Feeder Sprocket Rewinding Control for Tape Engagement
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Solution Overview
Problem
Existing feeder systems fail to prevent tape removal from the sprocket when rewinding, leading to production errors and downtime when a new tape is set but not sufficiently fed out, causing issues during reattachment to the component mounting machine.
Innovation Solution
A feeder system with a sensor to detect the sprocket's rotational position, a storage section to record the initial rotational position and cumulative feeding amount, and a control section to manage the motor's rotation direction, ensuring the sprocket does not exceed the initial position during rewinding, thereby preventing tape removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the empty tape is uniformly rewound by a predetermined amount, then the hanging portion is prevented from being caught when the feeder is attached next time, but the tape may be removed from the sprocket when the cumulative feeding amount is small
Solution Approach 1:
The control section dynamically adjusts the rewinding amount based on the cumulative feeding amount stored in the storage section. When the cumulative feeding amount is small, the control section limits the reverse rotation to prevent tape removal from the sprocket. When the cumulative feeding amount is sufficient, the control section allows full rewinding to prevent hanging tape. This dynamic adjustment resolves the contradiction between reliable tape engagement and simple operation.
Solution Approach 2:
The system uses feedback from the sensor that detects the sprocket's rotational position to determine the cumulative feeding amount. This feedback information is stored and used by the control section to calculate the appropriate rewinding amount. The feedback mechanism enables the system to adapt the rewinding operation to the actual tape feeding state, preventing both tape removal and hanging tape conditions.
2Reliability
If the sprocket rotates in reverse direction to rewind the tape, then the empty tape hanging down is prevented, but production stops and manual intervention is required when the tape is removed from the sprocket during reattachment
Solution Approach 1:
The control section performs preliminary calculation of the safe rewinding amount based on the cumulative feeding amount stored in the storage section before executing the rewinding operation. This preliminary action ensures that the tape will not be removed from the sprocket during rewinding, preventing the need for manual intervention during reattachment and maintaining production continuity.
Solution Approach 2:
The system automatically adjusts the rewinding operation based on its own stored history of cumulative feeding amounts, eliminating the need for external manual intervention. The control section uses the sensor feedback and stored data to autonomously determine the appropriate rewinding parameters, ensuring the tape remains engaged with the sprocket throughout the process.
Data Source
AI summary
A feeder includes a sprocket that feeds a tape accommodating multiple components; a motor that rotates the sprocket; a storage section to store the rotational position of the sprocket detected by a sensor as an initial rotational position when the tape is set in the feeder and store a cumulative feeding amount of the tape fed by the rotation of the sprocket; and a control section to control the motor such that the sprocket rotates in a forward direction based on a feeding amount of the tape required for a supply when supplying the components to the component mounting machine, and control the motor such that the sprocket does not rotate in a reverse direction in excess of the initial rotational position based on the initial rotational position and the cumulative feeding amount when rewinding the tape.