head and/or a component abnormality has occurred.

With this configuration, when a component recognition abnormality occurs, the operator can recognize that the cause is a pickup error by the mounting head and/or a component abnormality. This saves the operator the trouble of investigating the camera unit abnormality, allowing subsequent measures to be taken promptly and ultimately shortening the period of error stop of the mounting execution unit.

According to the component mounting device according to each of the above aspects, if a component recognition abnormality occurs during the component recognition process in the mounting machine, it is possible to determine an abnormality in the camera unit, such as lens dirt.

1 is a schematic plan view showing a component mounting system according to an embodiment of the present invention. FIG. 2 is a block diagram showing a configuration of the component mounting system. 2 is a plan view showing a mounter body of a mounter provided in the component mounting system. FIG. 3 is a schematic front view showing a head unit and a camera unit provided in the mounting machine main body. FIG. 10 is a flowchart illustrating control of component recognition processing by a mounting control unit. FIG. 13 is a diagram showing a normal state image acquired by the part recognition process. FIG. 11 is a diagram showing an example of an abnormal state image acquired by the part recognition process. FIG. 11 is a diagram showing another example of an abnormal state image acquired by the part recognition process.

The following describes in detail an embodiment of the present invention with reference to the drawings.

[Component Mounting System Configuration]
FIG. 1 is a schematic plan view showing a component mounting system 100 according to an embodiment of the present invention, and FIG. 2 is a block diagram showing the configuration of this component mounting system 100.

The component mounting system 100 comprises multiple mounting machines (in this example, four mounting machines 101-104) and a management device 110 connected to the mounting machines 101-104 so as to be able to communicate data. The mounting machines 101-104 are devices that mount electronic components (hereinafter referred to as "components") on a substrate P (see FIG. 3) such as a printed wiring board to produce component-mounted substrates. These mounting machines 101-104 are connected in series in the transport direction of the substrate P to form a component mounting line. The white arrow in the figure indicates the transport direction of the substrate P.

The basic configuration of each mounting machine 101 to 104 is the same. Below, the specific configuration will be explained using one mounting machine 101 as an example. As shown in FIG. 2, the mounting machine 101 comprises a mounting machine main body 1, a mounting control unit 2, a mounting communication unit 3, a display unit 4, and an operation unit 5. The mounting machine main body 1 corresponds to the "mounting execution unit" of the present invention, and the display unit 4 corresponds to the "notification unit" of the present invention.

The mounting machine main body 1 performs a component mounting process to mount components on the board P. The mounting communication unit 3 is an interface for data communication with the management device 110, and has the function of inputting and outputting various data and information to and from the management device 110. The mounting control unit 2 controls the component mounting process by the mounting machine main body 1 in accordance with board data stored in the memory unit 22 described below, and also controls data communication of the mounting communication unit 3. The display unit 4 displays various information related to the component mounting process. The operation unit 5 receives input operations of various commands to the mounting control unit 2 by the operator. The detailed configuration of each of these units will be described below.

Figure 3 is a plan view showing the mounting machine main body 1 of the mounting machine 101, and Figure 4 is a schematic front view showing the head unit 16 and camera unit 18 provided on the mounting machine main body 1. Note that in Figures 1, 3, and 4, the directional relationship is shown using XYZ Cartesian coordinates.

The mounting machine main body 1 includes a base 10, a conveyor 12, a component supply unit 14, a head unit 16, and a camera unit 18. The base 10 is a mounting base for various devices equipped in the mounting machine main body 1. The conveyor 12 is a transport line for the substrate P installed on the base 10 so as to extend in the X direction, and is composed of a pair of belt-type conveyors 12a. The conveyor 12 carries the substrate P from outside the machine to a predetermined work position, and after the mounting work, carries the substrate P from the work position to outside the machine. The position of the substrate P shown in FIG. 3 is the work position. The conveyor 12 is equipped with a clamping mechanism (not shown), and the substrate P is positioned and held at the work position by this clamping mechanism during the component mounting process.

