Electronic Component Transfer Device for Opaque Multi-Row Web
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Solution Overview
Problem
Current methods for transferring electronic components from one carrier to another face challenges in achieving high throughput and accuracy, especially when using non-transparent second carriers, which often result in reduced positional accuracy and increased complexity.
Innovation Solution
A device comprising a first receptacle for the first carrier, a second receptacle for the quasi-endless second carrier, a separating device, conveying devices, and inspection devices that allow for precise orientation and transfer of components onto multi-row web material without requiring transparency, enabling higher throughput and accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional transfer methods using transparent carriers are used, then positional accuracy can be maintained, but throughput is limited and device complexity increases
Solution Approach 1:
The system segments the transfer process into distinct functional modules: a separating device that detaches components from the first carrier, multiple conveying devices that independently transport the first carrier, second carrier, and separating device, and inspection devices that monitor component positions. This modular segmentation enables parallel operations and increases throughput while maintaining manageable device complexity through functional specialization.
Solution Approach 2:
The system employs dynamic control where the separating device and conveying devices can be independently positioned and moved along the second carrier's length. The first carrier can be moved transversely relative to the second carrier, and the separating device can be repositioned to different locations. This dynamic adaptability allows the system to handle multi-row web material efficiently, increasing throughput without sacrificing positional accuracy.
2Device complexity
If non-transparent second carriers are used, then device complexity may be reduced, but positional accuracy deteriorates
Solution Approach 1:
The system performs preliminary inspection of component positions on the first carrier and subassembly positions on the second carrier before the transfer operation. The inspection devices detect positions in advance, allowing the control system to calculate and execute the precise movements needed for accurate component placement, even when using non-transparent carriers that simplify the overall device structure.
Solution Approach 2:
The system incorporates feedback mechanisms where inspection devices continuously monitor the positions of components on the first carrier and subassemblies on the second carrier. This real-time position information is fed back to the control system, which adjusts the movement of conveying devices and the separating device to maintain precise positional accuracy throughout the transfer process, regardless of carrier transparency.
3Reliability
If components are handled with great care to prevent damage, then component reliability is maintained, but transfer speed decreases
Solution Approach 1:
The system replaces manual or simple mechanical handling with an automated separating device that can detach components from the first carrier and place them on the second carrier with precise control. This automated mechanism ensures consistent, gentle handling that prevents component damage while operating at high speeds, thereby maintaining both component integrity and transfer speed.
Solution Approach 2:
The system dynamically adjusts operational parameters such as the speed of conveying devices, the positioning accuracy of the separating device, and the timing of transfer operations. By optimizing these parameters, the system achieves a balance where components are handled gently enough to prevent damage but with sufficient speed to maintain high productivity.
Data Source
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AI summary
In a device for the transferring of components from a first to a second carrier, the first carrier carries individual components. The second carrier is quasi-continuous and carries subassemblies, to each of which one of the components is to be transferred from the first carrier. The device has a first receptacle for the first carrier. The first receptacle receives the first carrier in such a way that the components carried by the first carrier are oriented towards a second receptacle. A separating device separates the components from the first carrier for transfer to the second carrier. A first conveyor moves the first receptacle transverse to the conveying direction of the second carrier relative to the second receptacle. A second conveyor moves the separating device transverse to the conveying direction of the second carrier relative to the second receptacle. A first inspection device detects one of the components in its position relative to a storage position on the second receptacle guiding the second carrier. A second inspection device is arranged upstream of the storage position and detects one of the subassemblies on the second carrier relative to the second receptacle and signals the position of the subassembly to a controller. Based on information signalled from the controller, a third conveyor conveys the second carrier relative to the storage position in such a way that a subassembly on the second carrier arrives at the storage position on the second receptacle guiding the second carrier.