METHOD FOR PRODUCING SEPARATED STRIP-LIKE LAMINATE COMPONENTS COMPRISING AN ELECTRONIC COMPONENT EMBEDDED BETWEEN TWO LAMINATE LAYERS OF A TAPE LIKE ADHESIVE MATERIAL, AND DEVICE FOR PRODUCING SUCH LAMINATE COMPONENTS
20240100818 ยท 2024-03-28
Inventors
Cpc classification
B26D1/085
PERFORMING OPERATIONS; TRANSPORTING
B32B37/226
PERFORMING OPERATIONS; TRANSPORTING
B26D7/01
PERFORMING OPERATIONS; TRANSPORTING
B29D2030/0077
PERFORMING OPERATIONS; TRANSPORTING
B29D30/0061
PERFORMING OPERATIONS; TRANSPORTING
B29D2030/0083
PERFORMING OPERATIONS; TRANSPORTING
B32B41/00
PERFORMING OPERATIONS; TRANSPORTING
B26D5/00
PERFORMING OPERATIONS; TRANSPORTING
B60C19/00
PERFORMING OPERATIONS; TRANSPORTING
International classification
B32B41/00
PERFORMING OPERATIONS; TRANSPORTING
B32B37/22
PERFORMING OPERATIONS; TRANSPORTING
Abstract
A method for producing separated strip-like laminate components including an electronic component embedded between two laminate layers of a tape-like material. Individual components are placed at defined intervals by a placement device onto a tape-like, lower first laminate layer moved in a conveying direction by a transport device, after which a tape-like, upper second laminate layer moved in the conveying direction is applied to the first laminate layer with embedding of the components to form a laminate tape. The individual strip-like laminate components are cut from the laminate tape by a cutting device having a movable cutting blade, which laminate components are picked up by a gripper device and transported away. The front end of the laminate tape is gripped by the gripper device in the region of a component and moved synchronously with the clocked movement of the transport device by a predetermined distance through the cutting device and positioned relative to the cutting blade. The actual position of the component in the laminate component in relation to the conveying direction is detected by a measuring device connected downstream of the cutting device. When a deviation of the actual position from a defined target position is detected, the synchronous movement of the transport device and the gripper device is controlled in dependence on the detected deviation.
Claims
1. A method for producing separated strip-like laminate components comprising an electronic component embedded between two laminate layers of a tape-like material, in particular a rubberized material, in which method individual components are placed at defined intervals by means of a placement device onto a tape-like, lower first laminate layer moved in a conveying direction by means of a transport means, after which a tape-like, upper second laminate layer moved in the conveying direction is applied to the first laminate layer with embedding of the components so as to form a laminate tape, the individual strip-like laminate components being cut from the laminate tape, which is conveyed by means of the conveying means, by a cutting device comprising at least one movable cutting blade, which laminate components are picked up by means of a gripper device and transported away, the front end of the laminate tape being gripped by means of the gripper device in the region of a component and moved synchronously with the clocked movement of the transport means by a predetermined distance through the cutting device and positioned relative to the cutting blade, wherein the actual position of the component in the laminate component in relation to the conveying direction is detected by means of a measuring device connected downstream of the cutting device, and, when a deviation of the actual position from a defined target position is detected, the synchronous movement of the transport means and the gripper device is controlled in dependence on the detected deviation.
2. The method according to claim 1, wherein, in order to detect the actual position, at least one distance value of a component position assigned to the component relative to at least one edge of the laminate component running transversely to the conveying direction is determined by means of the measuring device, with any deviation being determined on the basis of the distance value.
3. The method according to claim 2, wherein a first distance value between a first component position and a first edge lying in the conveying direction as well as a second distance value between a second component position and a second edge lying against the conveying direction are determined, with any deviation being determined on the basis of both distance values.
4. The method according to claim 3, wherein two first distance values to separate first component positions offset transversely to the conveying direction and two second distance values to separate second component positions offset transversely to the conveying direction are determined and any deviation is determined on the basis of all four distance values.
5. The method according to claim 1, wherein an offset value describing the deviation is determined on the basis of the distance value or values and describes any offset of a distinguished component position, in particular the center of the component as seen in the conveying direction, from a target position, in particular the center of the laminate component as seen in the conveying direction, the transport means and the gripper device being controlled in dependence on the offset value.
6. The method according to claim 5, wherein the offset value is used as correction value by which the distance is increased or decreased, the transport means and the gripper device being controlled to move the laminate tape by the changed distance.
7. The method according to claim 1, wherein the synchronous movement of the transport means and the gripper device is controlled in dependence on a detected deviation only if the detected deviation or a determined offset or correction value is greater than a defined threshold value.
