U.S. patent application number 09/432834 was filed with the patent office on 2001-11-15 for component tape including a printed component count.
Invention is credited to EASTON, MARK.
Application Number | 20010040117 09/432834 |
Document ID | / |
Family ID | 23717774 |
Filed Date | 2001-11-15 |
United States Patent
Application |
20010040117 |
Kind Code |
A1 |
EASTON, MARK |
November 15, 2001 |
COMPONENT TAPE INCLUDING A PRINTED COMPONENT COUNT
Abstract
A component tape includes a carrier tape with an elongate cover
tape applied over pockets of the carrier tape. The component tape
includes information printed on a portion of the component tape.
The printed information includes a count or quantity of electronic
components carried by the component tape, where the count at a
particular location on the component tape indicates the position of
the corresponding electronic component on the component tape. An
indicator is printed corresponding to each quantity count that
indicates which component position of the tape corresponds to the
printed count. The printed information may also include a variety
of information associated with the components, information
comprising part number, tolerance and value description, batch
number, lot number, component manufacturer, and component vendor.
The printed information is produced by direct marking, as with
laser etching or printing, or by imaging. The print type used to
print the information includes alphanumeric characters and
Automatic Identification and Data Capture (AIDC) technologies.
Inventors: |
EASTON, MARK; (MONIFIETH,
GB) |
Correspondence
Address: |
WILSON SONSINI GOODRICH & ROSATI
650 PAGE MILL ROAD
PALO ALTO
CA
943041050
|
Family ID: |
23717774 |
Appl. No.: |
09/432834 |
Filed: |
November 3, 1999 |
Current U.S.
Class: |
206/714 ;
206/713 |
Current CPC
Class: |
H05K 13/0084 20130101;
H05K 13/084 20180801; H05K 13/0417 20130101 |
Class at
Publication: |
206/714 ;
206/713 |
International
Class: |
B65D 085/00; B65D
085/30 |
Claims
What is claimed is:
1. A component tape comprising: a carrier tape including at least
one area for carrying at least one component; and printed
information including a count of components at intervals along the
component tape, the count indicating a position of the at least one
component.
2. The component tape of claim 1, wherein the printed information
is printed on the carrier tape.
3. The component tape of claim 1, further comprising a cover tape
affixed to the carrier tape to encapsulate the at least one
component, wherein the printed information is printed on the cover
tape.
4. The component tape of claim 1, further comprising at least one
pocket to receive at least one electronic component.
5. The component tape of claim 1, wherein the printed information
further comprises at least one item selected from a group
comprising part number, tolerance and value description, batch
number, lot number, component manufacturer, and component vendor,
and wherein the printing comprises at least one type selected from
a group comprising alphanumeric characters and Automatic
Identification and Data Capture (AIDC) technologies, and wherein
the printing is produced using at least one method selected from a
group comprising printing, ink jet printing, laser etching, and
imaging.
6. The component tape of claim 5, wherein the AIDC technologies
comprise one-dimensional barcodes, two-dimensional barcodes,
three-dimensional barcodes, composite symbology, and Reduced Space
Symbology barcodes.
7. The component tape of claim 1, wherein the printed information
is compatible with at least one reading and scanning technology
selected from a group comprising Optical Character Recognition
(OCR), Optical Mark Recognition (OMR), Magnetic Ink Character
Recognition (MICR), infrared scanning, and machine vision, wherein
the machine vision technology uses at least one vision subsystem
selected from a group comprising linear imagers, laser imagers, and
charge coupled device (CCD) cameras.
Description
BACKGROUND OF THE INVENTION
[0001] 1 Field of the Invention
[0002] This invention relates to the field of automatic assembly of
electronic devices. In particular, the invention relates to
counting electronic components on a component tape and printing a
sequential count on the cover tape.
[0003] 2. Description of the Related Art
[0004] Companies in the electronics manufacturing services (EMS)
industry are constantly presented with the need to determine the
inventory of parts currently available for production of
complicated machinery and electrical devices and printed circuit
board assemblies (PCBAs). Miniaturization of electronic circuits
and parts in the electronics and electrical-mechanical arts has
evolved to the point where many of the parts used in devices such
as calculators, computers, pagers, telephones, and watches are
difficult to store and handle when the parts are in inventory or
are being used in conjunction with a mass production line utilizing
a large supply of components.
[0005] Many of the electrical parts, as an example, are so tiny
that they are stored on tapes, which are then rolled onto supply
reels for handling. The electrical parts may be encapsulated on the
surface of a storage tape by providing a cavity on the storage tape
over which another tape is placed in order to capsulate or capture
the tiny part and protect the parts from damage or destruction. The
component dispensing tape is usually provided in reel form, with a
single reel having many feet of tape. Depending on the density of
component carriers in the tape, such a reel may contain thousands
of components.
[0006] Along one side of the typical component dispensing tape are
tractor drive or index holes. The automated assembly equipment
generally includes a toothed drive wheel that advances the tape by
engagement with these holes. The spacing between the holes
corresponds to the spacing between the carrier compartments so that
when the tape is advanced a particular predetermined number of
holes, a number of components are advanced, usually to a robotic
assembly arm for placement on a circuit board.
[0007] In order to better manage component supply and demand, it is
desirable to provide each assembly station with only the number of
components that are expected to be used in a certain product run or
in a certain period of time. As many of the components are
individually quite valuable, a manufacturer must keep a running
account of the number of such parts in inventory for tracking
material flow, reducing waste, and preventing disruptions in daily
production line operation. The physical problem of handling the
total number of such small parts is extremely difficult from a bulk
handling point of view. As a result, the encapsulating storage
tapes become a useful method for maintaining these parts in
inventory.
[0008] The component tapes protect the components and provide a
supply reel of sufficient size for handling by employees. On the
other hand, such storage complicates the problem of counting parts
for the purpose of identifying a total number of such parts in
inventory. Furthermore, the small size of these parts becomes a
burden when the parts are placed on a manufacturing line where they
are used at a rapid pace. Also, it is imperative that the assembly
operation maintain a running inventory of parts available to the
manufacturing process at all times. Many electronic units contain
literally thousands of tiny parts for inclusion in a single
finished electrical unit. If one of these parts is exhausted during
the manufacturing process, then the entire manufacturing line may
be shut down until the exhausted parts can be replaced.
Consequently, a manufacturer is burdened with the problem of
keeping a running inventory of the number of parts available during
the continuous manufacturing of larger electrical units.
[0009] A variety of methods are used to track the storage and
manufacturing inventory of small parts, including weight, component
tape measuring, and component counting methods. Using the weight
method, some inventory systems rely on weight as a way of measuring
the total number of small items in inventory. Each unit has a known
weight, which can be used to calculate the number of units from a
total weight of a bulk container of such small units. The
disadvantage of this weight determination system is that expensive
electronic scales must be used to make the weight checks.
Furthermore, these electronic scales are subject to variations in
weight measured and therefore must be constantly recalibrated.
Also, weight counting systems are not particularly useful or
efficient in a continuous manufacturing process. Some of these
weight systems have variations caused by environmental conditions,
for example heat and dust, and packaging variables which tend to
result in erroneous weight calculations, thereby resulting in an
erroneous calculation as to the number of tiny parts in
inventory.
