Tape Feeder Cover Tape Winding With Torque-Limited Tension Control
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Solution Overview
Problem
Conventional tape feeders with limited installation space or smaller flanges can cause misalignment of cover tapes, leading to excessive tension and potential winding failures due to contact with the inner wall of the case.
Innovation Solution
A tape feeder with a pair of rotating members to separate and draw the cover tape, a drum member to wind the tape, and a torque limiter in the rotary shaft to prevent excessive tension, ensuring proper winding tension and preventing misalignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If the winding reel uses a flange with smaller diameter or no flange to reduce installation space, then the installation space constraint is satisfied, but the cover tape is not guided in the width direction causing misalignment and potential winding failure
Solution Approach 1:
A guide member is introduced as an intermediary component between the cover tape and the drum member. This guide member specifically guides the cover tape in the width direction during winding, preventing misalignment and contact with the inner wall of the case while allowing the drum member to maintain a smaller diameter for space efficiency.
Solution Approach 2:
The winding function is segmented into two parts: the drum member for winding the cover tape and the separate guide member for guiding the tape in the width direction. This segmentation allows each component to be optimized independently - the drum member can be compact while the guide member ensures proper tape alignment.
2Device complexity
If the cover tape is wound around a drum member without proper tension control, then the winding process is simple, but excessive tension causes the cover tape to contact the inner wall and generate excessive load on the driving source
Solution Approach 1:
The guide member acts as a mediator that ensures proper tension distribution during winding. By guiding the cover tape in the width direction, it prevents excessive tension buildup that would otherwise cause the tape to contact the case inner wall and overload the driving source.
3Area of stationary object
If the cover tape is not guided in the width direction, then the drum member can have a smaller diameter for space constraints, but the cover tape may become misaligned and contact the inner wall of the case
Solution Approach 1:
The guide member is positioned between the cover tape and the case inner wall, preventing direct contact. It guides the tape in the width direction, eliminating misalignment issues while allowing the drum member to maintain a compact size for space efficiency.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution effectively suppresses winding failures by maintaining proper tension and alignment of the cover tape, even in constrained spaces, reducing the risk of overload on the driving source.
Implementation Method 1
Since the torque limiter slips when a torque exceeding a prescribed torque is generated in the drum member, it is possible to suppress a possibility that an excessive tension may act on the cover tape wound around the drum member.
Data Source
AI summary
A tape feeder pulls out a component supply tape including a cover tape adhered on a carrier tape accommodating multiple components from a reel, feeds the component supply tape to a predetermined supply position, and separates the cover tape from the carrier tape in front of the supply position to expose a component on the carrier tape. The tape feeder includes a pair of rotating members configured to separate the cover tape from the carrier tape by pinching and drawing the cover tape; a drum member configured to rotate and wind the cover tape drawn by the pair of rotating members; and a torque limiter provided in a rotary shaft of the drum member.