Tape Feeder Shortage Detection Using Sensor and Residual Quantity
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Solution Overview
Problem
Conventional component mounting devices with splicing-less tape feeders inaccurately detect component shortages due to the component housing status at the rear end of the tape, leading to erroneous machine trouble recognition and unnecessary component discard.
Innovation Solution
A component shortage detection device is implemented, featuring a sensor at the midpoint of the tape transportation path upstream of the component extraction position, a residual quantity calculation unit, and a determination unit that uses output information from the sensor and residual quantity to accurately assess component shortages.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a sensor is provided at a midpoint of the tape transportation path to detect component shortage, then component shortage detection is enabled, but erroneous detection occurs due to empty tape area or component housing status at the rear end
Solution Approach 1:
The detection function is segmented into two independent parts: a sensor for detecting tape presence and a residual quantity calculation unit for tracking component count. This segmentation allows each unit to perform its specialized function without interference from the other, resolving the contradiction by enabling accurate shortage detection while maintaining reliability through functional separation.
Solution Approach 2:
The system implements feedback by continuously monitoring both sensor output information and component residual quantity, then comparing these against shortage criteria to determine actual shortage status. This feedback mechanism enables the system to correct for false readings by cross-validating sensor data with calculated residual quantities, thereby improving both measurement precision and detection reliability.
2Device complexity
If component shortage is determined based on sensor output information only, then detection simplicity is maintained, but incorrect determination occurs when rear end tape status is empty or components are housed
Solution Approach 1:
The detection system is segmented into a simple sensor for tape presence detection and a separate residual quantity calculation unit. This segmentation maintains operational simplicity while improving accuracy by combining sensor data with component count information, avoiding the need for a single complex detection system.
Solution Approach 2:
The sensor serves multiple functions: it detects both tape presence and provides data for residual quantity calculation. This multi-functionality allows the system to maintain simplicity by using a single sensor component while achieving improved accuracy through its dual role in both direct detection and indirect quantity assessment.
3Ease of operation
If the tape is detected by the sensor when component extraction mistake occurs with empty rear end tape, then machine trouble is incorrectly recognized instead of component shortage
Solution Approach 1:
The system uses feedback from both the sensor and the residual quantity calculation unit to cross-validate the cause of component extraction mistakes. By comparing sensor detection results with residual quantity data, the system can reliably distinguish between component shortage and machine trouble, preventing incorrect cause identification even when the tape is detected in the rear end area.
Solution Approach 2:
The system performs excessive verification by checking both sensor output and residual quantity against shortage criteria, rather than relying on a single detection method. This partial redundancy ensures that cause identification reliability is maintained by requiring multiple conditions to be met before declaring a component shortage, preventing false positives from empty tape areas.
4Measurement precision
If component shortage is determined when rear end of tape is between extraction position and sensor, then component is discarded uselessly even with full housing
Solution Approach 1:
The system implements feedback by continuously monitoring both sensor position data and residual quantity information. This dual-feedback mechanism prevents unnecessary component discard by cross-validating sensor detection with actual component count, ensuring that components are only discarded when genuine shortage is confirmed rather than when the tape simply passes through the sensor position.
Solution Approach 2:
The residual quantity calculation unit performs preliminary assessment of component availability before the sensor makes a final detection. This preliminary action allows the system to anticipate and prevent unnecessary component discard by evaluating the actual component count in advance, ensuring that components with full housing are not wasted due to premature sensor-triggered shortage determination.
Data Source
AI summary
A component shortage detection device detects a component shortage of a tape feeder installed in a component mounting device. The component shortage detection device includes a sensor, configured to detect the tape, and provided at a position that is a midpoint of a tape transportation path of the tape feeder and upstream of a component extraction position by a component mounting head in a tape transportation direction. The component shortage detection device further includes a residual quantity calculation unit configured to calculate a component residual quantity of the tape during a mounting operation; and a determination unit configured to determine whether a component shortage occurs on a basis of output information from the sensor and the component residual quantity when the head fails in extraction of the component.