Patent Application
20180088555
The present invention relates to a management system and a management method for managing a component reel which houses electronic components.
An electronic component which is mounted onto a board in a component mounter is supplied by a component reel that winds and stores a carrier tape that houses electronic components. On the side surface of the component reel, an identification code including information relating to the electronic component to be housed is affixed. In the factory, a worker recognizes the identification code which is affixed to the component reel to manage the electronic component (refer to PTL 1, for example). PTL 1 describes a method of newly generating an individual label having an individual ID associated with an identification code, attaching the individual label to a component reel, and managing the component reel using the individual ID when the component reel is delivered to the factory.
PTL 1: Japanese Patent Unexamined Publication No. 2005-515559
A management system of the disclosure which manages component information from an identification code which is attached to a component reel which houses electronic components includes a recognizer which scans the identification code which is attached to the component reel and recognizes a code which is recorded in the identification code, an information decoder that decodes at least any one of item name information, order information, serial number, number of components, and vendor information from the code which is recognized, and a storage unit which stores each item of the information which is decoded, in which in a case in which each item of the information is divided into a plurality of identification codes and recorded on the component reel, when the information of the component reel is registered, each item of the information which is decoded from all of the identification codes is associated with the identification code thereof and stored in the storage unit.
A management method of the disclosure which manages component information from an identification code which is attached to a component reel which houses electronic components includes recognizing in which the identification code which is attached to the component reel is scanned and a code which is recorded in the identification code is recognized, information decoding in which at least any one of item name information, order information, serial number, number of components, and vendor information is decoded from the code which is recognized, and storing in which each item of the information which is decoded is stored, in which in a case in which each item of the information is divided into a plurality of identification codes and recorded on the component reel, and when the information of the component reel is registered, each item of the information which is decoded from all of the identification codes is associated with the identification code thereof and stored in the storing.
According to the disclosure, it is possible to manage a component reel in a delivered state.
Before an exemplary embodiment of the disclosure is described, a problem in the related art is briefly described. In the related art including PTL 1, it may not be possible to manage a component reel within a factory unless an individual label which is provided with an individual ID is attached to the component reel, and there is a problem in that work of producing and attaching a label which is provided with an individual ID arises.
Therefore, an object of the disclosure is to provide a management system and a management method capable of managing component reels in a delivered state.
The exemplary embodiment of the invention will be described with reference to the drawings. First, description will be given of the configuration of component mounting system 1 with reference to
In addition to component storage device 7 which is connected to network 6, remaining number measuring device 9 and label printer 10 are installed in storage area 3. Component storage device 7 stores component reel 16 (refer to
Remaining number measuring device 9 measures the remaining number (number of components N) of the components of in-use component reel 16 in which a portion of the components are used in the production of the mounted board. Label printer 10 prints identification code D, such as a one-dimensional code or a two-dimensional code for recording number of components N which are housed in component reel 16, onto label L (refer to
Here, the configuration of component reel 16 will be described with reference to
In
Here, the configuration of component storage device 7 will be described with reference to
Automatic housing unit 7a transports and stores component reel 16 for which code C is recognized to a predetermined position of automatic housing unit 7a. Automatic housing unit 7a carries out component reel 16 which is specified by the worker using host system 2 or touch panel 7c of the component storage device to inlet-outlet 7b.
In
In the example illustrated here, carriage 12 which is scheduled to be exchanged with carriage 12(1) which is illustrated in
When exchanging carrier tape 15, component reel 16 is collated by portable terminal 13 which is provided with code reader 14. Portable terminal 13 is capable of transmitting and receiving data to and from host system 2 in a wireless manner. Code reader 14 includes a camera, a laser scanner, and the like, and scans identification code D which is printed on label L which is attached to component reel 16 to recognize code C which is recorded in identification code D. In other words, code reader 14 is a recognizer which scans identification code D which is attached to component reel 16 and recognizes code C which is recorded in identification code D.
