Tape Feeder Sprocket Control for Position Deviation

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Solution Overview

Problem

Existing tape feeders face challenges in suppressing electronic component supply errors when the sprocket rotates in an off state, and they struggle with width-direction miniaturization due to the accommodation of worm gears.

Innovation Solution

A tape feeder configuration that includes a sprocket with engagement protrusions, an angle sensor to detect the final and current angles of the sprocket, and a control device to set a target angle and rotate the sprocket to absorb any deviation, ensuring reliable component supply.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a worm gear is used to rotate the sprocket to restrict rotation in off state, then supply errors are suppressed, but the width-direction miniaturization is restricted

Engineering Contradiction:

Improvesupply error suppressionVSAvoidwidth-direction dimension

Core Design Contradiction:

ReliabilityVSLength of moving object

Solution Approach 1:

The patent replaces the mechanical worm gear system with an electrical control system. The control device uses power supply state detection and angle sensor feedback to control the sprocket motor, eliminating the need for a worm gear while maintaining the ability to prevent supply errors through software-based position management.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the control parameter from mechanical constraint (worm gear physical blocking) to electrical parameter control (motor power supply control and angle feedback). By monitoring power supply state and sprocket angle, the system dynamically adjusts motor operation to prevent position deviation without requiring additional mechanical space.

Inventive Principle:

Principle #35Parameter changes

2Length of moving object

If the sprocket is allowed to rotate freely in off state, then width-direction miniaturization is achieved, but supply errors occur when power is resumed

Engineering Contradiction:

Improvewidth-direction dimensionVSAvoidsupply error suppression

Core Design Contradiction:

Length of moving objectVSReliability

Solution Approach 1:

The patent implements a feedback control system using an angle sensor to continuously monitor the sprocket's position. When power is restored, the control device reads the current angle, compares it with the expected position, and calculates the required correction rotation to return the carrier tape to the correct position, thereby preventing supply errors.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The patent performs preliminary detection of the power supply state and sprocket position before resuming operation. When power interruption is detected, the system records the final angle; upon power restoration, it uses this recorded information to determine the necessary position correction, preparing the system in advance to prevent supply errors.

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS12207414B2Tape feeder

Publication Date: 2025.01.21 FUJI CORP

AI summary

A tape feeder including: an angle sensor configured to detect a final angle of the sprocket at a point in time at which interruption of power supply to the tape feeder is detected, and a current angle of the sprocket at a point in time at which resumption of power supply to the tape feeder is detected; and a control device configured to, when resumption of power supply to the tape feeder is detected, set a target angle of the sprocket based on the final angle, and perform control to rotate the sprocket from the current angle to the target angle so as to convey the carrier tape to a predetermined position.