A Brief Discussion on China’s Chip Pick and Place Machine Manufacturing
1.What is a pick and place machine?
The SMT pick and place machine is a production equipment that precisely mounts SMD components onto the surface of the circuit board. In the field of electronic component assembly, pick and place machines are very important and are indispensable equipment in the SMT industry. Unfortunately, they have always been monopolized by foreign brands.
2.Pick and Place Machine Classification
In terms of speed and function, pick and place machines are roughly classified into: high-precision proofing machines, medium-speed pick and place machines, high-speed pick and place machines, high-precision general-purpose pick and place machines, etc.
3.Technical Level
Imported chip pick and place machine manufacturers have accumulated abundant funds due to the support of the vast number of users. In addition, combined with the feedback from the vast number of users, they have accumulated a large amount of relevant data in technology research and development. Their products are excellent in speed, accuracy and stability. Sexually at a high level. Chinese chip pick and place machine manufacturers, with the rapid development of China's electronic manufacturing industry, especially China's high-end chip pick and place machine manufacturers, the manufacturing level and R&D level of chip pick and place equipment are gradually approaching that of imported equipment, and they are learning from the relevant experience of imported equipment. Based on the experience of our customers, some high-end equipment has reached or exceeded imported equipment.
4.Pick and Place Machine Performance and Cost Comparison
China's chip pick and place machines have made major breakthroughs in key technologies such as motion control, vision algorithms, and intelligent optimization, ensuring that the equipment has high performance in mounting speed, mounting stability, and mounting accuracy. equipment. The equipment accuracy of some high-end pick and place machine manufacturers in China can already meet the mounting needs of British 01005 devices. In terms of price, Chinese chip pick and place machines are more competitive in terms of price, can ensure production quality for a long time, and at the same time, the recycling speed is faster. cost of investment.
5.Technical Support and After-Sales Service
Due to geographical reasons, imported equipment generally uses agents to provide related services, while Chinese manufacturers can provide efficient and timely technical support, including faster replacement of spare parts, and greatly reduced procurement costs. Therefore, there are obvious advantages in terms of service and related costs.
6.Brand Recognition
Chinese chip mounter manufacturers have also been increasing investment in research and development in recent years and constantly developing new competitive products. Their speed, stability and reliability have also been verified by users, and they are rapidly moving towards the international stage. Chinese chip pick and place machines are bound to break the relevant monopoly and are expected to occupy an important role and position in the corresponding market.
Detailed Explanation of the Structure of the Pick and Place Machine
The pick and place machine is the core equipment of SMT, a high-precision technology product. Currently, there are many brands of pick and place machines, mainly foreign brands, such as Germany's Siemens (ASM), Japan's Panasonic, Fuji, Yamaha, South Korea's Samsung (Hanwha). There are many brands of pick and place machines, but their performance is still slightly different (such as mounting accuracy, speed, etc.). Therefore, which brand of pick and place machine to choose needs to be considered based on comprehensive factors such as your own budget and products. Topco Industrial focuses on Germany Today, we will focus on the topic of the pick and place machine structure of Siemens (ASM) and Panasonic pick and place machines, and give a detailed explanation based on the Siemens pick and place machine.
1.SMT machine frame
As a piece of hardware equipment, the first thing that comes into view is the rack. The rack includes a trolley and a body structure. The trolley is also called a material trolley. It is mainly used to provide fixed support for feeder for the pick-up and pick-up of the patch machine. Material, the body structure is the skeleton of the pick and place machine.
2.SMT cantilever
The cantilever of the pick and place machine is similar to a manipulator, fixed inside the fuselage. Through the movement of the X/Y/Z axis, combined with the scientific algorithm of mounting head and machine identification, the mounting head is moved to absorb and place materials.
3.SMT mounting head
The mounting head is the core component of the pick and place machine. It is similar to the brain of the human body and is the central nervous system of a pick and place machine. The core component includes various visual recognition systems and alignment systems. It also cooperates with the motor nozzle to identify materials ( Material number) and pad position (number), thereby achieving high-precision and high-speed mounting.
4.SMT parts
The pick and place machine contains many parts, such as tracks, roller screws, cylinders, belts, etc.
There are many brands of pick and place machines, but the structures are basically the same. They all include body frames, mounting heads, cantilevers, machine-related parts, etc. Although the physical objects can be seen and touched, the various systems in the core mounting heads are and algorithms are difficult to copy. This is the top-secret core technology of every pick and place machine manufacturer.
Things to Pay Attention to when Buying a Pick and Place Machine
You need to pay attention to the following points when purchasing a pick and place machine:
1. Machine Performance
The performance of the pick and place machine includes mounting speed, accuracy and stability. According to your own needs, choose the appropriate model to ensure that it can meet production requirements.
2. SMT Specifications
SMT machines have different specifications and sizes, choose the appropriate specifications according to your needs. Consider the size range of components that need to be mounted, as well as the machine's mounting capabilities.
3. Flexibility and Adjustability:
Some pick and place machines have high flexibility and adjustability and can adapt to different types of components and mounting processes. Make sure the machine you choose has the appropriate adjustability to accommodate possible future changes and needs.
4. Brand and Quality
Choosing a well-known brand of pick and place machine can ensure the quality and reliability of the machine. For critical production tasks, brand and quality are very important considerations.
5. After-sales Service and Support
After purchasing a pick and place machine, after-sales service and support are also factors that need to be considered. Ensure that suppliers can provide timely technical support and maintenance services to ensure the normal operation and use of machines.
6. Cost and Budget
Consider budget constraints and choose a pick and place machine that meets the budget range. At the same time, the performance and quality of the machine must also be considered to avoid sacrificing other needs just because of low price.
7.Reference and Evaluation
Before purchasing, you can check the evaluation and experience of other users to understand the advantages and disadvantages of different brands and models of pick and place machines. This can help you make more informed decisions.
In short, purchasing a pick and place machine is an important decision that requires comprehensive consideration of performance, specifications, brand, quality, after-sales service, cost and other factors. According to your needs and budget, choose a suitable pick and place machine to ensure production efficiency and quality.
Our company Charmhighis professional SMT machine manufacture in China over 14 years.Mainly produce and sell SMT pick and place machines and can provide whole productiom line solution like stencil printer&reflow oven.At present, our company has sold to Russia, USA,Pakistan, India and European, and has won unanimous praise from customers at home and abroad for our excellent quality and professional and dedicated service,which is your best choice.If you are interested in our products, please feel free to contact us.
The History of the Invention of the Pick and Place Machine
1. Manual Welding
SMD technology refers to the technology of patch-mounting electronic components on printed circuit boards. Its history can be traced back to the early 20th century. In the early decades, all electronic components were mounted on circuit boards by hand soldering. This method requires a lot of manpower and time, is inefficient, and is difficult to guarantee the quality of welding.
2. The Birth of Patch Technology
In the 1960s, more and more integrated circuits began to appear in the electronics industry. This technology made electronic components smaller and more powerful. This also means finding more efficient and precise installation methods. So people began to try to use patch technology, which can paste electronic components on the circuit board without manual soldering.
3. The Inventor of the First Pick and Place Machine
In 1976, Japanese engineer Kenji Terajima invented the first chip pick and place machine. The machine automatically sticks electronic components onto circuit boards, using thermal paste to ensure good connections. Before the emergence of pick and place machines, the entire electronics manufacturing industry had to rely on manual soldering, which was inefficient and costly.
4. The Emergence of High-Speed Pick and Place Machines
In 1981, Laser introduced the first high-speed pick and place machine, which greatly improved the efficiency and quality of electronic manufacturing. These machines can complete a large amount of placement work within seconds. This high-speed pick and place machine was quickly widely adopted and became a mainstream equipment in the electronics manufacturing industry.
5. Conclusion
With the continuous development of technology, pick and place machines are becoming more efficient and precise, becoming an indispensable part of the electronics manufacturing industry. The inventors of patch technology have made significant contributions to our electronics industry, making electronic components smaller and more powerful in terms of processor performance, energy consumption, power consumption, size, etc.
The TS10 pick and place machine was unveiled at NEPCON ASIA 2023, highlighting China’s new innovative power!
The NEPCON ASIA 2023 exhibition, which started on October 11, 2023, successfully concluded at 15:30 on October 13 at the Shenzhen International Convention and Exhibition Center! This is a grand event for the electronics industry. The exhibition brings together 1,200 companies and brands. At this NEPCON ASIA 2023 exhibition,the TS10 high-speed, high-precision general-purpose pick and place machine newly developed by Charmhigh made its wonderful debut at the exhibition, attracting qualified agents and visitors from India, Pakistan, Russia, Brazil, the United States, etc. to visit Inspection, through on-site communication and actual on-site machine inspection operations, it is favored by the majority of users and agents!
Team Photo
Hunan Charmhigh Electromechanical Equipment Co., Ltd. was established in 2009. It is a modern high-tech SMT industry with independent research and development, production and sales. It provides users with one-stop SMT solutions, allowing you to equip the most suitable production lines at the lowest cost. The company's sales and technical staff have an average working experience of more than 6 years. At the same time, the company has passed the ISO international quality management system certification and international certifications such as EU CE certification, RoHS certification and US、FCC、SGS, it has successively provided national scientific research institutes, national key laboratories, universities, and improved customized SMT service solutions to create industry models, which has been unanimously recognized and praised by customers at home and abroad !
International Certifications That Charmhigh Has Obtained
Charmhigh as China's SMT modern high-tech benchmark enterprise.At present, the 4-head small high-precision pick and place machine,6-head high-precision general-purpose pick and place machine and 8-head fully automatic high-precision high-speed pick and place machine have been on the market for many years. The pick and place machine is well recognized by customers in terms of accuracy, reliability, and ease of operation.
Charmhigh TS10 Pick And Place Machine Debuted This Time
This model adopts a precision mechanical integrated structure and uses Charmhigh's independent research and development results. It has the characteristics of high speed, high precision, high stability, complete functions and easy use. Theoretical speed is 42000/cph per hour, mounting accuracy is ±40μm, supports CPK inspection, Y-axis dual-drive servo control system, large-size component segmentation and identification, automatic nozzle replacement, automatic thermal compensation correction system. Can accurately place 0201 QFN BGA precision components can also achieve 1.2 meter long PCB and blue light lens mounting.
At present, Charmhigh has a self-built 40,000 square meters SMT modern industrial park. The company is gradually expanding its scale, increasing its industry visibility, and pursuing a more advanced, innovative, and up-to-date production concept to provide customers with good products and services.
Charmhigh’s Newly Built Smt Modern Industrial Park
Participating in NEPCON ASIA 2023 this time, for Charmhigh, it not only displayed innovative products but also successfully promoted brand awareness, allowing Charmhigh to expand the market and attract the attention of more potential customers. At the same time, it also demonstrates the huge commercial value and innovation and development potential of domestic brands, accelerating the pace of intelligent transformation of China's manufacturing industry, and empowering a major electronics manufacturing country to move towards a technological manufacturing power!
