JP7660306B2 - Automatic exchange system and automatic exchange method - Google Patents

Description

This disclosure relates to an automatic replacement system and an automatic replacement method for replacing a part container and a part supply device of a part supply unit.

The component mounting device has a component supply unit such as a cart that holds in parallel a component container such as a reel that stores multiple components, and a component supply device such as a feeder that moves the components stored in the component container to a component supply position, and mounts the components supplied to the component supply position on a board. An automatic replacement device that automatically replaces the component supply device attached to such a component mounting device is known (see, for example, Patent Document 1). Patent Document 1 discloses that a parts cassette that integrates a component container and a component supply device is kept waiting on a waiting table provided in the component mounting device, and is then grasped by a robot provided in the component mounting device and transferred to the component supply section for replacement.

Japanese Unexamined Patent Publication No. 4-283035

However, when replacing a component supply device and a component container that are installed separately, or when replacing a component supply device or a component container using a robot independent of the component mounting device, the robot and the item being replaced may be misaligned from their designated positions, and there is room for further improvement in replacing the component supply device or the component container without making a mistake in such cases.

The present disclosure provides an automatic replacement system and an automatic replacement method that can accurately replace part containers.

The automatic exchange system disclosed herein is an automatic exchange system for exchanging a component container of a component supply unit having a lower portion for holding a component container that holds components, and a feeder mounting portion to which a component supply device that moves the components held in the component container to a component supply position is mounted, and includes an end effector that holds the component container, a movement mechanism configured to move the end effector, a recognition portion that recognizes a plurality of unit recognition bodies for identifying the component supply unit, a path setting portion that sets a movement path for moving the end effector, and a control portion that controls the movement mechanism, and the control portion moves the end effector to the component supply device based on the set movement path and the recognition result of the recognition portion of the lower portion of the component supply unit and the unit recognition body provided on the feeder mounting portion.

The disclosed automatic replacement method is an automatic replacement method for replacing a component container of a component supply unit having a lower portion for holding a component container that stores components and a feeder mounting portion to which a component supply device that moves the components stored in the component container to a component supply position is mounted, by an automatic replacement system having a movable end effector, and includes the steps of recognizing a plurality of unit recognition bodies for identifying the component supply unit, setting a movement path for moving the end effector, and moving the end effector to the component supply device based on the set movement path and the recognition results of the unit recognition bodies provided on the lower portion of the component supply unit and the feeder mounting portion.

According to this disclosure, the part container can be replaced accurately.

FIG. 1 is a configuration explanatory diagram of a component mounting system according to an embodiment of the present disclosure; FIG. 1 is a configuration explanatory diagram of a component mounting line of a component mounting system according to an embodiment of the present disclosure. FIG. 1 is a configuration explanatory diagram of a component mounting device equipped with a component supply cart included in a component mounting system according to an embodiment of the present disclosure; FIG. 1 is a front view of a component supply cart included in a component mounting system according to an embodiment of the present disclosure. FIG. 1 is a configuration explanatory diagram of a component mounting device equipped with a tray feeder of a component mounting system according to an embodiment of the present disclosure; FIG. 1 is a perspective view of a tray feeder included in a component mounting system according to an embodiment of the present disclosure; FIG. 1 is a configuration explanatory diagram of a transfer device of a component mounting system according to an embodiment of the present disclosure; FIG. 1 is a block diagram showing a configuration of a control system of a component mounting system (automatic exchange system) according to an embodiment of the present disclosure. FIG. 1 is an explanatory diagram of an example of unit information used in a component mounting system (automatic exchange system) according to an embodiment of the present disclosure. FIG. 1 is an explanatory diagram of the outer dimensions of a component supply cart included in a component mounting system according to an embodiment of the present disclosure. FIG. 1 is an explanatory diagram of an example of external dimension information used in a component mounting system (automatic exchange system) according to an embodiment of the present disclosure; FIG. 1 is an explanatory diagram of an example of supply device information used in a component mounting system (automatic exchange system) according to an embodiment of the present disclosure; FIG. 1 is a diagram showing a flow of an automatic exchange method according to an embodiment of the present disclosure. FIG. 1 is a process diagram illustrating automatic replacement of component reels in a component mounting system (automatic replacement system) according to an embodiment of the present disclosure. FIG. 14B is a process diagram for automatically replacing a parts reel, which is a continuation of FIG. FIG. 14B is a process diagram for automatically replacing a parts reel. FIG. 14C is a process diagram for automatically replacing a parts reel. FIG. 15B is a process diagram for automatically replacing a parts reel, which is a continuation of FIG. FIG. 15B is a process diagram for automatically replacing a parts reel. FIG. 1 is a front view of a second component supply cart included in a component mounting system according to an embodiment of the present disclosure; FIG. 13 is a partial enlarged view of an example of a cart recognition target formed on a second component supply cart according to an embodiment of the present disclosure; FIG. 13 is a partial enlarged view of an example of a mounting unit recognition target formed on a second component supply cart according to an embodiment of the present disclosure; FIG. 1 is a configuration explanatory diagram of a second transfer device included in a component mounting system according to an embodiment of the present disclosure; FIG. 13 is a process diagram illustrating a contact detection operation for recognizing the position of a carriage recognition target by a second transfer device according to an embodiment of the present disclosure. FIG. 19B is a process diagram of the contact detection operation, which follows FIG. FIG. 19B is a process diagram of the contact detection operation. FIG. 11 is an explanatory diagram illustrating how the position of a second component supply cart is recognized by a second transfer device according to an embodiment of the present disclosure;

An embodiment of the present disclosure will be described in detail below with reference to the drawings. The configurations, shapes, etc. described below are illustrative examples and can be modified as appropriate depending on the specifications of the component mounting system, component mounting line, component mounting device, component supply cart, and tray feeder. In the following, the same reference numerals are used for corresponding elements in all drawings, and duplicated explanations will be omitted. In FIG. 1 and some of the drawings described below, the X direction of the board transport direction (left and right direction in FIG. 4) and the Y direction orthogonal to the board transport direction (left and right direction in FIG. 3) are shown as two axial directions that are orthogonal to each other in the horizontal plane. In addition, in FIG. 2, the Z direction (up and down direction in FIG. 3) is shown as the height direction that is orthogonal to the horizontal plane.

First, the configuration of component mounting system 1 will be described with reference to FIG. 1. Component mounting system 1 is configured such that three component mounting lines L1 to L3 arranged on floor F are connected by a wired or wireless communication network 2 and managed by a management computer 3. Each of component mounting lines L1 to L3 is configured by connecting multiple devices including a component mounting device as described below, and has the function of manufacturing mounted boards on which components are mounted. Note that component mounting system 1 does not need to have three component mounting lines L1, and may have one, two, or four or more.

A material storage facility W is installed on floor F. In material storage facility W, components to be supplied to the component mounting devices that make up component mounting lines L1 to L3 are stored in component reels, trays, stick cases, etc. The component reels, trays, and stick cases are component containers that store multiple components.

Floor F is equipped with multiple transport devices V, which are unmanned guided vehicles. The transport devices V have built-in wireless communication units T, and transmit and receive signals and information to and from the management computer 3 via the wireless management communication unit 3a of the management computer 3. The transport devices V autonomously move along the travel paths set on the floor F based on work instructions sent from the management computer 3 and information collected by the transport devices V using travel path tapes and beacons installed on the floor F (not shown), various sensors (GPS, obstacle sensors, etc.) built into the transport devices V, cameras, etc.