8. The method according to claim 1, wherein a control of the synchronous movement of the transport means and the gripper device is limited to a defined limit value in dependence on a detected deviation if the detected deviation or a determined offset or correction value is greater than the defined limit value.
9. The method according to claim 1, wherein, together with the transport means and the gripper device, the placement device, which can be moved in and against the conveying direction, is also controlled in dependence on the deviation determined.
10. The method according to claim 9, wherein the placement device is moved at least by the determined offset or correction value synchronously with the movement of the transport means and the gripper device with the changed distance.
11. The method according to claim 1, wherein the placement device is moved during each placement operation in such a way that the actual distance between two components placed on the first laminate layer is greater than a target length of the cut laminate component by a defined value compensating for a shrinkage of the laminate tape in the conveying direction.
12. The method according to claim 10, wherein the movement of the placement device results from the defined length dimension and the correction value.
13. The method according to claim 1, wherein the measuring device is a camera or a fluoroscopy device or a profile sensor, a deviation being determined on the basis of an evaluation of one or more recorded camera or fluoroscopy images or on the basis of sensor information supplied by the profile sensor.
14. The method according to claim 1, wherein, by means of a testing device, the functionality of the component of the laminate component is tested.
15. The method according to claim 1, wherein the gripper device transports the laminate component to a transfer device to which the measuring device and, optionally, the testing device are assigned.
16. The method according to claim 1, wherein a laminate component which has a deviation not exceeding a reject limit value and which, if detected, fulfills a requirement set for its functionality is deposited on a winding tape.
17. The method according to claim 1, wherein a laminate component having a deviation exceeding a reject limit value or not meeting a requirement set for its functionality is discarded.
18. The method according to claim 15, wherein the laminate component to be deposited on the winding tape is deposited on the winding tape by means of the transfer device, and in that the laminate component to be discarded is discarded directly by the transfer device.
19. The method according to claim 1, wherein the placement position of a component transverse to the conveying direction can be varied via the placement device.
20. A device for producing separated strip-like laminate components comprising an electronic component embedded between two laminate layers of a tape-like, adhesive material, in particular a rubberized material, comprising a first feed device for feeding a lower, tape-like first laminate layer and a transport means receiving the first laminate layer, a placement device for placing individual components at defined intervals on the first laminate layer, which is moved in a conveying direction by the transport means, a second feed device for feeding an upper, tape-like second laminate layer and placing the second laminate layer on the first laminate layer while embedding the components so as to form a laminate tape, a cutting device comprising at least one movable cutting blade for cutting off individual strip-like laminate components from the laminate tape conveyed by the transport means, a gripper device for picking up and transporting away the individual laminate components, the gripper device being designed for gripping the front end of the laminate tape in the region of a component and being movable synchronously with the transport means movable in clocked fashion by a predetermined distance for moving the laminate tape through the cutting device and positioning the laminate tape relative to the cutting blade, wherein a measuring device is provided downstream of the cutting device and is designed to detect the actual position of the component in the laminate component in relation to the conveying direction, it being possible, when a deviation of the actual position from a defined target position is detected, to control the synchronous movement of the transport means and of the gripper device via a control device in dependence on the detected deviation.
21. The device according to claim 20, wherein the measuring device is set up to determine one or more distance values of one or more component positions assigned to the component from at least one edge of the laminate component running transversely with respect to the conveying direction, and to determine an offset value describing the deviation on the basis of the distance value, the offset value describing any offset of a distinguished component position, in particular of the center of the component as seen in the conveying direction, from a target position, in particular of the center of the laminate component as seen in the conveying direction, the transport means and the gripper device being controllable via the control device in dependence on the offset value.
22. The device according to claim 21, wherein the offset value is used as a correction value by which the specified distance is increased or decreased, the transport means and the gripper device being controllable via the control device in such a way that the laminate tape can be moved by the changed distance.
23. The device according to claim 20, wherein the control device is set up in such a way that the synchronous movement of the transport means and the gripper device is controlled in dependence on a detected deviation only if the detected deviation or a determined offset or correction value is greater than a defined threshold value.
24. The device according to claim 20, wherein the control device is set up in such a way that control of the synchronous movement of the transport means and the gripper device is limited to a defined limit value in dependence on a detected deviation if the detected deviation or a determined offset or correction value is greater than the defined limit value.
25. The device according to claim 20, wherein, together with the transport means and the gripper device, the placement device, which can be moved in and against the conveying direction, can also be controlled via the control device in dependence on the deviation determined.