Common Knowledge of Pick and Place Machines and SMT Production (5)
91. Commonly used MARK shapes include: circle, "ten" shape, square, rhombus, triangle, and swastika;
92. Due to improper setting of Reflow Profile in the SMT section, the parts may be slightly cracked in the preheating area and cooling area;
93. Uneven heating at both ends of SMT parts can easily cause: empty welding, misalignment, and tombstones;
94. The cycle time of high-speed pick and place machines and general-purpose pick and place machines should be as balanced as possible;
95. The true meaning of quality is to do it right the first time;
96. The pick and place machine should place small parts first and then large parts;
97. BIOS is a basic input and output system, the full English name is: Base Input/Output System;
98. SMT parts are divided into two types: LEAD and LEADLESS based on whether the parts have legs;
99. There are three basic types of common automatic placement machines, continuous placement type, continuous placement type and mass transfer pick and place machine;
100. It can be produced without LOADER in the SMT process;
101. The SMT process is a board feeding system-solder paste printing machine-high-speed pick and place machine-general-purpose machine-separate flow oven -board collecting machine;
102. When temperature and humidity sensitive parts are opened, the color displayed in the circle on the humidity card is blue, and the parts can be used;
103. The dimension specification of 20mm is not the width of the tape;
104. Reasons for short circuits due to poor printing during the manufacturing process: a. Insufficient metal content in the solder paste, causing collapse; b. Too large openings in the steel plate, resulting in too much tin; c. Poor quality of the steel plate and poor tin placement. Replace the laser cutting template. d. If there is solder paste remaining on the back of the Stencil, reduce the pressure on the scraper and use appropriate VACUUM and SOLVENT;
105. The main engineering purposes of each area of the general reflow oven furnace Profile: a. Preheating area; engineering purpose: volatilization of the solder paste neutralizing agent. b. Uniform temperature zone; engineering purpose: flux activation, removal of oxides; evaporation of excess water. c. Reflow area; engineering purpose: solder melting. d. Cooling area; engineering purpose: alloy solder joints are formed, and part feet and pads are integrated;
106. The main causes of solder beads in the SMT process are: poor PCB PAD design, poor steel plate opening design, excessive component placement depth or component placement pressure, excessive rise slope of the Profile curve, solder paste collapse, and solder paste viscosity that is too low .
Common Knowledge of Pick and Place Machine and SMT Production (4)
61. The maximum temperature of the reflow furnace temperature curve is 215C, which is the most suitable;
62. When inspecting the tin furnace, the temperature of the tin furnace is 245°C;
63. The opening pattern of the steel plate is square, triangle, circle, star, and epitome;
64. Whether the exclusion of SMT segment is directional or not;
65. The solder paste currently on the market actually only has a sticking time of 4 hours;
66. The rated air pressure generally used by SMT equipment is 5KG/cm2;
67. Tools for SMT parts maintenance include: soldering iron, hot air extractor, tin suction gun, tweezers;
68. QC is divided into: IQC, IPQC. FQC, OQC;
69. The high-speed pick and place machine can mount resistors, capacitors, ICs, and transistors; the packaging methods are Reel and Tray, and Tube is not suitable for high-speed pick and place machines;
70. The characteristics of static electricity: small current, greatly affected by humidity;
71. What kind of welding method should be used when the front PTH and back SMT pass through the tin furnace? Disturbed double wave soldering;
72. Common inspection methods for SMT: visual inspection, X-ray inspection, machine vision inspection;
73. The heat conduction mode of ferrochrome repair parts is conduction convection;
74. At present, the main components of solder balls in BGA materials are Sn90 Pb10, SAC305, SAC405;
75. Laser cutting, electroforming, and chemical etching of steel plates;
76. The temperature of the welding furnace is pressed: use the temperature detector to measure the applicable temperature;
77. When the SMT semi-finished products from the soldering furnace are exported, their welding status is that the parts are fixed on the PCB;
78. The history of modern quality management development TQC-TQA-TQM;
79. ICT testing is a bed of needles test;
80. ICT testing can test electronic components using static testing;
81. The characteristics of solder are that the melting point is lower than other metals, the physical properties meet the welding conditions, and the fluidity at low temperature is better than other metals;
82. Siemens 80F/S is a relatively electronically controlled transmission;
83. The solder paste thickness gauge uses Laser to measure: solder paste thickness, solder paste thickness, and printed width of solder paste;
84. The feeding methods of SMT parts include vibrating feeder, disc feeder and tape feeder;
85. What mechanisms are used in SMT equipment: cam mechanism, side rod mechanism, screw mechanism, sliding mechanism;
86. If the visual inspection section cannot be confirmed, which operation BOM, manufacturer confirmation, and sample board must be followed;
87. If the parts packaging method is 12w8P, the counter Pinth size must be adjusted by 8mm each time;
88. Types of separate welding machines: hot air separate welding furnace, nitrogen separate welding furnace, laser separate welding furnace, infrared separate welding furnace;
89. Methods that can be used for SMT parts sample trial production: streamline production, hand-printed machine placement, hand-printed hand-mounted;
Common Knowledge of Pick and Place Machine and SMT Production (2)
16. The commonly used SMT steel plate is made of stainless steel;
17. The thickness of the commonly used SMT steel plate is 0.15mm (or 0.12mm);
18. The types of electrostatic charge generation include friction, separation, induction, electrostatic conduction, etc.; the impact of electrostatic charge on the electronics industry is: ESD failure, electrostatic pollution; the three principles of static electricity elimination are electrostatic neutralization, grounding, and shielding;
19. Inch size length x width 0603=0.06inch*0.03inch, metric size length x width 3216=3.2mm*1.6mm;
20. ERB-05604-J81 No. 8 code "4" means 4 loops, and the resistance value is 56 ohms. The capacitance of the capacitor ECA-0105Y-M31 is C=106PF=1NF=1X10-6F;
21. The full name of ECN in Chinese is: Engineering Change Notice; the full name of SWR in Chinese is: Special Requirements Work Order, which must be countersigned by relevant departments and distributed by the document center to be valid;
22. The specific content of 5S is sorting, rectification, sweeping, cleaning, quality;
23. The purpose of PCB vacuum packaging is to prevent dust and moisture;
24. The quality policy is: comprehensive quality control, implementing the system, and providing the quality required by customers; full participation, timely processing, to achieve the goal of zero defects
25. The three-no quality policy is: do not accept defective products, do not manufacture defective products, and do not export defective products;
26. The seven QC techniques refer to the checklist, stratification method, Plato, cause and effect diagram, scatter diagram, histogram, and control diagram;
27. The ingredients of solder paste include: metal powder, solvent, flux, anti-sagging agent, and active agent; by weight, metal powder accounts for 85-92%, and by volume metal powder accounts for 50%;
28. Solder paste must be taken out of the refrigerator to return to temperature when used. The purpose is to restore the temperature of the refrigerated solder paste to normal temperature for printing. If the temperature is not returned, the defect that is likely to occur after the PCBA enters the Reflow is tin beads;
29. The file supply modes of the machine include: preparation mode, priority exchange mode, exchange mode and quick connection mode;
30. SMT PCB positioning methods include: vacuum positioning, mechanical hole positioning, bilateral clamp positioning and board edge positioning;
Common Knowledge of Pick and Place Machine and SMT Production (1)
1. Generally speaking, the temperature specified in the SMT workshop is 23±7°C;
2. Materials and tools required for solder paste printing: solder paste, steel plate, scraper, wiping paper, dust-free paper, cleaning agent, mixing knife;
3. The commonly used solder paste composition is Sn96.5%/Ag3%/Cu0.5%;
4. The main components of solder paste are divided into two parts: tin powder and flux;
5. The main function of flux in soldering is to remove oxides, destroy the surface tension of molten tin, and prevent re-oxidation;
6. The volume ratio of tin powder particles and Flux (flux) in solder paste is about 1:1, and the weight ratio is about 9:1;
7. The principle of taking solder paste is first in first out;
8. When the solder paste is unpacked and used, it must go through two important processes of warming up and stirring;
9. The common production methods of steel plates are: etching, laser, electroforming;
10. The full name of SMT is Surface mount (or mounting) technology, which means surface adhesion (or mounting) technology in Chinese;
11. The full name of ESD is Electro-static discharge, which means electrostatic discharge in Chinese;
12. When making an SMT equipment program, the program includes five parts, which are PCB data; Mark data; Feeder data; Nozzle data; Part data;
13. The melting point of lead-free solder Sn/Ag/Cu 96.5/3.0/0.5 is 217C;
14. The control relative temperature and humidity of the parts drying box is < 10%;
15. Commonly used passive components (PassiveDevices) include: resistors, capacitors, inductors (or diodes), etc.; active components (ActiveDevices) include: transistors, ICs, etc.;
Tips to improve the mounting speed of pick and place machine!
When purchasing an SMT pick and place machine, mounting accuracy and mounting speed are one of the main reference factors.
Then, in order to improve production efficiency and reduce production cost,And how to improve the actual mounting speed of SMT mounting machine?
What is mounting rate?
Everyone knows that the so-called mounting rate refers to the ratio of the number of components accurately mounted on the PCB board to the number of components actually picked up by the nozzle within a unit of time. Components picked up by the suction nozzle that cannot be accurately placed on the designated position of the PCB are called discarded parts. The main reasons for the discarded parts are also the influence of the feeder, the influence of the suction nozzle, the influence of the component detection system and other factors.
Charmhigh Electromechanical Universal pick and place machine
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1.The Effect of the Feeding System
The drive methods of the feeder include motor drive, mechanical drive and cylinder drive.
Taking the mechanical drive as an example, due to the high-speed access of the feeding mechanism to the feeder, after a long period of use, the pawl of the feeder is severely worn, resulting in the pawl not being able to drive the plastic tape of the reel to be peeled off normally, so that the suction nozzle cannot Complete the pick-up work, which affects the mounting speed.
In addition, long-term use or improper operation by the operator will also cause deformation and corrosion of the cover plate, thimble, spring and other moving mechanisms, which will cause the device to absorb deviation, stand up or fail to absorb the device.
Therefore, the feeder should be checked regularly, and the worn ones should be repaired immediately, and those that cannot be repaired should be replaced in time.
Feeder
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2.The Effect of the Nozzle
The suction nozzle is also another important factor affecting the mounting rate. There are internal reasons and external reasons.
The internal reason is that the vacuum negative pressure is insufficient. The suction nozzle automatically switches the mechanical valve on the mounting head before picking up the parts, from blowing to vacuum adsorption, and a certain negative pressure will be generated. When the filter in the vacuum pump is polluted and blocked, it will cause insufficient vacuum negative pressure and affect the suction efficiency of the suction nozzle.
External causes often manifest as aging and rupture of rubber air pipes, aging and wear of seals, etc., as well as clogging of suction nozzles caused by a large amount of waste generated after cutting of paper braided components.
Therefore, check the cleanliness of the suction nozzle daily, and clean or replace the suction nozzle and filter that are clogged or poorly picked up in time to ensure a good condition.
3.Influence of Component Inspection System
The device detection system is a necessary guarantee to increase the mounting rate. The device detection system is divided into component thickness detection and recognition system and optical recognition system.
After long-term use, the linear sensor of the component thickness detection and identification system is easily affected by dust, debris, and oil pollution. The light source intensity of the optical camera system will also gradually decrease. As the light intensity of the light source decreases, the gray value converted by the camera will also decrease. When the gray value decreases to a certain value, the image will not be recognized.
Therefore, the device detection system needs to be regularly calibrated and tested.
About Us
Hunan Charmhigh Electromechanical Co., Ltd. is a high-tech enterprise specializing in R&D, manufacturing and sales of SMT multi-function pick and place machine and SMT intelligent supporting equipment.
Charmhigh Electromechanical takes the multi-functional pick and place machine as its core business, and at the same time provides SMT overall solutions and corresponding equipment for each station, including printing machines, plug-in machines, reflow oven, wave soldering, AOI and other products, which can be widely used in small household appliances, Power supply, high-end LED lighting, smart toys, automotive electronics, consumer electronics, aviation electronic information and other industries.
The Future Development Direction of the Pick and Place Machine
1.Double Track Structure
The development of the efficient two-way conveying structure of the pick and place machine improves production efficiency; on the basis of retaining the performance of the traditional single-way pick and place machine, the PCB transportation, positioning, inspection, repair, etc. are designed into a two-way structure, and the PCB jigsaw gradually The increase in the size of the mounter also increases the size of the mounter to reduce the effective working time and increase the productivity of the machine.
2.High speed, high precision, multifunctional.
