Tape Feeder Reverse Mechanism for Component Recovery
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Solution Overview
Problem
Existing tape feeders for electronic components often result in component waste due to unsuccessful pickup actions, as components fed to the pickup position are discarded when not successfully sucked or when the feeder is removed.
Innovation Solution
A tape feeder with a motorized sprocket and controller that allows for reverse feeding actions to return components to an upstream position, reducing waste and enabling safe removal of the feeder by retracting components to a covered position, and resumes operation based on stored return data upon reattachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the transfer head fails to suck a component or only feeding action is carried out without sucking, then the component is discarded to ensure proper mounting, but component waste occurs
Solution Approach 1:
The patent implements a reverse feeding mechanism that recovers components which were fed to the pickup position but not successfully picked up by the transfer head. The controller detects failed pickup attempts and activates the motor to rotate the sprocket in reverse, returning the component to an upstream position on the tape where it can be reused. This transforms the conventional discard approach into a recover-and-reuse system, directly addressing the contradiction between reliability and component waste.
2Reliability
If the tape feeder is removed from the mounting apparatus after a component has been fed to the pickup position, then the component may drop or be lost, but the feeder needs to be exchanged for different components
Solution Approach 1:
The patent implements a preliminary reverse feeding action that is automatically executed when the controller detects a removal instruction for the tape feeder. Before the physical removal occurs, the motor rotates the sprocket in reverse to return any component at the pickup position to a safe upstream position on the tape. This preliminary protective action ensures component retention during the subsequent feeder exchange operation, resolving the contradiction between reliability and adaptability.
3Loss of substance
If the motor rotates the sprocket in reverse direction to return components, then component reuse is enabled, but additional control complexity is introduced
Solution Approach 1:
The patent implements a feedback-based control system where the controller monitors the pickup operation status and automatically triggers the reverse feeding action when a failed pickup is detected. The controller receives feedback signals indicating whether the transfer head successfully picked up a component, and based on this feedback, it activates the motor to rotate the sprocket in reverse. This automated feedback mechanism enables component recovery without requiring complex manual intervention, balancing the benefit of waste reduction with acceptable control complexity.
Data Source
AI summary
When a component (X) is fed to a pickup position (53) but no suction action is carried out due to a variety of reasons, a reverse feeding action is carried out to return the component (X), which has been fed to the pickup position (53), to a position upstream of the pickup position (53) in the tape feeding direction. The same component (X) is thus not wasted but is resupplied to the pickup position (53) in the following pickup action, whereby the amount of waste of components is reduced.