[0010] In component tape measuring methods, the length of component
tape needed to supply a desired number of components to an assembly
station may be determined manually. Since counting each of the
desired number of components is impractical, the number of
components in a short length of the tape is counted instead. The
length of tape required for a particular assembly run is then
estimated based on the component density of the sampled length of
tape, taking into account the occurrences of empty carrier
compartments in the sampled tape. The desired length of tape is
then unrolled, measured and cut. Although somewhat wasteful of
components, the tape is generally cut slightly longer than the
computed length to ensure that the equipment does not prematurely
exhaust the component supply before the corresponding assembly run
is completed.
[0011] Component counting includes three typical methods for
counting reel quantities of electronic components: reel count,
gauge, and estimation methods. The accuracy of these methods
varies, but they each have numerous disadvantages.
[0012] The reel count method, while having an approximate accuracy
of 99%, is slow and has a risk of higher attrition. Reel count also
exhibits a lack of counters while being immobile. Furthermore, it
is time consuming, requires a great deal of training in operation,
and is highly susceptible to human setup error.
[0013] The disadvantages of the gauge method are that, while there
are over 50 possible variants, not every reel type is covered. This
method also requires training to operate accurately and is subject
to human error in the identity of the reel type, packaging type,
and correct components. The gauge method is also subject to
estimation error.
[0014] As the most commonly used method of counting reel
quantities, the estimation method is very inaccurate, even with
training. Human error inheres in the inconsistent visual clues.
Moreover, the estimation error trend is to underestimate the
quantities on almost full reels while overestimating the quantities
on almost empty reels.
[0015] The adverse effects of the typical counting and tracking
methods are numerous. For example, material flow cannot be
accurately tracked. This results in backflushing the quantity of
material assumed used in production. As production often consumes
only part of a reel, this means a significant amount of stock is
wasted. Furthermore, an estimated quantity of attrition called
autoscrap is added in an attempt to keep the stock accurate. Work
in progress (WIP) cycle counting is then used to verify or correct
the stock data. The typical error of over one million parts in WIP
indicates that this stock check technique is slow and inaccurate. A
typical WIP cycle count has an absolute accuracy level of 30%,
meaning that the post-hoc material tracking process is very time
consuming and, consequently, ineffective. As planning, purchasing,
manufacturing, and customer commitment decisions are based on the
material integrity, they are adversely affected. Furthermore, poor
data integrity causes disruptions in daily production line
operation and results in slow kitting times. Consequently, there is
a need for a method and apparatus for determining and printing an
electronic component count on the component tape and using the
count information to increase the efficiency of the production
process.
SUMMARY OF THE INVENTION
[0016] A component tape is provided including a carrier tape and a
cover tape. The carrier tape is a unitary flexible carrier tape
useful for the storage and delivery of electronic components by an
advancement mechanism. The carrier tape includes an elongate cover
tape applied over pockets of the carrier tape. The component tape
includes information printed on a portion of the component tape.
The printed information includes a count or quantity of electronic
components carried by the component tape, where the count at a
particular location on the component tape indicates the position of
the corresponding electronic component on the component tape. An
indicator is printed corresponding to each quantity count that
indicates which component position of the tape corresponds to the
printed count. The printed information may also include a variety
of information associated with the components, information
comprising part number, tolerance and value description, batch
number, lot number, component manufacturer, and component vendor.
The printed information is produced by direct marking, as with
laser etching or printing, or by imaging. The print type used to
print the information includes alphanumeric characters and
Automatic Identification and Data Capture (AIDC) technologies.
[0017] The descriptions provided herein are exemplary and
explanatory and are intended to provide examples of the claimed
invention.
BRIEF DESCRIPTION OF THE FIGURES
[0018] The accompanying drawings illustrate embodiments of the
claimed invention. In the drawings:
[0019] FIG. 1 is a component tape printer of an embodiment.
[0020] FIG. 2 is an isometric drawing of a component tape printer
of an embodiment.
[0021] FIG. 3 is a top view of a component tape of an embodiment
including a component count.
[0022] FIG. 4 is an alternate view of a component tape of an
embodiment.
[0023] FIG. 5 is a flowchart of a method for determining and
printing a component count of an embodiment.
[0024] FIG. 6 is block diagram of a surface-mount device (SMD)
machine capable of using the printed information on a component
tape of an embodiment for automatic production set-up
verification.
[0025] FIG. 7 is an alternate view of an SMD machine of an
embodiment for automatic production set-up verification.
[0026] FIG. 8 is a side elevation view of an SMD machine of an
embodiment for automatic production set-up verification.
[0027] FIG. 9 is a block diagram of an SMD machine coupled to an
automatic verification system of an embodiment using a Radio
Frequency Data Communications (RFDC) system.
[0028] FIG. 10 is a block diagram of a production control system of
an embodiment controlling equipment of a production facility using
the information printed at intervals along a component tape.
[0029] FIG. 11 is a block diagram of a device table (D-table) and
scanning device coupled to a production control system of an
embodiment using a RFDC system.
[0030] FIG. 12 is a flowchart of a method for controlling a
production operation of an embodiment.
DETAILED DESCRIPTION OF THE INVENTION
[0031] A variety of component tape printers are described herein
that count components on a component tape. These printers also
print information including the component count on a portion of the
tape at intervals along the component tape. The printed information
on the component tape is used to control a production operation by
electronically scanning and reading the printed information and
using components of the information to automatically control
production equipment and devices. In this manner, the component
tape printer provides an advantage to EMS industry companies by
providing higher stock turns, improving the supply of printed
circuit boards to mainline production, improving stock check
accuracy, providing for accurate and automatic material
backflushing, providing accurate information to action problem
areas, and providing 100% surface-mount device (SMD) material
integrity. These and other advantages may result in improved
decision making with an improved ability to meet customer
commitments, thereby raising customer satisfaction and employee
satisfaction.
[0032] FIG. 1 is a component tape printer 100 provided in
accordance with one aspect of the invention that includes a feeder
102, a counter 104, and a printer 106. The feeder 102 transfers the
component tape 108 from and to a component tape reel 110. A take-up
reel 112 may be used to receive the component tape 108 from the
component tape reel 110, but the embodiment is not so limited. The
counter 104 is a component reel counter that counts the electronic
components stored on the component tape 108. The counter 104 is
capable of differentiating between full and empty pockets of the
component tape 108. Furthermore, the counter 104 is capable of
identifying the beginning and the end of a length of component tape
108.
[0033] The printer 106 prints information on the component tape 108
at specified intervals along the component tape 108. The counting
and printing are performed during the transfer process. The printed
information can be printed on the carrier tape portion or the cover
tape portion of the component tape 108. The printed information may
include any information relating to the particular components, for
example specification data, tolerance data, and manufacturing
information, and the information may be encoded. In an embodiment,
the printed information includes a count of electronic components
where the count indicates the position of the corresponding
electronic components on the component tape 108. As the electronic
components are susceptible to electrostatic charge, the component
tape printer 100 is protected from electrostatic discharge
(ESD).
