Timing Belt Position Detection for Component Mounting Lines
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Solution Overview
Problem
Existing automatic exchanging devices in component mounting lines face issues with accurate position detection due to wear and manufacturing variance in rack and pinion systems, and the limitations of current distance sensors, leading to unsmooth rotation, noise, damage, and instability in measuring movement distance.
Innovation Solution
A component mounting line configuration using a driving wheel with a timing belt and pulley system, where a rotation angle sensor detects the position of the automatic exchanging device, allowing for accurate position calculation and easy adjustment of component mounter quantities without the need for frequent sensor recalibration or expansion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a rack and pinion system is used to move the automatic exchanging device, then the device can be moved along the moving lane, but wear and manufacturing variance cause tooth interference leading to unsmooth rotation, large noises, and damage
Solution Approach 1:
The patent replaces the rack and pinion mechanical transmission system with a linear motor system. The linear motor directly generates linear motion without mechanical contact between moving parts, eliminating tooth interference, noise, and wear. This substitution resolves the contradiction by maintaining reliable movement while removing the harmful factors generated by the mechanical engagement of rack teeth and pinion teeth.
2Object-generated harmful factors
If a drive wheel is used to move the automatic exchanging device, then the device can be moved smoothly, but the drive wheel slips in the traveling lane causing position detection errors
Solution Approach 1:
The patent replaces the drive wheel mechanical propulsion system with a linear motor system. The linear motor uses electromagnetic forces to directly propel the automatic exchanging device along the moving lane without mechanical contact or friction. This eliminates wheel slip entirely while maintaining smooth movement, thereby resolving the contradiction between smooth movement and position detection accuracy.
Solution Approach 2:
The patent introduces a linear scale as an intermediary measurement device that provides absolute position feedback independent of the propulsion mechanism. This allows accurate position detection even when using wheel-based propulsion, as the linear scale measures actual position directly rather than inferring it from wheel rotation.
3Measurement precision
If a linear scale or distance sensor is provided to measure movement distance, then position can be detected accurately, but wire-type sensors have poor durability, laser-type sensors are expensive and unstable
Solution Approach 1:
The patent introduces a linear scale as an intermediary measurement device that provides absolute position feedback. The linear scale is a mechanical measurement tool with high durability and stability, contrasting with the electronic distance sensors mentioned in the problem. It provides reliable, accurate position detection without the durability issues of wire-type sensors or the stability issues of laser-type sensors.
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
This configuration ensures smooth movement, low noise, improved durability, and accurate position detection, reducing operator workload and enabling easy expansion or contraction of the component mounting line without compromising measurement accuracy.
Implementation Method 1
a timing pulley configured to move together with the automatic exchanging device while maintaining a state of being engaged with teeth of the timing belt
Implementation Method 2
a rotation angle sensor configured to detect a rotation angle of the timing pulley
Implementation Method 3
a biasing means configured to bias the timing pulley in a direction pushed towards the timing belt
Data Source
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AI summary
A component mounting line (10) configured to move an automatic exchanging device (26) that performs setting and removing of feeders (14) to and from a feeder setting section (24) of multiple component mounters (12) that configure the component mounting line (10) along a moving lane on the front side of the component mounting line using a driving wheel (76). A position detecting device (81) that detects the position of the automatic exchanging device is configured from a timing belt (82) with an end and provided to extend in a straight line along the moving lane on the front side of the component mounting line, a timing pulley (83) that moves together with the automatic exchanging device while maintaining a state in which the teeth of the timing pulley are engaged with the teeth of the timing belt, and a rotary encoder (87) that outputs a rotation angle of the timing pulley, and the pulse output of the rotary encoder is counted to detect the position of the automatic exchanging device.