Next, the detailed configuration of component mounting lines L1 to L3 will be described with reference to Figure 2. Component mounting lines L1 to L3 have the same configuration, and below, component mounting line L1 will be described. Component mounting line L1 has, in order from the upstream side in the board transport direction (left side in Figure 2), a printer M1, component mounting device M2, component mounting device M3, component mounting device M4, and reflow device M5. Each device has a board transport mechanism such as a belt conveyor, and mounted boards are manufactured by transporting boards from upstream to downstream using the board transport mechanism of each device. Each device is connected to a management computer 3 by a wired or wireless communication network 2, and can send and receive data to and from the management computer 3.

In FIG. 2, the printer M1 has the function of printing a paste-like cream solder onto the board through a screen mask. The three component mounting devices M2 to M4 have the function of picking up components supplied to the component supply unit 4 by component suction nozzles attached to the mounting heads, and transporting and mounting the components to the mounting points on the board on which the cream solder has been printed. The component supply unit 4 of the component mounting devices M2 and M3 is equipped with a component supply trolley 5, which will be described later. The component supply unit 4 of the component mounting device M4 is equipped with a tray feeder 6, which will be described later.

The reflow device M5 has the function of heating the board on which the components are mounted to melt the cream solder and then solidifying it to solder the components to the board. The management computer 3 performs production management of the mounted boards manufactured on the component mounting lines L1 to L3, downloading the programs and data required for manufacturing mounted boards to each component mounting device, and also performs processes to support the supply work of replenishing components to the component mounting devices M2 to M4.

Next, the configuration of component mounting devices M2 and M3 will be described with reference to Figures 3 and 4. In Figure 3, a board transport mechanism 8 provided on the upper surface of a base 7 transports a board 9 in the X direction, positions it, and holds it. Above the board transport mechanism 8, a mounting head 10 is installed that moves in the horizontal direction (X direction, Y direction) by a head movement mechanism (not shown). A suction nozzle 10a is provided at the bottom end of the mounting head 10. The suction nozzle 10a vacuum-sucks and holds a component D. A component supply cart 5 is attached to a component supply unit 4 provided to the side of the board transport mechanism 8.

In FIG. 4, a feeder mounting section 12 is installed on the upper part of the component supply cart 5. On the upper surface of the feeder mounting section 12, multiple slots S for mounting tape feeders 13 or stick feeders 14 are formed in the board transport direction (X direction). When the component supply cart 5 is mounted on the component supply section 4, the feeder mounting section 12 is separated from the lower part 5a of the component supply cart 5 and coupled to the base 7. On the lower part 5a of the component supply cart 5, multiple upper reel holding sections 5U aligned in the X direction and multiple lower reel holding sections 5B aligned in the X direction are installed vertically. The upper reel holding section 5U and the lower reel holding section 5B each rotatably hold a component reel 16 around which a component storage tape 15 storing components D is wound.

In FIG. 3, a reel mark Mb is attached to the side of the parts reel 16. The reel mark Mb includes a barcode or two-dimensional code on which information identifying the parts reel 16 is recorded. The part storage tape 15 pulled out from the parts reel 16 held by the upper reel holding unit 5U or the lower reel holding unit 5B is inserted into the tape insertion port 13a of the tape feeder 13. The tape feeder 13 transports the part storage tape 15 inserted from the tape insertion port 13a in the tape feed direction and supplies parts D to the part supply position E. In other words, the tape feeder 13 is a part supply device that moves parts D stored in the parts reel 16 (parts container) to the part supply position E.

In FIG. 4, the stick feeder 14 supplies a plurality of components D stored in a series inside a long, hollow stick case 17 to a component supply position E. Methods for moving the components D in the stick feeder 14 to the component supply position E include vibration and pushing with a wire. The stick cases 17 are stored in a stacked state in a loading section 14a provided on the upper part of the stick feeder 14. In other words, the stick feeder 14 is a component supply device that moves the components D stored in the stick case 17 (component container) to the component supply position E. In this way, the component supply cart 5 has a component container (component reel 16, stick case 17) and a component supply device (tape feeder 13, stick feeder 14), and constitutes a component supply unit that supplies components D to the component mounting devices M2 and M3.

In FIG. 3, component mounting devices M2 and M3 have a mounting control unit 18 that controls the board transport mechanism 8, mounting head 10, and head movement mechanism. The mounting control unit 18 sends a supply command for component D to the tape feeder 13 or stick feeder 14 to supply component D to component supply position E. The mounting control unit 18 also controls the mounting head 10 and head movement mechanism to perform component mounting work by having the mounting head 10 pick up component D supplied to component supply position E by the component supply device and transport it to the mounting position of the board 9 held by the board transport mechanism 8.

In FIG. 4, a cart mark Mc is marked on the exterior of the lower part 5a of the parts supply cart 5. A mounting section mark Ma is marked on the exterior of the feeder mounting section 12. The cart mark Mc and the mounting section mark Ma include a barcode, a two-dimensional code, a unique mark, etc., on which information identifying the parts supply cart 5 is recorded. When multiple marks (here, two cart marks Mc and two mounting section marks Ma) are recorded on the parts supply cart 5, information identifying the position at which each mark is marked is also recorded.

In this way, the trolley mark Mc and the mounting part mark Ma are unit recognition bodies that are attached (formed) on the exterior of the parts supply unit (parts supply trolley 5). Note that the trolley mark Mc and the mounting part mark Ma may be attached on any of the front, side, top, back, or bottom surfaces when viewed from the side where each mark is recognized, as long as they are visible from the exterior.

A tape feeder mark Mt is provided on the side of the tape feeder 13 where the tape insertion port 13a is formed. The tape feeder mark Mt includes a bar code, a two-dimensional code, a unique mark, etc., on which information identifying the tape feeder 13 is recorded. A stick feeder mark Ms is provided on the side of the stick feeder 14 where the stick case 17 is supplied. The stick feeder mark Ms includes a bar code, a two-dimensional code, a unique mark, etc., on which information identifying the stick feeder 14 is recorded.

In this way, the tape feeder mark Mt and the stick feeder mark Ms are supply device identifiers that are affixed (formed) to the exterior of the component supply device (tape feeder 13, stick feeder 14). The supply device identifiers are provided to identify the component supply device.

The tape feeder mark Mt and stick feeder mark Ms may be placed on the front, side, top, back, or bottom as viewed from the side where each mark can be recognized, provided that the mark is visible from the outside.

The configuration of component mounting device M4 will now be described with reference to Figures 5 and 6. Component mounting device M4 is similar to component mounting devices M2 and M3, except that a tray feeder 6 is attached to component supply unit 4 instead of component supply cart 5. The configuration of tray feeder 6 will now be described. In Figure 5, on the top surface of feeder placement unit 20 of tray feeder 6, a rack unit 21 is installed at the front side of tray feeder 6 attached to component supply unit 4, and a pallet moving unit 22 is installed at the rear side.

In the rack section 21, multiple (here, two) magazine holding sections 26 are arranged vertically to store magazines 25 that store stacked pallets 24 on which trays 23 that contain parts D are attached. An openable rack door 26a is provided at the front of the operation surface of the rack section 21. The magazines 25 are inserted into and removed from the magazine holding sections 26 when the rack door 26a is open (lower side in FIG. 6). A pallet placement section 27 is provided above the topmost magazine holding section 26. An openable cover 27a (arrow a) is provided at the top of the operation surface of the rack section 21. When the openable cover 27a is opened, one pallet 24 with a tray 23 attached to the pallet placement section 27 can be inserted or removed from the tray feeder 6.

In FIG. 5, the pallet moving section 22 has a pallet placement table 28, a lifting mechanism 29, and a removal mechanism 28a. The lifting mechanism 29 raises and lowers the pallet placement table 28 (arrow b), moving the pallet placement table 28 to a height position at which the pallet 24 stored in the magazine 25 or the pallet 24 placed on the pallet placement section 27 can be inserted or removed, or to a component supply position E from which the mounting head 10 removes a component D. The removal mechanism 28a pulls out and holds the pallet 24 from the magazine 25 or the pallet placement section 27, and also stores the held pallet 24 in the magazine 25 or the pallet placement section 27.