The component supply units 14 are areas for supplying components, and are provided on both sides of the conveyor 12 in the Y direction. The component supply units 14 are provided with multiple feeders 14a, and components are supplied by each feeder 14a. In this example, each component supply unit 14 is provided with a tape feeder that supplies components by unwinding a tape containing components (small surface mount components) at regular intervals.

The head unit 16 picks up a component from the feeder 14a in the component supply unit 14, moves to a working position, and mounts the component on the board P held by the clamp mechanism. As shown in FIG. 4, the head unit 16 has multiple mounting heads 161, each equipped with a suction nozzle 161a at its tip (lower end). The mounting head 161 can move forward and backward (up and down) in the Z direction and rotate around its axis by driving a motor not shown. When picking a component from the feeder 14a, the mounting head 161 descends from a predetermined retreat position, sucks and holds the component with the suction nozzle 161a, and then rises to the retreat position. Then, when mounting a component on the board P, the mounting head 161 descends from the retreat position above the board P and releases the component by releasing the suction-holding state of the component. As a result, the component is mounted at the target mounting position set on the board P.

The head unit 16 can move horizontally (XY directions) at least in the space above the component supply unit 14 and the substrate P at the work position by operation of the head unit drive mechanism 17. As shown in FIG. 3, the head unit drive mechanism 17 includes fixed rails 171 fixed to a pair of elevated frames installed on the base 10, a beam member 172 that moves in the Y direction along the fixed rails 171, and a unit support part (not shown) that moves in the X direction along the beam member 172. The head unit 16 is attached to this unit support part. The beam member 172 and the unit support member each move due to the driving force of a motor. The movement of the beam member 172 and the unit support member moves the head unit 16 in the XY directions.

The camera unit 18 is installed between the component supply unit 14 and the conveyor 12 on the base 10. The camera unit 18 is a device that performs a component imaging process to image the component in order to recognize the state of the component being suctioned and held by the suction nozzle 161a. After the suction nozzle 161a of each mounting head 161 suctions and holds the component from the feeder 14a, the camera unit 18 passes above the camera unit 18 when the head unit 16 moves above the substrate P at the work position, and sequentially images the components suctioned and held by each suction nozzle 161a from below. The image obtained in this way is an image (sometimes called an adsorption process image) that can confirm, in addition to the suction failure of the component by the suction nozzle 161a (a state in which the component is not suctioned), for example, the posture, shape, and amount of deviation of the suction position of the component relative to the suction nozzle 161a. When the component is mounted on the substrate P, the movement direction and movement amount of the head unit 16 are corrected based on the posture and amount of deviation of the component. This ensures precision in placing components at the target placement position.

As shown in FIG. 4, the camera unit 18 includes a camera body 181 and an illumination device 182. The camera body 181 includes an imaging element, such as a CMOS (Complementary metal-oxide-semiconductor) or a CCD (Charged-coupled device), and an optical system including a plurality of lenses for forming an image of the component on the imaging element. The illumination device 182 includes a plurality of LEDs arranged in a dome shape, and irradiates illumination light from below onto the component held by the suction nozzle 161a. With this configuration, the camera unit 18 irradiates illumination light from below onto the component held by the suction nozzle 161a, and receives the light reflected by the component with the camera body 181a. In this way, an image of the component is captured.

Returning to FIG. 2, the display unit 4 is configured, for example, by a liquid crystal display, and displays various information on the component mounting process performed by the mounting machine main body 1. The display operation of the display unit 4 is controlled by a display control unit 28, which will be described later. The operation unit 5 is configured by a keyboard, a mouse, or a touch panel provided on the operation unit 5. The operation unit 5 receives input operations of various commands from the operator to the mounting control unit 2.