[0034] The component tape printer 100, while generally including
the functionality of a feeder 102, counter 104, and printer 106,
uses a number of specific components. FIG. 2 is an isometric
drawing of a component tape printer 200 of an embodiment. While not
so limited, the components of the component tape printer 200 are as
follows: one Trio MC202 motion controller; two IMS IM483 stepper
drive boards; two Cetronic MAE HY200 3424 310 A8 stepper motors
206; one LPC Kubler 8.3600.1112.1000 encoder; one Omron S82K-05024
24-volt power supply; one RS 214-6158IEC inlet/filter; one RS
311-5048 BCD switch; one Domino A100 (600 hour) high-speed ink jet
printer 202; one Domino 3m-60 micron head 204; one Domino 1L7HQ60
font; one Domino 270BK ink system; one Domino M37751 peltier kit;
one Domino M37775 RS232 kit; and, Domino Codenet communication
software. The motion controller is coupled to the printer 202 using
a serial link over which printing data is downloaded. The component
tape printer may be housed on a mobile frame 299, but is not so
limited.
[0035] The component tape printer of an embodiment may be
integrated with or used in combination with a variety of other
equipment of the component processing, manufacturing, and assembly
process. For example, the component tape printer may be integrated
with, used in combination with, or coupled to manual taping
machines and automatic taping machines. Furthermore, the component
tape printer may be integrated with, used in combination with, or
coupled to automatic component handing systems that integrate
component making, inspection, and testing. Moreover, the component
tape printer may be integrated with, used in combination with, or
coupled to an integrated taper, parts counter, and peel force
tester. Additionally, the component tape printer may be integrated
with, used in combination with, or coupled to a peel force
tester.
[0036] FIG. 3 is a top view of a component tape 300 of another
embodiment of the invention. FIG. 4 is an alternate view of a
component tape 300. The component tape 300 may accomodate
surface-mount devices (SMDs), or components, radial components, and
axial components, but is not so limited. Paper and plastic SMD
component tape is supported in a variety of sizes. While supporting
any width and step variant of component tape, the width and step
variant of component tape supported in an embodiment varies from 8
millimeter (mm) to 56 mm in steps of 8, 12, 16, 24, 32, 44, and 56.
While supporting any pitch and step variant of component tape, the
pitch and step variant of component tape supported in an embodiment
varies from 2 millimeter (mm) to 36 mm in steps of 2, 4, 8, 12, 16,
24, 32, and 36. While supporting any depth variant of component
tape, component tape having a depth up to 10 mm is supported in an
embodiment. While supporting any component reel diameter variant of
component tape, component reel diameters up to 75 mm are supported
in an embodiment.
[0037] The component tape 300 of an embodiment includes a carrier
tape 302 and a cover tape 304, but is not so limited. The carrier
tape 302 is useful for the storage and delivery of components by an
advancement mechanism. The components may be electronic components,
but are not so limited. The carrier tape 302 is a unitary flexible
carrier tape having a strip portion defining a top surface and a
bottom surface opposite the top surface. The strip portion includes
longitudinal edge surfaces, and a row of aligned advancement holes
306, or guide holes, formed in and extending along one, and
possibly both, edge surfaces. The advancement holes 306 provide a
means for receiving an advancement mechanism such as the teeth of a
sprocket drive for advancing the carrier tape toward a
predetermined location. Depending upon the size and type of
components carried by the component tape 300, and the type of
carrier tape 302 used, the cover tape 304 may not be used.
[0038] One type of carrier tape 302 includes a series of pockets
308 formed in and spaced along the strip portion of the carrier
tape 302. The pockets 308 open through the top surface of the strip
portion, but are not so limited. Within a given carrier tape 302,
each pocket 308 is usually essentially identical to the other
pockets. Typically, the pockets 308 are aligned with each other and
equally spaced apart. Each pocket 308 may include four side walls,
each at generally right angles with respect to each adjacent wall.
Side walls adjoin and extend downwardly from the top surface of the
strip portion and adjoin the bottom wall to form a pocket. The
bottom wall is generally planar and parallel to the plane of the
strip portion. The bottom wall may include an aperture or through
hole that is sized to accommodate a mechanical push-up to
facilitate removal of a component that is stored in pocket. The
aperture may also be used by an optical scanner to detect the
presence or absence of a component within any given pocket. In
addition, the aperture may be useful in applying a vacuum to the
pocket to permit more efficient loading of the pockets with
components.
[0039] The pockets 308 of the carrier tape 302 may be designed to
conform to the size and shape of the components that they receive.
However, the pockets 308 may also be designed so that a single
pocket 308 of generic design may readily accommodate components of
widely varying size and shape. The pockets 308 may have side walls
of various dimensions; however, in general, each pocket includes at
least one side wall that adjoins and extends downwardly from strip
portion, and a bottom wall that adjoins the side wall to form the
pocket 308. Thus, the pockets 308 may be circular, oval,
triangular, pentagonal, or have other shapes in outline. Each side
wall may also be formed with a slight draft in order to facilitate
insertion of the component, and to assist in releasing the pocket
from a mold or forming die during fabrication of the carrier tape
302. The depth of the pocket 308 can also vary depending on the
component that the pocket 308 is intended to receive. In addition,
the interior of the pocket 308 may be formed with ledges, ribs,
pedestals, bars, rails, appurtenances, and other similar structural
features to better accommodate or support particular components.
Although one embodiment has a single column of pockets, two or more
columns of aligned pockets could also be formed along the length of
the strip portion in order to facilitate the simultaneous delivery
of multiple components.
[0040] The strip portion of the carrier tape 302 of an embodiment
may be formed of any paper or polymeric material that has a
sufficient gauge and flexibility to permit the material to be wound
about the hub of a component reel, or storage reel. A variety of
polymeric materials may be used including, but not limited to,
polyester, polycarbonate, polypropylene, polystyrene, polyvinyl
chloride, and acrylonitrile-butadiene-styrene. The carrier tape 302
may also be an embossed tape. The strip portion may be optically
clear, pigmented, or modified to be electrically dissipative. In
the latter case, the strip may include an electrically conductive
material, such as carbon black or vanadium pentoxide, that is
either interspersed within the polymeric material or is
subsequently coated onto the strip. The electrically conductive
material allows an electric charge to dissipate throughout the
carrier tape and preferably to the ground. This feature may prevent
damage to components contained within the carrier tape due to an
accumulated static electric charge.
[0041] The carrier tape 302 may include an elongate cover tape 304.
When the carrier tape 302 includes pockets 308, the cover tape 304
is applied over the pockets 308 of the carrier tape 302 to provide
an additional method of retaining the components. The cover tape
304 can also protect the components from dirt and other
contaminants that could invade the pockets 308. The cover tape 304
is flexible, overlies part or all of the pockets 308, and is
disposed between the rows of advancement holes 306 and along the
length of strip portion of the carrier tape 302, but is not so
limited. The cover tape 304 is releasably secured to the top
surface of strip portion so that it can be subsequently removed to
access the stored components. The cover tape 304 includes parallel
longitudinal bonding portions that are bonded to longitudinal edge
surfaces of the strip portion. For example, a pressure sensitive
adhesive such as an acrylate material, or a heat-activated adhesive
such as an ethylene vinyl acetate copolymer, can be used to adhere
the cover to edge surfaces. Alternatively, the cover tape 304 can
be secured to the strip portion by a mechanical fastener such as a
snap fit interference fastener or a hook and loop fastener, with
the hooks being carried by either the cover or the strip portion
and the loops being carried by the other.