The new pick and place machine has been striving to develop towards high speed and high performance, and has done well in the direction of high precision and multi-function. With the continuous development of surface mount components, the requirements for new packages such as BGA, FC, CSP, etc. are getting higher and higher. Smart controls have been introduced in the new pick and place machines, which have a lower error rate while maintaining high production capacity, which not only improves the efficiency of IC mounting, but also ensures higher precision.
3.Multiple cantilevers, multiple mounting heads, and multiple feeding stations.
The number of mounting heads and the number of feeding stations are increasing compared to before, and the types of surface mount components are relatively increasing. For this reason, the future development direction of pick and place machines? For the development of the combination of multi-cantilever machine tools and turret machine tools
4.Modular
The module machine has different functions. According to the installation requirements of different components, it can achieve higher efficiency according to different precision and mounting efficiency. When the order increases, new functional module machines can be added as needed. To meet the flexible production needs in the future, the modular structure of this machine is very popular among customers.
5.Automatic Programming
The new visualization software tool has an automatic "learning" ability. Instead of manually entering parameters into the system, engineers only need to bring the device to the vision camera, then take a picture, and the system will automatically generate a comprehensive CAD-like description. This technology improves the accuracy of equipment descriptions and reduces many operator errors.
6.Development Direction of Accessories
The pick and place machine is equipped with a dust removal and static removal device, a maintenance-free Feeder with a static removal and automatic feeding function, a nozzle exchange station carrying a suction nozzle automatic cleaning device, a vacuum suction device for the mounting platform, and a closed-loop control of the mounting head and the suction force And digital display, etc.
Configure efficient SMT production line? Don't ignore these three points!
The main equipment of the general SMT production line includes solder paste printing machine, pick and place machine, reflow oven, AOI automatic optical inspection instrument. Since the pick and place machine is often the core link of the entire SMT production line, the selection of the pick and place machine is particularly critical.
When establishing an SMT production line, it is necessary to formulate a reasonable introduction plan based on factors such as the investment capacity of the enterprise, the size of the output, and the mounting accuracy requirements of the circuit board. When choosing equipment, you should "Made to size", and you must not blindly seek everything, so as not to cause unnecessary waste.
1.According to the type of product, output, and recent development plan
Clarify the electronic products processed on the patch production line, product types, product complexity, product components, and total annual output;
Clarify the need to establish a new patch production line, or to rebuild and expand the old patch production line;
In case of reconstruction or expansion, consider the extensibility of the production line according to the existing production status and future production planning.
If a new production line is needed, the scale of the mounting production line should be specified according to the plan, so as to calculate the specific pick and place machine needed.
2.According to the assembly density of electronic products, the type and quantity of mounted components
When the patch production line is to produce high-density, multi-pin, narrow-pitch and large-sized SMD devices and special-shaped components, a multi-functional pick and place machine is required;
If the mounting task is large, after configuring a multi-function pick and place machine, a medium-speed pick and place machine or a high-speed pick and place machine can also be configured.
3.According to the process of the product
If the products on the SMT production line are relatively simple, or when using pure surface assembly and single-sided mixed assembly process, you can choose a soldering equipment (reflow soldering oven or wave soldering machine);
If the product is more complicated, the assembly density is higher, and there are more plug-in components in the double-sided mixed form, two welding equipment, reflow oven and wave soldering machine, should be selected;
If the product needs to be cleaned, cleaning equipment must also be configured.
Charmhigh Electromechanical takes multi-functional pick and place machines as its core business, and at the same time provides SMT overall solutions and corresponding equipment for each station, including printing machines, plug-in machines, reflow soldering, wave soldering, AOI and other products, which can be widely used in small household appliances, Power supply, high-end LED lighting, smart toys, automotive electronics, consumer electronics, aviation electronic information and other industries.
What are the main accessories of SMT pick and place machine?
The pick and place machine is a high-precision, high-speed, fully automated PCB circuit board mounting equipment, and it is the key and intelligent equipment in the entire SMT production line. The quality of the pick and place machine depends on the quality of the main accessories of the equipment and the intelligence and optimization of related software. Here, Charmhigh domestic pick and place machine mainly introduces to you what are the main accessories of the SMT pick and place machine?
1.Feeder
Feeder, also called feeder , is a transliteration of English Feeder. The pick and place machine picks up the components on the feeder at a specified different position, and then mounts them. As one of the important components of the pick and place machine, the feeder has a great influence on the production efficiency and accuracy of the pick and place machine. There are many ways to classify feeders, such as belts, pallets, bulk boxes, tubes; they can also be divided into electric feeders and pneumatic feeders. Electric feeders are more expensive than pneumatic feeders, but they are more stable and durable, and can be equipped with 0201.
2.Nozzle
The suction nozzle of the pick and place machine is also one of the important components of the pick and place machine, which is used to pick up and place components. Using network information to conduct research on the role of vacuum adsorption is constantly absorbing, and then using high air pressure to mount components. The work of different parts requires us to use different nozzles.
3.Screw rod, guide rail, drive control motor
Screw rods, guide rails and drive motors are important components of the x, y-axis motion mechanism of SMT machines. At present, the quality management of domestic accessories is not as good as the quality of products imported from China. Imported accessories have the characteristics of high effect, high precision, high rigidity, high durability and low noise. Screws and rails also require regular maintenance.
4.Visual system
The vision system of the SMT machine determines the accuracy and stability of the SMT process. The vision system of SMT machines generally consists of two types of cameras. Marking cameras are used to capture PCB system coordinates and check for misalignment between camera components and nozzles. The machine vision system guarantees and corrects the accuracy of machine vision through precision cameras, light sources, image acquisition cards and processing systems.
5.Industrialcomputer, vacuum signal generator, photoelectric information sensor, cylinder, conveyor belt, etc.
SMT is also equipped with high-performance industrial computer, vacuum generator with stable and reliable suction, solenoid valve and other important accessories. When purchasing an SMT machine, it has certain reference value.
How to avoid component missing mounting?
Avoiding the missing mounting of components is one of the important steps to ensure the mounting accuracy and quality of the pick and place machine. Here are some ways to help you avoid missing components:
1.Check the Mounting of Components
Before mounting, it is necessary to carefully check the mounting of components to ensure that the components are placed correctly, the position is accurate, the size meets the requirements, and there are no problems such as looseness or damage.
2.Adjust Mounting Head Height and Pressure
The height and pressure of the mounting head will affect the accuracy and quality of component mounting. Therefore, before mounting, it is necessary to adjust the height and pressure of the mounting head according to the size and shape of the components to ensure that the components can be accurately clamped and placed during mounting.
3.Check Pcb Board Surface
Before mounting, it is necessary to check whether the surface of the PCB board is flat, and there are no problems such as unevenness or cracks, so as to ensure that the components can be mounted in the correct position.
4.Calibrate Pick and Place Machine
If the pick and place machine deviates, it may lead to missing mounting of components. Therefore, the pick and place machine needs to be calibrated regularly to ensure mounting accuracy and quality.
5.Check the Quality of Components
Poor quality or damaged components can also lead to missed mounting of components. Therefore, before mounting, it is necessary to check the quality and status of components, and replace or repair damaged components in time.
In short, to avoid missing mounting of components, it is necessary to carefully check the mounting of components, adjust the height and pressure of the mounting head, check the surface of the PCB board, regularly calibrate the pick and place machine, and check the quality and status of components before mounting. During the mounting process, it is also necessary to pay attention to the operating specifications to ensure that components are accurately clamped and mounted.
What problems can the CPK test reflect on the pick and place machine?
CPK is an indicator used to measure quality control, usually used to evaluate the stability and capability of the quality process. In the production process of the pick and place machine, the CPK value can reflect the mounting accuracy and stability of the pick and place machine, as well as possible problems in the production process.
The CPK value is jointly determined by the mean and standard deviation. The higher the CPK value, the more stable the quality process and the higher the quality of the produced product. Conversely, if the CPK value is low, it indicates that the quality process is unstable, and there may be problems with the quality of the produced products.
In the production process of the pick and place machine, the CPK value can reflect the following problems:
1.Component mounting accuracy
If the mounting position of the components is not accurate, it may lead to a lower CPK value, indicating that the mounting accuracy is not high enough and needs to be adjusted and improved.
2.Mount head height and pressure
The height and pressure of the mounting head will affect the mounting accuracy and stability of the components. If the height or pressure of the mounting head is not suitable for the components, it may lead to a lower CPK value, which needs to be adjusted and improved.
3.Pick and place machine setting parameters
The setting parameters of the pick and place machine, such as mounting speed, acceleration, residence time and other parameters, will have an impact on mounting accuracy and stability. If these parameters are not set properly, it may lead to lower CPK values, which need to be adjusted and improved.
4.Component quality
The quality of components also affects mounting accuracy and stability. If the quality of the components is not good, it may lead to a lower CPK value, and the damaged components need to be replaced or repaired in time.
When the CPK of the pick and place machine is low, it needs to be analyzed and improved, such as analyzing the mounting position of components, adjusting the height and pressure of the mounting head, checking the setting parameters of the pick and place machine, checking the quality of components, and regularly calibrating the pick and place machine a series of questions.
Is the SMT pick and place machine difficult to operate?
Is the SMT pick and place machine difficult to operate? In fact, it is very easy to operate the SMT pick and place machine according to the correct method. The pick and place machine is one of the key equipment of the placement equipment. Because of its high efficiency and stable performance, it has brought great advantages to our production. With SMT pick and place machines, we can greatly improve production efficiency. With SMT pick and place machines, we can provide customers with high-quality products. Therefore, the role of SMT is irreplaceable. As a manufacturer of high-end pick and place machines in China, Charmhigh Electromechanical professional technicians will tell you the operating points of SMT pick and place machines.
First, understand the common signs of the pick and place machine
We all know that many machines and equipment have specific signs that need to be learned before use, and SMT pick and place machines are no exception. Then, at this time, we need to fully understand the meaning and function of these signs, so as to play a warning role. After fully understanding the pick and place machine, we can use the pick and place machine more safely.
Second, do a good start-up inspection
First of all, it is very important to determine whether the air pressure of the patch is within the normal range; secondly, whether there is any debris inside the machine to prevent interference and failure; in addition, It is also very important to ensure that the mounting is in place， because it is the key to ensuring long-term normal use.
Third, to ensure the boot order
When using the pick and place machine, attention should be paid to whether the starting sequence is correct, which is closely related to the safety of employees and the use of the machine. The correct startup sequence is the guarantee for subsequent operations and work. Therefore, we also need to pay special attention to the boot sequence.
Fourth, we must actively troubleshoot
After using the pick and place machine for a long time, it will inevitably consume and damage the machine. Therefore, troubleshooting is also an important job. In this way, proactive troubleshooting can detect problems in time and solve them quickly and effectively. This is the main purpose and role of troubleshooting.
After listening to the interpretation of the Charmhigh technicians, do you have a deeper understanding of the operation of the SMT pick and place machine? In fact, it can be seen that it is not difficult to operate the pick and place machine as long as you follow the instructions on the pick and place machine and do a good job of safety inspection and installation inspection every step of the way!
Author: Charmhigh Electromechanical
How to change the line and load the SMT pick and place machine equipment?
The SMT pick and place machine production line needs to change the line and load the material when mounting new products. In order to reduce problems such as wrong material and reverse in the placement process, relevant operators need to standardize their operations. Charmhigh pick and place machine share how to change the line and load the SMT pick and place machine equipment?
常衡机电LOGO
During the refueling and line transfer process of the SMT pick and place machine, the corresponding positions of IPQC, team leader, technician and operator have corresponding check rules. The regular positions are arranged as follows:
1. Operator: Responsible for picking and loading materials, and self-checking the correctness of the loading station, specifications, and material numbers according to the station table;
2. Team leader: responsible for reviewing the correctness of the operator's feeding;
3. Technician: responsible for making or receiving the station list, and compiling the mounting program;
4. IPQC: Responsible for searching the BOM, patch diagram, engineering change order (ECN), history record table, and finally confirming the correctness of loading or refilling.