In this way, the tray 23 and the magazine 25 that stores multiple trays 23 are component containers that store multiple components D. The pallet moving unit 22, which has the pallet mounting table 28, the lifting mechanism 29, and the removal mechanism 28a, is a component supply device that moves the components D stored in the tray 23 (component container) to the component supply position E. The tray feeder 6 is a component supply unit that has a component container (tray 23) and a component supply device, and supplies components D to the component mounting device M4.

In FIG. 6, a rack mark Ml is attached to the exterior of each rack door 26a. The rack mark Ml includes a barcode, a two-dimensional code, a unique mark, etc., in which information identifying the tray feeder 6 and information on the position (upper level, lower level) of the rack door 26a (magazine holding section 26) are recorded. An opening/closing mark Mo is attached to the front of the opening/closing cover 27a. The opening/closing mark Mo includes a barcode or a two-dimensional code in which information identifying the tray feeder 6 is recorded. In this way, the rack mark Ml and the opening/closing mark Mo are unit identifiers attached (formed) to the exterior of the component supply unit (tray feeder 6). The unit identifier is provided to identify the component supply unit. Note that the rack mark Ml and the opening/closing mark Mo may be attached to any of the front, side, top, back, or bottom, as long as they are visible from the exterior, as viewed from the side from which each mark is recognized.

When the magazine 25 is inserted into the magazine holding section 26, a magazine mark Mm is affixed to the front of the magazine. The magazine mark Mm includes a barcode, a two-dimensional code, a unique mark, etc., on which information identifying the magazine 25 is recorded. When the tray 23 is stored in the tray feeder 6, a tray mark Mp (not shown) is affixed to the front of the tray 23. The tray mark Mp includes a barcode, a two-dimensional code, a unique mark, etc., on which information identifying the tray 23 is recorded. Note that the magazine mark Mm and the tray mark Mp may be affixed to the front, side, top, back, or bottom of the tray 23 as viewed from the side where each mark is recognized, provided that the marks are visible from the side other than the front.

Next, the configuration of the transport device V will be described with reference to Figure 7. The transport device V has a robot mechanism 31 and a storage unit 32 above the cart unit 30. The cart unit 30 has wheels 30a, a motor that drives the wheels 30a, a direction change mechanism that changes the direction of the wheels 30a, and a running mechanism 33 (see Figure 8) that includes a sensor that detects the position and posture of the transport device V.

The robot mechanism 31 is a multi-joint robot with an end effector 34 at its tip, and multiple servo motors move the end effector 34 in the X, Y, and Z directions, change its orientation, and rotate it by θ. There are no particular limitations on the control method for the robot mechanism 31, and examples of the control method include impedance control and compliance control, but other control methods, control methods that combine multiple control methods, and control using AI may also be used.

The end effector 34 has the function of gripping (holding) the component supply device (tape feeder 13, stick feeder 14) or the component container (component reel 16, stick case 17, tray 23, magazine 25). Note that the end effector 34 may have functions such as holding and suction in addition to gripping, so long as it can hold the component supply device or the component container. The end effector 34 is also provided with a moving camera 35 (imaging unit) that captures images of the unit recognition body (cart mark Mc, mounting unit mark Ma, rack mark Ml, open/close mark Mo), the supply device recognition body (tape feeder mark Mt, stick feeder mark Ms), the magazine mark Mm, the tray mark Mp, etc.

The various marks captured by the mobile camera 35 are subjected to recognition processing by the recognition processing unit 36 (see FIG. 8) possessed by the transfer device V, whereby the information recorded on each mark and its position are recognized. In this way, the mobile camera 35 (imaging unit) is a recognition unit that recognizes (captures) the unit recognizer (the mark formed on the component supply unit) and the supply device recognizer (the mark formed on the component supply device). The robot mechanism 31 is also a movement mechanism that moves the end effector 34 and the mobile camera 35, and aligns the imaging axis of the mobile camera 35 with the various marks.

In FIG. 7, the storage section 32 has multiple (four here) storage shelves 32a with the side facing the robot mechanism 31 open. Replacement component supply devices (tape feeder 13, stick feeder 14) and component containers (component reels 16, stick cases 17, trays 23, magazines 25) can be placed on the storage shelves 32a. The transfer device V places the replenishment component supply devices and component containers taken out of the material storage facility W on the storage shelves 32a and transports them to the component mounting devices M2 to M4 that are to be replenished.

A head camera 37 with its imaging axis facing downward is installed between the storage unit 32 and the robot mechanism 31. The head camera 37 captures an image of the reel mark Mb attached to the side of the part reel 16 held by the end effector 34 from above. The reel mark Mb captured by the head camera 37 is subjected to recognition processing by the recognition processing unit 36, whereby the information recorded on the reel mark Mb is recognized.

The mobile camera 35 may also have the function of the head camera 37. In this case, the mobile camera 35 is attached in a position where it can capture an image of the reel mark Mb on the side of the parts reel 16 when the end effector 34 is gripping the parts reel 16. Alternatively, the mobile camera 35 may capture an image of the reel mark Mb on the top surface of the parts reel 16 when the end effector 34 has pulled the parts reel 16 out of the storage section 32.

Next, the configuration of the control system of the component mounting system 1 will be described with reference to FIG. 8. Here, the configuration relating to the function of exchanging the component supply devices and component containers of the component mounting devices M2 to M4 by the transport device V in the component mounting system 1 will be described. The management computer 3 has a wireless management communication unit 3a, a management memory unit 40, a work instruction generation unit 41, a management input unit 42, and a management display unit 43. The management input unit 42 is an input device such as a keyboard, touch panel, or mouse, and is used when entering operation commands and data. The management display unit 43 is a display device such as an LCD panel, and displays various information such as an operation screen for operation by the management input unit 42.

The management memory unit 40 is a storage device, and stores part information 40a, unit information 40b, external dimension information 40c, supply device information 40d, replacement work information 40e, etc. The part information 40a includes, for each part number that identifies the part D, the part name (type), information about the part container in which the part D is stored (size, etc.), and information about marks attached to the part container, such as the reel mark Mb and the tray mark Mp. That is, the part information 40a includes the diameter and thickness of the part reel 16, which is the part container, and the external dimensions (length, width, depth) of the stick case 17, the tray 23, and the magazine 25. The unit information 40b includes unit-specific information, which is information specific to each part supply unit (part supply cart 5, tray feeder 6).

Now, referring to FIG. 9, the unit information 40b will be described in detail. The unit information 40b includes a unit number 50, a unit type 51, a recognition method 52, a reel correction value 53, and a slot correction value 54. The unit number 50 is information that identifies the component supply unit. The unit type 51 is information that identifies the type of the component supply unit. In the unit type 51, the "cart (17)" and the "cart (30)" are component supply carts 5 having 17 and 30 rows of slots S, an upper reel holding portion 5U, and a lower reel holding portion 5B, respectively, and the "tray (20)" is a tray feeder 6 that can store 20 pallets 24.

Recognition method 52 is information (unit recognition information) that specifies whether to image the unit recognition body (cart mark Mc, mounting unit mark Ma, rack mark Ml, open/close mark Mo) using the moving camera 35 (imaging unit, recognition unit) of transfer device V, or to recognize the external shape of the component supply unit, when determining the work position of the component supply unit. In recognition method 52, the "mark" refers to the unit recognition body that is imaged, and the "external shape" refers to the external shape of the entire or partial component supply unit that is imaged. By specifying the recognition method using recognition method 52 in this way, the same automatic exchange method described below can be applied even to component supply units with different configurations, such as the presence or absence of a unit recognition body.

