Project Objectives
This project integrates high-speed feeding, electrical testing, dual-side vision inspection, automatic NG rejection, carrier-tape insertion, sealing, and reel winding in one compact automated system for small capacitors, resistors, and similar electronic components.
- Automate the testing and tape-packaging process for small electronic components to reduce manual handling.
- Integrate electrical testing and visual inspection before packaging so nonconforming parts can be rejected automatically.
- Place accepted components into carrier-tape cavities, seal the tape, and rewind finished material into reels.
- Support high-throughput production while allowing operating parameters and production data to be managed through the HMI.
Our Solution
High-Speed Indexing Architecture
A motor-driven indexing disc moves components through feeding, electrical testing, reserved test positions, NG rejection, vision inspection, cleaning, and carrier-tape insertion in a controlled sequence.
Electrical and Vision Quality Control
Electrical test probes verify component performance, while CCD stations inspect the top and bottom surfaces and can identify reversed parts, missing parts, printing defects, chips, and cracks.
Integrated Carrier-Tape Packaging
Accepted parts are inserted into carrier-tape cavities during intermittent indexing, checked by CCD, sealed with cover tape, and transferred to the reel-winding section.
PLC and HMI Process Control
The machine uses PLC control with a touchscreen interface for parameter setting, counters, alarms, user access levels, emergency stop, and safety reset functions.
Process Flow
The process begins with vibratory-bowl feeding and component separation. Parts are indexed through electrical and reserved test stations, inspected on both surfaces by CCD, and rejected if nonconforming. Accepted parts are inserted into carrier tape, inspected again in the packaging position, sealed with cover tape, and rewound into finished reels.
Key Equipment Solutions
| No. | Equipment Solution | Role in the System |
| 1 | Vibratory Bowl Feeding System | Automatically feeds and orients small capacitors, resistors, and similar electronic components for continuous downstream processing. |
| 2 | Indexing Rotary Disc | Indexes components through feeding, electrical testing, visual inspection, NG rejection, and carrier-tape insertion positions. |
| 3 | Electrical Testing Unit | Uses test probes driven by an electromagnetic lifting mechanism to perform electrical testing on each component. |
| 4 | CCD Vision Inspection System | Inspects the top and bottom surfaces of components and can detect reversed parts, missing parts, marking defects, chips, and cracks. |
| 5 | Automatic NG Rejection Unit | Automatically removes components that fail electrical testing, reserved testing, or CCD inspection before packaging. |
| 6 | Carrier Tape Insertion System | Indexes the carrier tape and places qualified components into individual tape pockets during each stop cycle. |
| 7 | Tape Sealing System | Applies and seals the cover tape over the loaded carrier tape to secure packaged components. |
| 8 | Packaging CCD Inspection | Checks component placement and packaging condition in the carrier tape before final reel winding. |
| 9 | Automatic Reel Winding System | Collects the sealed carrier tape into reels for storage, handling, and downstream use. Automatic reel handling can be configured as an option. |
| 10 | PLC and Touchscreen Control System | Controls machine operation and displays parameters such as production count, reject count, throughput, and operating settings through the HMI. |
Specification
| Specification | Value | Notes |
| Application | Small Electronic Components | Designed for automatic testing and tape packaging of small capacitors, resistors, and similar components. |
| Feeding Method | Vibratory Bowl Feeding | Automatically feeds and orients components before testing and packaging. |
| Inspection Methods | Electrical Test + CCD Inspection | Combines electrical performance testing with visual inspection of component and packaging conditions. |
| Vision Inspection | CCD Vision System | Can detect reversed parts, missing parts, marking defects, chips, cracks, and abnormal packaging conditions. |
| Designed Production Capacity | 108,000–210,000 pcs/h | Actual throughput depends on the component model, test cycle, and related processing time. |
| Testing Speed | Product-Dependent | Determined by the actual electrical test time and other required processing cycles. |
| Packaging Method | Automatic Tape Sealing + Reel Winding | Qualified components are inserted into carrier tape, sealed with cover tape, and automatically wound into reels. |
| Control System | PLC + Touchscreen HMI | Supports parameter setting, production counting, reject counting, alarm handling, and operator-level access control. |
| Power Supply | AC 220V / 50Hz | Electrical supply specified for machine operation. |
| Compressed Air Supply | 0.5–0.7 MPa | Required operating air pressure for pneumatic mechanisms. |
| Operating Temperature | -5°C to 50°C | Intended for environments without corrosive gases, excessive dust, or other severe operating conditions. |
Stable operation depends on component dimensional consistency, carrier-tape tolerances, and routine maintenance of wear parts such as insertion nozzles, indexing discs, separation needles, test probes, test sockets, sealing edges, guide stops, and cutters.
READY TO AUTOMATE COMPONENT TESTING AND PACKAGING?
Robotlyne can evaluate your component dimensions, test requirements, carrier-tape format, inspection criteria, and target throughput to develop a tailored automated testing and tape-packaging solution.