When SMT produces new products or changes lines, the foreman and team leader will issue the correct station table for the corresponding product to the material changer, and then load the materials on the machine correctly according to the station table. Check the material code, brand, specification, model, feeder type, polarity, etc. of the components on the stamped and effective station table. After the inspection is OK, load the materials into the corresponding station, and then notify the team leader to review and IPQC to check; IPQC checks according to the station table, material specifications, and material numbers, and then notifies the technician to make the first piece and confirm the first piece after confirming that it is correct.
A: Confirm the specifications of the components (for example: 0402 0603 0805 1206, etc.);
B: Confirm the product name of the component (such as: R10K100K, etc.);
C: Confirm the error of the component (D±0.5%F±1%J±5%K±10%);
D: Confirm the direction of the IC installed in the tube or the diode with polarity, carefully check its polarity and product name.
How to Improve the Service Life of Smt Pick and Place Machines?
Pick and place machine is the most important equipment in the SMT production line, and it is also the equipment with the highest investment in the SMT production line. Therefore, it is necessary to use pick and place machine reasonably to maximize the service life of pick and place machine and effectively save costs. How to improve the service life of pick and place machine? Charmhigh Electromechanical teaches you how to improve the service life of SMT pick and place machines.
First of all, the maintenance of pick and place machine is very important
1. Regularly clean, remove and wash the dust and scale on the surface of the circuit board and pick and place machine to avoid poor heat dissipation inside the equipment due to scale and dust, which may cause the equipment to overheat and burn out.
2.Disassemble and clean the electromagnetic valve, internal air circuit, vacuum generating device, cylinder, etc. of the equipment; if the oil dirt in the air circuit cannot be cleaned in time, it will block the air circuit, causing the air circuit to be blocked, resulting in high throwing material; In severe cases, it will corrode the internal sealing rings and components of solenoid valves, vacuum generators, cylinders, etc., resulting in damage to components and affecting the normal production of equipment.
3.The equipment of pick and place machine manufacturer has passed the warranty period, and it has been running for a long time, so it is impossible to carry out comprehensive and professional maintenance on the equipment.There are hidden dangers in some parts of the equipment, and the equipment needs to be extensively maintained.Timely check and discover hidden dangers in the equipment and solve them, thereby reducing the frequency of equipment failures and improving production efficiency.
4. After long-term operation of the equipment, the relevant parts of the equipment may be worn, aged, and displaced. The most original parameters of the equipment can no longer adapt to the status quo of the equipment, and the mounting accuracy of the equipment has been seriously affected. Therefore, the equipment must be regularly checked. Calibrate to make the equipment produce in the state of highest precision and improve the quality of the product.
5.Periodic maintenance of the equipment, and reasonable planning of the maintenance cycle according to the company's production conditions can effectively reduce the throwing rate, reduce the number of alarms, improve machine production efficiency, and reduce pick and place machine failures.
6. (Prevent oxidation and corrosion of rolling elements) Work in a humid environment for a long time and be easily affected by moisture, which requires lubricants with better anti-emulsion properties. The type of installation is more complicated, and the dust in the air enters the hydraulic system, causing serious lubricant pollution, which requires the user to wipe and replace the lubricant frequently.
For SMT mounting and processing enterprises, improving the service life of pick and place machines can not only save costs, but also improve production efficiency. As long as pick and place machine is used reasonably and pick and place machine is maintained, the service life of pick and place machine will be improved and the value of pick and place machine will be maximized.
To choose SMT pick and place machine production, you must find a powerful enterprise. Hunan Charmhigh Electromechanical Co., Ltd. is a leading domestic high-end SMT intelligent equipment and actively participates in international level homogeneous competition! With more thorough customization, better quality, and better service, it is an enterprise that provides intelligent products and optimized solutions for the transformation, product upgrading, and large-scale production of various domestic and foreign enterprises in an all-round way.
The Abnormal Handling Method in the Production Process of Smt Pick and Place Machine
When the SMT pick and place machine is used for a period of time, due to various reasons, there may be abnormal situations in the production process. In some abnormal situations, SMT pick and place machine technicians can master certain knowledge to deal with them in time. Some abnormal situations It must be reported and processed in a timely manner.Charmhigh Electromechanical's domestic pick and place machine shares the abnormal handling method in the production process of SMT pick and place machine.
First-SMT pick and place machine production and operation alarm information and processing
1.Insufficient vacuum: the suction nozzle is blocked or the vacuum pipe is blocked, notify the technician to replace the suction nozzle or clean the suction nozzle and vacuum pipe;
2.Insufficient air pressure: check whether the air supply connector of the machine is leaking, and notify the technician or engineer to deal with it;
3.Mounting head X, Y displacement overflow: manual displacement overflow can be turned on and run normally, if there is an abnormality in the operation process, the engineer should be notified to check;
4.PCB transmission error: A. The in and out transmission is not smooth, and the size of the PCB board is abnormal. The size of the defective product should be fed back and sent to IPQC for inspection, simultaneously,and the technician should be fed back for improvement; B. The track problem of the SMT pick and place machine should be improved by the feedback technician;
5.Handling of products that have not been placed: A. In case of operational errors, the technician should be notified to re-send it into the machine for supplementary mounting; B. In case of abnormal shutdown, the technician should be notified to handle it;
6.Mounting flying parts or missed placement: A. The suction nozzle is bad, and the machine should be stopped to check the corresponding suction nozzle of the component; B. The vacuum is insufficient, and the technician should be notified to conduct a vacuum inspection; C. The PCB is not fixed well, check the PCB fixing state;
7.SMT mounting deviation: A.Fixed position deviation and regularity, and the coordinates are modified by a technician; B. The PCB is not fixed properly (the surface is uneven, sinking and shifting during placement), check and readjust the positioning device; C. It is caused by poor viscosity of solder paste, which needs to be analyzed and dealt with by technicians or engineers.
Second-SMT pick and place machine power failure or environmental (lightning) processing
1. In case of thunder and lightning weather, the products to be produced must be cleared as soon as possible and notified;
2. Turn off the power of the equipment during a power outage, restart the machine after the power is supplied, and process the products being produced in the machine.
Third-Handling of abnormal placement quality of SMT pick and place machine machine
When the relevant standards are not met, feedback must be given to the supervisor, equipment technician or engineer.
Forth-SMT pick and place machine machine throwing material exceeds the standard
Report to technicians, superiors and related personnel for processing.
Fifth-Troubleshooting of SMT pick and place machine equipment:
1.It should be stopped immediately, and the equipment technician or engineer should solve it and make a record.
2.In addition to the above-mentioned problems, if there are any different things in the future, you can communicate with us and deal with them!
Mounting Technology: Three Elements to Improve the Quality of Mounting
1. Correct Components
It is required that the characteristic marks such as type, model, nominal value and polarity of each assembly tag component must meet the requirements of the product assembly drawing and schedule, and cannot be pasted in the wrong place.
Charmhigh P&P Machine
2. Accurate Location
The terminals or pins of the components should be aligned and centered with the pad pattern as much as possible, and it is also necessary to ensure that the soldering end of the component contacts the solder paste pattern. The mounting position of components must meet the process requirements. The mounting position requirements for Chip components at both ends, wing-shaped pins and J-shaped pins devices, and ball-shaped pins devices are as follows:
①Chip components with two ends: the self-positioning effect of the Chip components at two ends is relatively large. When mounting, more than 1/2 of the component width is overlapped on the pad, and the two ends in the length direction only need to Lap to the corresponding pad and contact the solder paste pattern, it can be self-positioned during reflow, but if one of the terminals is not lapped to the pad or does not contact the solder paste pattern, it will shift during reflow or drawbridge.
②wing-shaped pins and J-shaped pins devices,For SOP, SOJ, QFP, PLCC and other devices, the self-positioning effect is relatively small,Mounting offset cannot be corrected by reflow soldering.
If the mounting position exceeds the allowable deviation range,It must be manually corrected before entering the reflow oven for welding.Otherwise, it must be repaired after reflow soldering,
It will cause waste of man-hours and materials, and even affect product reliability.When the mounting position is found to exceed the allowable deviation range during the production process, the mounting coordinates should be corrected in time.
Manual mounting or manual timing requires that the mounting position is accurate, the pins are aligned with the pad, and centered. Do not place it incorrectly. Drag it on the solder paste to find the alignment, so as to avoid sticking of the solder paste pattern and cause bridging.
③Ball Pin Devices:Since the pad area of BGA, CSP and other spherical pin devices is relatively large relative to the area of the component body,The self-positioning effect is very good, so as long as these two points are met,One is that the solder balls of the BGA correspond to the corresponding pads one by one;Second, the maximum offset between the center of the solder ball and the center of the pad is less than 1/2 of the diameter of the solder ball.
3. The pressure (pick and place height) is appropriate.
The pick and place pressure (Z-axis height) should be appropriate.The patch pressure is too small,component solder ends or pins float on the surface of the solder paste, and the solder paste cannot stick to the components., easy to produce position shift during transfer and reflow soldering,In addition, because the height of the Z axis is too high,When the component is dropped from a high place during the mounting, it will cause the position of the mounting to shift;
If the chip pressure is too high and the amount of solder paste is extruded too much, it is easy to cause solder paste sticking, Bridging is easy to occur during reflow soldering. At the same time, the position of the chip will be shifted due to sliding, and components will be damaged in severe cases.
How to Choose a Pick and Place Machine（2）？
With the rapid development of the global electronics manufacturing industry, my country's pick and place machine technology has become more and more mature, not only has a large SMT user base in China, but also opens its doors to foreign countries, and has won the trust of customers!
The pick and place machine is the main equipment in the SMT production line. It is a kind of equipment that accurately places surface mount components on the PCB pads by moving the mounting head. At present, the pick and place machine is divided into: trial production proofing type, high-precision small-volume type, economical general-purpose type, medium-speed general-purpose type, high-speed high-precision multi-functional type.
How do we choose the pick and place machine that suits us?
1. Production speed and efficiency: first consider the production demand, choose a pick and place machine that can meet the production speed, precision and efficiency, of course, also consider short-term and medium-term planning.
2. Evaluation of mounting suppliers: The supplier's focus on pick and place machines, self-research capabilities, and good reputation and word of mouth in the market are important factors for us to consider when choosing a pick and place machine, and it is also an important guarantee for choosing a pick and place machine.
3. The main elements of the pick and place machine evaluation:
(1) Y-axis dual drive: dual servo motors can effectively and synchronously drive the beam to move, ensuring that the pick and place machine is working at high speed for a long time. Improving precision and reliability, one of the key technologies for high-speed pick and place machines with Y-axis dual drive;
(2) Thermal compensation configuration: Affected by temperature or work-generated heat, the expansion coefficient of equipment-related accessories changes, thereby affecting the mounting accuracy of the machine. Thermal compensation can realize precision monitoring and automatic correction to ensure long-term stability of the machine.
（3）Whether to support CPK inspection: CPK is the most scientific statistical method for verifying the accuracy and stability of pick and place machines in the SMT industry. CPK accuracy refers to speed-related positioning accuracy, repetition accuracy, rotation accuracy, image acquisition accuracy, image recognition accuracy, mounting process control accuracy, PCB board calibration accuracy, heat-affected accuracy, and the vibration of the PCB board on the machine The comprehensive accuracy of batch mounting determined by a series of factors. If the pick and place machine does not support CPK testing, the data obtained by the test standards and methods customized by the manufacturer is not credible.
（4） The structure of the mounting head and the camera vision system: each mounting head is controlled by an independent mounting head motor and rotating motor, which can be recognized quickly and accurately.