The mounting control unit 2 is composed of a CPU (Central Processing Unit), a ROM (Read Only Memory) that stores a control program, a RAM (Random Access Memory) that is used as a working area for the CPU, etc. The mounting control unit 2 mainly includes a general control unit 21, a storage unit 22, a transport control unit 23, a component supply control unit 24, a head control unit 25, an imaging control unit 26, an image processing unit 27, a display control unit 28, and a communication control unit 29.

Based on the mounting program and various data stored in the memory unit 22, the overall control unit 21 controls the operation of the mounting machine 101, such as the component mounting process of the mounting machine main body 1 and the data communication of the mounting communication unit 3, and executes various calculation processes and judgment processes associated with the control. Specifically, the overall control unit 21 executes component recognition processes such as detecting component suction errors by the suction nozzle 161a and determining the amount of deviation of the component suction position relative to the suction nozzle 161a based on images captured by the camera unit 18, and further causes the display unit 4 to display the results of the component recognition process via the display control unit 28. In particular, in this example, when a component recognition abnormality occurs in the component recognition process, the overall control unit 21 also executes a process to determine whether or not there is an abnormality in the camera unit 18. This point will be described in detail later. In this example, the overall control unit 21 is configured to function as the "recognition unit" and "judgment unit" of the present invention.

The memory unit 22 stores mounting programs and various data. The various data includes board data referenced by the central control unit 21. This board data is the basis for the component mounting process of the mounting machine main body 1 by the central control unit 21, and includes multiple parameter information, target suction position information, and target mounting position information. The parameter information is information such as the type and shape (dimensions) of the component, the type of mounting head, the type of suction nozzle, and the type and arrangement of the feeder 14a. The target suction position information is information that indicates the target suction position (target suction position) when the component is picked up by the suction nozzle 161a. The target mounting position information is information that indicates the target mounting position of the component on the board P.

The transport control unit 23, the component supply control unit 24, the head control unit 25, the imaging control unit 26, the display control unit 28, and the communication control unit 29 control the operation of each unit based on instructions from the general control unit 21. That is, the transport control unit 23 controls the transport operation of the board P by the conveyor 12. The component supply control unit 24 controls the component supply operation by each of the feeders 14a arranged in the component supply unit 14. The head control unit 25 controls the operation of the head unit 16 and the mounting head 161. The imaging control unit 26 controls the component imaging operation by the camera unit 18. The display control unit 28 controls the display operation by the display unit 4. The communication control unit 29 controls the mounting communication unit 3 to control data communication between the mounting machine 101 and the management device 110. The image processing unit 27 performs a predetermined image processing on the image data input from the camera unit 18. Based on the image that has been subjected to this image processing, the general control unit 21 executes the component recognition processing and the determination processing of the presence or absence of an abnormality in the camera unit 18.

The above is the configuration of mounting machine 101, but as already mentioned, the configurations of the other mounting machines 102 to 104 are basically the same as this mounting machine 101.

The management device 110 is configured, for example, by a personal computer that is connected to the mounting machine 101 so as to be capable of data communication. The management device 110 includes a management control unit 111, a management communication unit 112, a management memory unit 113, a display unit 114, and an operation unit 115.

The management communication unit 112 is an interface for performing data communication with the mounting machines 101-104, and acquires the management data MD (described below) input from the mounting machines 101-104. The management memory unit 113 accumulates and stores the management data MD acquired by the management communication unit 112. The display unit 114 is configured, for example, by an LCD display, and displays information on the management data MD stored in the management memory unit 113. The operation unit 115 is configured by a keyboard, a mouse, or a touch panel provided on the management display unit 125. The operation unit 115 accepts input operations of various commands related to the display of the display unit 114 by the operator. The management control unit 111 controls the display unit 114 in accordance with the commands input to the operation unit 115. In addition, the management control unit 111 controls the management communication unit 112 in response to requests from the mounting machines 101 to 104, reads the management data MD stored in the management memory unit 113, and executes processing to output the management data MD to the mounting machine 101 to 104 that has made the request.