[0042] In an embodiment, the bottom wall of the pockets 308 may
include a ring of adhesive. The adhesive provides a means for
securely retaining components in the pockets 308. As a result, a
single pocket 308 having a generic design can be used to
accommodate components of widely varying shape and size since the
adhesive provides a means for retaining the component in the pocket
308. Consequently, pockets 308 need not be shaped to closely
receive the component nor must the pockets 308 be sized to match a
particular component. The shape and the placement of the adhesive
may take on a variety of configurations.
[0043] The component tape 300 includes information 310-312 printed
on a portion of the component tape 300. In an embodiment, the
printed information 310-312 is printed on the cover tape 304. In an
alternate embodiment, the printed information 310-312 may be
printed on the carrier tape 302. In another alternate embodiment,
the printed information 310-312 may be printed on the carrier tape
302 and the cover tape 304, with the same information printed in
the same format on both the carrier tape 302 and the cover tape
304. In still another alternate embodiment, the printed information
310-312 may be printed with a first portion of the information on
the carrier tape and a second portion of the information on the
cover tape. In yet another alternate embodiment, printed
information in a first format, for example a barcode format, can be
printed on a first portion of the component tape 300, for example
the cover tape, while printed information in a second format, for
example an alphanumeric format, can be printed on a second portion
of the component tape 300, for example the carrier tape.
[0044] The printed information 310-312 includes a count or quantity
310 of electronic components on a component tape 300 where the
count 310 at a particular location on the component tape 300
indicates the position of the corresponding electronic component on
the component tape 300. An indicator 311 is printed along with each
quantity count 310 that indicates which component position of the
tape 300 corresponds to the printed count 310. The printed
information 310-312 may also include a variety of information
associated with the components, information comprising part number,
tolerance and value description, batch number, lot number,
component manufacturer, and component vendor.
[0045] The printed information 310-312 may be produced by direct
marking, as with laser etching or printing, or by imaging. The
printing includes ink jet printing and laser printing. The
component tape printer of an embodiment supports printing that is
compatible with reading and scanning technologies including, but
not limited to, Optical Character Recognition (OCR) technology,
Optical Mark Recognition (OMR) technology, reading by infrared
scanners, and Magnetic Ink Character Recognition (MICR) technology.
Furthermore, the component tape printer supports printing that is
compatible with machine vision technology including linear imagers,
laser imagers, and charge coupled device (CCD) cameras or other
visual image sensors.
[0046] The print type used to print the information includes
alphanumeric characters and Automatic Identification and Data
Capture (AIDC) technologies, for example barcodes 312. The AIDC
technologies that may be used are varied and include
one-dimensional barcodes, two-dimensional barcodes, Composite
Symbology, Reduced Space Symbology (RSS) barcodes,
three-dimensional multi-color superimposed symbologies, and Radio
Frequency Identification. Combinations of different AIDC
technologies may be used, as well as combinations including AIDC
technologies and alphanumeric characters.
[0047] One-dimensional, or linear, barcodes are formed from a
series of varying-width parallel dark bars and light spaces. The
one-dimensional barcodes that may be accomodated in an embodiment
include, but are not limited to: Universal Product Code (UPC)
including UPC-A and UPC-E; European Article Numbering (EAN) system
codes including EAN-13 and EAN-8; Interleaved 2 of 5 (ITF);
Codabar; Code 39; Code 128; LOGMARS; Code 93; Code 11; Plessy code;
Matrix 2 of 5; Nixdorf Code; Postnet; 4-state Code; Industrial 2 of
5; Standard 2 of 5; and, MSI.
[0048] Two-dimensional, or multi-row, barcodes provide a means of
storing large amounts of data in a very small space. Two types of
two-dimensional barcode in use that are supported by an embodiment
include stacked symbologies and matrix symbologies. The
two-dimensional barcodes that may be accomodated in an embodiment
include, but are not limited to: Aztec Code; Small Aztec Code; CP
Code; Code One; Code 16K; Code 49; DataGlyph; DataMatrix; MaxiCode;
MiniCode; Portable Data File 417 (PDF417); MicroPDF417; Quick
Response (QR) Code; SuperCode; Ultracode; 3-DI; ArrayTag;
Codablock; Datastrip Code; Dot Code A; hueCode; SmartCode;
Snowflake Code; and, Ultracode.
[0049] Composite symbology incorporates a linear component with a
two-dimensional composite component. The composite symbologies that
may be accomodated in an embodiment include, but are not limited
to: EAN.UCC Composite symbol; Aztec Mesas; 93i Symbology; and, Code
128.
[0050] FIG. 5 is a flowchart of a method for determining and
printing a component count of an embodiment. Operation begins at
step 505, at which a component reel containing a component tape is
loaded onto the component tape printer of an embodiment. The
component tape may contain electronic components, but is not so
limited. The component tape printer is adjusted to accomodate the
component tape dimensions, at step 510. The component tape is
transferred from the component reel, at step 515, and transferred
back to the component reel, at step 520. The electronic components
on the component tape are counted, at step 525.
[0051] The component count, at prespecified intervals, is printed
on the component tape along with a corresponding indicator
indicating a particular component that is associated with a
particular value of the count, at step 530. The printed component
count represents the position of the corresponding component on the
component reel. The beginning number for the count, the beginning
position on the component tape, and the count interval are
preselected and prespecified. For example, the components of an
embodiment are numbered starting from the center of the component
reel with a component count printed at intervals of 10, but are not
so limited. Therefore, if printing is accomplished on a component
tape containing 5000 components, component number one is located at
the center of the component tape reel and component number 5000 is
located at the end of the component tape reel. As another example,
component number 5000 is located at the center of the component
tape reel and component number one is located at the end of the
component tape reel.
[0052] A number of alternate embodiments exist for determining and
printing a component count. A first alternate embodiment performs
both the counting and the printing as the component tape is
transferred from the component reel. A second alternate embodiment
performs the counting as the component tape is transferred from the
component reel, and performs the printing as the component tape is
transferred back to the component reel. Another alternate
embodiment performs both the counting and the printing as the
component tape is transferred to the component reel.
[0053] A number of counting techniques are supported for counting
the components of the component tape. In an embodiment, the
advancement holes, or guide holes, of the component tape are used
to calculate the number of components using a standard relationship
between the number of advancement holes per component for each size
of component tape. An alternate embodiment determines a number of
components using a number of components per a unit length of
component tape. The number of components per unit length of
component tape may be automatically determined or may be
preprogrammed, but the embodiment is not so limited. Another
alternate embodiment uses machine vision subsystems to count the
components of the component tape.
[0054] In using the advancement holes to calculate the number of
components, an embodiment uses a spindle to pull the carrier tape
through the cover tape printer using the guide holes. The spindle
is coupled to an encoder, and the encoder counts the number of
guide holes as the spindle rotates. The count is based on the
relationship between the spindle rotations, the guide holes, and
the component placement on the component tape. The counting device
is set to the specified starting value prior to advancing the
component tape. The counting and printing is initiated with the
first component or pocket on the component tape, and printing
continues at the specified interval until the end of the component
tape is reached.