In
Carriage 12 after the external setup work in which tape feeder 21 and component reel 16 are set in a disposition state corresponding to the product type in external setup area 4 is transferred to component mounting line 5 and attached to component mounters M4 and M5. In component mounting line 5, the components are mounted onto an unmounted board which is supplied by board supply device M1 using component mounters M4 and M5. Subsequently, the component-mounted board is sent to reflow device M6, and the mounted components are solder-bonded to the board. Then, the mounted board onto which the components are mounted by solder bonding is collected by board collection device M7.
Next, description will be given of the configuration and functions of component mounters M4 and M5 which perform the component mounting work in component mounting line 5 with reference to
Carriage installer 20(1) is provided on the front side of board transport mechanism 18, and carriage installer 20(2) is provided behind board transport mechanism 18. Carriages 12(1) and 12(2) which serve as component suppliers, in which a plurality of tape feeders 21 for supplying components are set, in carriage installers 20(1) and 20(2) are detachably installed in component mounters M4 and M5, respectively.
Feeder addresses 20a for specifying the installation positions of tape feeders 21 are set in feeder base 28 (refer to
Y-axis moving beam 22 which is provided with a linear drive mechanism is arranged on the end portion of one side on the top surface of table 17 in the X direction, and two X-axis moving beams 23 which are similarly provided with linear drive mechanisms are joined to Y-axis moving beam 22 to move freely in the Y direction. Mounting head 24 is installed on each of two X-axis moving beams 23 to move freely in the X direction. Mounting head 24 is provided with a plurality of holding heads, and suction nozzles 24a which hold the components by suction and are capable of being lifted and lowered are installed at the bottom end portions of the respective holding heads.
Mounting head 24 moves in the X direction and the Y direction due to Y-axis moving beam 22 and X-axis moving beam 23 being driven. Accordingly, using suction nozzles 24a, two mounting heads 24 pick up the components from the component suction positions of tape feeders 21 of carriage installers 20(1) and 20(2) corresponding to each mounting head 24, and transfer and mount the components onto mounting points on board 19 which is positioned in board transport mechanism 18. Y-axis moving beam 22, X-axis moving beams 23, and mounting heads 24 configure component mounting mechanism 25 which picks up the components from carriage installer 20(1) and 20(2) and moves and mounts the components onto board 19 by moving mounting heads 24 which hold the components.
Component recognition cameras 26 are arranged between carriage installers 20(1) and 20(2) and board transport mechanism 18. When mounting heads 24 which pick up the components from carriage installers 20(1) and 20(2) move above component recognition cameras 26, component recognition cameras 26 image and recognize the components in the state of being held by mounting heads 24. Board recognition camera 27 which is positioned on the bottom surface side of X-axis moving beam 23 and which moves integrally with the corresponding mounting head 24 is installed on mounting head 24. Due to the movement of mounting head 24, board recognition camera 27 moves above board 19 which is positioned in board transport mechanism 18, and board recognition camera 27 images and recognizes board 19. In a component mounting operation to board 19 carried out by mounting head 24, mounting position correction is performed, taking into account the recognition results of the component by component recognition camera 26 and the recognition results of the board by board recognition camera 27.
In carriage 12, the positions of carriage installers 20(1) and 20(2) are fixed by clamping feeder base 28 using a clamp mechanism (not illustrated). Additionally, carriage 12 is electrically connected to controller 48 (refer to
Controller 48 is capable of individually identifying each carriage 12 due to the storage unit (not illustrated) of carriage controller 50 storing component supplier ID 50a (refer to
On the device operation surface, operator 29 which is provided with display unit 29b and input unit 29a is provided. Operation buttons for performing various operation inputs are disposed on input unit 29a. Display unit 29b is a display device such as a liquid crystal panel, and various screens such as a guidance screen for performing operational input using input unit 29a are displayed. This screen includes work instruction information which is used in the instruction of setup changing work which accompanies the switching of the product type.