In FIG. 9, the reel correction value 53 is the amount of deviation from the ideal position P0 where the cart mark Mc is placed to the position P1 where it is actually placed, and is shown by the amount of deviation 53x (ΔX) in the X direction and the amount of deviation 53z (ΔZ) in the Z direction (see FIG. 10). The slot correction value 54 is the amount of deviation from the ideal position where the mounting part mark Ma is placed to the position where it is actually placed, and is shown by the amount of deviation 54x (ΔX) in the X direction and the amount of deviation 54z (ΔZ) in the Z direction. In this way, the unit type 51, recognition method 52, reel correction value 53, and slot correction value 54 for each component supply unit, including the unit number 50, constitute unit-specific information 55 that identifies the component supply unit. In other words, the unit-specific information 55 includes unit recognition information (recognition method 52).

The reel correction value 53 may include the amount of deviation in the Y direction between the transport device V and the component supply unit. The amount of deviation in the Y direction is the difference between the ideal distance between the transport device V and the component supply unit and the distance between the transport device V and the component supply unit when it is actually stopped, and can be calculated based on the size of the whole or part of the cart mark Mc captured by the moving camera 35. In addition, by capturing images of multiple cart marks Mc, the amount of deviation in the Y direction between the transport device V and the component supply unit can be approximately grasped. Then, by taking the amount of deviation in the Y direction into consideration, the amount of deviation in the X direction 53x (ΔX) and the amount of deviation in the Z direction 53z (ΔZ) can be calculated with higher accuracy. Similarly, the slot correction value 54 may include the amount of deviation in the Y direction.

In FIG. 8, the external dimension information 40c includes information regarding the external dimensions used in the automatic replacement operation of the component supply device and the component container for each type of component supply unit (component supply cart 5, tray feeder 6) and each type of component supply device (tape feeder 13, stick feeder 14).

Now, referring to FIG. 11, the details of the external dimension information 40c will be described. FIG. 11 shows information on the positions of the lower reel holding part 5B and the upper reel holding part 5U from the external dimension information 40c of the component supply cart 5 whose unit type 51 is "Cart (17)". The external dimension information 40c includes a holding part number 56 and a holding part position 57. The holding part number 56 is information that identifies the lower reel holding part 5B and the upper reel holding part 5U, with "B01" to "B17" indicating the lower reel holding part 5B and "U01" to "U17" indicating the upper reel holding part 5U. The holding part position 57 is indicated by an X position 57x and a Z position 57z that are based on the ideal position P0 of the cart mark Mc attached to the component supply cart 5 (see FIG. 10).

The external dimension information 40c when the unit type 51 is "Cart (17)" includes, in addition to the holding section position 57 shown in FIG. 11, information regarding the position of the slot S, and information regarding the external size (length, width, depth) of the part supply cart 5. The external dimension information 40c when the unit type 51 is "Cart (30)" includes the same information as the external dimension information 40c when the unit type 51 is "Cart (17)". The external dimension information 40c when the unit type 51 is "Tray (20)" includes information regarding the position of the rack door 26a, information regarding the position of the opening/closing cover 27a, and information regarding the external diameter size of the tray feeder 6.

In addition, the external dimension information 40c of the tape feeder 13 includes information on the position of the tape insertion opening 13a, information on the external size of the tape feeder 13, etc. The external dimension information 40c of the stick feeder 14 includes information on the position of the loading section 14a, information on the external size of the stick feeder 14, etc.

In FIG. 8, the supply device information 40d includes supply device specific information, which is information specific to each component supply device (tape feeder 13, stick feeder 14).

Now, referring to FIG. 12, the details of the supply device information 40d will be described. The supply device information 40d includes a feeder number 60, a feeder type 61, a recognition method 62, and a feeder correction value 63. The feeder number 60 is information that identifies the component supply device. The feeder type 61 is information that identifies the type of component supply device. In the feeder type 61, "tape (8 mm)" and "tape (16 mm)" are tape feeders 13 that transport component storage tapes 15 with widths of 8 mm and 16 mm, respectively, and "stick (10)" is a stick feeder 14 that can store 10 stick cases 17.

Recognition method 62 is information (supply device recognition information) that specifies whether to capture an image of a supply device recognition body (tape feeder mark Mt, stick feeder mark Ms) using the moving camera 35 (imaging unit, recognition unit) possessed by the transfer device V, or to recognize the external shape of the component supply device, when determining the working position in the component supply device. In recognition method 62, the "mark" refers to the supply device recognition body that is imaged, and the "external shape" refers to the external shape of the component supply device that is imaged. By specifying the recognition method using recognition method 62 in this way, the same automatic replacement method can be applied even to component supply devices with different configurations, such as the presence or absence of a supply device recognition body.

In FIG. 12, the feeder correction value 63 is the amount of deviation from the ideal position where the tape feeder mark Mt or stick feeder mark Ms is placed to the position where it is actually placed, and is indicated by the amount of deviation 63x (ΔX) in the X direction and the amount of deviation 63z (ΔZ) in the Z direction. In this way, the feeder type 61, recognition method 62, and feeder correction value 63 for each component supply device, including the feeder number 60, constitute supply device specific information 64 that identifies the component supply device. In other words, the supply device specific information 64 includes supply device recognition information (recognition method 62).

In FIG. 8, replacement work information 40e includes information identifying the part container to be replenished or replaced (such as the part number), the feeder number 60 of the part supply device to be replenished or replaced, the location, and the replacement order. The location of the part to be replenished or replaced is information that identifies the position of the part container or part supply device in question, such as the relevant part mounting lines L1-L3, part mounting devices M2-M4, unit number 50 and holder number 56 of the part supply cart 5, or unit number 50 of the tray feeder 6. Note that replacement work information 40e is created in advance based on the production plan, production data, material and equipment information, etc.

In FIG. 8, the work instruction generating unit 41 generates a work instruction including a destination of the transport device V based on the replacement work information 40e. The work instruction generating unit 41 also generates a work instruction that recognizes which unit recognition body is attached (formed) to the component supply unit, or a work instruction that recognizes the external shape of the component supply unit, based on the replacement work information 40e and the unit recognition information (recognition method 52). The work instruction generating unit 41 also generates a work instruction that recognizes which supply device recognition body is attached (formed) to the component supply device, or a work instruction that recognizes the external shape of the component supply device, based on the replacement work information 40e and the supply device recognition information (recognition method 62). The work instruction is generated for each work process, and the movement coordinates of the end effector 34 are calculated for each generated process.

The work instruction generating unit 41 generates work instructions including a movement target of the end effector 34 of the transport device V based on the replacement work information 40e, the unit specific information 55, the supply device specific information 64, and the external dimension information 40c of the component supply unit and the component supply device. For example, when the trolley mark Mc is recognized when replacing the component reel 16, the movement target of the end effector 34 is specified in XZ coordinates with the recognized trolley mark Mc as the base point. At that time, the deviation of the position where the trolley mark Mc is attached is corrected based on the reel correction value 53. For example, when the lower reel holding part 5B with the holding part number 56 of "B01" at the lower left end of the component supply trolley 5 in FIG. 10 is the work position, the movement target is corrected and specified as (X1 + ΔX, Z1 + ΔZ).

