Component Feeding Device Backlash Optimization
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Solution Overview
Problem
Existing component feeding devices face issues with sprockets not fitting properly with feed holes in component feeding tapes, leading to inefficient transportation and mounting of electronic components, due to accumulated pitch errors and the need for complex adjustments or costly motor systems.
Innovation Solution
The solution involves setting a larger backlash for the upstream sprocket than the downstream sprocket, allowing the sprockets to rotate at the same speed and ensuring proper fitting with feed holes regardless of accumulated pitch errors, thereby preventing non-fitting and optimizing component transportation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If sprockets are driven with motors to transport component feeding tape, then transportation speed and productivity are improved, but accumulated pitch errors cause sprockets to not fit properly with feed holes, deteriorating transportation precision
Solution Approach 1:
The invention changes the parameter of backlash, setting it to a specific range (0.01mm to 0.05mm) to optimize the fitting between sprocket and feed hole. This parameter adjustment ensures that even with accumulated pitch errors during high-speed transportation, the sprocket teeth properly engage with the feed holes, maintaining transportation precision while enabling high-speed operation
Solution Approach 2:
The invention applies beforehand cushioning by pre-setting the backlash value within a specific range before operation begins. This predetermined backlash compensation mechanism prevents the negative effects of accumulated pitch errors from manifesting during high-speed transportation, ensuring continuous proper fitting between sprockets and feed holes
2Manufacturing precision
If backlash is reduced to improve fitting precision, then sprocket and feed hole alignment is improved, but the complexity of the driving system increases due to need for precise motor control
Solution Approach 1:
Instead of reducing backlash to zero or using complex active control systems, the invention sets backlash to an optimal range (0.01mm to 0.05mm). This parameter optimization achieves high fitting precision while maintaining a simple driving system structure, avoiding the need for complex sensors, controllers, or adjustment mechanisms
3Manufacturing precision
If multiple motors are used to drive sprockets independently, then transportation precision can be maintained, but device complexity and cost increase
Solution Approach 1:
The invention makes a single motor perform multiple functions by setting the backlash to an optimal range that simultaneously ensures proper sprocket-feed hole fitting and accommodates accumulated pitch errors. This eliminates the need for multiple independent motors while maintaining transportation precision, achieving multi-functionality with a single driving component
Solution Approach 2:
By optimizing the backlash parameter within a specific range, the invention enables a single motor to maintain transportation precision without requiring multiple motors. This parameter change allows one motor to compensate for pitch errors that would otherwise require additional driving components
Data Source
Figure 1~2
Figure 3~4
Figure 5A~5C
AI summary
A component feeding device transports a tape (a component feeding tape) in which electronic components are stored with some transportation means, and exposes the components. Transportation of the component feeding tape may be performed by fitting a sprocket with a feed hole of the component feeding tape. In the present invention, it has been found that sprocket does not necessarily fit with the feed hole of the component feeding tape. More specifically, it has been found that this phenomenon takes place in a case of driving at least two or more sprockets with a driving means exemplified by a motor. When the sprocket does not fit with the feed hole, transportation of the tape is not correctly performed, but exerts an undesirable influence such as reduction of mounting efficiency on feeding of the components and subsequent mounting of the components. Consideration regarding this point is not sufficient in the prior art. One feature of the present invention resides in rendering a backlash of an upstream-side sprocket larger than a backlash of a downstream-side sprocket.