JP7578552B2 - Component Mounting Equipment - Google Patents

Description

This disclosure relates to a component mounting device.

The component mounting device described in the following Patent Document 1 (JP Patent Publication No. 7-183694) is known as a component mounting device that picks up components with a nozzle attached to a suction head. This component mounting device includes a suction head, a nozzle that is detachable from the suction head, a light emitting unit that irradiates laser light from the side in a substantially horizontal direction toward the vicinity of the suction head, and a light receiving unit that is disposed in a position facing the light emitting unit across the suction head and receives the laser light irradiated by the light emitting unit. When the laser light emitted from the light emitting unit is received by the light receiving unit beyond the nozzle attached to the suction head, the shape and dimensions of the nozzle can be measured based on the non-projected portion due to the presence of the nozzle. Therefore, for example, it is possible to check whether the diameter of the nozzle attached to the suction head matches pre-given nozzle diameter data.

Japanese Unexamined Patent Publication No. 7-183694

In the above configuration, the nozzle diameter is measured by irradiating the nozzle with laser light from only one direction, so depending on the direction of irradiation with the laser light, it may not be possible to accurately confirm the state of the nozzle. For example, if the chipped tip of the nozzle is in a position where the laser light is not irradiated, the chipped tip of the nozzle cannot be detected.

The component mounting device of the present disclosure is a component mounting device that mounts components on a board, and includes a mounting head having a nozzle that picks up the components attached on an axis, a rotation mechanism that rotates the nozzle around the axis, an imaging unit that images the nozzle from an imaging direction perpendicular to the axial direction of the axis, a memory unit that stores nozzle data, and a control unit, the nozzle data including a plurality of inspection angles, the plurality of inspection angles being angles around the axis of the nozzle such that a location of the nozzle where chipping is likely to occur at the tip is located at an end in a width direction perpendicular to both the axial direction and the imaging direction, the nozzle data including a plurality of standard sizes that are the sizes of the standard nozzle when a standard nozzle of the same type as the nozzle and having an unchipped tip is rotated to the plurality of inspection angles and the standard nozzle is viewed from the imaging direction, and the control unit rotates the mounting head to one or more of the plurality of inspection angles by the rotation mechanism. The component mounting device rotates the nozzle and captures images of the nozzle at the one or more inspection angles with the imaging unit to obtain one or more captured images, and inspects the state of the nozzle based on the one or more captured images and the nozzle data stored in the memory unit.

According to the present disclosure, it is possible to provide a component mounting device that can easily detect abnormalities such as chipping of the nozzle tip by imaging the nozzle at one or more angles around the axis.

FIG. 1 is a plan view of a component mounting apparatus according to a first embodiment. FIG. 2 is a diagram showing the positional relationship between the nozzle, the first camera, and the first lighting. FIG. 3 is a diagram showing the control of the nozzle angle by the R-axis servo motor. FIG. 4 is a diagram for explaining imaging of a nozzle using parallel light and the captured image. FIG. 5 is a diagram illustrating imaging of a nozzle using diffused light and the captured image. FIG. 6 is a diagram showing the electrical configuration of the component mounting apparatus. FIG. 7 is a diagram illustrating a plurality of inspection angles and a plurality of captured images of a nozzle having a rectangular tip. FIG. 8 is a diagram for explaining an inspection of a nozzle having a rectangular tip for chipping. FIG. 9 is a flowchart illustrating the process of the control unit in inspecting the tip of the nozzle for chipping. FIG. 10 is a diagram illustrating a plurality of inspection angles and a plurality of captured images of a nozzle having a square tip. FIG. 11 is a diagram for explaining an inspection of chipping at the tip of a nozzle having a square tip. FIG. 12 is a diagram illustrating a plurality of inspection angles and a plurality of captured images of a nozzle having a diamond-shaped tip. FIG. 13 is a diagram for explaining an inspection of chipping at the tip of a nozzle having a diamond-shaped tip. FIG. 14 is a diagram illustrating a plurality of captured images of a nozzle having a rectangular tip according to the second embodiment. FIG. 15 is a graph showing the relationship between the measured size of a plurality of captured images of the nozzle shown in FIG. 14 and the nozzle angle. FIG. 16 is a diagram illustrating a plurality of captured images of a nozzle having a diamond-shaped tip. FIG. 17 is a graph showing the relationship between the measured size of a plurality of captured images of the nozzle shown in FIG. 16 and the nozzle angle.

[Description of the embodiments of the present disclosure]
First, embodiments of the present disclosure will be listed and described.
(1) A component mounting device according to the present disclosure is a component mounting device that mounts components on a board, the component mounting device including: a mounting head having a nozzle that sucks up the component attached on an axis; a rotation mechanism that rotates the nozzle about the axis; an imaging unit that images the nozzle from an imaging direction perpendicular to an axial direction of the axis; a storage unit that stores nozzle data; and a control unit, the nozzle data including a plurality of inspection angles, the plurality of inspection angles being angles about the axis of the nozzle such that a portion of a tip of the nozzle that is prone to chipping is located at an end in a width direction perpendicular to both the axial direction and the imaging direction. the nozzle data includes a plurality of standard sizes which are sizes of the standard nozzle when a standard nozzle of the same type as the nozzle and having an unbroken tip is rotated to the plurality of inspection angles and the standard nozzle is viewed from the imaging direction, and the control unit rotates the nozzle to one or more inspection angles of the plurality of inspection angles using the rotation mechanism and images the nozzle at the one or more inspection angles using the imaging unit, thereby obtaining one or more captured images, and inspecting a condition of the nozzle based on the one or more captured images and the nozzle data stored in the memory unit.

With this configuration, the nozzle data includes multiple inspection angles for imaging the nozzle, so it is possible to obtain only one or more images required to inspect the state of the nozzle, thereby shortening the time required for inspection. Furthermore, with multiple inspection angles, the location where chipping of the nozzle tip is likely to occur is arranged at the end in the width direction, making it easy to detect nozzle abnormalities, particularly chipping of the nozzle tip. As this configuration makes it easy to detect nozzle abnormalities, it is possible to suppress a decrease in the component pickup rate and mounting misalignment.

