A tape dispenser includes a torque controller and a take-up cassette.
1. A tape dispenser comprising:
a supply spindle configured to receive a supply tape roll comprising an insulating tape and a tape liner;
a rewind spindle configured to receive the tape liner from the supply tape roll;
a tape liner path comprising a plurality of rollers positioned between the supply spindle and the rewind spindle and configured to guide the tape liner from the supply spindle to the rewind spindle, the plurality of rollers comprising at least one application roller configured to apply the insulating tape to a conductive surface;
at least one gripper configured to move, when tape dispensing ceases, and capture the insulating tape against at least one of the rollers to prevent unraveling of the insulating tape;
a rewind spindle motor connected to the rewind spindle, the rewind spindle motor having a first power input;
a rewind spindle torque controller comprising a tape liner diameter sensor, the first power input adjustable by the rewind spindle torque controller, and the rewind spindle torque controller being configured to control torque based on a predetermined value;
a supply spindle motor connected to the supply spindle, the supply spindle motor having a second power input;
a supply spindle torque controller comprising a supply roll diameter sensor, the second power input adjustable by the supply spindle torque controller; and
a computer configured to adjust a rotational rate of the at least one application roller based at least in part on a target dispensing rate.
2. The tape dispenser of claim 1 , further comprising:
a first speed sensor configured to detect a speed of a conveyor surface supporting the conductive surface; and
a second speed sensor configured to detect a speed of the insulating tape and the tape liner,
wherein the computer adjusts the rotational rate of the at least one application roller based on input from the first and second speed sensors, and
wherein each torque controller is configured to:
detect a tape diameter; and
calculate a tape tension based on the tape diameter.
3. The tape dispenser of claim 2 , wherein each torque controller adjusts power input of a motor based on the tape diameter.
4. The tape dispenser of claim 1 , wherein the conductive surface comprises an electrical connection.
5. The tape dispenser of claim 1 , wherein at least a portion of the tape liner path is positioned within a tape applicator head configured to apply a tape separated from a tape liner to a surface, the tape dispenser further comprising:
a post-application cutter; and
a pre-application tape detection sensor configured to detect the presence of tape.
6. A tape dispensing system comprising:
a body;
a supply cassette rotatably mounted to the body;
a take-up cassette rotatably mounted to the body;
an applicator rotatably mounted to the body for applying an insulating tape comprising a backing layer in a first direction, wherein the insulating tape is routed from the supply cassette to the applicator, wherein the backing layer is routed from the applicator to the take-up cassette, and wherein the applicator is configured to apply the insulating tape separated from the backing layer to a conductive surface in a first direction;
at least one gripper configured to move, when tape dispensing ceases, and capture the insulating tape against a roller rotatably mounted to the body to prevent unraveling of the insulating tape;
a take-up cassette motor connected to the take-up cassette, the take-up cassette motor having a first power input;
a take-up cassette torque controller comprising a backing layer diameter sensor, the first power input adjustable by the take-up cassette torque controller, the take-up cassette torque controller being configured to control torque based on a predetermined value;
a supply cassette motor connected to the supply cassette, the supply cassette motor having a second power input;
a supply cassette torque controller comprising a supply roll diameter sensor, the second power input adjustable by the supply cassette torque controller;
a vision system configured to monitor, in a direction normal to the first direction, a position of the insulating tape applied to the conductive surface; and
a computer configured to adjust a rotational rate of the applicator based at least in part on a target dispensing rate.
7. The system of claim 6 further comprising:
a pre-application tape detection sensor configured to detect the presence of tape, wherein the applicator is movable relative to the conductive surface;
a first speed sensor configured to detect a speed of a conveyor surface supporting the conductive surface; and
a second speed sensor configured to detect a speed of the insulating tape,
wherein the computer adjusts the rotational rate of the applicator based on input from the first and second speed sensors.
8. The system of claim 6 , wherein the conductive surface comprises an electrical connection.
9. The system of claim 6 , wherein the applicator is a driven roller.
10. The system of claim 6 , wherein the applicator has a diameter ranging from about 2 mm to about 20 mm.
11. The system of claim 6 , wherein the at least one gripper is located proximate to the applicator.
12. The system of claim 6 , further comprising a pre-application roller rotatably mounted to the body.
13. The system of claim 12 , wherein the pre-application roller has a diameter ranging from about 2 mm to about 20 mm.
14. The system of claim 12 , wherein the pre-application roller is an idler roller.
15. The system of claim 14 , wherein the at least one gripper is a pre-application gripper proximate to the pre-application idler roller.
16. The system of claim 14 , wherein the pre-application idler roller has an axis parallel to a supply cassette axis, and wherein the pre-application idler roller is intersected by a plane that is normal to the supply cassette axis and includes a midpoint of the supply cassette.
17. The system of claim 6 , further comprising a post-application idler roller rotatably mounted to the body.
18. The system of claim 17 , wherein the post-application idler roller has a diameter ranging from about 2 mm to about 20 mm.
19. The system of claim 17 , wherein the at least one gripper is a post-application gripper proximate to the post-application idler roller.
20. The system of claim 17 , wherein the post-application idler roller has an axis parallel to a take-up cassette axis, and wherein the post-application idler roller is intersected by a plane that is normal to the take-up cassette axis and includes a midpoint of the take-up cassette.
21. The system of claim 6 , further comprising a post-application cutter mounted to the body and configured to cut the insulating tape.
22. The tape dispenser of claim 1 , wherein the rewind spindle torque controller and the supply spindle torque controller are controlled by the computer.
23. The system of claim 6 , wherein the take-up cassette torque controller and the supply cassette torque controller are controlled by the computer.