Component Mounter Tape Feeder Replenishment Automation
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Solution Overview
Problem
In component mounting systems, operators face increased workload when determining the necessary termination processing for carrier tapes nearing component shortages, as they must manually decide on cutting and fixing releasing tasks, which can be complex and time-consuming.
Innovation Solution
A component mounting system that includes a storage unit for information related to the tape feeder and carrier tape, a detector to identify component shortages, a determiner to decide on termination processing based on stored information, and a notifier to inform the operator of required actions, thereby automating the decision-making process for termination processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual determination of termination processing is performed by the operator, then flexibility and adaptability are maintained, but the operator's workload increases and processing time is extended
Solution Approach 1:
The system enables self-service by allowing the tape feeder to automatically determine whether termination processing is needed based on detection of the previous tape's state. The control unit autonomously decides if the following tape should be connected to or inserted in the tape inlet, eliminating the need for manual operator determination and reducing workload.
Solution Approach 2:
The system implements feedback through the detector that monitors the state of the previous tape and provides information to the control unit. This feedback loop enables the system to automatically adjust its behavior based on real-time conditions, such as whether the previous tape has been completely pitch-fed or if component shortage is approaching.
2Productivity
If automatic determination of termination processing is implemented, then operator workload is reduced, but system complexity increases
Solution Approach 1:
The system performs preliminary action by detecting the state of the previous tape in advance and determining the appropriate termination processing before the actual replenishment occurs. The control unit prepares the following tape by either connecting it to or inserting it in the tape inlet based on pre-determined conditions, ensuring smooth and efficient processing.
Solution Approach 2:
The control unit serves multiple functions: it controls the pitch-feeding mechanism, processes detector signals, determines termination processing requirements, and manages the replenishment process. This multi-functionality consolidates complexity into a single control unit, improving productivity while managing system complexity through integration.
3Speed
If the following tape is automatically drawn into the tape feeder, then replenishment speed is improved, but the ability to handle various termination scenarios is reduced
Solution Approach 1:
The system implements dynamics by making the replenishment process adaptable based on detected conditions. When the previous tape is completely pitch-fed, the following tape is automatically drawn into the tape inlet. When component shortage is approaching, the system connects the following tape to the tape inlet. This dynamic response maintains high speed while adapting to different termination scenarios.
Data Source
AI summary
There is provided a component mounter including: a storage which stores information related to a tape feeder and information related to a carrier tape pitch-fed by the tape feeder; a detector which detects a state where the carrier tape becomes close to a component shortage; a determiner which determines whether to perform predetermined processing with respect to a termination portion of the carrier tape based on information related to the tape feeder and information related to the carrier tape which are stored in the storage, in a case where a state where the carrier tape is close to a component shortage is detected by the detector; and a notifier which notifies an operator of contents of the predetermined processing, in a case where the determiner determines that the predetermined processing is supposed to be performed with respect to the termination portion of the carrier tape.