Tape Feeder Torque Control Based on Reel Remaining Amount
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Solution Overview
Problem
The existing tape feeder systems consume excessive power due to motors being operated with torque greater than required as the tape reel's remaining amount decreases, leading to inefficient power usage and potential instability in tape feeding.
Innovation Solution
A control system that acquires remaining tape amount information to adjust motor operation parameters, such as speed profile or drive current, to reduce torque and power consumption while maintaining stable tape feeding, optionally utilizing an auxiliary actuator to reinforce drive power.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a motor with large torque is used to ensure stable tape feeding when tape remaining amount is large, then tape feeding stability is improved, but power consumption increases when tape remaining amount is small
Solution Approach 1:
The motor operation parameters (rotation speed, rotation amount, torque) are dynamically adjusted based on the real-time tape remaining amount. When tape remaining amount is large, the motor operates with higher torque and speed to maintain stable feeding. When tape remaining amount decreases, the motor parameters are reduced accordingly, optimizing power consumption while maintaining adequate feeding stability.
Solution Approach 2:
The invention changes the motor operation parameters according to the tape remaining amount. Specifically, the rotation speed, rotation amount, and torque are modified as the tape remaining amount changes, allowing the system to adapt to varying load conditions and achieve both stability and energy efficiency.
2Use of energy by moving object
If a motor with small torque is used to reduce power consumption, then power consumption decreases, but tape feeding stability deteriorates when tape remaining amount is large
Solution Approach 1:
The motor torque is not fixed but dynamically adjusted based on the tape remaining amount. When tape remaining amount is large, the motor operates with sufficient torque to ensure stable feeding. When tape remaining amount decreases, the torque is reduced accordingly, allowing the use of a motor with smaller torque rating while maintaining stability when needed.
Solution Approach 2:
The invention modifies the motor operation parameters (torque, speed, rotation amount) according to the tape remaining amount, enabling the system to achieve stable tape feeding with a motor that has smaller torque margin, thereby reducing power consumption while maintaining reliability when required.
3Device complexity
If motor operation parameters are kept constant regardless of tape remaining amount, then control simplicity is maintained, but power consumption increases and feeding stability may be compromised
Solution Approach 1:
The invention implements a feedback mechanism where the tape remaining amount is detected and used to adjust the motor operation parameters. The detection unit continuously monitors the tape remaining amount, and the control unit modifies the motor parameters accordingly, creating a closed-loop control system that optimizes power consumption while maintaining feeding stability.
Solution Approach 2:
The control system automatically adjusts motor parameters based on the detected tape remaining amount without requiring manual intervention. The system serves itself by using the detection information to autonomously optimize its operation, balancing power consumption and feeding stability according to real-time conditions.
Data Source
AI summary
A control system of a tape feeder that includes a reel on which is wound component supply tape, and a tape feeding device configured to draw out the component supply tape from the reel to a component pickup position, the control system including a sensor configured to detect information relating to a remaining amount of the tape on the reel; and a motor control section configured to change an operation parameter of a motor that is a drive source of the tape feeding device based on the tape remaining amount information detected by the sensor. Specifically, the motor control section changes the operation parameter of the motor so as to reduce the motor torque as the tape remaining amount on the reel decreases, based on the tape remaining amount information detected by the sensor.