(2) It is preferable that the control unit executes a size calculation process that calculates one or more measurement sizes based on the one or more captured images, and a determination process that determines whether or not the tip of the nozzle is chipped by comparing the one or more measurement sizes with one or more standard sizes among the plurality of standard sizes.

With this configuration, the control unit determines whether the tip of the nozzle is chipped by comparing one or more measured sizes calculated based on one or more captured images with one or more standard sizes among the multiple standard sizes included in the nozzle data, thereby improving the accuracy of inspection for chipping of the nozzle tip.

(3) It is preferable that the multiple inspection angles are set taking into account an offset amount specific to the mounting head to which the nozzle is attached.

This configuration allows the nozzle condition to be inspected accurately even when the mounting head used is changed.

(4) The component mounting device according to the present disclosure may be a component mounting device that mounts components on a board, and includes a mounting head having a nozzle that adsorbs the component attached on an axis, a rotation mechanism that rotates the nozzle around the axis, an imaging unit that images the nozzle from an imaging direction perpendicular to the axial direction of the axis, a memory unit that stores nozzle data, and a control unit, in which the control unit rotates the nozzle using the rotation mechanism and images the nozzle using the imaging unit at multiple angles around the axis of the nozzle, thereby obtaining multiple captured images for each nozzle, and inspects the state of the nozzle based on the multiple captured images and the nozzle data stored in the memory unit.

With this configuration, the state of the nozzle is inspected based on multiple captured images obtained by capturing images of the nozzle at multiple angles around the axis and the nozzle data stored in the memory unit, making it easy to detect abnormalities such as chipping of the nozzle tip. In addition, because the configuration makes it easy to detect nozzle abnormalities, it is possible to suppress a decrease in the component pickup rate and mounting misalignment.

(5) The nozzle data includes a first maximum size, a second maximum size equal to or smaller than the first maximum size, and an exclusion angle, and a standard nozzle of the same type as the nozzle and having an unbroken tip is rotated 180° or more around the axis, and the size of the standard nozzle when viewed from the imaging direction takes maximum values at the first maximum size and the second maximum size, and the control unit performs a continuous imaging process to obtain the multiple captured images by continuously capturing images of the nozzle using the imaging unit while rotating the nozzle by 180° or more using the rotation mechanism, and The method may include a size calculation process for calculating multiple measurement sizes based on the multiple captured images, an image extraction process for extracting a first image having the maximum measurement size and a second image having the maximum measurement size excluding the captured images captured at the exclusion angle before and after the angle of the nozzle when the first image was captured, and a determination process for determining whether the tip of the nozzle is chipped by comparing the measurement size of the first image with the first maximum size and comparing the measurement size of the second image with the second maximum size.

With this configuration, the nozzle condition is inspected based on multiple captured images obtained by continuously capturing images of the nozzle while rotating the nozzle by 180° or more. This makes it possible to inspect the nozzle condition, particularly the tip of the nozzle for chipping, even when the nozzle data does not include the angle at which the nozzle should be captured or when an angle offset specific to the mounting head is not taken into account. In addition, the control unit extracts a first image and a second image from the multiple captured images, compares the measured size of the first image with the first standard size, and compares the measured size of the second image with the second standard size to determine whether the tip of the nozzle is chipped, thereby improving the accuracy of the inspection for chipping of the nozzle tip.

(6) It is preferable that the control unit inspects the state of the nozzle at at least one of the following times: immediately after the nozzle is attached to the mounting head, immediately before the nozzle is stored in the nozzle stocker, when a suction error occurs, at a preset regular timing, and when the substrate is transported.

With this configuration, the nozzle condition is inspected at at least one set timing, making it easier to detect nozzle abnormalities and reducing the drop in component pickup rate and mounting misalignment.

(7) It is preferable that the imaging unit includes an inspection camera that images the nozzle and an inspection light arranged to sandwich the nozzle together with the inspection camera in the imaging direction, and that the light source of the inspection light is a parallel light.

With this configuration, the light source for the inspection illumination is parallel light, making it easier to accurately calculate the size of the nozzle tip based on multiple captured images, and making it easier to detect nozzle abnormalities.

[Details of the First Embodiment of the Present Disclosure]
A first embodiment of the present disclosure will be described with reference to Figures 1 to 13. Note that the present disclosure is not limited to these examples, but is intended to include all modifications within the scope of the claims and meaning equivalent thereto. As shown in Figure 1, the first embodiment illustrates a component mounting device 10 that mounts components such as electronic components (not shown) on a board B such as a printed circuit board.

<Overall configuration of component mounting device>
1, the component mounting apparatus 10 includes a base 11, a transport conveyor 14 for transporting the board B, a head unit 30, and a drive device 20 for moving the head unit 30 on the base 11. In the following description, the longitudinal direction of the base 11 (left-right direction in FIG. 1) is referred to as the left-right direction, the depth direction of the base 11 (up-down direction in FIG. 1) is referred to as the front-rear direction, and the direction perpendicular to the paper surface of FIG. 1 is referred to as the up-down direction. In each figure, the X direction indicates the right, the Y direction indicates the front, and the Z direction indicates the upward direction.

The transport conveyor 14 is disposed in the center of the base 11. The transport conveyor 14 is equipped with a pair of transport belts 15 that are driven in a circulating manner in the left-right direction, and transports the board B on the transport belts 15 to the right by friction with the transport belts 15. In this embodiment, the board B is carried into the component mounting device 10 from the left side through the transport conveyor 14. The carried-in board B is carried by the transport conveyor 14 to a working position in the center of the base 11, where it is stopped.

Four part supply units 12 are provided on the base 11, surrounding the work position. Each part supply unit 12 has multiple feeders 13 adjacent to each other in the left-right direction that supply parts.

At the work position, components are supplied by the feeder 13, and the components are mounted on the board B by the mounting head 31 of the head unit 30. The board B on which the components are mounted is then transported to the right via the transport conveyor 14 and taken out of the component mounting device 10.

The driving device 20 transports the head unit 30 in the X-axis direction and the Y-axis direction within a predetermined movable range. As shown in FIG. 1, the driving device 20 includes an X-axis beam 21, a Y-axis frame 22, an X-axis servo motor 23, and a Y-axis servo motor 24. The head unit 30 is supported by the X-axis beam 21, and can be moved back and forth in the X-axis direction by the X-axis servo motor 23. The X-axis beam 21 is supported by the Y-axis frame 22, and can be moved back and forth in the Y-axis direction by the Y-axis servo motor 24.