Similarly, when the slot S of the part supply cart 5 is the working position, the movement target is corrected based on the slot correction value 54. Also, when the tape insertion port 13a of the tape feeder 13 or the loading section 14a of the stick feeder 14 is the working position, the movement target is corrected based on the feeder correction value 63. That is, the work instruction generation unit 41 generates a work instruction in which the movement target of the end effector 34 is corrected based on at least one of the unit position correction value (reel correction value 53, slot correction value 54) and the supply device position correction value (feeder correction value 63). The unit position correction value (reel correction value 53, slot correction value 54) is a value for correcting the movement target of the end effector 34 based on the positional deviation of the unit recognition body, and the supply device position correction value (feeder correction value 63) is a value for correcting the movement target of the end effector 34 based on the positional deviation of the supply device recognition body.

In this way, by correcting the movement target with the pre-stored correction value, the end effector 34 can be moved accurately even if the positions of the various marks vary for each component supply unit or each component supply device. The work instructions generated by the work instruction generation unit 41 are transmitted to the transport device V that performs the replacement work via the wireless management communication unit 3a. Note that the work instruction generation unit 41 may generate a work instruction with a movement target that is not corrected with a correction value, transmit the unit position correction value and the supply device position correction value together with the work instruction, and correct the movement target when the path setting unit 47 described later in the transport device V sets the movement path.

As described above, the management computer 3 has a memory unit (management memory unit 40), unit-specific information 55, and work instruction generation unit 41. The management memory unit 40 associates and stores external dimension information 40c of the component supply unit with unit-specific information 55 that identifies the component supply unit. The work instruction generation unit 41 generates work instructions including a movement target for the end effector 34 based on the external dimension information 40c of the component supply unit. The management computer 3 is a management device that generates work instructions for a transport device V having a movable end effector 34. Note that the management computer 3 does not need to be configured as a single computer, and may be configured as multiple devices. For example, part or all of the management memory unit 40 may be stored in the cloud via a server.

In FIG. 8, the transport device V has a traveling mechanism 33, a robot mechanism 31, an end effector 34, a mobile camera 35, a recognition processing unit 36, a head camera 37, a transport memory unit 44, a travel control unit 45, an exchange control unit 46, a route setting unit 47, and a wireless communication unit T. The transport memory unit 44 is a storage device, and stores work instruction information 44a, recognition result information 44b, etc. The work instruction information 44a stores work instructions sent from the management computer 3 (management device) and received by the wireless communication unit T.

The recognition result information 44b stores information recorded on each mark obtained by the recognition processing unit 36 recognizing the image captured by the mobile camera 35 (imaging unit, recognition unit), information on the position of each mark, and component information recorded on the reel mark Mb obtained by the recognition processing unit 36 recognizing the image captured by the head camera 37. The recognition result information 44b also stores information obtained by the recognition processing unit 36 recognizing the external shapes of the component supply unit and component supply device captured by the mobile camera 35, such as the positions of the slot S, upper reel holding unit 5U, and lower reel holding unit 5B of the component supply cart 5, the positions of the rack door 26a and opening/closing cover 27a of the tray feeder 6, the position of the tape insertion port 13a of the tape feeder 13, and the position of the loading unit 14a of the stick feeder 14.

The travel control unit 45 controls the travel mechanism 33 based on the destination of the transport device V included in the work instruction, and moves the transport device V to the specified destination. The exchange control unit 46 controls the robot mechanism 31 based on the recognition destination included in the work instruction, and causes the mobile camera 35 to capture an image of the recognition destination. The path setting unit 47 sets a movement path (e.g., arrows c2 to c6 in Figures 14B to 15C) along which the end effector 34 will move, based on the movement target of the end effector 34 included in the work instruction.

At that time, the path setting unit 47 sets a movement path so that the end effector 34 does not interfere with the main body of the component supply unit based on the external size (length, width, depth) of the component supply unit contained in the external dimension information 40c of the component supply unit. In other words, the movement path is set so that the end effector 34 moves along a different trajectory depending on the object that the end effector 34 is not holding or is holding.

The exchange control unit 46 (control unit) controls the robot mechanism 31 (movement mechanism) based on the movement path set by the path setting unit 47 and the recognition result (recognition result information 44b) by the moving camera 35 (imaging unit, recognition unit) to move the end effector 34 to at least one of the component supply device and the component container. This allows the end effector 34 to accurately grasp the component supply device or the component container even if the stopping position of the transfer device V is shifted from the specified transfer destination or the position of the component supply device or the component container in the component supply unit is shifted from the specified position.

Thus, the transfer device V has an end effector 34, a moving mechanism (robot mechanism 31) that moves the end effector 34, a recognition unit (moving camera 35), a path setting unit 47, and a control unit (exchange control unit 46) that controls the moving mechanism. The transfer device V and a management device (management computer 3) that has a work instruction generation unit 41 that generates work instructions constitute an automatic exchange system that exchanges at least one of the component supply device and the component container of the component supply unit.

Next, following the flow of Figure 13 and with reference to Figures 14A to 15C, an automatic replacement method for replacing at least one of the component supply device and the component container of a component supply unit by a transport device V having a movable end effector 34 will be described. Below, an example will be described in which a component reel 16, which is a component container, is removed from a component supply cart 5 (component supply unit) attached to a component mounting device M2 and replaced. Note that for convenience, the robot mechanism 31 of the transport device V is not shown in Figures 14A to 15C.

In FIG. 13, first the management computer 3 (management device) generates a work instruction specifying the destination as the location in front of the parts supply cart 5 on which the parts reel 16 to be replaced is attached, and transmits this to the transport device V carrying the parts reel 16 to be replenished. In the transport device V that has received the work instruction, the travel control unit 45 moves the transport device V to the specified destination in accordance with the work instruction (ST1: Transport device moving process). When the movement is complete, the transport device V transmits this to the management computer 3. Note that even when the transport device V has moved to the specified destination, a stopping error of several centimeters or millimeters may occur.

Then, the work instruction generation unit 41 in the management computer 3 generates a work instruction to remove the parts reel 16 to be replaced from the parts supply cart 5 and attach the parts reel 16 to be replenished (ST2: work instruction generation process). Here, in the work instruction generation process (ST2), the cart mark Mc (unit recognition body) is recognized, and a work instruction is generated that includes a movement target for the end effector 34 with the recognized cart mark Mc as the base point. Next, the management computer 3 transmits the generated work instruction to the transport device V (ST3: work instruction transmission process).

In FIG. 13, when the transfer device V receives a work instruction, it carries out the replacement work in accordance with the work instruction. First, if the work instruction instructs recognition of various marks (Yes in ST4), the replacement control unit 46 controls the robot mechanism 31 to move the mobile camera 35 (imaging unit, recognition unit) in front of the cart mark Mc (arrow c1 in FIG. 14A) and recognize the cart mark Mc (ST5: unit recognition process). In other words, the unit recognition body (cart mark Mc) attached (formed) to the exterior of the component supply unit (component supply cart 5) is recognized.

When instructed to recognize various marks, the transfer device V may determine whether the marks match those specified in the work instructions. It determines whether the marks are correct, and if they do not match, stops the work. This makes it possible to prevent work errors that may occur due to a worker misoperating and switching the part supply unit, etc.

Then, the mobile camera 35 (imaging section, recognition section) moves in front of the supply device recognition object (tape feeder mark Mt, stick feeder mark Ms) and recognizes the supply device recognition object (ST6: supply device recognition process). Note that since the work instruction does not include recognition of the supply device recognition object here, the supply device recognition process (ST6) is skipped. If the work instruction instructs recognition of the external shape (No in ST4), the exchange control section 46 controls the robot mechanism 31 to recognize the external shape of the component supply unit and component supply device instructed by the mobile camera 35 (ST7: external shape recognition process).