[Control of component recognition processing, etc. by mounting control unit 2]
5 is a flowchart showing control of component recognition processing and the like by the mounting control unit 2 (general control unit 21). This control is executed from the time when each mounting head 161 (suction nozzle 161a) of the head unit 16 performs a component suction process (a process of picking up a component from the feeder 14a) until the time when the component sucked and held by each mounting head 161 is mounted on the substrate P.

The general control unit 21 first determines whether the part imaging process by the camera unit 18 has been completed (step S1), and if the result is Yes, executes part recognition processing based on the suction processing image that has been subjected to a predetermined image processing by the image processing unit 27 and that corresponds to the first mounting head 161 in the preset order (step S3). Then, it determines whether the result of the part recognition is normal (step S5).

In the process of step S5, if the component can be recognized in the suction process image and the component's posture, shape, and suction position deviation amount are all within a predetermined tolerance range, the general control unit 21 determines that the component recognition is normal. In this case, the general control unit 21 creates management data MD that associates the parameter information and suction position deviation amount data, etc. with the suction process image determined to be normal (referred to as a "normal state image"), and inputs this management data MD to the management device 110 via the mounting communication unit 3. The management device 110 accumulates and stores the management data MD input from each mounting machine 101 to 104 in the management memory unit 113 for each mounting machine (step S7).

Next, the central control unit 21 judges whether the component recognition process has been completed for all components, i.e., whether the component recognition process has been completed for the suction process images corresponding to all mounting heads 161 (step S9). If the answer is No, the process returns to step S1, and the component recognition process is executed based on the suction process image corresponding to the next mounting head 161 in the order. Finally, when it is judged that the component recognition process has been completed for all components (Yes in step S9), the central control unit 21 ends control of this flowchart.

On the other hand, if it is determined in step S5 that the part recognition result is abnormal (No in step S5), that is, if the part cannot be recognized in the adsorption processing image, or if any of the part's posture, shape, and adsorption position deviation amount exceeds the allowable range, the central control unit 21 transitions the process to step S11.

In step S11, the central control unit 21 outputs an inquiry signal to the management device 110 and checks whether the management data DM of its own machine, i.e., the management data DM of the mounting machine equipped with the central control unit 21, which includes a normal state image of the same part (same type of part) as the part where the component recognition abnormality occurred, is stored in the management memory unit 113. If the answer is No, the central control unit 21 further outputs inquiry information to the management device 110 and checks whether the management data DM of a machine other than its own machine, which includes a normal state image of the same part as the part where the component recognition abnormality occurred, is stored in the management memory unit 113 (step S13).

If step S13 is No, i.e., if there is no management data DM containing a normal state image for either the machine itself or any of the other mounting machines 101-104, the central control unit 21 controls the display unit 4 via the display control unit 28 to display a screen indicating the occurrence of a component recognition abnormality on the display unit 4, and further stops the operation of each feeder 14a via the component supply control unit 24 and stops the operation of the head unit 16 via the head control unit 25 (steps S15, S17). As a result, the operator is notified of the occurrence of the component recognition abnormality, and the component mounting process by the mounting machine main body 1 is interrupted (error stop).

After the error stop, the central control unit 21 waits for the operator to input a predetermined release operation via the operation unit 5 (step S19), and if the release operation is input (Yes in step S19), the central control unit 21 releases the error stop and transitions to step S9.

On the other hand, if the processing in step S11 or step S13 is Yes, i.e., if management data DM including a normal state image is stored in the management device 110, the general control unit 21 outputs a read command signal to the management device 110 and acquires the management data DM from the management device 110 (step S21).

When the integrated control unit 21 acquires the management data MD including the normal state image, it compares this normal state image with the abnormal state image (the adsorption processing image determined to be a component recognition abnormality in step S5) as follows (step S23).