（5） Automatic nozzle change: automatic nozzle change is based on the size of various components, automatically distribute and replace nozzles, to meet the needs of different component mounting without stopping the machine. If there is no automatic nozzle change, the impact on production will be explained:
If: the number of mounting points corresponding to each suction nozzle is: the total number of components is 288, the number of stickers is 6, the number of components corresponding to CN040 is 240, the number of components corresponding to CN065 is 20, the number of components corresponding to CN100 is 20, and the number of components corresponding to CN220 is The number of pieces is 8 pieces.
Automatic replacement of suction nozzles According to the above corresponding relationship, the program will automatically optimize the allocation and replacement of suction nozzles to ensure simultaneous production of 6 heads. The total number of rounds is: (240+20+20+8)/6=48, and 48 rounds are required to complete production.
No automatic nozzle change: In the case of non-stop, the 6 mounting heads of the pick and place machine need to be equipped with different nozzles to meet the production. The number of components corresponding to CN040 is 240. According to the optimal allocation of 3 attachment heads, 3 suction nozzles are allocated, and the other 3 heads are required to install CN065, CN100 and CN220 nozzles respectively. It takes 80 rounds to complete the mounting.
（6） Mounting speed: When consulting the speed, the standard question is what is the actual mounting speed of IPC9850? In the past, manufacturers of pick and place machines used their own defined parameters and methods to describe the performance of their equipment's output and mounting capabilities. As a result, the definition of many technical indicators and the inconsistency of measurement methods, the marked speed has no comparison. It is precisely this need that the Assembly Equipment Subcommittee under the IPC organization organized the pick and place machine manufacturers and users to cooperate to formulate the IPC9850 surface mount equipment performance testing program, and proposed a set of measurement principles, tools, methods, and data processing and analysis models. , officially became the industry standard in July 2002. Therefore, if the speed marked by the current pick and place machine manufacturer is not based on the IPC9850 standard, there is no reference value.
(7) Vacuum pump: A high-speed pick and place machine vacuum pump is a necessary configuration, which can ensure a stable vacuum, and the high-speed adsorption device is more reliable during mounting.
In addition, pay attention to the cost performance of a good pick and place machine is often directly proportional, do not choose blindly because of the price, I hope the above content can help you find a suitable pick and place machine for you.
The Future Development Direction of the Pick and Place Machine
1.Double track structure
The efficient two-way conveying structure of the SMT pick and place machine is developed to improve production efficiency; on the basis of retaining the performance of the traditional single-way pick and place machine, the PCB transportation, positioning, inspection, repair, etc. are designed into a two-way structure, and the PCB is assembled. The gradual increase also creates a pick and place machine to cope with the increase in size to reduce the effective working time and improve machine productivity.
2.High speed, high precision, multi-function
The new pick and place machine has been striving to develop towards high speed and high performance, and has done well in the direction of high precision and multi-function. With the continuous development of surface mount components, the requirements for new packages such as BGA, FC, CSP, etc. are getting higher and higher. Smart controls have been introduced in the new pick and place machines, which have a lower error rate while maintaining high production capacity, which not only improves the efficiency of IC mounting, but also ensures higher precision.
3. Multiple cantilevers, multiple mounting heads, and multiple feeding stations
The number of mounting heads and the number of feeding stations are increasing compared to before, and the types of surface mount components are relatively increasing. For this reason, the future development direction of pick and place machines? For the development of the combination of multi-cantilever machine tools and turret machine tools
4.Modular
The module machine has different functions. According to the installation requirements of different components, it can achieve higher efficiency according to different precision and mounting efficiency. When the order increases, new functional module machines can be added as needed. To meet the flexible production needs in the future, the modular structure of this machine is very popular among customers.
5. Automatic programming
The new visualization software tool has an automatic "learning" ability. Instead of manually entering parameters into the system, engineers only need to bring the device to the vision camera, then take a picture, and the system will automatically generate a comprehensive CAD-like description. This technology improves the accuracy of equipment descriptions and reduces many operator errors.
6. Development direction of accessories
The pick and place machine is equipped with a dust removal and static removal device, a maintenance-free Feeder with a static removal and automatic feeding function, a nozzle exchange station carrying a suction nozzle automatic cleaning device, a vacuum suction device for the mounting platform, and a closed-loop control of the mounting head and the suction force And digital display, etc.
How Much do you Know about the Operation and Debugging Methods of the Pick and Place Machine?
Today, I will introduce to you the operation and debugging methods of the pick and place machine when making new products. When the new product sequence is completed and optimized, it is necessary to run this sequence on the pick and place machine for mounting production. The ideal state is that after the products are sequentially loaded to the controller of the machine, and the components have been installed according to the material list of the feeder, then pick and place machine can start stable and continuous mass production. But in fact, it is often necessary to go through some long-term sequential debugging and trial production before the pick and place machine can truly stably and continuously produce. The following areas, order and database may need to be adjusted.
1.Parameters in the component database
At the beginning of programming, sometimes there are no samples of circuit boards and components, and programming can only be performed through CADB0M or mounting graphics of circuit boards. Since local components are not standard components, the same component information cannot be found in the standard database that comes with it. The newly created component database may be difficult to achieve the purpose of correction through identification on the machine, such as the identifiable features of components, the absorption of components, etc. Nozzle selection, camera recognition lighting settings, feeder selection and component orientation, etc.
2.Mounting coordinates of components
During sequential production, sometimes the original coordinate data of the circuit board cannot be obtained, and the coordinates in the sequence are obtained by the sequence machine, or obtained by the sequence of other machines.
3.coordinates of datum point
Sometimes the obtained circuit board coordinate data only have the mounting coordinates of the components, but not the coordinates of the reference point.
4.Feeder model and orientation
In sequential production, there are often no samples of components and packaging, and the model of the feeder and the direction of the components need to be determined based on past experience. Some components' pick-up centers are inconsistent with the default values of the feeder, and the pick-up position of the component feeder needs to be re-calibrated and modified.
The above content is some pick and place machine operation and debugging methods that must be seen when making new products. I hope it can be helpful to you who are reading the content!
Charmhigh Electromechanical Co., Ltd. specializes in R&D, production and sales of multi-functional placement machines, a leading brand of pick and place machines!
What to do if the SMT Pick and Place Machine Throws Materials Abnormally?
SMT pick and place machine throwing material refers to the above-mentioned throwing action that does not stick after absorbing the material in the production process of the SMT industry, throwing the material into the throwing box or other places, or performing the above throwing action without absorbing the material.
The loss of materials caused by throwing materials prolongs the production time, reduces the production efficiency and increases the production cost.
Material throwing of the pick and place machine is a common phenomenon in the operation of the pick and place machine, whether domestic or imported pick and place machines will have the phenomenon of material throwing. However, once the throwing rate is higher than the standard level, it means that the pick and place machine has failed, and it is necessary to find a way to solve it when the throwing rate is too high.
SMT industry recognized pick and place machine throwing standard
Class A material (IC class) is 0
Class B materials (transistor diodes) are 1‰
Class C material (Chip material) is 3‰
The common reasons for the abnormal material throwing of the pick and place machine mainly include: nozzle blockage, poor vision, incorrect feeding, lack of air pressure, wrong component parameters, bad components, and deformation of the feeder.
So how should we solve the problem of abnormal material throwing in daily production?
1
Reason: The suction nozzle of the SMT pick and place machine is deformed, blocked, and damaged, resulting in lack of air pressure, air leakage, resulting in inability to absorb materials, incorrectly retrieving materials, and throwing materials because they cannot be identified.
Countermeasures: Check, clean and replace the suction nozzle regularly.
2
Reason: SMT pick and place machine has poor vision, the visual or laser lens is not cleaned, there are sundries that interfere with identification, the identification light source is improperly selected and the intensity and gray scale are not enough, and the identification system may be broken.
Countermeasures: Clean and wipe the appearance of the identification system, keep it clean and free of sundries, etc., adjust the intensity and grayscale of the light source, and replace the identification system components.
3
Reason: The pick and place machine is not in the center of the material, and the height of the pick-up is incorrect (generally, it is based on the 0.05mm press down after hitting zero) to form a deviation. The pick-up is not correct, and there is an offset. The data parameters do not match and are discarded by the identification system as invalid.
4
Reason: The air pressure of the pick and place machine is insufficient, the vacuum air pipe channel is not smooth, there is a guide blocking the vacuum channel, or the vacuum leaks, resulting in insufficient air pressure and the material cannot be picked up or falls on the way to paste after picking up.
l Countermeasures: adjust the air pressure steep slope to the required air pressure value of the equipment (such as 0.5~0.6Mpa), clean the air pressure pipeline, and repair the leaking air path
5
Reason: The parameter setting of the component in the modified SMT pick and place machine program is incorrect, and it does not match the parameters such as the size and brightness of the incoming material, resulting in identification failure and being thrown away.
Countermeasures: modify the component parameters, and search for the best parameter settings of the component.
6
Reason: The incoming materials of SMT chip components are irregular, and they are unqualified products such as pin oxidation.
Countermeasures: IQC does a good job in the inspection of incoming materials, and communicates with component suppliers about defective products.
7
Reason: The position of the feeder of the pick and place machine is deformed, and the feeding of the feeder is poor (the ratchet gear of the feeder is damaged, the hole of the material belt is not stuck on the ratchet gear of the feeder, there are foreign objects under the feeder, the spring is aging, Or electrical failure), resulting in material failure or poor material removal, and damage to the feeder.
Countermeasures: adjust the feeder, clean the feeder platform, replace damaged parts or feeders.
What are the Precautions and Details for SMT Pick and Place Machine Operation?
The core production equipment in the SMT production process is the SMT pick and place machine. All production equipment is developed around the SMT pick and place machine. At the same time, the SMT pick and place machine is also a sophisticated automated production equipment, which is equivalent to a robot. If the pick and place machine fails, all the work in the SMT production workshop can only be stopped, so the operation of the SMT pick and place machine must memorize the operation precautions. Charmhigh Electromechanical's high-end domestic pick and place machines share the precautions and details of the SMT pick and place machine operation here. have those?
First,what are the precautions and details for the operation of the SMT pick and place machine?
1. Check whether there are impurities and foreign objects inside the SMT pick and place machine, and clean them in time if there are any;
2. Check whether the feeder is placed abnormally;
3. Check whether the nozzle configuration status is abnormal;
4. Check whether the safety shield is abnormal;
5. Check whether there are unsafe safety hazards around the equipment;
6. First, according to the safety technical operation specification of SMT equipment, the SMT pick and place machine power supply, check whether the air pressure and rated voltage are normal, and then turn it on;
7. Secondly, we need to check whether the vacuum pressure of the SMT pick and place machine meets the requirements of the equipment. The vacuum value of the pick and place machine is usually around 5.5bar;
8. Turn on the pick and place machine servo system;
9. Return the x and y axes of the pick and place machine to the initial position of the source point;
10. According to the width of the pcb circuit board, adjust the guide rail width of the transmission system of the SMT pick and place machine. The guide rail width should be greater than the pcb width by 1mm, and at the same time ensure that the pcb slides freely on the guide rail;
11. Set up the pcb positioning device at the same time.
Second,precautions for safe use of SMT pick and place machine.
1. When the machine is in operation, it is not allowed to extend the head, hands, and other parts into the machine.
2. When changing materials, be sure to stop the machine and open the safety door, or press the emergency switch to change materials.
3. If there is an emergency, press the emergency switch first, and then notify the equipment technicians to solve it.
Third,precautions for refueling operation of SMT pick and place machine
When changing the material of the SMT pick and place machine, it is necessary to see the spacing of the material. The standard distance between the hole and the hole on the material belt is 4mm, and the spacing of the general material is 4mm. The special material packaging depends on how many holes there are between the materials to determine the distance between the materials.
Forth,matters needing attention before and after loading when changing the line of SMT pick and place machine.
1. Before feeding, clean the Feeder Table and check whether there are components or other sundries under the Feeder that cause the Feeder to deviate. If there are, remove them.