As shown in Figures 1 and 2, the head unit 30 has a box-shaped head unit body 31, three mounting heads 32 that perform component mounting operations, and an imaging unit 40 for imaging each mounting head 32.

The mounting head 32 protrudes downward from the head unit body 31. As shown in FIG. 2, the mounting head 32 has a shaft 33 that extends in the vertical direction, and a nozzle 60 that is detachable from the lower end of the shaft 33. A line that passes through the center of the mounting head 32 and extends in the vertical direction (an example of the axial direction) is the axis L, and the nozzle 60 is attached to the axis L of the mounting head 32. Negative pressure is supplied to the mounting head 32 from an air supply device (not shown), generating a suction force at the tip 61 of the nozzle 60. This allows the nozzle 60 to pick up and mount components.

A Z-axis servo motor (not shown) is attached to the shaft 33 and is provided inside the head unit body 31. The shaft 33 (and the nozzle 60) can be raised and lowered in the vertical direction by the Z-axis servo motor.

In this embodiment, as shown in FIG. 3, one R-axis servo motor 36 (an example of a rotation mechanism) is provided for each of the three mounting heads 32 (shafts 33) of the head unit 30. A drive pulley 36A is provided on the outer periphery of the R-axis servo motor 36, and a shaft pulley 33A is provided on the outer periphery of the shaft 33. A belt 37 is stretched between the drive pulley 36A and the shaft pulley 33A. The belt 37 is also stretched between the drive pulley 36A and the shaft pulley 33A, as well as the auxiliary pulley 38 provided in the head unit 30. When the R-axis servo motor 36 is driven, the rotation of the R-axis servo motor 36 is transmitted to the shaft pulley 33A via the belt 37 stretched around the drive pulley 36A. This causes the shaft 33 (and the nozzle 60) to rotate around the axis L.

As shown in FIG. 1, the imaging unit 40 of this embodiment is provided for each of the three mounting heads 32. As shown in FIG. 2, the imaging unit 40 includes a first camera 41 (an example of an inspection camera) provided behind each mounting head 32, and a first light 42 (an example of an inspection light) provided in front of each mounting head 32. The first camera 41 and the first light 42 are arranged to sandwich the mounting head 32 in the front-rear direction. The imaging unit 40 can capture images of the periphery of the lower end of the mounting head 32, i.e., the nozzle 60 and the component adsorbed to the nozzle 60, from the front-rear direction (an example of the imaging direction).

As shown in FIG. 4(A), the light emitted from the first lighting 42 passes around the object and enters the lens of the first camera 41. That is, the first camera 41 captures the transmitted light. Therefore, as shown in FIG. 4(B), the object appears as a silhouette (shown by the shaded area) in the captured image. Note that FIG. 4(A) is a schematic diagram showing the positional relationship of the first lighting 42, the tip 61 of the nozzle 60, which is the object, and the first camera 41, as viewed from the top and bottom, and FIG. 4(B) is a diagram showing the captured image captured in the state of FIG. 4(A). In the captured image, only the silhouette corresponding to the tip 61 of the nozzle 60 is shown, and the vertical direction in the figure corresponds to the height direction (Z direction) of the tip 61 of the nozzle 60. FIG. 5 is a diagram similar to FIG. 4, but the light source used for the first lighting 42 is different, as described below.

The light source of the first illumination 42 may be parallel light as shown in FIG. 4(A) or diffuse light as shown in FIG. 5(A). However, if diffuse light is used as the light source of the first illumination 42, the light will wrap around the side of the object (tip 61 of the nozzle 60 in FIG. 5). For this reason, as shown in FIG. 5(B), the contrast of the left and right ends of the silhouette in the captured image becomes unclear. Therefore, in order to accurately measure the size of the object, it is more preferable to use parallel light, which does not wrap around, as the light source of the first illumination 42. For simplicity, the following describes the case where parallel light is used as the light source of the first illumination 42.

As shown in FIG. 1, a second camera 50 is disposed on the head unit 30 with its imaging surface facing downward. The second camera 50 is configured to capture an image of a fiducial mark (not shown) on the substrate B in order to recognize the position and orientation of the substrate B. In addition, a second illumination 51 (see FIG. 6) is provided near the second camera 50. The second illumination 51 is configured to irradiate the substrate B with visible light when the second camera 50 captures an image. This allows the second camera 50 to capture a clear image of the substrate B.

As shown in FIG. 1, a third camera 52 is disposed on the base 11 with its imaging surface facing upward. The third camera 52 captures an image (bottom image) of the component picked up by the nozzle 60, and detects the suction posture of the component by the nozzle 60. In addition, a third illumination 53 (see FIG. 6) is provided near the third camera 52. The third illumination 53 is configured to irradiate the component picked up by the nozzle 60 with visible light when the third camera 52 captures an image. This allows the third camera 52 to clearly capture an image of the component picked up by the nozzle 60.

<Electrical configuration of component mounter>
Next, the electrical configuration of the component mounting device 10 will be described with reference to Fig. 6. The component mounting device 10 includes a CPU (Central Processing Unit) 81, a storage unit 82, a memory 83, a display unit 84, an input device 85, a motor controller 86, a camera I/F 87, a lighting controller 88, various I/Os 89, a motor amplifier 90, and a motor 91. The CPU 81 is an example of a control unit.

The CPU 81 is configured to control the component mounting operation by the mounting head 32. Specifically, the CPU 81 is configured to control the overall operation of the component mounting device 10, such as the transport operation of the board B by the pair of transport conveyors 14, the mounting operation by the head unit 30, and the imaging operation by the first camera 41, the second camera 50, and the third camera 52.

The memory unit 82 stores a mounting program for mounting components on the board B and various data. The various data includes board information related to the dimensions and transport speed of the board B to be produced, identification information of the shaft 33 and nozzle 60 attached to the head unit 30, the position of the object measured by the first camera 41, the second camera 50, and the third camera 52, and a reference position for determining the positional deviation of the object. The memory unit 82 includes, for example, a hard disk drive (HDD) and a solid state drive (SSD).