Figure 6 shows a schematic diagram of an example of a normal state image. As shown in the figure, the normal state image G0 includes a part image Ga0 consisting of a group of pixels showing a part held by the suction nozzle 161a, and a background image Gb0 consisting of a group of pixels showing the peripheral area of this part image Ga0. In the process of step S23, the general control unit 21 obtains the brightness of the background image Gb0 of the normal state image G0 and the brightness of the image of the area of the abnormal state image that corresponds to the background image Gb0 of the normal state image G0 (i.e., the background image of the abnormal state image), and compares the brightness of these background images. In this case, for example, the average value of the gradation of each pixel in the group of pixels showing the background image can be set as the brightness of the background image.

Then, the general control unit 21 judges whether the brightness B2 of the background image of the abnormal state image is lower than the brightness B1 of the background image of the normal state image G0 and whether the brightness B2 of the abnormal state image is equal to or lower than a preset threshold value Bt (step S25). The threshold value Bt is a value that assumes a background image captured in a state where, for example, dust or the like has adhered to the camera body 181 and the entire lens is clouded (wide-area dirt), or where the illumination light does not meet a specified brightness level due to a malfunction of the illumination device 182, and is a value based on, for example, a simulation result. In other words, in step S25, it is judged whether the cause of the component recognition abnormality is an abnormality of the camera unit 18, such as a clouded lens (wide-area dirt) or poor illumination.

Figure 7 shows a schematic example of an abnormal state image. The abnormal state image G1 shown in the figure includes a part image Ga1 and a background image Gb1, but the whole image appears dark due to lens fogging (wide-area dirt) or poor lighting in the camera unit 18. In the case of such an image, even if a part is properly suctioned and held by the suction nozzle 161a, the part image Ga1 may not be accurately recognized due to the small contrast difference between the part image Ga1 and the background image Gb1, and the part recognition may be determined to be abnormal in the processing of step S5. Therefore, as described above, by comparing the brightness B1 of the background image Gb0 of the normal state image G0 with the brightness B2 of the background image Gb1 of the abnormal state image G1, it is possible to determine whether or not there is an abnormality in the camera unit 18, such as fogging of the lens of the camera unit 18 (wide-area dirt) or poor lighting.

If the result of the process in step S25 is Yes, the central control unit 21 moves the process to step S31. On the other hand, if the result of the process in step S25 is No, the central control unit 21 moves the process to step S27, and further executes a process of detecting foreign matter adhering to the lens of the camera unit 18 based on a comparison between the background image Gb0 of the normal state image G0 and the background image of the abnormal state image, and determines whether or not a foreign matter is adhering (step S29). In this case, the central control unit 21 can determine whether or not a foreign matter is adhering by, for example, binarizing each background image using a specific gradation as a threshold, taking the difference between the background image Gb0 of the normal state image G0 and the background image of the abnormal state image, and calculating the area of the remaining black pixels.

Figure 8 shows another example of an abnormal state image, abnormal state image G2, in which a foreign object is attached to the lens of the camera unit 18. In this abnormal state image G2, a foreign object image Gf is captured in a position in the background image Gb2 that is relatively close to the part image Ga2. In such a case, the part image Ga2 and the foreign object image Gf are likely to be recognized as a single part, and even if the part is properly suctioned and held by the suction nozzle 161a, a part recognition abnormality may be determined. Therefore, as described above, by comparing the background image Gb0 of the normal state image G0 with the background image Gb1 of the abnormal state image G1, it is possible to determine whether or not there is an abnormality in the camera unit 18, such as the attachment of a foreign object to the lens (narrow area dirt).

If it is determined in step S29 that no foreign matter is attached, i.e., if the process of step S29 returns No, the central control unit 21 makes a final determination that "there is no abnormality in the camera unit 18." On the other hand, if the processes of steps S25 and S29 return Yes, i.e., if it is determined that the lens is clouded (wide-area dirt) or that foreign matter is attached (narrow-area dirt), the central control unit 21 makes a final determination that "there is an abnormality in the camera unit 18."

