Tape Feeder Positional Correction for Component Retention
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Solution Overview
Problem
In component mounting systems, smaller components are at risk of exposure and falling out due to the opening size being set for the largest component, leading to potential loss during suction, especially under vibration.
Innovation Solution
A component mounter and mounting method that includes a tape feeder with a recognition mark and camera system for positional correction, ensuring that adjacent components are not exposed beyond a predetermined amount from the opening, thereby preventing fallouts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the opening size is set to match the largest component, then the largest component can be suctioned properly, but smaller components may be exposed and fall out
Solution Approach 1:
The opening is made movable relative to the carrier tape, allowing its position to be dynamically adjusted based on component size. The opening can shift upstream or downstream to optimize coverage for different component dimensions while maintaining proper suction for the target component.
Solution Approach 2:
The position parameter of the opening is changed adaptively according to the size of the component being processed. By adjusting the opening's position along the tape feed direction, the system optimizes both component retention and suction effectiveness for varying component sizes.
2Ease of operation
If the opening is positioned to suction the target component, then the target component can be picked up, but adjacent components may be exposed and fall out
Solution Approach 1:
The opening's position is locally optimized for each suction operation based on the specific component size. Instead of a fixed position, the opening moves to the appropriate location upstream or downstream to provide local coverage that prevents adjacent components from falling out while maintaining suction capability for the target component.
Solution Approach 2:
The opening position is adjusted in advance before the suction operation based on the detected component size. This preliminary positioning ensures that when suction occurs, the opening is already optimally positioned to both capture the target component and prevent adjacent components from falling out.
3Device complexity
If a fixed opening design is used, then the device structure is simple, but it cannot adapt to differently sized components
Solution Approach 1:
Rather than using multiple fixed openings for different component sizes, the system employs a single movable opening that can dynamically reposition itself. This dynamic approach maintains structural simplicity while achieving adaptability to various component sizes through position adjustment in the tape feed direction.
Data Source
AI summary
A recognition mark which is formed on a tape retaining cover which retains a carrier tape, which holds components in pockets, in relation to a sprocket with which the tape feeder is provided, and the component or the pocket which is positioned at a suction position through an opening which is formed in the tape retaining cover are recognized. Based on recognition results, tape feed positional correction for positioning the suction target component at the suction position is performed such that the component, which is adjacent on an upstream side in a tape feed direction to the component which is positioned at the suction position, is not exposed by greater than or equal to a predetermined amount from the opening.