Description will be given of the configuration and functions of tape feeder 21 with reference to
Accordingly, tape feeder 21 is installed in a fixed manner to carriage installers 20(1) and 20(2), and tape feeder 21 is electrically connected to controller 48 (refer to
Tape feeding unit 31 which is provided with a tape feed mechanism for pitch feeding carrier tape 15 is embedded in main body 21a. Tape feeding unit 31 is provided with a drive mechanism for rotationally driving a sprocket for feeding the tape which is provided at a tip portion of the tape guideway, and feeder controller 30 for controlling the drive mechanism. Carrier tape 15 which is pulled out from component reel 16 is pitch fed by tape feeding unit 31 to the pickup position by suction nozzle 24a of mounting head 24.
A feeder ID code for identifying and specifying tape feeder 21 from others is stored in a memory device which is embedded in feeder controller 30, and controller 48 is capable of individually identifying each tape feeder 21 due to tape feeders 21 being installed in carriage 12.
The storage unit which is embedded in feeder controller 30 stores number of components N which are housed by carrier tape 15 which is installed in tape feeder 21, and number of components N is counted down each time a component is picked up by suction nozzle 24a. Therefore, number of components N of the components which are housed by component reel 16 is stored in the storage unit of feeder controller 30. The stored number of components N (the number of remaining components) which are housed in component reel 16 is transmitted to host system 2 via controller 48 of component mounters M4 and M5 and network 6 at a predetermined timing such as the exchanging of board 19.
Next, description will be given of the configuration of the control system of component mounting system 1 with reference to
Component supplier disposition information 41a is information relating to the disposition state of tape feeders 21 in all carriages 12 which are present in the production area, such as carriages 12 which are attached to component mounters M4 and M5 of component mounting line 5 and spare carriages 12 which are disposed in external setup area 4. Component information 41b is information including item name information In, order information Io, serial number Is, number of components N, vendor information Iv, and the like which are recorded on label L which is attached to component reel 16 in addition to the type and location of the component which is housed in component reel 16 (information which specifies tape feeder 21 which is installed, component storage device 7 which is stored, and the like).
Item name information In is an encoded component name. Order information Io is a management number which is assigned by an ordering party who orders the components from the vendor. Serial number Is is a management number which is allocated by the vendor. Number of components N is the number of components (the remaining number of components) which are housed in component reel 16. Vendor information Iv is the maker number. In component mounting system 1, serial number Is in component information 41b is used as a unique management number Im for managing component reel 16. A unique number which is obtained by combining a plurality of items of information such as a combination of serial number Is and item name information In may be used as management number Im.
In
Recognition controller 44 controls batch recognition reader 8 to scan, as a batch, a plurality of identification codes D which are printed on the plurality of labels L which are attached to component reel 16 and recognize codes C which are recorded in identification codes D. Information decoder 44a decodes each item of the information such as item name information In, order information Io, serial number Is, number of components N, and vendor information Iv from the plurality of codes C which are recognized by batch recognition reader 8.
In other words, information decoder 44a decodes at least any one of item name information In, order information Io, serial number Is, number of components N, and vendor information Iv from the recognized code C. Each item of the decoded information is stored in recognition storage unit 45 as component information 45a and is also transmitted to host system 2 and stored in main storage unit 41 as component information 41b. In this manner, recognition storage unit 45 (or main storage unit 41) is a storage unit that stores each item of decoded information.
Here, description will be given of examples of identification code D which is printed on label L1, and code C which is recorded in identification code D, with reference to
Information decoder 44a decodes each item of information based on predetermined rules from the recognized code C. The predetermined rules are defined based on the type of identification code D such as bar code B and two-dimensional code Q, the number of digits of code C of each item of information, the type of characters which are used in each item of information, the position of delimiter SP, and the like. In other words, information decoder 44a decodes each item of information based on the type of identification code D, the number of digits of code C that is allocated to each item of information, and the type of characters which are used in each item of information.
When each item of information is registered in recognition storage unit 45 (or in main storage unit 41), information identifying identification code D which includes the information is also associated therewith and stored. In other words, in a case in which each item of information is divided into a plurality of identification codes D and recorded on component reel 16, when the information of component reel 16 is registered, each item of information which is decoded from all identification codes D is associated with identification code D thereof and stored in recognition storage unit 45 (or in main storage unit 41). Identification code D need not be printed on one label L, and identification codes D for recording different information may be printed on a plurality of corresponding labels L.
