Tape Feeder Motor Control for Stable Low-Torque Reel Feeding
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Solution Overview
Problem
The existing tape feeder systems consume excessive power due to using motors with higher torque than necessary, especially when the tape reel is nearly empty, leading to inefficient operation and potential instability in tape feeding.
Innovation Solution
A control system that includes a tape remaining amount information acquiring section, an auxiliary actuator to reinforce drive power, and a control section that adjusts the operation parameters of the motor and auxiliary actuator based on the tape remaining amount, allowing for reduced power consumption without compromising stability by decreasing torque as the tape reel empties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a motor with large torque is used to ensure stable tape feeding when the reel is full, then the tape feeding stability is improved, but the power consumption increases when the reel is nearly empty
Solution Approach 1:
The patent applies dynamics by making the motor torque adjustable based on the tape remaining amount. The control section dynamically changes the motor's operation parameters (rotation velocity and rotation amount) according to the detected tape quantity, transitioning from high torque when the reel is full to low torque when nearly empty. This resolves the contradiction by adapting the motor output to match the actual load requirements at different operational stages.
Solution Approach 2:
The patent changes the motor's operational parameters (torque, rotation velocity, rotation amount) based on the tape remaining amount detected by the detection section. When the reel is full, the motor operates with high torque and specific rotation parameters to ensure stable feeding. When the reel is nearly empty, the control section adjusts these parameters to reduce torque and power consumption, while maintaining sufficient feeding capability. This parameter adaptation resolves the contradiction between stability and energy efficiency.
2Use of energy by moving object
If a motor with small torque is used to reduce power consumption, then the energy efficiency is improved, but the tape feeding stability deteriorates when the reel is full
Solution Approach 1:
The system dynamically adjusts motor torque based on real-time detection of tape remaining amount. When the reel is full and load is high, the control section increases motor torque and adjusts rotation parameters to ensure stable feeding. When the reel is nearly empty and load decreases, the system reduces torque to minimize power consumption. This dynamic adaptation eliminates the need to choose between small torque (low power) and large torque (high stability) as fixed configurations.
Solution Approach 2:
The control section changes motor operational parameters including torque, rotation velocity, and rotation amount based on the detected tape quantity. This parameter modulation allows the motor to operate at optimal torque levels for each operational phase: high torque when the reel is full to maintain stability, and low torque when nearly empty to reduce power consumption, thus resolving the contradiction.
3Reliability
If the motor operates at constant high torque throughout, then the tape feeding stability is maintained, but the power consumption is wasteful when the tape remaining amount is small
Solution Approach 1:
The patent implements feedback control by using the detection section to continuously monitor the tape remaining amount and feed this information back to the control section. Based on this feedback, the control section adjusts the motor's operation parameters in real-time. This closed-loop feedback mechanism enables the system to reduce power consumption when the reel is nearly empty while maintaining feeding stability, resolving the contradiction between constant high torque operation and energy efficiency.
Solution Approach 2:
The control section modifies motor operational parameters (torque, rotation velocity, rotation amount) based on feedback about tape remaining amount. When the detection section determines the reel is nearly empty, the control section reduces motor torque and adjusts rotation parameters to decrease power consumption. This dynamic parameter change based on feedback resolves the contradiction by eliminating wasteful energy consumption while preserving feeding stability when needed.
4Use of energy by moving object
If the motor torque is reduced dynamically, then the power consumption decreases, but the risk of insufficient torque and out-of-step operation increases
Solution Approach 1:
The system dynamically adjusts motor torque based on the actual load conditions determined by tape remaining amount. The control section reduces torque only when the detection section confirms the reel is nearly empty and the load has genuinely decreased. This dynamic adjustment maintains sufficient torque for stable operation during high-load conditions while reducing power consumption during low-load conditions, preventing out-of-step operation.
Solution Approach 2:
The control section carefully modulates motor parameters (torque, rotation velocity, rotation amount) based on detected tape quantity, ensuring that torque is reduced only to the extent necessary for power savings while maintaining adequate levels for stable operation. This controlled parameter change prevents the motor from entering out-of-step conditions by maintaining sufficient torque margins even during dynamic reduction.
Data Source
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AI summary
A control system of a tape feeder (23) that includes a reel (25) on which is wound component supply tape (24) in which components are packaged by being arranged in a line, and a tape feeding device (31) configured to draw out the component supply tape from the reel and pitch feed the component supply tape such that a leading component in the component supply tape is moved to a component pickup position, the control system including: a sensor (42) configured to detect information relating to a remaining amount of the tape on the reel ("tape remaining amount information"); and a motor control section (41) configured to change an operation parameter of a motor that is a drive source of the tape feeding device based on the tape remaining amount information detected by the sensor. Specifically, the motor control section changes the operation parameter of the motor so as to reduce the motor torque as the tape remaining amount on the reel decreases, based on the tape remaining amount information detected by the sensor.