The memory unit 82 in this embodiment stores nozzle data as parameters used to inspect the state of the nozzle 60. The nozzle data in this embodiment includes multiple inspection angles and multiple standard sizes, which will be described later. These parameters are set for each type of nozzle 60.

The memory 83 is configured to store information when the CPU 81 is operating. The display unit 84 is configured to display the status of the component mounting device 10 and information about the board B being produced. The input device 85 is configured to input operations by the user for the component mounting device 10. The input device 85 includes, for example, a mouse, a keyboard, a switch, a touch panel, etc.

The motor controller 86 is configured to drive various motors 91 (X-axis servo motor 23, Y-axis servo motor 24, Z-axis servo motor, R-axis servo motor 36, etc.) via a motor amplifier 90 under the control of the CPU 81. The first camera 41, the second camera 50, and the third camera 52 are connected to the camera I/F (interface) 87. The camera I/F 87 is also connected to the CPU 81. This is configured to connect the CPU 81 to the first camera 41, the second camera 50, and the third camera 52, respectively.

The lighting controller 88 is configured to drive the first lighting 42, the second lighting 51, and the third lighting 53 under the control of the CPU 81. The various I/O (input/output) 89 are configured to control the signals input and output to the CPU 81.

<Inspection of nozzle condition>
The component mounting device 10 according to this embodiment acquires one or more captured images by rotating the nozzle 60 around the axis L and capturing images of the nozzle 60 with the imaging unit 40 at a plurality of preset inspection angles. Then, the device is characterized in that the state of the nozzle 60 is inspected based on the acquired one or more captured images and the nozzle data stored in the storage unit 82. The state of the nozzle 60 here includes, for example, whether the type and mounting posture of the nozzle 60 are correct, whether the tip 61 of the nozzle 60 is chipped, and the like.

Small components mounted on the board B often have a rectangular shape. For this reason, the tip 61 of the nozzle 60 used to pick up small components is often elongated in a direction perpendicular to the axial direction (up and down direction) of the axis L of the nozzle 60. For example, the tip 61 of the nozzle 60 has a rectangular shape in a plan view. The corners and edges of the tip 61 of such nozzles 60 for small components are susceptible to stress, and may be prone to chipping, for example, depending on the material. If chipping occurs in the tip 61 of the nozzle 60, the suction power of the nozzle 60 decreases, which may cause the component to be picked up unstable or the component to be unable to be mounted in the correct position.

As described in detail below, the component mounting device 10 of this embodiment can inspect the condition of the nozzle 60, particularly the tip 61 of the nozzle 60 for chipping, thereby preventing a decrease in the component pickup rate and a decrease in mounting position accuracy.

As shown in FIG. 7, the tip 61 of the nozzle 60 has four corners 62A-62D and two suction holes 63 for suctioning components. The four corners 62A-62D are locations on the tip 61 of the nozzle 60 where chipping is likely to occur. In the following description, there are cases where the four corners 62A-62D are not differentiated from one another and any of the four is simply referred to as a corner 62. The two suction holes 63 are circular in plan view and are arranged side by side along the long side of the nozzle 60.

<Multiple inspection angles>
The multiple inspection angles of nozzle 60 are angles at which corners 62 of tip 61 of nozzle 60 are located at ends in a width direction (left-right direction, X direction) perpendicular to both the axial direction (up-down direction, Z direction) and the imaging direction (front-back direction, Y direction). That is, in multiple captured images of nozzle 60 at multiple inspection angles, corners 62 are located at ends in the left-right direction.

In this embodiment, the multiple inspection angles include a first inspection angle and a second inspection angle. The captured image of the nozzle 60 at the first inspection angle is the first captured image. In the first captured image, the two corners 62A and 62C are located at the ends of the silhouette in the width direction. The captured image of the nozzle 60 at the second inspection angle is the second captured image. In the second captured image, the two corners 62B and 62D are located at the ends of the silhouette in the width direction.

In addition, in this embodiment, when the nozzle 60 is rotated to multiple inspection angles, the multiple inspection angles are set so that the diagonal line connecting the corners 62 of the tip 61 of the nozzle 60 is parallel to the reference axis SA extending in the width direction (left-right direction). This makes it possible to increase the width dimension of the silhouette in the captured image, making it even easier to inspect the condition of the nozzle 60.

The angle θ at which the nozzle 60 rotates around the axis L is defined as the reference angle (θ = 0°) at which the long side of the rectangle is parallel to the reference axis SA, and the counterclockwise direction in a plan view is defined as the positive direction. In this case, the first inspection angle is θ = θ1 (> 0°), and the second inspection angle is θ = θ2 (= -θ1 < 0°).

As shown in FIG. 3, in this embodiment, the three mounting heads 32 of the head unit 30 are rotated by one and the same R-axis servo motor 36. Even if the multiple mounting heads 32 have the same type of nozzle 60, the angles of the nozzles 60 of the multiple mounting heads 32 may be different from each other. For example, in FIG. 3, when the angle of the nozzle 60 at the left end is θ=0°, the angle of the nozzle 60 at the center is θ=α (>0°), and the angle of the nozzle 60 at the right end is θ=β (<0°). Note that the deviation in angle between the multiple mounting heads 32 is less than ±0.5° at the time of shipment, but in FIG. 3, the deviation in angle is exaggerated so that it is easy to see. When there is a deviation in angle between the multiple mounting heads 32, the inspection angle of each nozzle 60 is set differently for each mounting head 32. For example, in FIG. 3, if the first inspection angle of the leftmost nozzle 60 is θ=θ1, the first inspection angle of the central nozzle 60 is θ=θ1-α, and the first inspection angle of the rightmost nozzle 60 is θ=θ1+β. In this way, when the component mounting device 10 has multiple mounting heads 32 (and nozzles 60), the inspection angle of each nozzle 60 is set taking into account the offset amount specific to each mounting head 32.