After mark recognition (ST5, ST6) or external shape recognition (ST7) is completed, the path setting unit 47 then sets a movement path for moving the end effector 34 based on the work instructions and the recognition results (ST8: path setting process). This sets a movement path that corrects for stopping errors of the transport device V and misalignments of the component supply devices and component containers in the component supply unit. Next, the replacement control unit 46 controls the robot mechanism 31 based on the set movement path to move the end effector 34 to the component reel 16 to be replaced (arrow c2 in Figure 14B) and have the end effector 34 grip the component reel 16.

In FIG. 13, the replacement control unit 46 then moves the end effector 34 gripping the parts reel 16 to remove it from the upper reel holding unit 5U (ST9), rotates the parts reel 16 90 degrees, moves it to the storage unit 32 (arrow c3 in FIG. 14C), and stores it in an empty storage shelf 32a (ST10). Next, the replacement control unit 46 grips the parts reel 16 to be replenished from the storage shelf 32a with the end effector 34 and removes it (ST11) (arrow c4 in FIG. 15A). At that time, the head camera 37 captures an image of the reel mark Mb affixed to the parts reel 16, and checks whether it is the parts reel 16 to be replenished as specified.

Then, the replacement control unit 46 rotates the end effector 34 that grips the parts reel 16 by 90 degrees and moves it to the front of the parts supply cart 5 (arrow c5 in FIG. 15B), and attaches the parts reel 16 to be replenished to the instructed upper reel holding unit 5U (ST12) (arrow c6 in FIG. 15C). Next, if there are parts reels 16 (parts containers) to be replaced remaining and the replacement work is not complete (No in ST13), the process returns to the work instruction generation process (ST2) and the replacement work for the next parts reel 16 is performed. When the replacement work for all parts reels 16 is complete (Yes in ST13), the automatic replacement ends.

If the work instructions (first time ST2, ST3) generated and sent by the management computer 3 include the entire process of the replacement work, the process does not return to the work instruction generation process (ST2) but returns to ST4 to carry out the next replacement work. Also, if the necessary information has been acquired the first time, the second and subsequent mark recognition (ST5, ST6) or external shape recognition (ST7) are skipped.

Thus, steps ST9 to ST12 are movement steps in which the end effector 34 is moved to at least one of the component supply device and the component container based on the movement path set in the path setting step (ST8) and the recognition results in the unit recognition step (ST5), the supply device recognition step (ST6), or the external shape recognition step (ST7). In other words, the automatic replacement method of this embodiment includes the unit recognition step (ST5), the path setting step (ST8), and movement steps (ST9 to ST12). This allows the component reel 16 (component container) to be replaced accurately.

In the automatic replacement method shown in FIG. 13, when replacing the component supply device (tape feeder 13, stick feeder 14), the mounting part mark Ma is recognized in the unit recognition process (ST5). When replacing the tray 23 (component container) of the tray feeder 6 (component supply unit), the opening/closing mark Mo is recognized in the unit recognition process (ST5), and in the movement process, the opening/closing cover 27a is opened and closed, and the tray mark Mp of the tray 23 in the pallet placement section 27 is recognized by the moving camera 35 (imaging section, imaging means).

When the magazine 25 (component container) of the tray feeder 6 (component supply unit) is replaced, the rack mark Ml is recognized in the unit recognition process (ST5), and in the movement process, the rack door 26a is opened and closed, and the magazine mark Mm of the magazine 25 in the rack section 21 is recognized by the moving camera 35. When the component storage tape 15 is inserted into the tape insertion port 13a of the tape feeder 13 after replacing the component reel 16, the tape feeder mark Mt is recognized in the supply device recognition process (ST6). When the stick case 17 (component container) of the stick feeder 14 is replaced, the stick feeder mark Ms is recognized in the supply device recognition process (ST6).

As described above, the component mounting system 1 of this embodiment replaces at least one of the component supply devices (tape feeder 13, stick feeder 14, pallet moving unit 22) and the component container (component reel 16, stick case 17, tray 23, magazine 25). The component container stores multiple components D. The component supply device moves the components D stored in the component container to the component supply position E. The component supply device and the component container are included in the component supply unit (component supply cart 5, tray feeder 6).

The automatic exchange system has a transport device V. The transport device V includes an end effector 34, a moving mechanism (robot mechanism 31), a recognition unit (moving camera 35), a path setting unit 47, and a control unit (exchange control unit 46). The end effector 34 grips the component supply device or the component container. The robot mechanism 31 moves the end effector. The moving camera 35 recognizes the unit recognition bodies (cart mark Mc, mounting unit mark Ma, rack mark Ml, open/close mark Mo) attached to the exterior of the component supply unit (formed on the component supply unit). The path setting unit 47 sets a movement path for moving the end effector 34. The exchange control unit 46 controls the movement mechanism.

Then, the control unit moves the end effector 34 to at least one of the component supply device and the component container based on the set movement path and the recognition result by the recognition unit. This allows the component container to be replaced accurately.

Note that the above description is an example of so-called internal setup, in which a component supply device or a component container is replaced in a component supply unit (component supply cart 5, tray feeder 6) attached to component mounting devices M2 to M4, but the present disclosure is not limited to internal setup. For example, the present disclosure can also be applied to so-called external setup, in which a component supply device or a component container is replaced in a component supply unit (component supply cart 5, tray feeder 6) removed from component mounting devices M2 to M4. In this case, the replacement work information 40e specifies a preparation area for performing external setup as the location of the supply target or replacement target. In external setup, the component supply unit may move to a transport device V fixed to the floor F, and the component supply device or the component container may be replaced at the replacement position.

In addition, various marks do not have to be composed of a single figure. For example, they may be composed of multiple figures, such as enclosed characters, and the mark composed of multiple figures may be recognized as a whole, with a specific figure being used as the coordinate for correction.

Next, a second embodiment of the component supply cart (hereinafter referred to as "second component supply cart 70") will be described with reference to Figures 16, 17A, and 17B. Like the component supply cart 5 described above, the second component supply cart 70 has a component container and a component supply device, and is a component supply unit that supplies components D to component mounting devices M2 and M3. The second component supply cart 70 differs from the component supply cart 5 in that it has cart recognition targets G1 and G2 instead of the cart mark Mc, and mounting part recognition targets G3 and G4 instead of the mounting part mark Ma. Hereinafter, the same components as those of the component supply cart 5 are given the same reference numerals, and detailed description will be omitted.

In FIG. 16, a lower plate 71 extending in the XY plane (horizontal plane) in the board transport direction (X direction) is installed on the front of the lower part 5a of the second component supply cart 70. Left and right side plates 72, 73 extending in the YZ plane are installed at both ends of the lower plate 71 in the X direction and extend upward. On the left side of the lower plate 71, a left rear plate 74 is installed, which extends in the ZX plane perpendicular to the left side plate 72 and the lower plate 71 (see also FIG. 17A). The lower plate 71, the left side plate 72, and the left rear plate 74 form the left cart recognition target G1. The corner where the lower plate 71, the left side plate 72, and the left rear plate 74 intersect is the position Q1 of the left cart recognition target G1.

To the right of the lower plate 71, a right side plate 73 and a right rear plate 75 are installed, which extend in the ZX plane perpendicular to the lower plate 71. The lower plate 71, the right side plate 73, and the right rear plate 75 form the right trolley recognition target G2. The corner where the lower plate 71, the right side plate 73, and the right rear plate 75 intersect is the position Q2 of the right trolley recognition target G2.

In FIG. 16, left and right support plates 76, 77 extending in the YZ plane are installed at both ends of the feeder mounting section 12 in the X direction, extending upward. An upper plate 78 extending in the X direction on the XY plane is installed between the top of the left support plate 76 and the top of the right support plate 77. On the left side of the upper plate 78, a left back plate 79 is installed, extending in the ZX plane perpendicular to the left support plate 76 and upper plate 78 (see also FIG. 17B). The upper plate 78, left support plate 76, and left back plate 79 form the left mounting section recognition target G3. The corner where the upper plate 78, left support plate 76, and left back plate 79 intersect is position Q3 of the left mounting section recognition target G3.