If the processing in step S29 is Yes, the central control unit 21 proceeds to step S31. In step S31, the central control unit 21 controls the display unit 4 via the display control unit 28 to cause the display unit 4 to display a screen indicating the occurrence of a part recognition abnormality. In this case, if the processing in step S25 or step S29 is Yes, that is, if it is determined that there is an abnormality in the camera unit 18, the central control unit 21 controls the display unit 4 so that information indicating the part recognition abnormality is displayed together with information indicating the abnormality in the camera unit 18. In this way, in addition to the occurrence of the part recognition abnormality, the operator is notified that the cause of the part recognition abnormality is an abnormality in the camera unit 18.

If the result of the process in step S29 is No, that is, if it is determined that there is no abnormality in the camera unit 18, the general control unit 21 controls the display unit 4 so that information indicating the component pick-up error by the mounting head 161 and the component abnormality are displayed together with information indicating the component recognition abnormality. A pick-up error is a state in which the above-mentioned component is not picked up. A component abnormality is a state in which any of the component's posture, shape, and pick-up position deviation amount exceeds the allowable range. When the cause of the component recognition abnormality is other than the camera unit 18, it is empirically determined that most of these are either a pick-up error or a component abnormality. Therefore, in this example, if it is determined that there is no abnormality in the camera unit 18, the general control unit 21 causes the display unit 4 to display information indicating the component pick-up error and/or the component abnormality.

The central control unit 21 further stops the operation of each feeder 14a via the component supply control unit 24, and stops the operation of the head unit 16 via the head control unit 25, thereby interrupting (error stop) the component mounting process by the mounting machine main body 1 (step S33). After the error stop, the central control unit 21 waits for the operator to input a predetermined release operation via the operation unit 5 (step S35), and if the release operation is input (Yes in step S35), the central control unit 21 releases the error stop and returns the process to step S9.

[Effects, etc.]
In the above-mentioned component mounting system 100, the general control unit 21 executes a component recognition process to recognize the component suction state of the mounting head 161 based on the image captured by the camera unit 18 (step S2 in FIG. 5). When the general control unit 21 determines that the component recognition is abnormal in this component recognition process (No in step S5 in FIG. 5), it acquires management data DM including a normal state image G0, which is a past suction process image by the camera unit 18 and is an image of a normal component suction state, from the management device 110, compares this normal state image G0 with the abnormal state image (G1, G2), which is the suction process image determined to be abnormal in the component recognition, and determines whether or not there is an abnormality in the camera unit 18 based on the difference between these images (steps S25, S29). In detail, as described above, the general control unit 21 compares the brightness B1 of the background image Gb0 of the normal state image G0 with the brightness B2 of the background image Gb1 of the abnormal state image G1, and thereby determines whether or not there is lens fogging (wide-area dirt) or poor lighting. In addition, the background image Gb0 and the background image Gb1 are compared to determine whether or not there is any foreign matter (narrow area dirt) attached to the lens.

If it is determined that there is an abnormality in the camera unit 18 (Yes in steps S25 and S29 in FIG. 5), the central control unit 21 controls the display unit 4 to display information indicating an abnormality in the camera unit 18 together with information indicating an abnormality in component recognition (step S31). Conversely, if there is no abnormality in the camera unit 18 (No in step S29 in FIG. 5), the central control unit 21 controls the display unit 4 to display information indicating a component pickup error by the mounting head 161 and a component abnormality (step S31).

According to this embodiment of the component mounting system 100, when the mounter main body 1 stops due to an error caused by a component recognition abnormality, the operator can determine whether the cause is the camera unit 18 or something else (a component pickup error or a component abnormality). This allows the operator to quickly begin work to resolve the error stop of the mounter main body 1. This leads to a shortened period of the error stop of the mounter main body 1, and ultimately contributes to improving the productivity of component mounting boards by the mounters 101 to 104.