2. After loading the material, check whether the material is in place, and use the moving lens to check whether the feeder is out of position.
Classification of Pick and Place Machines
In addition to multi-function pick and place machines and high-speed pick and place machines, what are the classifications of pick and place machines that are often heard?
The pick and place machine is the most important production equipment in the SMT production process. Generally, the common pick and place machines are classified according to speed and function, such as medium-speed and high-speed pick and place machines, single-function and multi-function pick and place machines, etc. In fact, there are many types of pick and place machines. Let me introduce it to you.
——— Charmhigh Electromechanical Multifunctional Pick and Place Machine
1. Classify pick and place machines by speed
Medium-speed pick and place machine,high-speed pick and place machine and ultra-high-speed pick and place machine.
2. Classify pick and place machines by function
High-speed/ultra-high-speed pick and place machine (mainly mount some regular components) and multi-function pick and place machine (mainly mount some irregular components).
3. Classify the pick and place machine by mounting method
Sequential pick and place machine, simultaneous pick and place machine and simultaneous online pick and place machine.
4. Classify pick and place machines by working principle
Boom type pick and place machine, composite pick and place machine, turret pick and place machine and large parallel system pick and place machine.
(1)the boom-type pick and place machine has good flexibility and precision, and is suitable for most components. High-precision machines are generally of this type, but their speed cannot be compared with compound, turntable and large parallel systems. Compare. It can be divided into single-arm type and multi-arm type;
(2) The composite machine is developed from the swing arm machine, which combines the characteristics of the turntable and swing arm. A turntable is installed on the swing arm. For example, the latest HS50 machine launched by Siemens has four such Advanced rotary head, the mounting speed can reach 50,000 pieces per hour;
(3) The pick-up and mounting actions of the turret-type pick and place machine are carried out at the same time, which greatly improves the mounting speed. For example, the MSH3 machine mounting speed of Panasonic can reach 0.075 seconds/piece;
(4) A large parallel system consists of a series of small independent assemblers. Each has a lead screw positioning system manipulator, and the manipulator has a camera and a mounting head. For example, the FCM machine of PHILIPS company has 16 installation heads, which achieves a mounting speed of 0.0375 seconds/piece, but for each installation head, the mounting speed is about 0.6 seconds/piece.
What to do if the Air Pressure of the Pick and Place Machine is Insufficient?
Many friends who use the pick and place machine know that the pressure of the pick and place machine is a very important part. In the process of using the pick and place machine, not only voltage is needed, but also pressure is needed to help use it. Sometimes we find that the pressure of the pick and place machine is insufficient.
What should I do if the alarm is generated due to insufficient air pressure? Insufficient air pressure? Now Charmhigh Electromechanical will explain in detail the consequences and solutions of the insufficient air pressure of the pick and place machine, and see if it can help everyone!
When our machine is running, since the air pressure is limited by the machine, when the air pressure is lower or higher than the target value, the pick and place machine will give an alarm, and the related parts of the pick and place machine will also fail due to the following reasons:
1. Abnormal paper supply: the paper feeder cannot supply paper normally. If the nozzle is working correctly at this point, the nozzle may be damaged.
2.Abnormal stop: This will seriously affect the visual positioning of the pick and place machine, and may cause the pick and place machine head to touch the PCB board.
3. Improper head placement: The action of placing the head is affected, making it impossible to expand and contract in the usual way.
We know the danger of too low air pressure, and we have to address it. Usually the cause of low air pressure is deformation, damage, clogged nozzle, insufficient air pressure, air leakage and premature, which cause the nozzle to not absorb or absorb materials normally. If the material is not correct, the nozzle needs to be replaced frequently and the nozzle should be maintained frequently to make the mounting operation of the pick and place machine go smoothly. To sum up, the above is the solution shared by Charmhigh Electromechanical website if you encounter the problem of insufficient air pressure of the pick and place machine. I hope it will be helpful to you. If you need to know and consult other product content, you can enter our official website of Charmhigh Electromechanical pick and place machine to learn more or contact us about your needs and so on.
The Main Accessories of SMT Pick and Place Machine
The pick and place machine is a high-precision, high-speed, fully automated PCB circuit board mounting equipment, and it is the key and intelligent equipment in the entire SMT production line. The quality of the pick and place machine depends on the quality of the main accessories of the equipment and the intelligence and optimization of related software. Here, Charmhigh pick and place machine mainly introduces to you what are the main accessories of the SMT pick and place machine?
1.Feeder
The pick and place machine picks up the components on the feeder at a specified different position, and then mounting them. As one of the important components of the pick and place machine, the feeder has a great influence on the production efficiency and precision of the pick and place machine. There are many ways to classify feeders, such as belts, pallets, bulk boxes, tubes; they can also be divided into electric feeders and pneumatic feeders. Electric feeders are more expensive than pneumatic feeders, but they are more stable and durable, and can be equipped with 0201.
2. Nozzle
The nozzle is also one of the important components of the pick and place machine, which is used to pick up and place components. Using network information to conduct research on the role of vacuum adsorption is constantly absorbing, and then using high air pressure to mount components. The work of different parts requires us to use different nozzles.
3.Screw、Guide、Drive Control Motor
Screw rods, guide rails and drive motors are important components of the x, y-axis motion mechanism of SMT machines. International famous brand accessories have the characteristics of high effect, high precision, high rigidity, high durability and low noise. But screws and rails also require regular maintenance.
4. Visual System
The vision system of the SMT machine determines the accuracy and stability of the SMT process. The vision system of SMT machines generally consists of two types of cameras. Mark cameras are used to capture PCB system coordinates and check for misalignment between camera components and nozzles. The machine vision system guarantees and corrects the accuracy of machine vision through precision cameras, light sources, image acquisition cards and processing systems.
5.Industrial computer, vacuum signal generator, photoelectric information sensor, cylinder, conveyor belt, etc.
SMT is also equipped with high-performance industrial equipment, vacuum generator with stable and reliable suction, solenoid valve and other important accessories. When purchasing an SMT machine, it has certain reference value.
Daily Management and Maintenance of Pick and Place Machine
In order to improve the efficiency and benefit of the SMT pick and place machine production line, as well as the daily management and maintenance of the pick and place machine, we must carefully understand and use it well. Today, I will talk to you about some daily management and maintenance of the pick and place machine.
1. Filter
The filter plays the role of compression and filter pressure during the mounting process to ensure the cleanliness of the compressed air. If the filter is dirty, the filtering effect will be poor, which will affect the suction of the nozzle, thus directly affecting the placement effect . When maintaining the equipment, develop the habit of replacing the filter regularly, usually once a month, which is a consumable accessory. Therefore, there must be a certain number of spare parts.
2. Reflective Cap and Reflective Plate
The reflector is used for detection of component electrodes, component size and nozzle number. If the above three functions are poorly recognized during the placement process, the reflector and reflector cap must be inspected or replaced.
3. Conveyor Belt
The conveyor belt is used to transfer the target board during mounting. The conveyor belt will wear out during long-term use, and it will break when worn to a certain extent. Therefore, in daily use, at least one copy is required for backup replacement, and multiple copies can be backed up for some frequently worn parts.
(Charmhigh Electromechanical High-precision Flexible Pick and Place Machine)
4. Cylinder
The cylinder is generally used in conjunction with the solenoid valve in the pick and place machine to play the role of lifting and stopping. In the mechanism of the pick and place machine, the cylinder is widely used. For example, the cylinder used on the mounting head can be used to set whether the placement head is used and stop it; the cylinder expands and contracts according to the signal of the solenoid valve to make the workbench rise and fall, etc. . During the use of the cylinder, there will be wear or dust, and it should be checked regularly. Frequently encountered problems are:
a.The compressed air is not clean, causing the cylinder to expand and contract inflexibly or not in place. At this time, it should be cleaned immediately.
b.Air leakage may be due to the aging of the sealing ring, and the sealing ring can be replaced.
c.The piston is worn out, and the cylinder needs to be replaced at this time.
5. Bearing
Bearings serve two purposes.
a. Limit, bearing limit means that the fixed shaft can only realize rotation, but cannot move axially and radially;
b.Support, support refers to bearing the radial load of the shaft. Bearings are divided into rolling axial axial bearings, ball bearings and thrust bearings according to their functions.
Bearings are widely used standard parts in the structure of pick and place machines. If they run for a long time, they will wear out. Therefore, it is necessary to check regularly, and if the bearing is found to have radial movement, which affects the normal operation of the equipment, it must be replaced immediately to ensure stable operation. Such as joint bearings and rolling bearings used in pick and place machines.
6. Timing Belt
The synchronous belt is composed of an endless belt with equidistant teeth on the surface and corresponding matching wheels. It combines the advantages of belt drive, chain drive and gear drive. When working, the power is transmitted through the meshing of the belt teeth and the tooth grooves of the wheel. Synchronous belt transmission has accurate transmission ratio, can obtain constant speed ratio, no slip, low noise, stable transmission, can absorb vibration, wide range of transmission ratio, generally up to 1 to 10, allowable linear speed up to 50m/s, Transfer power from a few watts to kilowatts. High transmission efficiency, generally up to 98%, compact structure, suitable for multi-axis transmission, no pollution, no lubrication, so it can work normally in places where pollution is not allowed and the working environment is relatively harsh.
The Principle of Pick and Place Machine
Introduction of SMT
1. Why use surface mount technology (SMT)?
Electronic products pursue miniaturization.
2. Electronic products have more complete functions, especially large-scale and highly integrated ICs, and surface mount components have to be used product batching, production automation, the factory must produce high-quality products at low cost and high output to meet customer needs and strengthen market competitiveness
3. The development of electronic components, the development of integrated circuits (IC), and the multiple applications of semiconductor materials, Electronic technology revolution is imperative
The Characteristics of SMT
1.High assembly density, small size and light weight of electronic products. The volume and weight of SMD components are only about 1/10 of traditional plug-in components. Generally, after SMT is used, the volume of electronic products is reduced by 40%~60%, and the weight is reduced by 60% %~80%.
2. High reliability and strong anti-vibration ability. Solder joint defect rate is low.
3.Good high frequency characteristics. Reduced electromagnetic and radio frequency interference.
4.It is easy to realize automation and improve production efficiency.
5. Reduce the cost by 30%~50%. Save material, energy, equipment, manpower, time, etc.
Technical Components Related to SMT
1. Design and manufacture technology of electronic components and integrated circuits
2. Circuit design technology of electronic products
3.Manufacturing technology of circuit board
4, Design and manufacturing technology of automatic mounting equipment
5. Circuit assembly manufacturing technology
6.Development and production technology of auxiliary materials used in assembly manufacturing
The Key Factors of Pick and Place Machine
1.location system
Ⅰ Arch Type (Gantry):
A.
The component feeder and the substrate (PCB) are fixed, and the mounting head (installed with multiple vacuum suction nozzles) moves back and forth between the feeder and the substrate, and the components are taken out from the feeder. After adjusting the position and direction of the components , and then placed on the substrate. Because the patch head is installed on the X/Y coordinate moving beam of the arch type, it is named.
B.
The method of adjusting the position and direction of the components: (1) The position is adjusted by mechanical centering, and the direction is adjusted by the rotation of the suction nozzle. The accuracy that this method can achieve is limited. (2) Laser recognition, X/Y coordinate system adjustment position, suction nozzle rotation adjustment direction, this method can realize the identification during the flight, but it cannot be used for the ball grid display component BGA. (3) Camera identification, X/Y coordinate system adjustment position, suction nozzle rotation adjustment direction, generally the camera is fixed, and the mounting head flies across the camera for imaging identification, which takes a little longer than laser identification, but can identify any component, There is also a camera recognition system that realizes recognition during flight, and there are other sacrifices in terms of mechanical structure.
C.