To the right of the upper plate 78, a right support plate 77 and a right back plate 80 are installed, which extend in the ZX plane perpendicular to the upper plate 78. The upper plate 78, the right support plate 77, and the right back plate 80 form the right attachment recognition target G4. The corner where the upper plate 78, the right support plate 77, and the right back plate 80 intersect is the position Q4 of the right attachment recognition target G4.

The cart recognition targets G1, G2 and the mounting unit recognition targets G3, G4 are unit recognition bodies for recognizing the position of the second component supply cart 70 and the position of the feeder mounting unit 12. In the second component supply cart 70, the recognition method 52 of the unit information 40b stored in the management storage unit 40 of the management computer 3 is stored as "target." In addition, the position information of the cart recognition targets G1, G2 and the mounting unit recognition targets G3, G4 in the second component supply cart 70 is stored in the unit information 40b.

Next, a second embodiment of the transfer device (hereinafter referred to as "second transfer device V1") will be described with reference to Figure 18. Similar to the transfer device V described above, the second transfer device V1 has a robot mechanism 31 and a storage section 32 above the cart section 30, and an end effector 34 is disposed at the tip of the robot mechanism 31. The second transfer device V1 differs from the transfer device V in that a contact sensor 81 is installed at the tip of the end effector 34. Below, the same components as the transfer device V are given the same reference numerals, and detailed explanations will be omitted.

In FIG. 18, the contact sensor 81 has a thin, cylindrical shape that protrudes from the front of the end effector 34. When the robot mechanism 31 moves the end effector 34 in the X, Y, and Z directions, the contact sensor 81 moves together with the end effector 34 in the X, Y, and Z directions. When the contact sensor 81 moves and the tip or side of the cylinder comes into contact with an object, it can detect in which direction the contact occurred. The detection result of the contact sensor 81 is sent to the recognition processing unit 36. The recognition processing unit 36 recognizes (calculates) the position where the contact sensor 81 comes into contact with the object based on the position of the end effector 34 (the operation of the robot mechanism 31).

Next, referring to Figures 19A to 19C, the unit recognition process (ST5) will be described, which is executed when the second transfer device V1 automatically replaces the tape feeder 13, which is a component supply device, and the component reel 16, which is a component container, mounted on the second component supply cart 70 (component supply unit). Here, it is assumed that the transfer device movement process (ST1), in which the second transfer device V1 is moved in front of the second component supply cart 70 in accordance with a work instruction, has been completed. In other words, it is assumed that the second transfer device V1 and the second component supply cart 70 are in the same positional relationship as the transfer device V and the component supply cart 5 shown in Figures 14A to 15C.

Below, an example of recognizing the left cart recognition target G1 will be described. That is, in the work instruction generation process (ST2), the work instruction generation unit 41 generates a work instruction including information on the unit recognition body that specifies the left cart recognition target G1 as the recognition target to be recognized by the contact sensor 81 (recognition unit). Then, in the unit recognition process (ST5), the exchange control unit 46 controls the robot mechanism 31 to move the contact sensor 81 in front of the left cart recognition target G1 and execute a contact detection operation described below to recognize the position Q1 of the left cart recognition target G1.

In Fig. 19A, in the contact detection operation, first, the exchange control unit 46 moves the contact sensor 81, which is moving in front of the left cart recognition target G1, in the Y direction (arrow d1). In Fig. 19B, when it is detected that the tip surface of the contact sensor 81 has come into contact with the left rear plate 74, the exchange control unit 46 stops the movement of the contact sensor 81 in the Y direction. Next, the exchange control unit 46 moves the contact sensor 81 in the X direction toward the left side plate 72 while abutting the tip surface of the contact sensor 81 against the left rear plate 74 (arrow d2).

In FIG. 19C, when it is detected that the side of the contact sensor 81 has come into contact with the left side plate 72, the exchange control unit 46 stops the movement of the contact sensor 81 in the X direction. Next, the exchange control unit 46 moves the contact sensor 81 in the Z direction toward the lower plate 71 while abutting the side of the contact sensor 81 against the left side plate 72 (arrow d3). When it is detected that the side of the contact sensor 81 has come into contact with the lower plate 71, the exchange control unit 46 stops the movement of the contact sensor 81 in the Z direction. Through this series of contact detection operations, the contact sensor 81 stops at the corner where the lower plate 71, the left side plate 72, and the left rear plate 74 intersect.

Then, the recognition processing unit 36 calculates (recognizes) the position Q1 of the left cart recognition target G1 based on the position where the contact sensor 81 stopped. The recognized position Q1 (recognition result) of the left cart recognition target G1 is stored in the transfer memory unit 44 as recognition result information 44b. Note that the order in which the contact sensor 81 makes contact by the contact detection operation is not limited to the above. For example, it may make contact in the order of the left rear plate 74, the lower plate 71, and the left side plate 72. In addition, in the unit recognition process (ST5), the position Q2 of the right cart recognition target G2 may also be recognized. By recognizing the positions Q1 and Q2 of the two cart recognition targets G1 and G2, the position of the second component supply cart 70 can be recognized more accurately.

In addition, in the supply device recognition process (ST6), the exchange control unit 46 controls the robot mechanism 31 to move the contact sensor 81 in front of the left attachment unit recognition target G3 and execute a contact detection operation to recognize the position Q3 of the left attachment unit recognition target G3. Note that in the supply device recognition process (ST6), the position Q4 of the right attachment unit recognition target G4 may also be recognized. By recognizing the positions Q3 and Q4 of the two attachment unit recognition targets G3 and G4, the position of the feeder attachment unit 12 can be recognized more accurately.

In this way, the cart recognition targets G1, G2 and the mounting unit recognition targets G3, G4 are contactable bodies (unit recognition bodies) formed on the component supply unit (second component supply cart 70). The contact sensor 81 is a detection unit (recognition unit) that moves together with the end effector 34 and detects contact with the contactable body. The recognition result by the contact sensor 81 (recognition unit) is the position (positions Q1 to Q4) where the detection unit comes into contact with the contactable body.

Note that the recognition of the position Q2 of the right-side trolley recognition target G2 in the unit recognition process (ST5) may be performed in combination with the distance detection operation described below, in addition to the contact detection operation described above, in which the target is recognized by contacting the right-side rear plate 75, the right-side side plate 73, and the bottom plate 71 in order.

Now, the distance detection operation will be described with reference to Figure 20. In the distance detection operation, after the contact sensor 81 detects the position Q1 of the left cart recognition target G1 by the contact detection operation, the exchange control unit 46 controls the robot mechanism 31 to move the contact sensor 81 in the X direction toward the right side plate 73 while abutting the side of the contact sensor 81 against the lower plate 71 (arrow e1). When it is detected that the side of the contact sensor 81 has come into contact with the right side plate 73, the exchange control unit 46 stops the movement of the contact sensor 81 in the X direction.

This distance detection operation causes the contact sensor 81 to stop at the corner where the lower plate 71, right side plate 73, and right rear plate 75 intersect. The recognition processing unit 36 then calculates the distance R traveled after the contact sensor 81 detects the position Q1 of the left cart recognition target G1. Furthermore, the recognition processing unit 36 calculates (recognizes) the position Q2 of the right cart recognition target G2 from the position Q1 of the left cart recognition target G1 and the distance R traveled by the contact sensor 81. The distance detection operation makes it possible to shorten the time required to recognize the position Q2 of the right cart recognition target G2.