<Multiple standard sizes>
The nozzle 60 shown in FIG. 7 is a nozzle 60 in which the tip 61 is not chipped, and is referred to as a standard nozzle 60S in the present disclosure. The size of the tip 61 of the standard nozzle 60S when the standard nozzle 60S is rotated to a plurality of inspection angles and viewed from the imaging direction is referred to as a plurality of standard sizes. That is, the plurality of standard sizes are equal to the sizes of the silhouettes of the first captured image and the second captured image in FIG. 7. Here, the first captured image and the second captured image of the standard nozzle 60S are illustrated and described so that the meaning of the standard size can be easily understood, but it is not necessary to capture the standard nozzle 60S and calculate the standard size when inspecting the actual state of the nozzle 60. The standard size can be included in advance as a numerical parameter in the nozzle data in the storage unit 82. As the standard size, a numerical value corresponding to the area of the silhouette or the dimension in the width direction can be adopted. The standard size in this embodiment is referred to as a numerical value corresponding to the area of the silhouette. The standard size of the first captured image is referred to as the first standard size, and the standard size of the second captured image is referred to as the second standard size.

<Multiple measurement sizes>
Specifically, the determination of whether the corner 62 of the nozzle 60 attached to the mounting head 32 is chipped is performed by comparing the above-mentioned multiple standard sizes with multiple measurement sizes calculated from multiple captured images of the nozzle 60. Here, the multiple measurement sizes are measurement values corresponding to multiple standard sizes. The measurement size of the first captured image is set to the first measurement size, and the measurement size of the second captured image is set to the second measurement size. Therefore, if the first measurement size matches the first standard size and the second measurement size matches the second standard size, it can be determined that the tip 61 of the nozzle 60 is not chipped.

More specifically, if the measured size is within a tolerance range determined based on the corresponding standard size (e.g., 95% or more of the standard size), the corner 62 is determined to be not chipped. Conversely, if the measured size is outside the tolerance range, the corner 62 is determined to be chipped. The tolerance can be set taking into consideration the shape and dimensions of the tip 61 that allows the nozzle 60 to normally pick up and mount components. For example, chipping of the tip 61 that changes the shape of the suction hole 63 tends to reduce the pickup rate, so it is preferable to set the tolerance so that the measured size of a nozzle 60 with such chipping of the tip 61 is outside the tolerance range. The tolerance range is included in the nozzle data in the memory unit 82.

The procedure for inspecting the state of the nozzle 60 will be described below with reference to the flowchart in Figure 9. The timing for inspecting the state of the nozzle 60 can be, for example, at least one of the following: immediately after the nozzle 60 is attached to the mounting head 32, immediately before the nozzle 60 is stored in a nozzle stocker (not shown) in the component mounting device 10, when a suction error occurs, at a preset regular timing, and when the board B is being transported.

When inspection of the state of the nozzle 60 begins, the CPU 81 controls the R-axis servo motor 36 to execute an angle setting process that rotates the nozzle 60 to the first inspection angle (S10).

The CPU 81 performs an imaging process in which the tip 61 of the nozzle 60 at the first inspection angle is imaged by the imaging unit 40 to obtain a first image (S20).

The CPU 81 executes a calculation process to calculate the first measurement size based on the first captured image (S30).

The CPU 81 executes a determination process to determine whether the tip 61 of the nozzle 60 is missing, depending on whether the first measured size is within the tolerance range set by the first standard size (S40). If the first measured size is within the tolerance range (S40: YES), the process proceeds to S50. If the first measured size is not within the tolerance range (S40: NO), the process proceeds to S100.

For example, in the case shown in FIG. 8, the first measured size, which is the area of the silhouette, matches the first standard size (see FIG. 7), so the process moves from S40 to S50. Below, we will explain S50 and subsequent steps using the flowchart in FIG. 9.

The CPU 81 controls the R-axis servo motor 36 and executes an angle setting process to rotate the nozzle 60 to the second inspection angle (S50).

The CPU 81 performs an imaging process in which the tip 61 of the nozzle 60 at the second inspection angle is imaged by the imaging unit 40 to obtain a second image (S60).

The CPU 81 executes a calculation process to calculate the second measurement size based on the second captured image (S70).

The CPU 81 executes a determination process to determine whether the tip 61 of the nozzle 60 is chipped, depending on whether the second measured size is within the tolerance range set by the second standard size (S80). If the second measured size is within the tolerance range (S80: YES), the process proceeds to S90. In other words, it is determined that none of the corners 62 of the tip 61 of the nozzle 60 are chipped, and component mounting is performed using the nozzle 60. If the second measured size is not within the tolerance range (S80: NO), the process proceeds to S100.

In the case shown in FIG. 8, the corner 62D of the nozzle 60 is chipped, damaging the shape of the suction hole 63. The second measured size is approximately 90% of the second standard size shown by the dashed line in the captured image. If 95% or more of the second standard size is within the acceptable range, the CPU 81 determines that the second measured size is outside the acceptable range and is able to detect chipping of the tip 61 (S80: NO).

If the inspection of the state of the nozzle 60 shown in FIG. 8 were performed based only on the first captured image, any chipping in the tip 61 of the nozzle 60 would be overlooked. However, in this embodiment, as described above, after the first captured image is acquired at the first inspection angle and the state of the nozzle 60 is inspected, the second captured image is acquired at the second inspection angle and the state of the nozzle 60 is inspected again, making it easier to detect any chipping in the tip 61 of the nozzle 60. This makes it easier to suppress a decrease in the component pickup rate, mounting misalignment, etc.

8, if the first measurement size calculated from the first captured image is not within the range of the allowable value (S40: NO), it is determined that the tip 61 of the nozzle 60 is chipped, and the second captured image is not acquired and the inspection of the state of the nozzle 60 ends. In this way, the present disclosure also includes a case where the inspection of the state of the nozzle 60 ends when an abnormality in the nozzle 60 is detected based on at least one captured image, without acquiring all captured images (the same number as the number of inspection angles) that are planned to be acquired.
The steps from S100 onwards in the flow chart of FIG. 9 will be described below.

If it is determined that the tip 61 of the nozzle 60 is chipped, the CPU 81 determines whether there are spare nozzles 60 in the nozzle stocker (S100). The number of nozzles 60 prepared in the nozzle stocker can be stored in advance by the user in the nozzle data in the memory unit 82 via the input device 85, and the CPU 81 makes the determination based on the nozzle data.

