Component mounter including a nozzle, camera, and a transfer device

• US 10,250,815 B2
• Filed: 05/13/2013
• Issued: 04/02/2019
• Est. Priority Date: 05/13/2013
• Status: Active Grant

• Current Assignee: Fuji Company Limited
• Original Assignee: Fuji Company Limited
• Inventors: Nozawa, Tatsuji
• Primary Examiner(s): Atala, Jamie J
• Assistant Examiner(s): Abaza, Ayman A
• Application Number:
  US14/785,384
• Publication Number:
  US 20160100089A1
• Time in Patent Office: 2,150 Days
• Field of Search: 348 95
• CPC Class Codes: G01N 2021/95646 Soldering
• CPC Class Codes: G01N 21/93 Detection standards; Calibrating baseline adjustment, drift correction
• CPC Class Codes: G01N 21/956 Inspecting patterns on the surface of objects contactless testing of electronic circuits G01R31/308; testing currency G07D; manufacturing processes per se of semiconductor devices implementing a measuring step H01L22/10
• CPC Class Codes: G06T 2207/30152 Solder
• CPC Class Codes: G06T 7/0004 Industrial image inspection
• CPC Class Codes: H04N 23/73 by influencing the exposure time
• CPC Class Codes: H05K 13/0817 Monitoring of soldering processes inspection of solder joints or of printed solder paste G01N21/95684

Abstract

Component mounter includes a transfer inspection device that inspects the transfer state of solder by imaging the bottom surface of a component, and a transfer inspection data creation device that creates transfer inspection data. The transfer inspection data creation device performs imaging of the bottom surface of a pre-transfer component with a camera at multiple shutter speeds, acquires the multiple pre-transfer images of different shutter speeds, obtains pre-transfer bump portion pixel values, performs imaging of the bottom surface of a post-transfer component with the camera at the same multiple shutter speeds, acquires the multiple post-transfer images of different shutter speeds, obtains post-transfer bump portion pixel values, and determines the shutter speed to be used when performing transfer inspection based on the post-transfer bump portion pixel values. Transfer inspection data is created based on the pre- and post-transfer bump portion pixel values of images captured at the determined shutter speed.

Claims

1. A component mounter comprising:

a conveyor configured to convey a circuit board;

a suction nozzle configured to hold a component;

a camera configured to image a bump on a bottom surface of the component held by the suction nozzle;

a transfer device configured to hold fluid that is one of solder, flux, conductive paste, and adhesive; and

a control device configured to image the bump onto which the fluid is not transferred at multiple shutter speeds using the camera to acquire multiple pre-transfer images captured at the multiple shutter speeds, to transfer the fluid held by the transfer device onto the bump, and to image the bump onto which the fluid is transferred at the multiple shutter speeds to acquire multiple post-transfer images captured at the multiple shutter speeds, the control device including an image processing unit, wherein

while the suction nozzle maintains suction on the component, the image processing unit is configured to determine pixel values of each of the pre-transfer images by performing gray processing on each of the pre-transfer images, and to determine pixel values of each of the post-transfer images by performing gray processing on each of the post-transfer images, the image processing unit including a transfer inspection data creation device configured to create transfer inspection data and a transfer inspection device configured to inspect a transfer state of the fluid transferred onto a bump using the transfer inspection data created by the transfer inspection data creation device,

the transfer inspection data creation device includes a shutter speed determining device configured to determine a transfer state shutter speed as a minimum shutter speed from the multiple shutter speeds for which a minimum value for the pixel values of each of the post-transfer images is equal to or larger than a predetermined value,

the transfer inspection data creation device is configured to create the transfer inspection data based on the pixel values of a pre-transfer image and a post-transfer image captured with the transfer state shutter speed determined by the shutter speed determining device, and

the control device is configured to mount the component used for the creation of the transfer inspection data on the circuit board conveyed by the conveyor.

2. The component mounter according to claim 1, wherein the transfer inspection data creation device calculates an intermediate value between the minimum value of the pixel values of the pre-transfer image and a maximum value of the pixel values of the post-transfer image captured at the transfer state shutter speed determined by the shutter speed determining device to be used as transfer-recognition-use transfer inspection data,

and the transfer inspection device uses the transfer-recognition-use transfer inspection data as a threshold value for determining fluid transfer portions and fluid non-transfer portions.

3. The component mounter according to claim 1, wherein the transfer inspection data creation device calculates a value which is smaller than a minimum value of the pixel values of the post-transfer image captured at the transfer state shutter speed determined by the shutter speed determining device by a predetermined value as image-processing-error-determination-use transfer inspection data,

and the transfer inspection device uses the image-processing-error-determination-use transfer inspection data as a threshold value for determining image processing errors.

4. The component mounter according to claim 1, wherein the transfer inspection data creation device, in cases in which production is performed using components onto which fluid is transferred, creates the transfer inspection data when the transfer inspection data has not been created.

5. The component mounter according to claim 1, wherein the transfer inspection data creation device recreates the transfer inspection data when the transfer inspection device determines that a transfer defect or image processing error has occurred during production using a component onto which fluid is transferred.

6. The component mounter according to claim 1, after the transfer inspection data is created, the suction nozzle holds the component used for the creation of the transfer inspection data while the camera images the component using the transfer state shutter speed determined by the shutter speed determining device and the component is mounted on the circuit board.