[0055] In using the advancement holes to calculate the number of
components, an alternate embodiment of the component tape printer
includes a surface mounted device parts counter apparatus having a
guide track and first and second detectors. The guide track
positions the component tape in a desired orientation as the tape
moves through the component tape printer. A first detector, or
index hole detector, is positioned for detecting advancement holes
in the carrier tape when the tape moves through the guide track. A
second detector, or sense hole detector, is positioned for
detecting sense holes, indicative of empty carrier compartments,
when the carrier tape moves through the guide track.
[0056] The outputs from the first and second detectors are fed to a
counter circuit through a logic circuit. The counter typically
counts index holes as they are detected by the first detector.
When, however, the second detector detects an empty carrier
compartment, a logic circuit inhibits the counter from counting the
next index hole. Thus, the total count accumulating in the counter
equals the number of index holes detected less the number of empty
carrier compartments detected. This count equals the number of fall
component carrier compartments that have passed the first and
second detectors.
[0057] The first and second detectors may be photoelectric source
and detector pairs positioned for detecting optical continuity
through index holes and sense holes, respectively. The
photoelectric sources can comprise simple light emitting diodes.
The photoelectric detectors can comprise phototransistor
circuits.
[0058] The phototransistor circuits may include a potentiometer for
adjusting the sensitivity of the circuit. This adjustment provides
a way to adjust the sensitivity of the photodetectors in order to
optimize performance of the apparatus with tapes of differing
optical qualities. For example, if the tape is optically
translucent, the sensitivity of the photodetectors may be reduced
in order to prevent the photodetectors from sensing light passed
through the tape itself. In alternative embodiments, the
sensitivity of the photodetectors can be varied by varying the
intensity of light emitted by the photoelectric sources. Such an
alternative system comprises a potentiometer for varying the
current through the light emitting diode.
[0059] When the carrier tape is formed from a clear plastic, the
index hole photodetector may not be able to optically distinguish
between an index hole and the intervening clear tape. The clear
tape is accomodated by changing the sense hole photodetector
utility from detecting optical continuity, indicative of an empty
carrier compartment, to detecting optical discontinuity, indicative
of a fall carrier compartment. The number of optical interruptions
detected by the sense hole photodetector as the tape is advanced
through the apparatus thus corresponds to the number of components
carried by the tape. Accordingly, to count components in an
optically transmissive tape, the counter is arranged so that it
counts optical discontinuity signals from the sense hole
photodetector.
[0060] The counter apparatus of an embodiment automatically detects
whether the component tape is optically opaque or transmissive.
This is done by monitoring the output from the index hole
photodetector. If the output from this photodetector continuously
indicates optical continuity, it is determined that an optically
transmissive tape is being used. If, however, the output signal
from the index hole photodetector occasionally indicates optical
discontinuity, it is determined that an opaque tape is being
used.
[0061] Component tapes containing printed component information as
described herein are used to control a production or assembly
operation by using the printed information to control resources of
the production operation, resources including components,
equipment, and facilities. Applications capable of being controlled
by the printed component information within the production
operation include, but are not limited to, automatic production
initial set-up verification, automatic production feed change
set-up verification, feeder performance verification, material
monitoring including automatic backflushing and stock
check/work-in-process cycle counting, and production system
control.
[0062] Typically, during initial set-up of a production run, a
manual verification procedure is used in which barcoded information
affixed to the side of component reels is scanned using a hand-held
scanning unit at the time the component reel or kit is loaded on
the placement machine. This, however, introduces human error into
the production process because, while the barcode is scanned
correctly, the component reel may be loaded onto the wrong
placement machine or in the wrong position on the placement
machine. The potential for error introduction may also be
introduced when an operator chooses not to scan a component reel
during set-up. These errors allow wrong feeds into the production
process.
[0063] Automatic scanning and verification of component tapes,
however, prevents human error in the production line from resulting
in errors in the products produced. FIG. 6 is block diagram of an
SMD machine 600 capable of using the printed information on a
component tape of an embodiment for automatic production set-up
verification. FIG. 7 is an alternate view of an SMD machine 600 of
an embodiment for automatic production set-up verification.
[0064] The SMD machine 600 of an embodiment comprises a device
table (D-table) 602, feeders 604, and a scanning device 606. The
scanning device 606 is capable of electronically scanning 699 the
component tapes provided by the feeders 604, and is positioned to
perform such scanning 699. The SMD machine 600 is also coupled to
an automatic verification system 610. The automatic verification
system 610 of an embodiment includes a component database 612, an
alternative component database 614, a rules database 616, and a
feeder database 618.
[0065] In an alternate embodiment, the automatic verification
system 610 is coupled to a host system (not shown) that includes
the component database 612, alternative component database 614,
rules database 616, and feeder database 618. In another alternate
embodiment, the automatic verification system 610 is coupled to
multiple host systems (not shown) that, using some combination of
the host systems, include the component database 612, alternative
component database 614, rules database 616, and feeder database
618. The automatic verification system 610, as well as any of the
host systems, may comprise a personal computer (PC), but is not so
limited. The coupling between the automatic verification system 610
and any host systems may be via wired network, wireless network, or
some combination of wired and wireless network.
[0066] FIG. 8 is a side elevation view of an SMD machine 600 of an
embodiment for automatic production set-up verification. The SMD
machine 600 includes a parts cassette 802, or component feeder, set
on the D-table 602. The parts cassette 802 serves as the parts
supply device of an embodiment. The parts cassette 802 includes a
component reel mounting section 804 provided in the rear portion of
the unit for rotatably mounting a component reel 806 on the parts
cassette 802. A feeding section 808 intermittently feeds a carrier
tape 810 of the unit 812 so as to sequentially move each of the
parts carried by the carrier tape 810 to a parts removing position.
A winding section 814 is positioned at a rear portion of the
feeding section 808 and winds a cover tape 816 of the unit 812. The
scanning device 606 is positioned to scan 699 and read printed
information from the component tape 810 as the component tape 810
advances.
[0067] In the operation of the SMD machine 600 of an embodiment,
the printed information on the component tape 810 is exposed at the
end of each feeder 802 when the component reel 806 is loaded onto
the feeder 802. The scanning device 606 scans and reads the printed
information from each component tape loaded onto each feeder 802 of
each D-table position. The scanned information is transferred,
using a network, to the automatic verification system 610 where the
information is used to verify the correct feed against the correct
D-table position. The network may be a wired network, a wireless
network, or a combination of wired and wireless networks. Any
set-up errors are signalled by an alarm and an instruction for the
operator to correct the set-up. The production operation is
inhibited until the correct set-up is accomplished and verified.
Thus, by scanning each component tape of each production position,
the human error in the manual scanning of component-reel barcodes
is eliminated.
[0068] The automatic verification system 610 includes a component
database 612, an alternative component database 614, a rules
database 616, and a feeder database 618, but is not so limited.
Some combination of the databases 612-618 and interaction among the
databases 612-618 of the automatic verification system 610 is used
to verify the correct production set-up, control production
resources, and maintain, control, and track a component inventory,
as described herein.