If there is a spare nozzle 60 in the nozzle stocker, the CPU 81 replaces the nozzle 60 attached to the mounting head 32 with the spare nozzle 60 and continues production (S110).

If there are no spare nozzles 60 in the nozzle stocker, the CPU 81 notifies the user of the abnormality in the nozzle 60 by sending an error message or the like, and stops the machine operation (S120). The user can resume production by replenishing the nozzle stocker with nozzles 60.

<When the nozzle tip is square shaped>
Next, inspection of the state of a nozzle 65 having a tip 66 that is square in plan view will be described with reference to Figures 10 and 11. Items that can be explained in the same way as the nozzle 60 described above will not be described. As shown in Figure 10, if the rotation angle θ of the nozzle 65 is defined in the same way as the nozzle 60, the multiple inspection angles of the nozzle 65 consist of a first inspection angle of θ = 45° and a second inspection angle of θ = -45°.

The tip 66 of the nozzle 65 has four corners 67A-67D and a generally X-shaped suction hole 68. For example, as shown in FIG. 11, if a nozzle 65 with a chipped corner 67D is imaged from multiple inspection angles, the chipped corner 67D can be detected based on the second captured image.

<When the nozzle tip is diamond-shaped>
Next, with reference to Fig. 12 and Fig. 13, the inspection of the state of the nozzle 70 whose tip 71 is rhombic in plan view will be described. The description of matters that can be explained in the same manner as the nozzle 60 described above will be omitted. As shown in Fig. 12, the angle θ at which the nozzle 70 rotates around the axis L is defined as the reference angle (θ = 0°) at which the longer diagonal of the rhombic shape is parallel to the reference axis SA, and the counterclockwise direction in plan view is defined as the positive direction. The multiple inspection angles of the nozzle 70 consist of a first inspection angle of θ = 0° (reference angle) and a second inspection angle of θ = 90°.

The tip 71 of the nozzle 70 has four corners 72A-72D and two suction holes 73. When the nozzle 70 is at the first inspection angle, the two corners 72A, 72C, which are acute angles (<90°), are located at the ends in the width direction of the first captured image. When the nozzle 70 is at the second inspection angle, the two corners 72B, 72D, which are obtuse angles (>90°), are located at the ends in the width direction of the second captured image. For example, as shown in FIG. 13, when a nozzle 70 with a chipped corner 72C is imaged at multiple inspection angles, the chipped corner 72C can be detected from the first captured image.

[Effects of the First Embodiment]
As described above, the component mounting device 10 according to the first embodiment is a component mounting device 10 that mounts components on a board B, and includes a mounting head 32 in which the nozzle 60 that picks up components is attached on the axis L, a rotation mechanism (R-axis servo motor 36) that rotates the nozzle 60 about the axis L, an imaging unit 40 that images the nozzle 60 from an imaging direction perpendicular to the axial direction of the axis L, a storage unit 82 that stores nozzle data, and a control unit (CPU 81), and the nozzle data includes a plurality of inspection angles, and the plurality of inspection angles are such that a portion of the tip 61 of the nozzle 60 where chipping is likely to occur is disposed at an end in a width direction perpendicular to both the axial direction and the imaging direction. The nozzle data includes a plurality of standard sizes which are the sizes of the standard nozzle 60S when a standard nozzle 60S of the same type as the nozzle 60 and having an unbroken tip 61 is rotated to a plurality of inspection angles and viewed from the imaging direction, and the control unit (CPU 81) rotates the nozzle 60 to one or more inspection angles among the plurality of inspection angles using the rotation mechanism (R-axis servo motor 36) and images the nozzle 60 at the one or more inspection angles using the imaging unit 40, thereby obtaining one or more captured images, and inspects the condition of the nozzle 60 based on the one or more captured images and the nozzle data stored in the memory unit 82.

With this configuration, the nozzle data includes multiple inspection angles for imaging the nozzle 60, so that it is possible to obtain only one or more images required to inspect the state of the nozzle 60, thereby shortening the time required for inspection. Furthermore, with multiple inspection angles, the location where chipping of the tip 61 of the nozzle 60 is likely to occur is arranged at the end in the width direction, so that it is easy to detect abnormalities in the nozzle 60, particularly chipping of the tip 61 of the nozzle 60. Because this configuration makes it easy to detect abnormalities in the nozzle 60, it is possible to suppress a decrease in the component pickup rate and mounting misalignment.

In the first embodiment, the control unit (CPU 81) executes a size calculation process that calculates one or more measurement sizes based on one or more captured images, and a determination process that determines whether or not the tip 61 of the nozzle 60 is chipped by comparing the one or more measurement sizes with one or more standard sizes among a plurality of standard sizes.

With this configuration, the control unit (CPU 81) determines whether or not the tip 61 of the nozzle 60 is chipped by comparing one or more measured sizes calculated based on one or more captured images with one or more standard sizes among the multiple standard sizes included in the nozzle data, thereby improving the accuracy of inspection for chipping of the tip 61 of the nozzle 60.

In the first embodiment, the multiple inspection angles are set taking into account the offset amount specific to the mounting head 32 to which the nozzle 60 is attached.

With this configuration, the state of the nozzle 60 can be accurately inspected even if the mounting head 32 used is changed.

In the first embodiment, the control unit (CPU 81) inspects the state of the nozzle 60 at least one of the following times: immediately after the nozzle 60 is attached to the mounting head 32, immediately before the nozzle 60 is stored in the nozzle stocker, when a suction error occurs, at a preset regular timing, and when the substrate B is transported.

With this configuration, the state of the nozzle 60 is inspected at at least one set timing, making it easier to detect abnormalities in the nozzle 60 and suppressing a decrease in the component pickup rate, mounting misalignment, etc.

In the first embodiment, the imaging unit 40 includes an inspection camera (first camera 41) that images the nozzle 60, and an inspection illuminator (first illuminator 42) that is arranged to sandwich the nozzle 60 together with the inspection camera (first camera 41) in the imaging direction. The light source of the inspection illuminator (first illuminator 42) is preferably a parallel light.

With this configuration, the light source of the inspection illumination (first illumination 42) is parallel light, making it easier to accurately calculate the size of the tip 61 of the nozzle 60 based on multiple captured images, and making it easier to detect abnormalities in the nozzle 60.