In addition, each time a component suction abnormality occurs, the presence or absence of an abnormality in the camera unit 18 is judged. Therefore, if an abnormality is judged to exist in the camera unit 18, the operator can check the condition of the camera unit 18 and perform maintenance such as cleaning. This prevents camera unit 18 abnormalities such as dirty lenses or poor lighting from being left unattended for long periods of time, and prevents the camera unit 18 abnormality from being mistakenly recognized as a component recognition abnormality even when the component suction state by the mounting head 161 is normal. Furthermore, by suppressing the occurrence of such erroneous recognition, the amount of parts discarded due to the erroneous recognition is reduced. This also has the advantage of reducing the number of parts that are needlessly discarded.

Furthermore, in the component mounting system 100, when a component recognition abnormality occurs and management data DM is acquired from the management device 110 (step S21 in FIG. 5), the management data DM including a normal state image of the same component as the component where the component recognition abnormality occurred is acquired, and the normal state image in the management data DM is compared with the abnormal state image (the adsorption processing image determined to have a component recognition abnormality). With this configuration, since the subject component is the same in both images, there is less error in the area of the compared background images, and the background images can be compared more accurately. Therefore, the presence or absence of an abnormality in the camera unit 18 can be determined with high accuracy.

In addition, in the component mounting system 100, when management data DM including a normal state image is obtained from the management device 110, the management data DM of the own machine is obtained preferentially as described above (step S11 in FIG. 5), and if management data DM of the own machine is not present, management data DM of the mounting machines 101-104 other than the own machine is obtained (step S13 in FIG. 5), and the normal state image and abnormal state image of the management data DM are compared. Therefore, when a component recognition abnormality occurs, there is a high possibility that management data DM including a normal state image can be obtained, making it possible to more reliably determine whether or not there is an abnormality in the camera unit 18.

As described above, since the basic configuration of the mounting machines 101 to 104 is the same, even when acquiring the management data DM of the mounting machines 101 to 104 other than the own machine, the presence or absence of an abnormality in the camera unit 18 can be determined at a level comparable to that when acquiring the management data DM of the own machine. In this case, if the imaging conditions of the camera unit 18 (for example, the brightness level of the lighting device, etc.) differ between the mounting machines 101 to 104, or if there are errors even if the imaging conditions are the same, the general control unit 21 can be configured to correct the acquired normal state image of the management data DM of the mounting machines 101 to 104 other than the own machine according to the difference in the imaging conditions, errors, etc., and determine the presence or absence of an abnormality in the camera unit 18 based on the corrected normal state image.

[Modification]
The component mounting system 100 described above is one example of a preferred embodiment of the component mounting system according to the present invention, and the specific configuration can be appropriately changed without departing from the scope of the present invention. For example, the following configuration also belongs to the present invention.

(1) In the component mounting system 100 of the embodiment, management data DM is output from each of the mounting machines 101 to 104 to the management device 110, and is accumulated and stored in the management memory unit 113 of the management device 110. However, each of the mounting machines 101 to 104 may be configured to accumulate and store its own management data DM in its own memory unit 22.

In this case, the overall control unit 21 is configured to obtain the management data DM by reading it from the memory unit 22 of the own machine, and to determine the presence or absence of an abnormality in the camera unit 18 based on the normal state image contained in the management data DM. Furthermore, if the management data DM including the normal state image is not stored in the memory unit 22 of the own machine, the overall control unit 21 is configured to obtain the management data DM including the normal state image from the mounting machines 101-104 other than the own machine, and to determine the presence or absence of an abnormality in the camera unit 18 based on the normal state image in the management data DM. In such a modified configuration, each of the mounting machines 101-104 constitutes the component mounting system of the present invention.