26. The device according to claim 20, wherein the control device for controlling the placement device is set up in such a way that the placement device can be moved at least by the determined correction value synchronously with the movement of the transport means and the gripper device with the changed distance.
27. The device according to claim 20, wherein the control device for controlling the movement of the placement device during each placement operation is set up in such a way that the actual distance between two components placed on the first laminate layer is greater than a target length of the cut laminate component by a defined value that compensates for shrinkage of the laminate tape in the conveying direction.
28. The device according to claim 20, wherein the measuring device is a camera or a fluoroscopy device or a profile sensor, wherein a deviation can be determined on the basis of an evaluation of one or more recorded camera or fluoroscopy images or sensor information.
29. The device according to claim 20, wherein a testing device is provided for testing the functionality of the component of the laminate component.
30. The device according to claim 20, wherein a transfer device is provided, which is connected downstream of the gripper device and receives the laminate component from the gripper device and to which the measuring device and, optionally, the testing device are assigned.
31. The device according to claim 30, wherein the pivotably designed transfer device is designed for placing a laminate component on a winding tape and for delivering a laminate component to be discarded to a collecting container.
32. The device according to claim 20, wherein the placement position of a component transverse to the conveying direction can be varied via the placement device.
Description
BRIEF DESCRIPTION OF THE DRAWING
[0054]
[0055]
[0056]
[0057]
[0058]
[0059]
[0060]
[0061]
[0062]
[0063]
[0064]
[0065]
[0066]
DETAILED DESCRIPTION OF THE INVENTION
[0067]
[0068] Furthermore, a placement device 5 is provided for placing the individual components to be embedded on the first laminate layer 3, wherein the individual components, i.e., the RFID chips in this case, are fed from a supply roll 6 via a feed belt and are then gripped and placed in a defined manner via the placement device 5, a pick-and-place device.
[0069] Furthermore, a second feed device 7 is provided for feeding an upper, tape-like second laminate layer 8, which, see
[0070] Also provided is a cutting device 9 comprising at least one movable cutting blade for cutting off individual strip-like laminate components from the laminate tape fed by the transport means 4. Downstream of the cutting device 9 is a gripper device 10 for picking up and transporting away the individual laminate components, which are finally placed on a winding tape 11 of a winding device 12, which winding tape 11 is then wound onto a roll 13.
[0071] Also shown in principle is a control device 14 for controlling the main components of the device 1, which will be discussed in greater detail below.
[0072]
[0073] Further shown is, among other things, the actual laminating roller 20, which is arranged above the transport means 4, and below which the upper second laminating layer is also fed, which is then laminated onto the lower first laminating layer 3 by means of the laminating roller 20.
[0074]
[0075] Downstream of the transport means 4, as described, is the cutting device 9 comprising a linearly movable cutting blade 21 which runs transversely to the conveying direction 19 and cuts the laminate tape 22 to form the individual laminate components. The lifting operation of the cutting blade 21 is controlled by a suitable lifting device 23, such as a pneumatic cylinder or an electric motor, by means of which the cutting blade 21 moves down precisely at the required time in order to make the cut.
[0076] Downstream of the cutting device 9 is a gripper device 10 as described, comprising two separate grippers 24, which will be described in detail below. The two grippers 24 are arranged rotated by 180? relative to one another and they can be moved at least linearly in the horizontal; the entire unit can also be rotated by 180?, which will be discussed in greater detail below. Each gripper 24 is equipped to pick up, lift and transport away a cut laminate component and transfer it to a transfer device 25, which will also be described in detail below. From this transfer device 25, a previously measured and inspected laminate component is transferred to the winding device 12 or separated out, which will also be described later.
[0077] Associated with the area of transfer of a laminate component from a gripper 24 to the transfer device 25 is a measuring device 26, which is used to precisely measure the position of a component embedded between the two laminate layers 3, 8, in order to determine, on the basis of this measurement, whether or not any position correction is required. The aim is to ensure that the laminated component is positioned at a defined position, preferably the center of the laminate component as seen in the conveying direction. Any misalignment can be determined via the measuring device 26, with corresponding misalignment compensation then being controlled via the control device 14. For this purpose, an intervention is made in the movement mode of the gripper device 10, via which, among other things, the clocked transport of the laminate tape 22 through the cutting device 10 also takes place, just as an intervention is made in the clocked transport mode of the transport means 4, so that the transport movement of the laminate tape 22 can be influenced via this for correction purposes. The measuring device 26 is preferably a camera device, as will be discussed below.
