Component Mounting Apparatus Automatic Feed Pitch Adjustment

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

In electronic component mounting, when the feed pitch of a carrier tape differs from the formation pitch of its pockets, it leads to component wastage and suction errors, increasing operator workload and reducing productivity due to the need for manual feed pitch changes.

Innovation Solution

A component mounting apparatus and method that includes an imaging unit to measure the formation pitch of pockets and adjust the feed pitch of the carrier tape, ensuring accurate component supply to the suction position, thereby reducing operator workload and preventing errors.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If the carrier tape is intermittently fed based on a predetermined feed pitch set in component data, then components can be supplied to the mounting head, but when the formation pitch of pockets differs from the feed pitch, suction errors occur and components are wasted

Engineering Contradiction:

Improvecomponent mounting speedVSAvoidsuction accuracy

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The system dynamically changes the feed pitch parameter based on the detected formation pitch of the carrier tape pockets. The control unit adjusts the feed pitch to match the actual formation pitch, ensuring accurate component supply regardless of variations between different carrier tapes or manufacturers.

Inventive Principle:

Principle #35Parameter changes

2Reliability

If the feed pitch is changed to match different formation pitches, then suction accuracy improves, but operator workload increases due to manual feed pitch change operations

Engineering Contradiction:

Improvesuction accuracyVSAvoidoperator workload

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The system performs self-adjustment by automatically detecting the formation pitch of the carrier tape and changing the feed pitch without operator intervention. The imaging unit captures pocket positions, the control unit calculates the formation pitch, and the system automatically updates the feed pitch parameter, making the system self-sufficient.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The manual mechanical operation of changing feed pitch by the operator is replaced by an automated system using imaging technology and control algorithms. The optical measurement and automated control substitute for manual mechanical adjustment.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Adaptability or versatility

If manual feed pitch change operation is performed, then feed pitch can be adjusted, but wrong feed pitch may be set due to artificial mistakes and productivity is lowered

Engineering Contradiction:

Improvefeed pitch adjustabilityVSAvoidmounting cycle time

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

The system uses feedback from the imaging unit to detect the actual formation pitch and automatically adjusts the feed pitch accordingly. This closed-loop feedback mechanism eliminates manual intervention errors and ensures the correct feed pitch is always used, maintaining high productivity.

Inventive Principle:

Principle #23Feedback

4Productivity

If the carrier tape with replacement components is fed based on registered component feed pitch, then feeding operation can proceed, but about half the components are not suctioned due to pitch mismatch

Engineering Contradiction:

Improvefeeding operation continuityVSAvoidcomponent wastage

Core Design Contradiction:

ProductivityVSLoss of substance

Solution Approach 1:

The system performs preliminary detection of the formation pitch before the mounting operation begins. By measuring the actual pocket positions in advance and adjusting the feed pitch beforehand, the system prevents component wastage during the actual mounting process while maintaining continuous operation.

Inventive Principle:

Principle #10Preliminary action

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

Automatically adjusts the feed pitch of the carrier tape to match the formation pitch of the pockets, minimizing component wastage and suction errors, and reducing operator effort in feed pitch changes, enhancing productivity.

Implementation Method 1

an imaging unit that images the pockets

Methodology Applied

Scientific EffectImaging: Photography

Data Source

PatentUS9936620B2Component mounting method

Publication Date: 2018.04.03 PANASONIC INTELLECTUAL PROPERTY MANAGEMENT CO LTD

AI summary

A component mounting apparatus includes a component supply device that intermittently feeds a carrier tape, in which components are stored in a plurality of pockets formed with a uniform pitch, based on a predetermined feed pitch to supply the components stored in the pockets to a component suction position, and picks up the components supplied to the component suction position to mount the components onto a board, an imaging unit that images the pockets, and a control unit that measures a formation pitch of the pockets based on obtained image data, and changes a feed pitch of the carrier tape from the predetermined feed pitch to the formation pitch of the pockets when the measured formation pitch of the pockets and the predetermined feed pitch are different from each other, and the component supply device intermittently feeds the carrier tape based on the changed feed pitch.