In a case in which information decoder 44a decodes the information which is not stored in recognition storage unit 45 (or in main storage unit 41), information decoder 44a determines that the decoded information is bar-code B5 of label L3 which is attached to component reel 16 later. Number of components N is decoded from code C which is recorded in bar-code B5, and number of components N of component information 45a (or component information 41b) is updated. In other words, when collating the registered component reel 16, in a case in which batch recognition reader 8 (the recognize′) recognizes identification code D (bar-code B5) which is different from identification code D which is stored in recognition storage unit 45 or main storage unit 41 (the storage unit), number of components N is decoded and stored from code C which is recorded in identification code D.
In
Carriage 12 is individually provided with component supplier ID 50a, and each tape feeder 21 which is installed in carriage 12 is individually provided with a feeder ID. Based on component supplier ID 50a and feeder ID, controller 48 identifies carriage 12 which is installed in carriage installer 20 and tape feeder 21 which is installed in carriage 12. Management number Im of component reel 16 for winding and housing carrier tape 15 which is installed in tape feeder 21 which is attached to feeder address 20a of each carriage 12 is identified by comparing the identification results with the data which is defined in production data 49a in advance.
The number of components N of carrier tape 15 which is installed in tape feeder 21 is transmitted to host system 2 and number of components N of the corresponding component reel 16 which is stored in component information 41b is updated based on management number Im. Input unit 29a and display unit 29b are provided on operator 29 of the device operation surface illustrated in
In
Setup changing work support device 11 is provided with work instruction information derivation processor 51, work instruction information storage unit 52, input unit 53, and display screen 54. Based on the component supplier disposition information 41a which is stored in main storage unit 41 of host system 2, work instruction information derivation processor 51 derives work instruction information for defining the setup changing work such as removing, attaching, and changing the position of tape feeder 21 in carriage 12* which serves as the work target, and exchanging carrier tape 15 to be installed in tape feeder 21. The work instruction information which is derived is stored in work instruction information storage unit 52 and is displayed on display screen 54. While performing operational input via input unit 53, the worker sequentially executes the setup changing work according to the displayed work instruction information.
Component reel 16 for winding and housing carrier tape 15 which is installed in tape feeder 21 in the setup changing work is picked up from component storage device 7 and carried into external setup area 4 from storage area 3. When installing the loaded carrier tape 15 in the instructed tape feeder 21, identification code D of label L which is attached to component reel 16 is collated using portable terminal 13. Component reel 16 which is removed from tape feeder 21 is conveyed to storage area 3 and stored in component storage device 7.
Next, description will be given of the configuration of the control system of portable terminal 13 with reference to
Terminal controller 60 controls code reader 14 to sequentially scan a plurality of identification codes D which are printed on the plurality of labels L which are attached to component reel 16 and recognize codes C which are recorded in identification codes D. Information decoder 60a decodes each item of information such as item name information In, order information Io, serial number Is, number of components N, and vendor information Iv from the plurality of codes C which are recognized by code reader 14.
In other words, information decoder 60a decodes at least any one of item name information In, order information Io, serial number Is, number of components N, and vendor information Iv from code C which is recognized. Each item of decoded information is stored in terminal storage unit 61 as component information 61a and is also transmitted to host system 2 and stored in main storage unit 41 as component information 41b. In this manner, terminal storage unit 61 is a storage unit that stores each item of the information which is decoded.
In the setup changing work, when installing carrier tape 15 in the instructed tape feeder 21, the worker recognizes identification code D of label L which is attached to component reel 16 and collates whether or not component reel 16 is the specified component reel 16 using portable terminal 13. During the collation, serial number Is, which is management number Im of component reel 16 to be collated, is transmitted to portable terminal 13 from host system 2. Terminal controller 60 continues scanning using code reader 14 until serial number Is is recognized.