[0078] Furthermore, a testing device 27 is shown, which is also positioned in the area of the transfer of a laminate component from a gripper 24 to the transfer device 25. This testing device can be used to check the proper functioning of the laminated component, i.e., the RFID chip, whereby such a laminate component is only transferred to the winding device 12 if the component is also functioning properly. Otherwise, the laminate component is expelled by transfer to a collecting container 28. The checking device 27 may be a corresponding reading or transmitting device which, for example, enters into contactless communication with the RFID chip in order to read out its response signals or its identification code, etc., the corresponding information being given to the control device 14 and also being stored there.
[0079]
[0080] Each gripper is provided with a suitable gripping means 35 which makes it possible, on the one hand, to grip and fix the laminate tape at the leading edge so that the laminate tape can be moved by a defined distance through the cutting device 9, i.e., under the cutting blade 31, in synchronism with the clocked feed of the transport means 4 by a linear movement of the corresponding gripper 24 along its linear guide 31. This gripper means 35 is also capable of fixing the then cut laminate component, also during the subsequent linear lifting and pivoting movement into the transfer position, where the laminate component is then deposited. An example of such a gripper device is given in DE 20 2021 101 889 U1, although the device according to the invention is not limited to the use of such a gripper device described there.
[0081]
[0082] The cutting device 9 is shown with the cutting blade 21, which can be moved linearly as shown by the double arrow 36. Also shown is the transport means 4 with the laminate tape 22 lying thereon, on which the laminated components 37 are shown. The laminate tape 22 is pulled through and positioned under the cutting blade 21 shown here in the lowered cutting position, after which the cutting blade 21 moves off and runs against a blade table 38 on which the laminate tape 22 lies, and where the cut is made. The small distance between the end of the transport means 4 and the knife table 38 is bridged by a transfer table 39, on which the laminate tape 22 lies.
[0083] Shown, as described, are the two grippers A and B, which are connected via a movement device 40, only stylized here, which permits the corresponding linear adjustments, stroke adjustments and rotational adjustments as described with respect to
[0084] The function of this gripper device 10 is as follows:
[0085] With the cutting blade 21 raised, it is assumed that the gripper A is moved into a position in which it can grip the leading edge of the laminate tape, i.e., it is ultimately positioned with its gripping means 35 above this edge area. For gripping, it is brought into corresponding contact with the laminate tape 22. The transport means 4 and the gripper A are then operated synchronously. The transport means 4 conveys by a defined distance in conveying direction 19, at the same time the gripper A lifts the leading edge of the laminate tape 22 slightly and also moves linearly in conveying direction 19 also by the defined distance until the final cutting position is reached, where the transport means 4 stops, as does the gripper A, which then deposits the laminate tape 22 on the knife table 28.
[0086] Parallel to this, there is also a corresponding movement of gripper B, which was previously in the position of gripper A and picked up a laminate component there. It is now in the transfer position and is now able to transfer the laminate component to the transfer device 25.
[0087] After the cut has been made via the cutting blade 21, when this has been raised again, the gripper A lifts the separate laminate component now located on the gripping means 35, and, if necessary, it moves again a short distance in the conveying direction. At the same time, the gripper B transfers the laminate component to the transfer device 25. Now, a rotation of the entire gripper device about the vertical axis 34 takes place, so that the occupied gripper A is rotated into the transfer area, while the empty gripper B is rotated into the area of the cutting device 9. The process described above now starts again from the beginning, i.e., for the next cut the gripper B is brought into the gripping area for receiving the leading edge of the laminate tape 22, which is then gripped and pulled through the cutting device 9, synchronously clocked together with the transport means with the gripper B by the corresponding linear movement. At the same time, the gripper A is also brought into the corresponding transfer position. After the cut has been made, the cut laminate strip is lifted again by the gripper B, while at the same time the gripper A has delivered its laminate strip to the transfer device 25.
[0088]
[0089] If the function test is positive and the measurement also shows that the component is correctly positioned, the transfer plate 24 pivots to the right, as shown by the double arrow 45, and places the laminate component on the winding tape 11 of the winding device 12. Via a presser 46, which can be moved vertically up and down as shown by the arrow 47, after the transfer plate 44 has pivoted back again, the placed laminate component is pressed slightly against the winding tape 11, where the laminate component, since it consists of a tacky material, adheres slightly. The winding tape 11 is then wound up into a roll.
[0090] If the function test, and if necessary also the measurement, shows that either the component is not functioning correctly or that the component is outside the position tolerance, the transfer plate 44 pivots to the left, i.e., tilts downwards, so that the laminate component found not to be in order is discharged into the collection container 28.