In this form, due to the long distance of the patch head moving back and forth, the speed is limited. Nowadays, multiple vacuum suction nozzles are generally used to pick up materials at the same time (up to ten) and a double-beam system is used to increase the speed, that is, the mounting head on one beam is picking up materials, while the mounting head on the other beam is placing element, almost twice as fast as a single-beam system. However, in practical applications, it is difficult to achieve the condition of taking materials at the same time, and different types of components need to be replaced with different vacuum suction nozzles, and there is a time delay in changing the suction nozzles.
D.
The advantages of this type of machine are: the system is simple in structure and can achieve high precision (the position and movement of the shaft beam can control the mounting accuracy of components to below 50µm (0.05mm)), suitable for components of various sizes and shapes, Even odd-shaped components, the feeder is available in strip, tube, and tray formats. It is suitable for small and medium batch production, and can also be combined with multiple machines for mass production.
Ⅱ Turret Type (Turret)
A.
The component feeder is placed on a single-coordinate moving feeder, the substrate (PCB) is placed on a worktable that moves in an X/Y coordinate system, and the mounting head is installed on a turret. When working, the feeder feeds the components The feeder moves to the pick-up position, the vacuum suction nozzle on the patch head picks up the components at the pick-up position, and rotates through the turret to the pick-up position (180 degrees from the pick-up position). Adjust the direction and place the components on the substrate.
B.
The method of adjusting the position and direction of the components: (1) Adjust the position by mechanical centering, and adjust the direction by rotating the suction nozzle. This method can achieve limited accuracy, and later models are no longer used. (2) Camera identification, X/Y coordinate system adjustment position, suction nozzle self-rotation adjustment direction, fixed camera, mounting head flying across the camera for imaging identification.
C.
Generally, there are more than a dozen to twenty patch heads installed on the turret, and each patch head is equipped with 2~4 vacuum nozzles (earlier models) to 5~6 vacuum nozzles (current models) ). Due to the characteristics of the turret, the actions are miniaturized, such as selecting and changing the suction nozzle, moving the feeder in place, picking up components, component recognition, angle adjustment, worktable movement (including position adjustment), and placing components can all be performed in the same time period. It is completed within, so it achieves high speed in the true sense. At present, the fastest time period reaches 0.08~0.10 seconds for one component.
D.
This model is superior in speed and is suitable for mass production, but it can only use strip-packed components. If it is a dense-foot, large-scale integrated circuit (IC), it cannot be completed only with tray packaging. Therefore, it also depends on other models to work together. This kind of equipment has complex structure and high cost. The latest model is about US$500,000, which is more than three times that of the arch type.
Ⅲ Massively Parallel System
A.
Use a series of small individual mounting units. Each unit has its own screw position system, equipped with cameras and mounting heads. Each mounting head picks up a limited tape feeder and places a portion of the board, which is stepped through the machine at fixed intervals. Individually each unit machine runs slowly. However, their continuous or parallel operation results in high throughput.
image system
B.
The accuracy of automatic component mounting is accomplished by the vision system, which is generally divided into down-looking, up-looking, head-up or laser positioning, depending on the position or camera.
C.
Look down at the camera to find the mark called the reference point on the PCB, which is mainly used to align the PCB to the correct position before component mounting. Up-view cameras are used to inspect components from a fixed position, so components must be moved over the camera for vision prior to mounting. Film shooters (i.e. turret types) do just that, with components moving around the turret.
D.
Recognition time usually increases as components become larger or more complex. To compensate for this extra time, mounting equipment can use two up-looking cameras—one on each side of the machine—to reduce the distance traveled.
2.Feeding system
A.
The overhead arch machine can support different feeder types, including bulk, tape-and-real, tube, odd-form and other customer designs. In contrast, high-speed turrets and massively parallel systems are fed entirely from bulk magazines or tape packs.
B.
Overhead arch machines may be the only option when component packaging is not in bulk or in strip form: high-speed machines are excluded from consideration because they cannot feed these materials automatically.
C.
Therefore, manufacturers should look for component mounting equipment that can expand their existing mounting options flexible Choice (Human Factors)
D.
In addition to microscopic flexibility in positioning systems, imaging systems, and component feeding systems, macroscopic flexibility to adjust manufacturing throughput and accommodate product changeovers becomes critical to making decisions about new assembly equipment.
Classification of Surface Mount Methods
the First Category:
TYPE IA only has single-sided assembly for surface mount
Process: silk screen solder paste => mounting components => reflow soldering
TYPE IB only has double-sided assembly for surface mount
Process: silk screen solder paste => mounted components => reflow soldering => reverse side => silk screen solder paste => mounted components => reflow soldering
the Second Category:
TYPE II Single-sided or double-sided assembly with a mix of surface mount and through-hole components
Process: Silk screen printing solder paste (top) => mounting components => reflow soldering => reverse side => dripping (printing) glue (bottom surface) => mounting components => drying glue => reverse side => inserting components => wave soldering
the Third Category:
TYPE III uses through-hole components on the top surface and surface mount components on the bottom surface
Process: dripping (printing) glue=>mounting components=>drying glue=>reverse side=>inserting components=>wave soldering
Process Capability (Cpk, Process Capability): refers to the level of mounting accuracy related to X, Y and Θ. A machine's X, Y, and Θ errors are considered individually, not collectively.
Throughput: Involves the measurement of delivery, manufacturing and takt time.
Mounting Defects: the probability that mounting defects usually occur
Pickup Defects: Pickup defects can be categorized as feeder failures, vacuum failures, or visual failures. Picking defects reduces net output and wastes good parts
Reliability, availability and maintainability: Data on reliability, availability and maintainability are published by the supplier based on actual field experience.
Preventive Maintenance (Preventive Maintenance): Preventive and corrective maintenance keeps the SMT mounting system running at its specified speed and accuracy.
A Common Language: When suppliers and users use the same language to achieve consensus on standards and communications about equipment performance, the result will be increased efficiency in the industry and ultimately greater customer satisfaction and growth.
0201 mounting challenges
The mounting of 0201 components is more challenging than the component intervention before it. The main reason is that the 0201 package is approximately one-third the size of the corresponding 0402.
The previously acceptable machine mounting accuracy immediately became a limiting factor for the introduction of 0201. In addition, traditional industrial tape packaging (taping) specifications allow too much movement for reliable 0201 mounting, and the level of process control must also be improved to make 0201 mounting a production reality.
The Key to Reliable 0201 Mounting
1.Component Feeder Workbench: The ability to precisely position the carriage workbench.
2.Component Feeder: The feeder must be manufactured to extremely tight tolerances to ensure repeatability of the pick position is maintained. Additionally, the materials used to make the feeders must be strong and lightweight.
3.Feeder Drive Sprocket: The drive sprocket plays a key role in the machine's ability to position the component strip. The shape, taper and length of the drive sprocket teeth significantly affect the ability of the feeder to position the strip
4.Pickup Tips: Material selection, material hardness, machining tolerances and thermal characteristics must all be understood in order to construct a reliable pick up tip.
5.The nozzle must move freely within its holder.
6.Nozzle shaft assembly: In order to pick up components of 0.6x0.3 mm, the nozzle must have an outer diameter no larger than 0.40mm. This results in a long, thin nozzle shaft that is fragile to bend but must still maintain precision to maintain high reliability of suction.
7.Substrate Construction: All machinery vibrates during operation. Base frame design is a critical first step in reducing the effects of speed and motion that create vibration and harmonic resonance.
How to Improve the Mounting Speed of Pick and Place Machines
When purchasing an SMT pick and place machine, mounting accuracy and mounting speed are one of the main reference factors.
Then, in order to improve production efficiency and reduce production cost,
And how to improve the actual mounting speed of SMT pick and place machine?
the Interior of the Machine
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What is mounting rate？
Everyone knows that the so-called mounting rate refers to the ratio of the number of components accurately mounted on the PCB board to the number of components actually picked up by the nozzle within a unit of time. Components picked up by the suction nozzle that cannot be accurately placed on the designated position of the PCB are called discarded parts. The main reasons for the discarded parts are also the influence of the feeder, the influence of the suction nozzle, the influence of the component detection system and other factors.
Charmhigh Electromechanical Universal Pick and Place Machine
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the Effect of the Feeder
There are several types of drive methods for the feeder, such as motor drive, mechanical drive, and cylinder drive.
Taking the mechanical drive as an example, due to the high-speed access of the feeding mechanism to the feeder, after a long period of use, the pawl of the feeder is severely worn, resulting in the pawl not being able to drive the plastic tape of the reel to be peeled off normally, so that the suction nozzle cannot Complete the pick-up work, which affects the mounting speed.
In addition, long-term use or improper operation by the operator will also cause deformation and corrosion of the cover plate, thimble, spring and other moving mechanisms, resulting in partial suction of the device, stand-up or failure to suck the device.
Therefore, the feeder should be checked regularly, and the worn ones should be repaired immediately, and those that cannot be repaired should be replaced in time.
Feeder
▼
the Effect of the Nozzle
The suction nozzle is also another important factor affecting the mounting rate. There are internal reasons and external reasons.
The internal reason is that the vacuum negative pressure is insufficient. The suction nozzle automatically switches the mechanical valve on the mounting head before picking up the parts, from blowing to vacuum adsorption, and a certain negative pressure will be generated. When the filter in the vacuum pump is polluted and blocked, it will cause insufficient vacuum negative pressure and affect the suction efficiency of the suction nozzle.
External causes often manifest as aging and rupture of rubber air pipes, aging and wear of seals, etc., as well as clogging of suction nozzles caused by a large amount of waste generated after cutting of paper braided components.
Therefore, check the cleanliness of the suction nozzle daily, and clean or replace the suction nozzle and filter that are clogged or poorly picked up in time to ensure a good condition.
Nozzle
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Influence of Component Inspection System
The device detection system is a necessary guarantee to increase the mounting rate. The device detection system is divided into component thickness detection and recognition system and optical recognition system.
After long-term use, the linear sensor of the component thickness detection and identification system is easily affected by dust, debris, and oil pollution. The light source intensity of the optical camera system will also gradually decrease. As the light intensity of the light source decreases, the gray value converted by the camera will also decrease. When the gray value decreases to a certain value, the image will not be recognized.
Therefore, the device detection system needs to be regularly calibrated and tested.
Charmhigh Electromechanical High Speed Pick and Place Machine
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About Us
Hunan Charmhigh Electromechanical Co., Ltd. .A high-tech enterprise specializing in R&D, manufacturing and sales of SMT multi-function pick and place machine and SMT intelligent supporting equipment.
Charmhigh Electromechanical takes the multi-functional pick and place machine as its core business, and at the same time provides SMT overall solutions and corresponding equipment for each station, including printing machines, plug-in machines, reflow soldering, wave soldering, AOI and other products, which can be widely used in small appliances, Power supply, high-end LED lighting, smart toys, automotive electronics, consumer electronics, aviation electronic information and other industries.
