Force/Torque-Controlled SMD Reel Reloading for Tape Connection
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Solution Overview
Problem
The manual process of attaching the beginning of a new SMD component reel to the end of a running-out reel in SMD assembly machines is labor-intensive and lacks consistency in quality, necessitating fully automated solutions.
Innovation Solution
A method involving a robot arm controlled by a robot controller performs force/torque-controlled movements to automatically remove a first SMD reel, thread its tape into a belt connector, separate it, deposit it, pick up a second reel, thread its tape, and insert it into the exchange magazine, ensuring seamless connection without manual intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If manual process is used to attach new SMD component reel to running-out reel, then flexibility and adaptability are maintained, but labor intensity increases and quality consistency deteriorates
Solution Approach 1:
The system enables automatic reel replacement where the machine serves itself by detecting when a reel is nearly depleted and autonomously performing the replacement process including removing the old reel, threading the new reel, and connecting tapes without human intervention
Solution Approach 2:
The patent replaces manual mechanical operations with an automated robot arm system that uses force/torque control to perform delicate operations such as threading tapes through connectors and handling reels, substituting human dexterity with controlled robotic mechanisms
2Productivity
If manual reel replacement is performed, then equipment complexity remains low, but productivity decreases due to interruption and quality consistency deteriorates
Solution Approach 1:
The system maintains continuous operation by automatically detecting when component supply is nearly depleted and performing reel replacement during or between production cycles, ensuring the SMD assembly machine operates without interruption and maintains continuous productive action
Solution Approach 2:
The system incorporates detection mechanisms that monitor component consumption levels on reels and provide feedback to trigger the automated replacement process, ensuring reels are changed at the optimal moment to maintain continuous operation without over-complicating the system
3Manufacturing precision
If force/torque-controlled movement control mode is used, then manufacturing precision and quality consistency are improved, but device complexity increases
Solution Approach 1:
The system changes the control parameter from simple position control to force/torque control, allowing the robot arm to delicately manipulate tapes and reels by controlling applied forces rather than just positions, achieving precise tape connection and proper tensile force application
4Ease of operation
If automated reel replacement is implemented, then labor costs decrease and productivity increases, but device complexity and initial investment increase
Solution Approach 1:
The robot arm system is designed with multi-functionality, capable of performing multiple operations including reel removal, tape threading, connector operation, and reel insertion using the same automated mechanism, simplifying the overall system architecture while achieving ease of operation
Data Source
AI summary
A method for automatically reloading SMD component reels on SMD assembly machines wherein SMD component reels between an exchange magazine of an SMD assembly machine and a belt connector are automatically handled by a robot arm controlled by a robot controller in a force/torque-controlled movement control mode of the robot arm.