[0091] For fixing the laminate component to the transfer plate 44, a fixing device may be provided, for example in the form of an adjustable magnet 48, which may be adjusted between a holding position, in which the laminate component is magnetically fixed to the embedded component via a magnetic coupling of the magnet 48, and a release position, which permits delivery either to the winding tape 11 or to the collection container 28. Like all movements of the movable components, this movement is controlled by the control device 14.
[0092]
[0093] Also shown is the testing device 27, which is clearly also immediately adjacent to the laminate component 50 and can thus perform the functional test.
[0094]
[0095] The principle illustration according to
[0096] On the left in
[0097] This offset is illustrated again with reference to
K=[(A1+A2)/2?(B1+B2)/2]/2
[0098]
[0099] Here, any offset can not only be given against the conveying direction, as indicated in the example, it can also be given in the conveying direction. This means that the actual correction value can be either positive or negative. Primarily, however, it can be assumed that, after shrinkage resulting from the reduction of inherent tensions sets in, a positive correction value, i.e., an increase in the linear dimension, will be given.
[0100] As described, the correction value K is preferably determined by the control device 14, which controls the corresponding conveying cycle operation. The control device 14 can be set up here so that a correction is not carried out for every infinitesimally small deviation, i.e., for every correction value K, no matter how small. It is conceivable that a kind of tolerance interval is set around the actual center position, and a correction is omitted if the determined correction value K lies within this tolerance range. If, for example, a target width of the laminate component, i.e., the length L according to
[0101] At the same time, an upper limit can also be set with regard to a maximum permissible correction. For a cutting width of 10 mm, for example, this upper limit can be set to +/?0.35 mm. If a correction value of, for example, 0.4 mm is now obtained, only a correction of a maximum of 0.35 mm is carried out, in spite of everything. This serves to avoid any overshoots or overcorrections. In fact, the ideal situation can ultimately be approached again iteratively, since a corresponding check is carried out for each cut, so that the success of a correction made can be checked immediately.
[0102] As already described above, the placement device 5 or the gripper arrangement 15 can also be moved in the conveying direction 19, as shown by the arrow 18. This means that the placement position can be varied by this. In this way, it is possible to counteract any known change in position of the component positions within the laminate tape 22 to a certain extent or to compensate for such a change in advance. If, for example, it is known that shrinkage always occurs in the material to be processed, and that this shrinkage is at least 0.15 mm in the region between the lamination point 53 and the interface 52, this known shrinkage offset can be compensated for to some extent inherently by changing the placement position. For example, with a cut length, i.e., a length L of the laminate component of 10 mm, a placement distance of 10.15 mm can be controlled instead of the placement distance of 10 mm given without shrinkage. Although the transport means 4 and the gripper device 10 transport the laminate tape by (ideally, because uncorrected) 10 mm, the placement device 5 nevertheless performs the placement with 10.15 mm. This is because the correcting 0.15 mm shrink during the shrinkage between the laminating point 53 and the cut line 52, although the shrinkage may also be somewhat greater, so that at least partial compensation takes place.
[0103] In order to be able to make a placement on the material by the transport means 4 and the gripper device 10 with a slightly larger distance, with a given feed of 10 mm, it is necessary for the placement device 5 or the gripper arrangement 15 to also move in a clocked manner for each placement operation by the correction dimension, in the example described 0.15 mm, more specifically, if placement is to be performed with a total of 10.15 mm, against the conveying direction 19.
[0104] In the event that a correction value K has been determined and an intervention is made in the clocked placement operation of the transport means 4 and the gripper device 10 via the control device 14, the correction value must be taken into account in the movement of the placement device 5, i.e., the basic shrinkage compensation. If, for example, a correction value of 0.3 mm results by which the clocked feed increases the distance, this increase of 0.3 mm is to be taken into account in the movement of the placement device 5. In this case, the placement device would be moved by 0.15 mm in the conveying direction as part of the immediately following placement operation carried out synchronously with the change in the distance, in order, on the one hand, to take into account the distance correction of the clocked feed, but, on the other hand, to in turn carry out the basic shrinkage compensation. This means that both a basic correction and a determined actual correction are ultimately taken into account cumulatively.
[0105] As already described, a transverse correction of the placement position via the placement device 5 or the gripper 15 in the direction of the arrow 17 in
[0106] An RFID chip was described above as an example of a component 37. Of course, it is also conceivable to laminate in other types of electronic components, although in these cases, too, there are corresponding requirements for the positioning accuracy of the components within the laminate component.
[0107] While specific embodiments of the invention have been shown and described in detail to illustrate the inventive principles, it will be understood that the invention may be embodied otherwise without departing from such principles.