[0069] The component database 612 provides a database of suitable
components for each component part and each component production
position. The scanned information is used by the automatic
verification system 610 and the component database 612 to verify
the correct feed against the correct D-table position. Set-up
errors are signaled by an alarm and an instruction for the operator
to correct the set-up. The production operation is inhibited until
the correct set-up is accomplished and verified. Furthermore, if an
error is detected when comparing the scanned information against
information of the component database 612, the automatic
verification system 610 may compare the scanned information against
the information of the alternative component database 614.
[0070] The automatic verification system 610 of an embodiment
includes an alternative component database 614 that provides a
database of suitable alternative components for each component
part. Upon scanning a component tape and recognizing that the
component tape does not contain the preferred components called for
at that production position by the production records, the
automatic verification system 610 accesses the alternative
component database 614 to determine if the component tape loaded
contains suitable alternative components. The information contained
in the alternative component database 614 is used as a frame of
reference by the automatic verification system 610 to verify
equivalent components. If the component tape is not verified as
containing primary or alternative components, the production
process is blocked by the automatic verification system 610.
[0071] In the event that an equivalent component is not in the
alternative component database 614, a manual confirmation may be
made by an individual, whereupon the verifying individual scans
their identification badge barcode into the system. The
identification badge barcode is used by the automatic verification
system 610 to verify that the confirming individual is authorized
to make such a confirmation. Upon such authorization, the
production block placed by the automatic verification system 610 is
overriden and production is allowed to commence or continue. As a
result of the alternative component database 614, the time required
for a set-up or product changeover is reduced by eliminating the
manual verification of alternative component tolerance and
specification values.
[0072] The automatic verification system 610 of an embodiment also
includes a rules database 616. The rules database 616 contains
rules or conditions upon which commencing or continuing production
depend. For example, a printed circuit board (PCB) is due to change
revision as a result of a change associated with two components of
the PCB. While the two responsible components are not changing
tolerance or value, they are only to be sourced from a particular
vendor for the new revision. The automatic verification system 610
is programmed to accept only components from the specified vendor
at the associated D-table positions during production runs of this
version of the PCB,
[0073] During a mid-run feed change operation, the printed
information on the component tape serves many useful functions,
including advance warning of material exhaustion, a reduction in
the amount of material stored on the production floor, and feed
change component verification. In providing advance warning,
scanning and monitoring of the quantity information during
production runs allows for a programmable advance warning regarding
when material will be exhausted on a particular feeder. The amount
of time programmed for the warning can be programmed to correspond
to the typical time required to locate and transport the additional
component tapes. This minimizes lost production time.
[0074] Providing the quantity information to material stores may
also result in a reduction in the amount of material stored on the
production floor. The automatic verification system 610 can
continuously track the quantity of material used at each D-table
position during a production run. The average run-rate of a
position is used to calculate an approximate time that a particular
component part is projected to run out in production, and stores is
notified of this approximate time, along with the production line
and the D-table position. This allows stores to transact the
required material from a stores location into work in process (WIP)
for use in production. This allows for a reduction in the volume of
the WIP by eliminating the requirement to store large quantities of
material on the production floor.
[0075] As in initial set-up verification, the automatic
verification system 610 is used to verify that a feed change is
properly accomplished during a production run. As component tapes
are exhausted during a production run, the production run is
temporarily halted while the exhausted component tapes are
replaced. The replacement component tapes are verified using the
feed change verification to ensure that the exhausted component
tapes are replaced with component tapes containing the correct
components or appropriate equivalent components in the correct
feeder position prior to resuming the production run. Also, the
system provides very useful information on vendor quality and
allows for the identity and isolation of problem components and
packaging issues.
[0076] An embodiment of the automatic verification system 610
includes a feeder verification component for monitoring feeder
performance. The feeder verification component includes a feeder
database 618 coupled to the automatic verification system 610. The
feeder database 618 is used to aid feeder maintenance and ensure
that malfunctioning feeders are removed from the production
operation.
[0077] In performing feeder verification, each feeder is identified
using a barcode. A feeder database 618 is created that includes
information on the feeders of the production process, including
maintenance records, performance history, and product production
history. During production runs, the automatic verification system
610 identifies each feeder using the feeder barcode and notifies
production of the identity and position of any feeders having a
high rate of attrition. A record of feeder performance may be
automatically created by the automatic verification system 610 in
the feeder database 618 or, alternatively, in a production records
database. The poorly performing feeder is replaced, and
automatically logged to feeder maintenance with a description of
the fault. A placement machine will not accept a feeder tagged as a
poorly performing feeder until it has been deleted from the feeder
maintenance records, thereby creating a closed-loop feeder
maintenance system.
[0078] In addition to the closed-loop feeder maintenance system, an
advantage of the feeder verification component is that the
maintenance history of every feeder is automatically tracked.
Furthermore, trends and root causes of feeder damage are
identified. Moreover, it helps to generate effective corrective
actions as a result of data collected on the specific line, shift,
operators, and equipment used.
[0079] The printed information on each component tape allows for
exact material monitoring through automatic backflushing. This is
accomplished by scanning the printed information on the component
tape at the beginning of a production run to determine the quantity
of material issued to the production run. A final scan is performed
upon completion of the production run. The initial and final scans
allow for the calculation of the exact quantity of material used
during production. A comparison of the issued quantity of
components with the production use quantities allows for automatic
backflushing of the correct amount of material used to build the
PCBs and for writing-off the exact quantity and type of attrition
at the time of use.
[0080] Automatic backflushing provides many advantages over typical
systems. The exact monitoring of production material means that
assumptions do not have to be made regarding the quantity of
components used by production to which estimated levels of
attrition are added. A high level of material integrity is
accomplished by accurately backflushing materials at the time of
use. This overcomes the problems associated with out-of-sequence
backflushing and manual backflush data gathered by operators. The
automatic backflushing also eliminates the time consuming activity
of countback and reduces the potential for error in the production
system. Moreover, automatic tracking of the sequence of lot numbers
of components issued to production allows for verification of the
first-in-first-out inventory system. Additionally, exact material
monitoring allows for better tracking of vendor quality issues
through more accurate identification and tracking of problems
identified in production.
[0081] The automatic backflushing system provided in an embodiment
improves material accuracy to such an extent that annual stock
checks and periodic WIP cycle counting may be eliminated. However,
if a stock check is accomplished, the printed information on the
component tape will increase the speed of the stock check process
in the production area and eliminate inaccurate count methods like
estimating and guaging component reel quantities. A stock check
could be accomplished, with the printed information, using the
D-table scanners to scan all component tapes in production
positions. Alternatively, hand-held or portable scanners could be
used to scan the component tape information. This would streamline
the typical inventory process and cause minimal disruption to the
production process. Furthermore, component reels would not have to
be stripped from a feeder or taken from a trolley to be counted
accurately. Consequently, there would be a reduced risk of
attrition, incorrect feeding, or misplacement of material.
[0082] Furthermore, the cover tape printer is not limited to a
backflushing process. The cover tape printer can be used with a
work order process, in which the cover tape printer provides for a
quick, simple, and accurate method of issuing exact quantities to
be consumed by a work order. In this case, the material is
transacted before the production run, rather than after the run, as
in backflushing.