[Details of the second embodiment of the present disclosure]
A second embodiment of the present disclosure will be described with reference to Fig. 14 to Fig. 17. Hereinafter, the description of the configuration and the operation and effect similar to those of the first embodiment will be omitted. Also, the same configuration as that of the first embodiment will be described using the same reference numerals.

In the component mounting device 110 of the second embodiment, the CPU 81 acquires multiple captured images by continuously capturing images of the nozzle 60 using the imaging unit 40 while rotating the nozzle 60 by 180° or more around the axis L. That is, in the second embodiment, the multiple inspection angles of the first embodiment are not used, so the nozzle data does not need to include multiple inspection angles. Also, since only the relative value of the angle θ matters, there is no need to take into account the offset amount of the angle θ specific to the mounting head 32.

The CPU 81 calculates the measured size of each of the multiple captured images. For example, taking the nozzle 60 with a chipped tip 61 shown in FIG. 14 as an example, the measured size of the captured image shows a relationship with the angle θ as shown by the solid line in FIG. 15 (the dashed line is for the standard nozzle 60S). As shown by the white arrows in FIG. 15, the measured size is maximum at angles θ=θ3 (>0°) and θ4 (<0°), and is minimum at angles θ=-90°, 0°, and 90°. Captured images with maximum and minimum measured sizes are shown in FIG. 14.

The CPU 81 extracts the captured image with the largest measurement size, i.e., the image captured at angle θ=θ3, as the first image. Next, the CPU 81 extracts the captured image with the largest measurement size, i.e., the image captured at angle θ=θ4, as the second image, excluding the captured images captured at the exclusion angle dθ before and after the angle θ=θ3 of the nozzle 60 when the first image was captured. By excluding the captured images at the exclusion angle dθ before and after the first image, it is possible to avoid, for example, the image captured at angle θ=θ5 in FIG. 15 being extracted as the second image.

The CPU 81 compares the measured size of the first image with the first maximum size, and compares the measured size of the second image with the second maximum size to determine whether the tip 61 of the nozzle 60 is chipped. Here, the first maximum size and the second maximum size are the maximum values of the size of the standard nozzle 60S (same type as the nozzle 60, with the tip 61 not chipped; see FIG. 7 of the first embodiment) with respect to the angle θ when viewed from the imaging direction by rotating the standard nozzle 60S by 180° or more around the axis L, and the second maximum size is equal to or smaller than the first maximum size. In the case shown in FIG. 14 and FIG. 15, the tip 61 of the standard nozzle 60S without chipping has a rectangular shape in a plan view, so the first maximum size and the second maximum size are equal. The first maximum size and the second maximum size are included in advance in the nozzle data of the storage unit 82 as numerical parameters.

In this embodiment, as shown in FIG. 15, the exclusion angle dθ is appropriately set, so that the captured image at angle θ=θ4, which reflects the chipping of the tip 61 of the nozzle 60, is extracted as the second image. Therefore, as shown in FIG. 14, by comparing the measured size of the second image with the second maximum size (the dashed dotted line in the captured image), it is possible to detect the chipping of the tip 61.

<When the nozzle tip is diamond-shaped>
Next, a description will be given of the nozzle 70 having a diamond-shaped tip 71. For simplicity, the nozzle 70 is assumed to be a standard nozzle 70S in which the tip 71 is not chipped.

The measured size of the captured image of the tip 71 of the nozzle 70 shown in Figure 16 shows a relationship with the angle θ as shown by the solid line in Figure 17. As shown by the white arrows in Figure 17, the measured size is maximum at angles θ = -90°, 0°, and 90°, and is minimum at angles θ = θ6 (> 0°) and θ7 (< 0°). Figure 16 shows captured images where the measured size is maximum or minimum.

However, the first and second maximum sizes for the standard nozzle 70S are significantly different, and the second maximum size is close to the minimum measured size. Therefore, for example, it is necessary to set the exclusion angle Dθ so that the image captured at θ = θ8 is not extracted as the second image. If the image captured at θ = θ8 is extracted as the second image, the images captured around angles θ = -90° and 90° that should have been extracted will not be extracted, and chipping of corners 72B and 72D may not be detected.

As described above, in inspecting the state of nozzles 60, 70 in embodiment 2, it is important to appropriately set the exclusion angles dθ, Dθ in order to extract true first and second images from multiple captured images obtained by successive imaging.
[Effects of the Second Embodiment]

The component mounting device 110 according to the second embodiment is a component mounting device 110 that mounts components on a board B, and includes a mounting head 32 on which a nozzle 60 that picks up components is attached on an axis L, a rotation mechanism (R-axis servo motor 36) that rotates the nozzle 60 around the axis L, an imaging unit 40 that images the nozzle 60 from an imaging direction perpendicular to the axial direction of the axis L, a storage unit 82 that stores nozzle data, and a control unit (CPU 81). The control unit (CPU 81) rotates the nozzle 60 using the rotation mechanism (R-axis servo motor 36) and images the nozzle 60 using the imaging unit 40 at multiple angles around the axis L of the nozzle 60, thereby obtaining multiple captured images for each nozzle 60, and inspects the state of the nozzle 60 based on the multiple captured images and the nozzle data stored in the storage unit 82.

With this configuration, the state of the nozzle 60 is inspected based on multiple captured images obtained by capturing images of the nozzle 60 at multiple angles around the axis L and the nozzle data stored in the memory unit 82, making it easy to detect abnormalities such as chipping of the tip 61 of the nozzle 60. In addition, because the configuration makes it easy to detect abnormalities in the nozzle 60, it is possible to suppress a decrease in the component pickup rate and mounting misalignment.

In embodiment 2, the nozzle data includes a first maximum size, a second maximum size equal to or smaller than the first maximum size, and an exclusion angle dθ, and a standard nozzle 60S of the same type as the nozzle 60 and having an unbroken tip 61 is rotated 180° or more around the axis L, and the size of the standard nozzle 60S when viewed from the imaging direction takes maximum values at the first maximum size and the second maximum size, and the control unit (CPU 81) captures multiple images of the nozzle 60 continuously using the imaging unit 40 while rotating the nozzle 60 by 180° or more using the rotation mechanism (R-axis servo motor 36). The system performs a continuous imaging process to acquire captured images of the nozzle 60, a size calculation process to calculate multiple measurement sizes based on the multiple captured images, an image extraction process to extract a first image with the maximum measurement size and a second image with the maximum measurement size excluding captured images captured at an exclusion angle dθ before and after the angle of the nozzle 60 when the first image was captured, and a determination process to determine whether the tip 61 of the nozzle 60 is chipped by comparing the measurement size of the first image with the first maximum size and comparing the measurement size of the second image with the second maximum size.

