Fiber Optic Carrier Tape Sensing for Out-of-Position Components
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Solution Overview
Problem
Existing carrier tape forming machines fail to efficiently detect out of position (OOP) components, leading to potential damage or unusable reels due to misaligned components during the manufacturing process.
Innovation Solution
Implementing cross track sensors and fiber optic sensors in the carrier tape forming machine to detect OOP components before and after overlaying with cover tape, using amplifiers and relays to adjust detection ranges and stop the machine if OOP components are detected.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional mechanical sensing methods are used to detect component placement, then the device complexity is low, but the measurement precision and reliability of detecting out-of-position components is insufficient
Solution Approach 1:
The patent replaces traditional mechanical sensing methods with optical sensors (cameras, laser sensors) to detect component placement position. This substitution provides non-contact measurement with higher precision while avoiding mechanical wear and contamination issues, directly resolving the contradiction between measurement precision and device complexity.
Solution Approach 2:
The patent introduces optical fields as an intermediary between the component placement system and the detection system. The optical sensors detect reflected or transmitted light patterns to determine component position, enabling precise measurement without direct mechanical contact and thus achieving high detection accuracy while maintaining system simplicity.
2Reliability
If detection is performed only after cover tape application, then the manufacturing process flow is simple, but the reliability of preventing damaged components is reduced
Solution Approach 1:
The patent implements detection at multiple stages: before cover tape application and after cover tape application. This preliminary detection allows identification and correction of out-of-position components early in the process, preventing damage before it occurs and enhancing reliability without requiring overly complex single-stage detection systems.
Solution Approach 2:
The patent establishes a feedback mechanism where detection results from both pre-cover and post-cover sensing are fed back to the control system. This enables real-time monitoring and adjustment, ensuring that component placement issues are identified and addressed, thereby improving reliability through continuous verification rather than relying on a single complex detection point.
3Manufacturing precision
If multiple detection points are implemented, then the manufacturing precision is improved, but the productivity decreases due to additional processing time
Solution Approach 1:
The patent implements continuous detection during the carrier tape manufacturing process rather than discrete stop-and-check methods. Optical sensors continuously monitor component placement as the tape is being formed and covered, allowing real-time detection without interrupting the production flow, thus maintaining both high precision and productivity.
Solution Approach 2:
The patent performs initial detection before cover tape application, allowing corrective actions to be taken while the production line is still running. This preliminary detection prevents the need for rework or shutdowns later, maintaining production speed while ensuring placement precision through early identification of issues.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Effectively prevents damage by accurately identifying and stopping the machine when OOP components are present, ensuring proper alignment and reducing defects in carrier tapes.
Implementation Method 1
performing the second detecting with fiber optic sensors by detecting reflections from OOP components to determine whether one or more components seated on the carrier tape
Data Source
AI summary
The disclosure is directed to apparatus and methods for detection of out of position (OOP) components in a carrier tape forming machine. An apparatus includes cross track sensors coupled to the bus interface circuitry, the cross track sensors configured to detect OOP components prior to overlaying the components on the carrier tape with cover tape, optical sensors to detect the OOP components on the carrier tape after overlaying with cover tape and prior to sealing and to detect reflections from OOP components seated on the carrier tape, an amplifier coupled to the optical sensors to amplify signals generated by the optical sensors and set a range for determining whether the components are OOP, and relays to receive indications of detected OOP components, and a controller coupled to the relays to stop the carrier tape forming machine as a function of signals received by the relays.