[0083] The scanning device 606 of an embodiment may be located over
the D-table 602 or mounted to the D-table 602 so that the scanning
device 606 has a view of the printed information on the component
tape 810 as the component tape 810 is fed from the component reel
806. The scanning device 606 may span the length of the D-table 602
or may be movably mounted to scan the entire length of the D-table
602, but is not so limited. Moreover, the scanning device 606 may
include one scanner servicing one feeder or one scanner servicing
several feeders.
[0084] While the scanning device 606 of an embodiment is compatible
with the reading and scanning technologies discussed herein,
various embodiments may use different symbol scanning systems.
While different symbol scanning systems are discussed herein, the
embodiment is not so limited. One embodiment uses a self-adjusting
adaptive scanning system including a scanner, responsive to
coordinate control signals, for directing a light beam in a pattern
at a symbol, for detecting a reflected portion of the light beam,
and for generating feedback signals reflecting successful decodes.
A microprocessor, responsive to the feedback signals, generates
pattern control signals, and a pattern generator generates
coordinate control signals in response to the pattern control
signals to select a desirable light beam pattern.
[0085] An alternate embodiment uses an optical scanner for reading
symbologies at variable depths of field. The scanning device has a
light source for projecting emitted light toward the symbol image
to be reflected back to an optical assembly, or zoom lens. The zoom
gives multiple field of view capability to a CCD detector for
detecting the reflected light, and generating a proportional
electrical signal. The sensor is aimed for reading the symbology by
a frame locator including a light source that emits a beam divided
by diffractive optics into beamlets matching the dimensions of the
respective field of views. Refractive optics are shifted in
response to movement of the zoom lens for aiming the beamlets to
form an aiming frame in accordance with the depth of field selected
by the zoom lens. The device includes a microcomputer that
communicates with a host computer including an application program
interface library with downloadable applications for image
processing, including segmenting, analyzing, and decoding.
[0086] Another alternate embodiment uses a scanning system
including an imaging camera to determine an orientation of a symbol
on a scanned article. In response to determinations of a symbol
location, orientation, size and type, the scanning system adjusts a
scanning speed, shape, and orientation of the light beam pattern
and a location of the light beam pattern. The resulting light beam
is directed at the bar code symbol location and a signal
corresponding to the reflected light beam portion is generated.
[0087] Moreover, another alternate embodiment includes a scanning
system that first uses an aim mode to scan symbols using a scan
pattern that is relatively small and dense. Thereafter, a second
larger scan pattern is used for decoding. During aiming, the symbol
is partially decoded to determine type and orientation, and this
information is applied to control the angle of the scan pattern
produced, the rate at which the scan pattern is increased for
optimum decoding, and the ultimate pattern size.
[0088] Still another alternate embodiment uses a symbol scanning
system that adaptively changes scanning system parameters including
light beam pattern and focus to improve symbol readability.
Furthermore, other alternate embodiments include scanners that
produce scan lines of light along two axes of a symbol, and the
resultant signals are processed for decoding the barcode in both
axes.
[0089] A further alternate embodiment uses an infrared scanner
system. The infrared scanner system reads an ink that is compatible
with the infrared scanner, but is not so limited. Use of this
system when scanning and reading from the component tapes
eliminates any affects due to the background contrast and
color.
[0090] The SMD machine of an embodiment may be coupled to the
automatic verification system using Radio Frequency Data
Communications (RFDC) technology. FIG. 9 is a block diagram of an
SMD machine 602-604 coupled to an automatic verification system 902
of an embodiment using a RFDC system 904-906. The RFDC system
904-906 includes radio frequency local area networks (LANs) and
radio frequency wide area networks (WANs), but is not so limited.
The RFDC system 904 of an embodiment may use narrow band,
direct-sequence modulation spread spectrum, and frequency hopping
spread spectrum communication techniques, but is not so
limited.
[0091] The RFDC system 904-906, as enabling technology for AIDC
implementations, uses wireless terminals 906 that include a radio
transmitter and receiver, or transceiver, and a scanner. The
wireless terminals 906 may also include a data entry device (not
shown) and a display (not shown). The wireless terminals 906
support bidirectional communications 999 with at least one master
radio transceiver, or base station or wireless gateway 904, which
receives and routes messages from the individual wireless terminals
906 to a radio frequency network controller (not shown). The radio
frequency network controller acts as a gateway for communications
between a host computer and other components of the radio frequency
system. The base station 904 may also route messages such as
instructions and exceptions from a host system to the wireless
terminals 906.
[0092] Depending on the system configuration, the network
controller function may be subsumed by a host system. In one
embodiment, the automatic verification system 902 serves as the
host platform for the application program, database, network
controller, and base station of the RFDC system. In another
alternate embodiment, the host system subsumes the automatic
verification system 902, wherein the host computer of the RFDC
system serves as the host for the automatic verification system
902.
[0093] The base station 904 receives data from the wireless
terminals 906 by means of polling or contention protocols. With
polling, each wireless terminal 906 is polled or queried in a
specific sequence. In a contention system, each wireless terminal
906 transmits on its own accord; if the channel is busy, the
wireless terminal 906 retransmits after a specified set delay. The
polling method is typically used for systems with few wireless
terminals 906 and approximately uniform transaction rates. Systems
with many wireless terminals 906 and high transaction rates achieve
more consistent response rates with the contention method.
[0094] The radio frequency network controller, which may be a
personal computer (PC), acts as the interface between the wireless
terminal network and the host computer and/or data collection
program. The controller may interface via wire with an autonomous
host, or the controller may be the host where the data collection
program or database resides. Repeaters or multiple base stations
may be used, depending on the size and layout of a production
facility, to assure complete radio coverage.
[0095] The RFDC system of an embodiment uses a client/server
approach. The client/server approach provides each wireless
terminal with a network driver, thereby allowing access to the
network so that the each wireless terminal can communicate directly
with the host or any other available application. The client/server
architecture provides fast response rates because the data
collection program does not have to run on the host as it would
with terminal emulation.
[0096] FIG. 10 is a block diagram of a production control system
1002 of an embodiment controlling equipment of a production
facility 1000 using the information printed at intervals along a
component tape. The production control system 1002 includes at
least one processor 1004 coupled to at least one memory device
1006. The processor 1004 and memory device 1006 are coupled to
receive information from and provide control information to at
least one component 1010-1016 of a production operation or facility
1000. The components of the production operation 1000 include, but
are not limited to, at least one component tape printer device 1010
described herein, at least one device table (D-table) with a
scanning device 1012, or SMD machine as described herein, an
inventory system or database 1014, and a production records system
or database 1016. The production control system 1002 may be located
at the production facility 1000 or it may be located at a different
location. A production control system 1002 located at a location
different from the production facility may be coupled to the
components of the production facility using a wired network, a
wireless network, or some combination of a wired and a wireless
network.
[0097] The production control system 1002 of an embodiment is
coupled to receive information from the component tape printers
1010 including the number of components on a component tape, part
number, tolerance and value description, batch number, lot number,
component manufacturer, component vendor, and component reel
information, as described herein. The information from the
component tape printers 1010 is used to update the inventory and
material tracking system. The information from the component tape
printers 1010 may be received by the production control system 1002
at the time the component tape is counted and printed, or at a time
subsequent to the counting and printing operation. The information
received from the component tape printers 1010 may be stored in a
database for later retrieval and use or may be stored using a
temporary buffer or register storage for more immediate use.