In FIG. 20, the recognition of the position Q4 of the right-side mounting unit recognition target G4 in the supply device recognition process (ST6) may also be performed by combining the contact detection operation and the distance detection operation. That is, after recognizing the left-side mounting unit recognition target G3, the contact sensor 81 may be moved in the X direction along the upper plate 78 (arrow e2), and the position Q4 of the right-side mounting unit recognition target G4 may be calculated based on the distance moved by the contact sensor 81. The recognition result by the contact sensor 81 (recognition unit) in the distance detection operation includes the distance moved until the detection unit (contact sensor 81) comes into contact with the contacted object (right-side trolley recognition target G2, right-side mounting unit recognition target G4).

In the above, the contactable objects detected by the contact sensor 81 (detection unit) are the cart recognition targets G1, G2 formed on the lower portion 5a of the second component supply cart 70 and the mounting unit recognition targets G3, G4 formed on the feeder mounting unit 12, but recognition targets (contactable objects) may be formed on other objects and detected (recognized) by the contact sensor 81. For example, instead of the tape feeder mark Mt formed on the tape feeder 13 or the stick feeder mark Ms formed on the stick feeder 14, a recognition target may be formed as a supply device recognition object, and the position of the component supply device may be detected (recognized) by the contact sensor 81.

The automatic replacement system, management device, and automatic replacement method disclosed herein have the effect of enabling accurate replacement of component containers, and are useful in the field of mounting components to circuit boards.

LIST OF SYMBOLS 1 Component mounting system 2 Communication network 3 Management computer 3a Wireless management communication unit 4 Component supply unit 5 Component supply cart 5a Lower unit 5B Lower reel holding unit 5U Upper reel holding unit 6 Tray feeder 7 Base 8 Board transport mechanism 9 Board 10 Mounting head 10a Suction nozzle 12 Feeder mounting unit 13 Tape feeder 13a Tape insertion port 14 Stick feeder 14a Loading unit 15 Component storage tape 16 Component reel 17 Stick case 18 Mounting control unit 20 Feeder placement unit 21 Rack unit 22 Pallet moving unit 23 Tray 24 Pallet 25 Magazine 26 Magazine holding unit 26a Rack door 27 Pallet placement unit 27a Opening/closing cover 28 Pallet placement stand 28a Removal mechanism 29 Lifting mechanism 30 Cart section 30a Wheels 31 Robot mechanism (movement mechanism)
32 Storage unit 32a Storage shelf 33 Travel mechanism 34 End effector 35 Mobile camera (recognition unit)
36 Recognition processing unit 37 Head camera 40 Management storage unit 40a Part information 40b Unit information 40c External dimension information 40d Supply device information 40e Replacement work information 41 Work instruction generation unit 42 Management input unit 43 Management display unit 44 Transfer storage unit 44a Work instruction information 44b Recognition result information 45 Travel control unit 46 Replacement control unit 47 Path setting unit 50 Unit number 51 Unit type 52, 62 Recognition method 53 Reel correction value 53x, 54x, 63x X-direction deviation amount 53z, 54z, 63z Z-direction deviation amount 54 Slot correction value 55 Unit specific information 56 Holding unit number 57 Holding unit position 57x X-position 57z Z-position 60 Feeder number 61 Feeder type 63 Feeder correction value 64 Supply device specific information 70 Second component supply cart 71 Lower plate 72, 73 Side plates 74, 75, 79, 80 Back plate 76, 77 Support plate 78 Upper plate 81 Contact sensor D Component E Component supply position G1, G2 Carriage recognition target G3, G4 Mounting part recognition target Ma Mounting part mark Mc Carriage mark Ml Rack mark Mo Open/close mark Ms Stick feeder mark Mt Tape feeder mark T Wireless communication unit V Transport device V1 Second transport device

Claims (14)

1. An automatic component replacement system for replacing a component container of a component supply unit, the component supply unit comprising: a lower portion for holding a component container for storing components; and a feeder mounting portion for mounting a component supply device for moving the components stored in the component container to a component supply position, the component supply unit comprising:
an end effector for holding the part container;
a movement mechanism configured to move the end effector;
a recognition unit that recognizes a plurality of unit recognition bodies for identifying the component supply unit;
a path setting unit that sets a movement path along which the end effector is moved;
A control unit that controls the movement mechanism,
the control unit moves the end effector to the component supply device based on the set movement path and a recognition result of the recognition unit of the lower portion of the component supply unit and the unit recognition body provided on the feeder mounting unit.
Automatic exchange system. a management device having a work instruction generation unit that generates a work instruction including a movement target of the end effector based on external dimension information of the component supply unit,
The route setting unit sets the movement route based on the work instruction.
2. The automatic switching system according to claim 1. The work instruction generation unit generates the work instruction so as to further include information of the unit recognition body recognized by the recognition unit.
3. The automatic switching system according to claim 2. The work instruction generation unit,
a unit position correction value for correcting the movement target of the end effector based on a positional deviation of the unit recognition body;
a supply device position correction value for correcting the movement target of the end effector based on a positional deviation of a supply device recognizer for identifying the component supply device provided on the component supply device, and a supply device position correction value for correcting the movement target of the end effector based on at least one of the positional deviation of a supply device recognizer for identifying the component supply device provided on the component supply device, and generating the work instruction including the corrected movement target.
3. The automatic switching system according to claim 2. The component supply device is provided with a supply device recognition unit for identifying the component supply device,
The recognition unit further recognizes the supply device recognition body,
the control unit moves the end effector to the component supply device based on the set movement path and a recognition result of the supply device recognition body by the recognition unit.
2. The automatic switching system according to claim 1. the unit recognition object is a mark formed on the component supply unit,
The recognition unit is an imaging unit that images the mark.
2. The automatic switching system according to claim 1. the unit recognition body is a contactable body formed on the component supply unit,
The recognition unit is a detection unit that moves together with the end effector and detects contact with the contacted object.
2. The automatic switching system according to claim 1. The recognition result is a position where the detection unit contacts the contacted object.
8. The automatic switching system according to claim 7. The recognition result includes a distance traveled by the detection unit until the detection unit comes into contact with the contacted object.
8. The automatic switching system according to claim 7. 1. An automatic replacement method for replacing a component container of a component supply unit, the component container having a lower portion for holding a component container for storing components and a feeder mounting portion for mounting a component supply device for moving the components stored in the component container to a component supply position, by an automatic replacement system having a movable end effector, comprising:
a step of recognizing a plurality of unit recognition objects for identifying the component supply unit;
A step of setting a movement path along which the end effector is moved;
and moving the end effector to the component supply device based on the set movement path and the recognition result of the unit recognition body provided on the lower portion of the component supply unit and the feeder mounting portion.
Automatic exchange method. The method further includes a step of generating a work instruction including a movement target of the end effector based on external dimension information of the component supply unit,
setting the movement route based on the work instruction;
The automatic exchange method according to claim 10. generating the work instruction so as to include information of a recognition target to be recognized in the step of recognizing the unit recognition body;
The automatic exchange method according to claim 11. a unit position correction value for correcting the movement target of the end effector based on a positional deviation of the unit recognition body;
a supply device position correction value for correcting the movement target of the end effector based on a positional deviation of a supply device recognizer for identifying the component supply device provided on the component supply device, and a supply device position correction value for correcting the movement target of the end effector based on at least one of the positional deviation of a supply device recognizer for identifying the component supply device provided on the component supply device, and generating the work instruction including the corrected movement target.
The automatic exchange method according to claim 11. The component supply device further includes a step of recognizing a supply device recognition object provided in the component supply device for identifying the component supply device,
moving the end effector to the component supply device based on the set movement path and the recognition result of the supply device recognition body;
The automatic exchange method according to claim 10.

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