(2) In the component mounting system 100 of the embodiment, in the process of step S23 in FIG. 5, if the brightness B2 of the background image of the abnormal state image is lower than the brightness B1 of the background image of the normal state image G0 and the brightness B2 of the abnormal state image is equal to or lower than a preset threshold value Bt, the central control unit 21 determines that there is an abnormality in the camera unit 18 (step S25). However, it may be determined that there is an abnormality in the camera unit 18 when either brightness B2 < brightness B1 or brightness B2 < threshold value Bt is satisfied. However, in order to more accurately determine the presence or absence of lens fogging (wide-area dirt) or poor lighting, a configuration like that of the embodiment is considered to be desirable.

(3) In the component mounting system 100 of the embodiment, if it is determined in the process of step S29 in FIG. 5 that there is no abnormality in the camera unit 18, the overall control unit 21 controls the display unit 4 in the process of step S33 so that information indicating a component suction error by the mounting head 161 and a component abnormality is displayed together with information indicating a component recognition abnormality. However, if the overall control unit 21 can distinguish between a component suction error and a component abnormality, the display unit 4 may be configured to display either the suction error or the component abnormality, whichever is applicable.

(4) In the embodiment, an application example of the present invention has been described in which the presence or absence of an abnormality in the camera unit 18 that captures an image of a component held by suction nozzle 161a of mounting head 161 from below has been determined. However, the present invention is also applicable to cases in which the presence or absence of an abnormality in a camera unit that captures an image of a component held by suction nozzle 161a from the side has been determined.

1 Mounting machine main body (mounting execution unit)
REFERENCE SIGNS LIST 14 Component supply area 14a Feeder 16 Head unit 161 Mounting head 18 Camera unit 181 Camera body 182 Illumination device 2 Mounting control unit 21 General control unit 22 Memory unit 4 Display unit (notification unit)
5 Operation unit 100 Component mounting system 101, 102, 103, 104 Mounting machine 110 Management device G0 Normal state image G1, G2 Abnormal state image

Claims (7)

a mounting execution unit including a mounting head that performs a component mounting process of suction-holding and removing components from a feeder that supplies components and mounting the components on a board, and a camera unit that captures an image relating to the state in which the components are sucked and held by the mounting head;
a recognition unit that performs a component recognition process to recognize a state in which the component is picked up by the mounting head based on an image captured by the camera unit;
a determination unit that determines whether or not there is an abnormality in the camera unit when a component recognition abnormality occurs in the component recognition process,
The component mounting system is characterized in that the judgment unit acquires a normal state image that is a past image captured by the camera unit and is an image of a normal component recognition state, compares this normal state image with an abnormal state image that is an image in which the component recognition abnormality has occurred, and judges whether or not there is an abnormality in the camera unit based on the differences between these images. 2. The component mounting system according to claim 1,
each of the abnormal state image and the normal state image includes a part image made up of a pixel group representing a part, and a background image made up of a pixel group representing a peripheral area of the part image;
The component mounting system according to claim 1, wherein the determination unit determines whether or not there is an abnormality in the camera unit based on differences between the background image in the abnormal state image and the background image in the normal state image. 3. The component mounting system according to claim 2,
A component mounting system characterized in that the judgment unit judges that there is an abnormality in the camera unit when the brightness of the background image in the abnormal state image is lower than the brightness of the background image in the normal state image. 4. The component mounting system according to claim 3,
The component mounting system according to claim 1, further comprising: a determination unit that determines that there is an abnormality in the camera unit when the brightness of the background image in the abnormal state image is equal to or lower than a threshold value. 5. The component mounting system according to claim 1,
A component mounting system, characterized in that the determination unit acquires an image of a component of the same type as the component that is the subject of the abnormal state image as the normal state image. 6. The component mounting system according to claim 1,
A component mounting system, further comprising a notification unit that notifies of an abnormality in the camera unit when the determination unit determines that an abnormality exists in the camera unit. 7. The component mounting system according to claim 6,
When the determination unit determines that there is no abnormality in the camera unit, the determination unit determines that a pickup error by the mounting head and/or a component abnormality has occurred,
The component mounting system according to claim 1, wherein the notification unit notifies the occurrence of a pickup error by a mounting head and/or a component abnormality.