Common Knowledge of Pick and Place Machine and Smt Production
Generally speaking, the temperature specified in the SMT workshop is 23±7°C;
Materials and tools required for solder paste printing: solder paste, steel plate, scraper, wiping paper, dust-free paper, cleaning agent, mixing knife;
The commonly used solder paste composition is Sn96.5%/Ag3%/Cu0.5%;
The main components of solder paste are divided into two parts: tin powder and flux;
The main function of flux in soldering is to remove oxides, destroy the surface tension of molten tin, and prevent re-oxidation;
The volume ratio of tin powder particles and Flux (flux) in solder paste is about 1:1, and the weight ratio is about 9:1;
The principle of taking solder paste is first in first out;
When the solder paste is unpacked and used, it must go through two important processes of warming up and stirring;
The common production methods of steel plates are: etching, laser, electroforming;
The full name of SMT is Surface mount (or mounting) technology, which means surface adhesion (or mounting) technology in Chinese;
The full name of ESD is Electro-static discharge, which means electrostatic discharge in Chinese;
When making an SMT equipment program, the program includes five parts, which are PCB data; Mark data; Feeder data; Nozzle data; Part data;
The melting point of lead-free solder Sn/Ag/Cu 96.5/3.0/0.5 is 217℃;
The control relative temperature and humidity of the parts drying box is 90 degrees, it means that the solder paste has no adhesion to the wave soldering body;
After the IC is unpacked, the humidity on the display card is greater than 30%, indicating that the IC is damp and absorbs moisture;
The weight ratio and volume ratio of tin powder and flux in the solder paste composition are correct 90%:10%, 50%:50%;
The early surface mount technology originated from the military and avionics fields in the mid-1960s;
At present, the contents of Sn and Pb in the most commonly used solder paste for SMT are: 63Sn 37Pb; the eutectic point is 183°C;
The feeding distance of the common paper tape tray with a bandwidth of 8mm is 4mm;
The most widely used electronic component material in SMT is ceramics;
The temperature curve of the reflow furnace is most suitable for the maximum temperature of the curve at 215C;
During the tin furnace inspection, the temperature of the tin furnace is 245°C;
The opening pattern of the steel plate is square, triangle, circle, star, and epitome;
The solder paste currently on the market actually only has a sticking time of 4 hours;
The rated air pressure generally used by SMT equipment is 5KG/cm2;
Tools for SMT parts maintenance include: soldering iron, hot air extractor, tin suction gun, tweezers;
The high-speed pick and place machine can mount resistors, capacitors, ICs, and transistors; the packaging methods are Reel and Tray, and Tube is not suitable for high-speed pick and place machines;
The characteristics of static electricity: small current, greatly affected by humidity;
What kind of welding method is used when the front PTH and the back SMT pass through the tin furnace;
Common inspection methods for SMT: visual inspection, X-ray inspection, machine vision inspection;
The heat conduction mode of ferrochrome repair parts is conduction convection;
At present, the main components of solder balls in BGA materials are Sn90 Pb10, SAC305, SAC405;
Laser cutting, electroforming, and chemical etching of steel plates;
The temperature of the welding furnace is pressed: use the temperature detector to measure the applicable temperature;
When the SMT semi-finished products of the welding furnace are exported, the welding status is that the parts are fixed on the PCB;
The history of modern quality management development TQC-TQA-TQM;
The ICT test is a bed of needles test;
ICT testing can test electronic components using static testing;
The characteristics of solder are that the melting point is lower than other metals, the physical properties meet the welding conditions, and the fluidity at low temperature is better than other metals;
The measurement curve must be re-measured when the welding furnace parts are replaced and the process conditions are changed;
The solder paste thickness gauge uses Laser to measure: solder paste thickness, solder paste thickness, and printed width of solder paste;
The feeding methods of SMT parts include vibrating feeder, disc feeder and tape feeder;
Which mechanisms are used in SMT equipment: cam mechanism, side rod mechanism, screw mechanism, sliding mechanism;
If the packaging method of the parts is 12w8P, the size of the counter Pinth must be adjusted by 8mm each time;
Types of welding machines: hot air welding furnace, nitrogen welding furnace, laser welding furnace, infrared welding furnace;
Methods that can be used for SMT parts sample trial production: streamline production, hand-printed machine placement, hand-printed hand-mounted;
Commonly used MARK shapes are: circle, "ten" shape, square, rhombus, triangle, swastika;
Due to improper setting of Reflow Profile in the SMT section, it is the preheating zone and cooling zone that may cause microcracks of the parts;
Uneven heating at both ends of the SMT part is easy to cause: empty welding, deviation, tombstone;
The cycle time of the high-speed running machine and the pick and place machine should be balanced as much as possible;
The pick and place machine should paste small parts first, and then paste large parts;
SMT parts can be divided into two types: LEAD and LEADLESS according to whether there are parts or not;
There are three basic types of common automatic pick and place machines, continuous placement type, continuous placement type and mass transfer pick and place machine;
It can be produced without LOADER in the SMT process;
The SMT process is a board feeding system-solder paste printing machine-high-speed running machine-pick and place machine-reflow soldering-board receiving machine;
Reasons for short circuit caused by poor printing in the manufacturing process:
Insufficient metal content of solder paste, resulting in collapse
Excessive opening of the steel plate, resulting in excessive tin content
Poor quality of steel plate, poor tin application, change the laser cutting template
There is solder paste on the back of the stencil, reduce the pressure of the scraper, and use appropriate VACUUM and SOLVENT;
The main engineering purpose of each area of the general reflow furnace Profile:
Preheating area; engineering purpose: solvent volatilization in solder paste.
Uniform temperature zone; engineering purpose: activation of flux, removal of oxides; evaporation of excess water.
Reflow area; engineering purpose: solder melting.
Cooling area; engineering purpose: alloy solder joints are formed, part feet and pads are connected as one;
In the SMT process, the main reasons for solder balls are: poor design of PCB PAD, poor design of steel plate openings, excessive placement depth or pressure, excessive rising slope of Profile curve, collapse of solder paste, and low viscosity of solder paste .
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If you have any questions, please come to Charmhigh Electromechanical official website for consultation, and technical staff can answer online at any time.
E-mail:sales@charmhigh.com
How to Choose a SMT Pick and Place Machine（1）?
1、The CPK test data is a key indicator to test the accuracy and stability of the equipment.
At present, most domestic pick and place machines generally use a stepping system, which is difficult to meet the requirements of SMT processing accuracy and speed.Charmhigh breaks through the core key technology, self-developed dual-axis servo control technology, independent servo control technology for each head and advanced assembly craft, ensuring high stability and high precision when the pick and place machine works at high speed. Charmhigh's general-purpose high-speed and high-precision series pick and place machines are not afraid of CPK detection. The speed is tested according to the IPC9850 standard, and false labels are rejected. Everything speaks with data. It is truly caring and mounting to the "chip", so that users can rest assured.
2、Advanced vision system (take CHM-861 as an example)
Charmhigh self-developed industrial-grade vision system can quickly candid photos high-definition identify and absorb components, 1.3 million pixels x 8 images are transmitted, and the frame rate reaches 300 frames per second. Realize multi-heads take at the same time, greatly improve production efficiency.
3、ATC Automatic Nozzle Change
The automatic replacement of the suction nozzle is one of the technical indicators to measure the automation of the pick and place machine. According to production requirements, different types of nozzles can be preset to meet the mounting of different devices. Intelligent software management replaces manual replacement, improving mounting efficiency and safety.
4、Motion structure with high precision control
Dual Y-axis servo control technology is the core technology of advanced pick and place machines. It can effectively guarantee the accuracy and stability of the equipment when it works at high speed for a long time.
5、System accuracy compensation
Accuracy compensation correction in device mounting motion. Realize the compensation of precision deviation caused by heat energy, the position deviation and angle compensation generated when electronic components are picked up.
6. Intelligent operation software
Software is also the key to a successful high-precision pick and place machine. In terms of mounting accuracy and speed, the post-optimization of the software played a big role. The control software developed by Charmhigh Electromechanical has the following advantages:
6.1、Component library management: support the import of standard component libraries, and support the editing of non-standard components.
6.2、Path optimization: The software uses intelligent algorithms to automatically optimize the material suction and mounting paths to achieve the best utilization rate of equipment.
7、Coordinate import: realize one-key import of coordinates. One-click import of mounting coordinates can be realized through text files such as text format and EXCEL files.
8、Online monitoring and recording of production data: Users can manage production more easily based on information
9、ATC nozzle library management: the model and position of each nozzle are clear at a glance.
Software intelligent integration, simple and convenient, easy to use.
If you have any questions, please come to Charmhigh Electromechanical official website for consultation, and technical staff can answer online at any time.
E-mail:sales@charmhigh.com
Christmas——Every Snowflake Is a Winter Letter
“Christmas is coming soon!”
We've all come to look forward to it,and it gives us a valuable connection to the world.In today's fast-paced era,it gently knocks on the guarded door in the hearts of city dwellers.
And Christmas will never live up to the people of this mellow waiting,it has already shown a variety of warm and comfortable attitude,slowly coming to us.
The streets were bustling with people,and inside the house the fire was steaming.Everything,because Christmas is coming, and appear more happy jump off,full of life.
Every snowflake falling,every bunch of fireworks lit,every second time flow,every miss transmission......That is the eternal blessing of Christmas to people!We are looking forward to the arrival of this happy moment,meet friends,share the warmth of the holiday!
Some people say that there is no Santa Claus because all the gifts and warmth come from the people in your life.In fact,each of us can become the embodiment of Santa's spirit of love,so that the world is full of warmth.Give a rose,the hand has lingering fragrance.While warming others,we will also warm ourselves with this love!
Christmas 2022 is here.Hunan Charmhigh Electromechanical Co.,Ltd.sincerely wishes everyone a happy holiday and all your wishes come true!
How to Configure an Efficient SMT Production Line？
Charmhigh High-end SMT Production Line
Generally speaking, a complete SMT production line includes solder paste printing machine, pick and place machine, reflow oven, and AOI. Since pick and place machine is the core equipment of the entire SMT production line, the selection of it is particularly critical.
Charmhigh Eight-series High-end Placement Machine
When choosing a SMT production line, reasonable procurement plan should be formulated according to factors such as the company's investment capacity, production scale, and circuit board mounting accuracy requirements. When choosing equipment, you must not blindly seek the most expensive, so as not to cause unnecessary waste.
Next, let's introduce some basic ideas on how to configure an efficient and practical SMT production line:
1. Choose SMT production line according to product type, output and recent development plan.
Specify the electronic products, product types, product complexity, product components, and total annual output that would be processed on the SMT production line;
Consider whether to build a new SMT production line or to rebuild and expand the old SMT production line;
If rebuilding or expanding, consider the scalability of the production line according to the existing production conditions and future production plan;
- If a new production line is required, the scale of the placement production line should be clarified according to the plan, so as to determine the placement machine based on the expected performance.
2. Choose SMT production line according to the density,type, and quantity of components.
- When the SMD production line is needed to produce high-density, multi-pin, narrow-pitch and larger-sized SMD devices and special-shaped components, it is necessary to choose a multi-function pick and place machine;
- In the case of large production tasks, after configuring a multi-function pick and place machine, you can also configure a medium-speed or a high-speed pick and place machine.
3. Choose SMT production line according to the technological process of the product.
- when the product is relatively simple, or when pure surface assembly and single-sided mixed assembly process are used, single type of soldering equipment (reflow oven or wave soldering machine) can be selected;
- If the product is more complex, that is to say, the density of components is relatively high, and the quantity of plug-in components is very large in the case of double-sided mixing, two types of welding equipment, reflow oven and wave soldering machine, should be selected;
- If the product needs to be cleaned, it is also necessary to configure cleaning equipment.
Charmhigh always takes high-speed pick and place machine as its core business, and can provide various SMT production equipment, including printer machine, plug-in machines, reflow oven, wave soldering machine, AOI, and so on, which can be widely used in the fields of small household appliances, power supplies, high-end LED lighting, smart toys, automotive electronics, consumer electronics, avionics, universities and research institutes, etc.
Hunan Charmhigh Electromechanical Equipment Co., Ltd.
Warmly welcome customers at home and abroad to call or email us for consultation or visit our company for negotiation!
Company contact information：
Hunan Charmhigh Electromechanical Equipment Co., Ltd.
Address: 104-604, Building D Jindao Industrial Park, No. 179 Huizhi Middle Road, National High-tech Development Zone, Changsha City, Hunan Province, China
Telephone: +86-731-85504084
E-mail: sales@charmhigh.com
Mobile Phone/WeChat/WhatsAPP/Skype: +86-159-0731-7458
Website Address: http://www.charmhigh.com
YouTube Home Page Address:
https://www.youtube.com/channel/UCCLeC22z0tQ55JGLp0odC0A
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