Taping Resistor Forming Machine: Automation for Efficient Resistor Processing

What is a Taping Resistor Forming Machine?

A Taping Resistor Forming Machine is an automated device designed to process bulk resistors (or other axial-leaded components) that are packaged in tapes. It automatically cuts, bends, and shapes these resistors, then re-inserts them into the tape or directly places them on circuit boards for assembly.

Unpacking (Taping): This refers to removing resistors from the feed tape.

Forming: This is the process of shaping the straight leads of the resistors into the required forms (e.g., “Ω” shape, arc shape, vertical, etc.).

Taping: After shaping, the resistors are re-inserted into an empty tape, creating a new packaging form that is easy for automatic pick-and-place machines or insertion machines to handle.

In essence, it acts as the “automated assembly line worker” in resistor processing, significantly improving production efficiency, consistency, and reliability.

Core Structure and Functions (“Deconstructing” the Machine)

A standard Taping Resistor Forming Machine typically consists of the following core modules:

Feeding and Winding System

• Function: Carries and transports the raw feed tape (with resistors) and empty tape (carrier tape + cover tape).

• Components: Usually includes a feeding tray, winding tray, tension control devices, and stepper motor-driven tape winding mechanism.

Taping and Cover Tape Handling System

• Function: Strips the cover tape from the raw feed tape, exposing the resistors for picking; also handles waste cover tape.

• Components: Cover tape stripping knives, waste tape collection spools or crushing systems.

Component Picking and Transport System

• Function: This is the “hand” of the machine. It accurately picks up the exposed resistors from the feed tape and transports them to the forming station.

• Components: Vacuum nozzles, nozzle holders, precise X-Y or rotary transport robotic arms.

Forming System – The Core of the Machine

• Function: Cuts and bends the leads of the resistors.

• Components:

  • Cutting Unit: Precision cutters that cut off excess leads from the resistor body to achieve the required lead length.

  • Bending Unit: A set of precision molds (upper and lower molds) that bends the leads into a predefined shape (e.g., the commonly seen “rainbow” horizontal shape).

Electrical Control System

• Function: The brain of the machine, coordinating all the movements.

• Components: PLC (Programmable Logic Controller) or Industrial PC, servo/stepper motor drivers, Human-Machine Interface (HMI touchscreen), sensors (photoelectric, optical fiber, etc.), and pneumatic control systems.

Frame and Shell

• Function: Supports all the components, providing stability and safety, typically including noise reduction and protective design.

Tape Type Resistor Forming Machine Technical Parameters

1. Loading: The operator places the rolls of raw resistor tape and empty tape on the feeding trays.

2. Taping and Picking: The machine pulls the raw tape forward, stripping the cover tape, and the vacuum nozzle accurately picks up the exposed resistors.

3. Transport: The robotic arm moves the resistors to the forming station.

4. Forming:

   • Cutting: The cutter trims the leads to the preset length.

   • Bending: The upper and lower molds press the leads into the desired shape.

5. Taping: The finished resistors are placed into the empty tape, and a new cover tape is applied and sealed by heat pressing.

6. Winding: The packaged resistor tape is wound onto the receiving tray, completing the process.

The entire process is fully automated and cycles continuously, with speeds reaching thousands or even tens of thousands of parts per minute.

Workflow (“Taping” Process)

1. Loading: The operator places the rolls of raw resistor tape and empty tape on the feeding trays.

2. Taping and Picking: The machine pulls the raw tape forward, stripping the cover tape, and the vacuum nozzle accurately picks up the exposed resistors.

3. Transport: The robotic arm moves the resistors to the forming station.

4. Forming:

   • Cutting: The cutter trims the leads to the preset length.

   • Bending: The upper and lower molds press the leads into the desired shape.

5. Taping: The finished resistors are placed into the empty tape, and a new cover tape is applied and sealed by heat pressing.

6. Winding: The packaged resistor tape is wound onto the receiving tray, completing the process.

The entire process is fully automated and cycles continuously, with speeds reaching thousands or even tens of thousands of parts per minute.

Molding parameters