Development of a Continuous Tape Solution for Flat-Head Pins

The Challenge:

An alarm-systems manufacturer needed an automated way to package, store, transport and load custom flat-head pins for final assembly.

The task was to develop an effective solution for a very small footprint, automated packaging and unloading and full protection for the pins in storage and transit to the assembly factory.

The Solution:

Keaco developed a unique continuous tape solution tailored to the part, with a custom in-line punch die producing precisely sequenced holes in multiple rows for automated assembly. Pins were inserted into the holes and dangle from their flat-head tops.

Pins are covered with KEAPAK™ Cover Tape and wound onto KEAPAK™ 13″ Reels. The tape layers rest on the side wells so pins stay secure and ready for immediate unloading with no added processing.

The die was designed with spacer wells to protect the pins and packed them close together to save material while still maximizing pick-and-place speed.

Reels were boxed and shipped to the client’s assembly plant. From there, the tape feeds into the pick-and-place machine, where a robot arm pulls each pin from its hole and loads it directly into the client’s product assembly.

The Results:

A repeatable, automation-ready format holding a tight +/- 0.1mm tolerance, 100% pocket-inspected with lot traceability.

320,000 units released per shipment, on a 2-week ARO turnaround.

Assembled in the U.S. and distributed worldwide.

Product Name Continuous, Custom Punched Pocket Tape
Product Description Continuous pocket tape with multiple rows of holes with protective side-wells.
Capabilities applied/Processes Requirements :

  • Multiple pins packaged in a small surface area
  • Protect the pins
  • Line up the pins in a sequenced format for automated pick and place

Process:

  • Designed custom punch to create rows of holes in the tape
  • Pins are inserted into the holes and dangle from their flat-head top
  • The pins are covered with KEAPAK™ Cover Tape and wound on to KEAPAK™ 13″ Reels
  • The tape layers lay on the side wells as they are wound on to the reel allowing for plenty of room for the pins to remain safely in place.
  • Reels are put into boxes and shipped to the client’s assembly plant.
  • Tape is inserted into the pick-and-place machine and a robot arm pulls the pin out of the hole and loads into the client’s product assembly.
Equipment/Products Used to Manufacture Systems Inline, precision thermoforming machine with a custom punch
Overall Part Dimensions 72mm wide pocket tape
Tightest Tolerances +/- .1mm
Material Used .45mm thick x 72mm wide – KEASTAT™ I.S. Polystyrene
Material Finish Matte Finish to reduce glare for vision systems
In process testing/inspection performed 100% pocket inspection w/ measurements logged & lot traceability
Industry for Use Industrial
Volume 320,000 units released per shipment
Delivery/Turnaround Time 2 Weeks ARO
Delivery Location Assembled in the US and distributed worldwide
Standards Med Customer Specifications

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