Tape Feeder Replenishment Error Prevention

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Solution Overview

Problem

In component mounting systems, automatic loading-type tape feeders often mistakenly allow excess carrier tapes to be inserted, leading to incorrect replenishment, as they can accept a succeeding tape even when a preceding tape protrudes from the insertion port.

Innovation Solution

A component supply method that includes a detector to identify the replenishment operation and a notifier to alert operators when a carrier tape needs to be replenished, utilizing a shutter mechanism to prevent excess tape insertion by determining if the tape to be replenished is the (N+1)-th, ensuring only the correct number of tapes are supplied.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If an automatic loading-type tape feeder is used to automatically load and pitch-feed the carrier tape, then the burden of replenishing operation by an operator is reduced, but the risk of incorrect replenishment increases because the tape feeder can accept a succeeding tape even when a preceding tape protrudes from the insertion port

Engineering Contradiction:

Improvereplenishing operationVSAvoidcorrectness of replenishment

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The system uses a detector to sense whether a preceding tape protrudes from the insertion port and provides feedback to the controller. The controller then determines whether to allow insertion of the succeeding tape based on this feedback, preventing incorrect replenishment while maintaining automatic operation.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The system performs a preliminary check before allowing tape insertion by detecting the presence of a preceding tape protruding from the insertion port. This preliminary action prevents the incorrect insertion of excess tapes while maintaining the automatic loading function.

Inventive Principle:

Principle #10Preliminary action

2Productivity

If the tape feeder allows automatic insertion of carrier tapes, then productivity is improved, but manufacturing precision deteriorates because excess carrier tapes may be inserted leading to incorrect replenishment

Engineering Contradiction:

Improveautomatic tape loadingVSAvoidcorrect number of tapes

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The detector provides feedback information about the presence of a preceding tape to the controller, which then controls the shutter mechanism to prevent excess tape insertion, ensuring manufacturing precision while maintaining high productivity through automatic operation.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The shutter mechanism acts as an intermediary between the insertion port and the internal tape storage area. It controls access based on the detector's feedback, allowing only the correct number of tapes to be inserted while maintaining automatic loading functionality.

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentUS10798860B2Component supply method and component mounting system

Publication Date: 2020.10.06 PANASONIC INTELLECTUAL PROPERTY MANAGEMENT CO LTD

AI summary

A component mounting system includes an automatic loading-type tape feeder (a component supply unit) being capable of supplying up to N (N is a natural number equal to or larger than 1) carrier tapes for storing a component, and automatically transporting an inserted carrier tape, and a component mounting apparatus which mounts the component supplied from the tape feeder on a substrate, in which a replenishing operation of carrier tape with respect to the tape feeder is detected, and a case where a carrier tape with which the tape feeder is to be replenished is an (N+1)-th is notified to an operator.