According to this configuration, the state of the nozzle 60 is inspected based on multiple captured images obtained by continuously capturing images of the nozzle 60 while rotating the nozzle 60 by 180° or more. Therefore, even if the nozzle data does not include the angle θ at which the nozzle 60 should be captured or the offset amount of the angle θ specific to the mounting head 32 is not taken into account, it is possible to inspect the state of the nozzle 60, particularly the chipping of the tip 61 of the nozzle 60. In addition, the control unit (CPU 81) extracts a first image and a second image from the multiple captured images, compares the measured size of the first image with the first maximum size, and compares the measured size of the second image with the second maximum size to determine whether the tip 61 of the nozzle 60 is chipped, thereby improving the accuracy of the inspection for chipping of the tip 61 of the nozzle 60.

<Other embodiments>
(1) In embodiment 1, the three shafts 33 are rotated around the axis L by one and the same R-axis servo motor 36. However, an R-axis servo motor may be provided on each of the multiple shafts, and each shaft may be rotated by a separate R-axis servo motor.
(2) In the first embodiment, the tip portions 61, 66, and 71 of the nozzles 60, 65, and 70 have a rectangular shape. However, for example, the shape of the tip portions of the nozzles may be a rounded polygonal shape, an elliptical shape, or a circular shape.

(3) In the first embodiment, if chipping of the tip 61 of the nozzle 60 is detected and there is no spare nozzle 60 in the nozzle stocker, the CPU 81 is configured to inform the user of the abnormality in the nozzle 60 and stop the machine operation (S120), but this is not limited to this. For example, production of one board using the nozzle for which an abnormality was detected may be stopped, and the machine operation may be stopped after completion. Alternatively, production using the nozzle for which an abnormality was detected may be stopped, the nozzle shortage may be notified to the integrated management system, production may be continued, and production using the nozzle may be resumed once spare nozzles have been replenished.

(4) In the first embodiment, the CPU 81 acquires the first captured image, calculates the first measurement size, and executes a check for chipping of the tip 61 of the nozzle 60. If no chipping is detected, the CPU then acquires the second captured image. However, this is not limited to this. For example, the CPU may acquire the first captured image, then acquire the second captured image, and then calculate the first and second measurement sizes to check for chipping of the tip of the nozzle.

10, 110... component mounting device 11... base, 12... component supply unit, 13... feeder, 14... transport conveyor, 15... transport belt 20... drive unit, 21... X-axis beam, 22... Y-axis frame, 23... X-axis servo motor, 24... Y-axis servo motor 30... head unit 31... head unit main body, 32... mounting head, 33... shaft, 33A... shaft pulley, 36... R-axis servo motor, 36A... drive pulley, 37... belt, 38... auxiliary pulley, 40... imaging unit, 41... first camera, 42... first lighting 50... second camera, 51... second lighting, 52... third camera, 53... third lighting 60... nozzle (tip is rectangular)
60S: Standard nozzle; 61: Tip; 62A, 62B, 62C, 62D: Corners; 63: Suction hole; 65: Nozzle (with square tip)
66: tip portion; 67A, 67B, 67C, 67D: corner portions; 68: suction hole; 70: nozzle (tip portion has a diamond shape)
71...tip portion, 72A, 72B, 72C, 72D...corner portion, 73...suction hole 81...CPU, 82...storage portion, 83...memory, 84...display portion, 85...input device, 86...motor controller, 87...camera I/F, 88...lighting controller, 89...various I/O, 90...motor amplifier, 91...motor B...circuit board, dθ, Dθ...exclusion angle, L...axis, SA...reference axis

Claims (5)

A component mounting apparatus for mounting components on a substrate, comprising:
a mounting head having a nozzle for suctioning the component attached on an axis thereof;
A rotation mechanism that rotates the nozzle about the axis;
an imaging unit that images the nozzle from an imaging direction perpendicular to an axial direction of the axis;
A storage unit that stores nozzle data;
A control unit,
the nozzle data includes a plurality of test angles;
the plurality of inspection angles are angles about the axis of the nozzle such that a portion of the tip of the nozzle where chipping is likely to occur is disposed at an end in a width direction perpendicular to both the axial direction and the imaging direction;
the nozzle data includes a plurality of standard sizes which are sizes of the standard nozzle when a standard nozzle of the same type as the nozzle and having an unbroken tip is rotated to the plurality of inspection angles and the standard nozzle is viewed from the imaging direction,
The control unit rotates the nozzle to one or more inspection angles among the multiple inspection angles using the rotation mechanism, and images the nozzle at the one or more inspection angles using the imaging unit, thereby obtaining one or more captured images, and inspects the condition of the nozzle based on the one or more captured images and the nozzle data stored in the memory unit. The control unit is
a size calculation process for calculating one or more measurement sizes based on the one or more captured images;
a determination process for determining whether or not the tip of the nozzle is chipped by comparing the one or more measured sizes with one or more standard sizes among the plurality of standard sizes;
The component mounting apparatus according to claim 1 , The component mounting device according to claim 1 or 2, wherein the multiple inspection angles are set taking into account an offset amount specific to the mounting head to which the nozzle is attached. 4. The component mounting device according to claim 1, wherein the control unit inspects the state of the nozzle at at least one of the following times : immediately after the nozzle is attached to the mounting head, immediately before the nozzle is stored in a nozzle stocker, when a suction error occurs, at a predetermined regular timing, and when the substrate is transported. the imaging unit includes an inspection camera that images the nozzle, and an inspection light that is disposed so as to sandwich the nozzle together with the inspection camera in the imaging direction;
5. The component mounting apparatus according to claim 1 , wherein a light source of the inspection illumination emits parallel light.

Images