In other words, when collating the registered component reel 16, terminal controller 60 performs control such that code reader 14 (recognize′) does not cancel scanning until identification code D, in which serial number Is which is specified among identification codes D which are stored is recorded, is recognized. When serial number Is is recognized, terminal controller 60 collates whether or not serial number Is matches the specified management number Im and causes touch panel 62 to display the result.
As described above, component mounting system 1 of the exemplary embodiment is a management system which manages component information (component information 45a, 61a, and 41b) from identification code D which is attached to component reel 16 which houses electronic components (components) includes a recognizer (batch recognition reader 8 and code reader 14) which scans identification code D which is attached to component reel 16 and recognizes code C which is recorded in identification code D, information decoder (information decoders 44a and 60a) which decodes at least any one of item name information In, order information Io, serial number Is, number of components N, and vendor information Iv from the recognized code C, and a storage unit (recognition storage unit 45, terminal storage unit 61, and main storage unit 41) which stores each item of decoded information.
In the management system, in a case in which each item of information is divided into a plurality of identification codes D and recorded on component reel 16, when the information of component reel 16 is registered, each item of information which is decoded from all identification codes D is associated with identification code D thereof and stored in the storage unit. Accordingly, it is possible to manage component reel 16 by using label L which is attached during the delivery without attaching label L on which identification code D for exclusive management is printed when delivering component reel 16.
Next, description will be given of a first example of a management method which manages component information from identification code D which is attached to component reel 16 which houses electronic components (components), according to the flow of
First, when the worker inserts component reel 16 into component storage device 7 from inlet-outlet 7b, batch recognition reader 8 (the recognize′) of component storage device 7 scans, as a batch, all identification codes D which are printed on label L which is attached to component reel 16 and recognizes code C which is recorded in identification code D (ST1: recognizing step). Next, information decoder 44a decodes at least any one of item name information In, order information Io, serial number Is, number of components N, and vendor information Iv from the recognized code C (ST2: information decoding step). In information decoding step (ST2), information decoder 44a decodes each item of information based on the type of identification code D, the number of digits of code C that is allocated to each item of information, and the type of characters which are used in each item of information.
Next, recognition controller 44 stores each item of information which is decoded in recognition storage unit 45 (the storage unit) (ST3: storing step). In a case in which each item of information is divided into a plurality of identification codes D and recorded on component reel 16, when the information of component reel 16 is registered, in the storing step (ST3), each item of information which is decoded from all identification codes D is associated with identification code D thereof and stored.
Each item of decoded information is transmitted to host system 2, stored in main storage unit 41 (the storage unit), and used in the management of component reel 16 in component mounting system 1 (the management system). Accordingly, it is possible to manage component reel 16 by using label L which is attached during the delivery without attaching label L on which identification code D for exclusive management is printed when delivering component reel 16.
Next, description will be given of a second example of a management method which manages component information from identification code D which is attached to component reel 16 which houses electronic components (components), according to the flow of
First, the operator scans one identification code D which is printed on label L which is attached to component reel 16 using code reader 14 (the recognizer) of portable terminal 13, and code C which is recorded in identification code D is recognized (ST11: recognizing step). Next, information decoder 44a decodes the information which is recorded from code C which is recognized (ST12: information decoding step). Next, recognition controller 44 determines whether or not the decoded information includes management number Im, that is, whether or not code reader 14 recognizes the specified identification code D including management number Im (ST13).
In a case in which the specified identification code D is not recognized (No in ST13), code reader 14 holds the scan state, returns to the recognizing step (ST11), and scans the next identification code D. In a case in which the specified identification code D is recognized (Yes in ST13), code reader 14 cancels the scan state. In other words, when collating the registered component reel 16, in recognizing step (ST11), recognition controller 44 does not cancel scanning until identification code D, which is specified among identification codes D which are stored, is recognized. Accordingly, even if the operator does not know the position of label L on which the specified identification code D as management number Im is printed, the operator is capable of executing the collation of component reel 16 by sequentially scanning identification codes D using portable terminal 13.