[0098] When a component tape is loaded into a feeder position on a
D-table, the scanning device scans and reads the component tape and
provides the scanned information to the production control system
1002. The production control system 1002 uses this information to
correlate the components of the scanned component tape to
associated database information for the component tape, database
information including that gathered during the counting and
printing operation associated with the particular component tape by
the component tape printer. Furthermore, the production control
system 1002 uses the scanned information to verify that the correct
component tape is loaded at the proper position for the programmed
production operation that is being set-up or is in process, as
described herein. The production control system 1002 may
simultaneously monitor and control numerous pieces of production
equipment at numerous production positions throughout the
production facility using the information scanned from numerous
component tapes at numerous production positions.
[0099] In the operation of the production control system 1002 of an
embodiment, the printed information on the component tape is
exposed at the end of each D-table feeder when the component reel
is loaded onto the feeder. The scanning device scans and reads the
printed information from each loaded component tape. The scanned
information is transferred using a network to the production
control system 1002 where the information is used to verify the
correct feed against the correct D-table position. Any errors are
signalled by an alarm and an instruction for the operator to
correct the set-up. The production operation is inhibited until the
correct set-up is accomplished and verified.
[0100] As during a production run, the production control system
1002 monitors and controls the production operation by
electronically reading printed information from the component tapes
as the component tapes are run through the feeders at the
respective D-table positions. This printed information is
transmitted to the production control system 1002 where it is used
to track and control inventory and inventory movement, as described
herein.
[0101] The production control system 1002 of an embodiment also
includes a component database, an alternative component database, a
rules database, and a feeder database. In an alternate embodiment,
the production control system is coupled to a host system that
includes the component database, alternative component database,
rules database, and feeder database. In another alternate
embodiment, the production control system is coupled to multiple
host systems that, among some combination of the host systems,
include the component database, alternative component database,
rules database, and feeder database.
[0102] The component database provides a database of suitable
components for each component part and each component production
position. The scanned information is used by the production control
system 1002 and the component database to verify the correct feed
against the correct D-table position. Any set-up errors are
signalled by an alarm and an instruction for the operator to
correct the set-up. The production operation is inhibited until the
correct set-up is accomplished and verified. Furthermore, if an
error is detected when comparing the scanned information against
information of the component database, the production control
system 1002 may compare the scanned information against the
information of the alternative component database.
[0103] The production control system 1002 of an embodiment includes
a database of suitable alternative components to each component
part. Upon scanning a component tape and recognizing that the
component tape does not contain the preferred components called for
at that production position by the production records, the
production control system 1002 accesses the database of
alternatives to determine if the component tape loaded contains
suitable alternative components. The information contained in the
database of alternatives is used as a frame of reference by the
production control system 1002 to verify equivalent components. If
the component tape is not verified as containing primary or
alternative components, the production process is blocked by the
production control system 1002.
[0104] The production control system 1002 of an embodiment also
includes a rules database. The rules database contains rules or
conditions upon which commencing or continuing production depend.
The production control system 1002 is programmed to allow
production runs to proceed when the applicable rules or conditions
are satisfied.
[0105] During a mid-run feed change operation, the printed
information on the component tape serves many useful functions,
including advance warning of material exhaustion, a reduction in
the amount of material stored on the production floor, and feed
change component verification. In providing advance warning,
scanning and monitoring of the quantity information during
production runs allows for a programmable advance warning regarding
when material will be exhausted on a particular feeder. The amount
of time programmed for the warning can be programmed to correspond
to the typical time required to locate and transport the additional
component tapes. This minimizes lost production time.
[0106] As in initial set-up verification, the production control
system 1002 is used to verify that a feed change is accomplished
correctly during a production run. As component tapes are exhausted
during a production run, the production run is temporarily halted
by the production control system 1002 while the exhausted component
tapes are replaced. The new component tapes are verified using the
feed change verification to ensure that the exhausted component
tapes are replaced with component tapes containing the correct
components or appropriate equivalent components in the correct
feeder position prior to resuming the production run. Also, the
system provides very useful information on vendor quality and
allows for the identity and isolation of problem components and
packaging issues.
[0107] An embodiment of the production control system 1002 includes
a feeder verification component for monitoring feeder performance.
The feeder verification component includes a feeder database
coupled to the production control system 1002. The feeder database
is used to aid feeder maintenance and ensure that malfunctioning
feeders are removed from the production operation.
[0108] In performing feeder verification, each feeder is identified
with a barcode. A feeder database is created that includes
information on the associated feeder, including maintenance
records, performance history, and product production history.
During production runs, the production control system 1002
identifies each feeder using the feeder barcode and notifies
production of the identity and position of any feeders having a
high rate of attrition. The poorly performing feeder is replaced,
and automatically logged to feeder maintenance with a description
of the fault. A placement machine will not accept a feeder tagged
as a bad feeder until it has been deleted from the feeder
maintenance records, thereby creating a closed-loop feeder
maintenance system.
[0109] The D-table scanning device 1012 of an embodiment may be
coupled to the production control system 1002 using a Radio
Frequency Data Communication (RFDC) system, as described herein.
FIG. 11 is a block diagram of a D-table and scanning device 1012
coupled to a production control system 1002 of an embodiment using
a RFDC system. The RFDC system may be used in a radio frequency
local area network (LAN) or a radio frequency wide area network
(WAN), but is not so limited.
[0110] The RFDC system, as enabling technology for AIDC
implementations, uses wireless terminals that include a radio
transmitter and receiver, or transceiver, and a scanner that is
integrated or co-located with the D-table to receive information
therefrom. The wireless terminals support bidirectional
communications 1199 with at least one master radio transceiver 1
102, or base station or wireless gateway, which receives and routes
messages from the individual wireless terminals to a radio
frequency network controller (not shown). The radio frequency
network controller acts as a gateway for communications between a
host computer and other components of the radio frequency system.
However, depending on the host system, a network controller may not
be used. In one embodiment, the production control system 1002
serves as the host system for the application program, database,
network controller, and base station of the RFDC system. In another
alternate embodiment, the host computer of the RFDC system is the
host for the production control system 1002.
[0111] FIG. 12 is a flowchart 1200 of a method for controlling a
production operation of an embodiment. Operation begins at step
1205, at which printed information is electronically scanned and
read at intervals along a component tape. The printed information
may be continuously scanned and read from the carrier tape portion
or the cover tape portion of the component tape as components are
removed from the component tape during production. In a production
facility, many component tapes are scanned and read simultaneously,
and the data from each tape is transmitted to a production control
system. Processing of the data accumulated from the component tapes
is performed at the production control system. The data processed
from the printed information is used to automatically control at
least one piece of production or assembly line equipment, at step
1210. The data processed from the printed information is used to
automatically track, at step 1215, and control, at step 1220, a
component inventory. Production records are generated, at step
1.225, using the data processed from the printed information on the
component tape.
[0112] Although the invention has been described in terms of
preferred embodiments, it will be understood that numerous
variations and modifications may be made without departing from the
spirit and scope of the present invention as described herein and
as set forth in the accompanying claims.
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