In a case in which the recognition step (ST11) is performed for a first predetermined number of times (for example, three times) in the determination (ST13) of whether or not the specified identification code D is recognized, it may be determined as to whether or not the specified identification code D that is configured is stored in the plurality of recognized codes C.
At this time, in a case in which the specified identification code D which is formed of the plurality of recognized codes C is stored, it is determined that the specified identification code D is not yet recognized, and code reader 14 holds the scan state, the process returns to the recognizing step (ST11), and the next identification code D is scanned. In a case in which the specified identification code D which is formed of the plurality of recognized codes C is not stored, it is determined that an abnormality such as code C being replaced or another component reel 16 being read occurs, the scan is interrupted, and the worker is notified of the abnormality.
In a case in which the recognizing step (ST11) is performed greater or equal to a second predetermined number of times exceeds (for example, 10 times) which exceeds the first predetermined number of times, if it is determined that an abnormality such as an inability to recognize the specified identification code D or the specified identification code D being peeled off arises, the scan may be canceled and the worker may be notified of the abnormality.
Next, description will be given of a third example of a management method which manages component information from identification code D which is attached to component reel 16 which houses electronic components (components), according to the flow of
However, due to the consumption of components that tape feeder 21 may not recognize, such as losses during the supplying of components, number of components N which is stored in host system 2 may contain an error. Therefore, the unused components of component reel 16 which is returned in storage area 3 is weighed using remaining number measuring device 9, and number of components N which is stored is corrected to an accurate value. Number of components N which are weighed is printed on label L3 as bar-code B5 by label printer 10 (refer to
First, when the worker inserts component reel 16 into component storage device 7 from inlet-outlet 7b, batch recognition reader 8 (the recognize′) of component storage device 7 scans, as a batch, all identification codes D (bar-codes B1 to B5 and two-dimensional code Q1) which are printed on the plurality of labels L1, L2, and L3 which are attached to component reel 16 and recognizes code C which is recorded in identification code D (ST21: recognizing step) (refer to
In a case in which identification code D which is outside of the memory is recognized (Yes in ST22), that is, in a case in which bar-code B5 is recognized, information decoder 44a decodes number of components N from code C of the recognized bar-code B5, and updates and stores number of components N of component information 45a (ST23). In other words, when collating the registered component reel 16, in the recognizing step (ST21), in a case in which identification code D (bar-code B5) which is different from identification code D which is stored is recognized, number of components N is decoded and stored from code C which is recorded in identification code D.
Number of components N is transmitted to host system 2, and number of components N of component information 41b which is stored in main storage unit 41 is also updated to an accurate value. Accordingly, it is possible to update number of components N to an accurate value during the storage work of component reel 16. Next, component reel 16 is housed in automatic housing unit 7a of component storage device 7. In a case in which identification code D outside of the memory is not recognized (No in ST22), component reel 16 is housed in automatic housing unit 7a without updating number of components N.
As described above, in the management method of the present embodiment, in a case in which each item of information is divided into a plurality of identification codes D and attached to component reel 16, when the information of component reel 16 is recorded, in the storing step, each item of information which is decoded from all identification codes D is associated with identification code D thereof and stored. Accordingly, it is possible to manage component reel 16 by using label L which is attached during the delivery without attaching label L on which identification code D for exclusive management is printed when delivering component reel 16.
The storage of component reel 16 in storage area 3 is not limited to storage carried out by component storage device 7 which is provided with batch recognition reader 8 and automatic housing unit 7a. For example, identification code D of component reel 16 may be recognized by portable terminal 13 instead of batch recognition reader 8, and the worker may stock (carry in), store, and ship (carry out) component reel 16 in relation to a storage warehouse having a plurality of shelves instead of automatic housing unit 7a.
A management system and a management method of the invention include the effect of being capable of managing a component reel in a delivered state, and are applicable in the field of component mounting in which electronic components are mounted onto a board.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2016-189651 | Sep 2016 | JP | national |
