Category Archives: Training

Free Gerber File Download

Attention PCB Design Engineers:

For a brief time, we will be giving away a FREE Gerber File.

SMTHelp.com Gerber File Download

For the first time, Southern Machinery is giving away a FREE Gerber File! If you need help with your design process, we are gladly here to help. Let us make your manufacturing set-up easy and efficient.

We at Southern Machinery know and understand what is needed for a successful PCB Assembly. If you need guidance with design, CAD, equipment configuration, training, just ask! Southern Machinery is not just a place to buy machines, but also a place to get your technical questions answered. So ask us! We want to help you find your PCBA solutions.

Get the Best in After-Sales Service

Our Process Today Matters

After-Sales Installation Service

SMThelp.com Get the Best in After-Sales Service

Industrial IoT, exciting words that get thrown around in today’s EMS. While we are actively engaged with developing Smart Factories with embedded technologies, we know that today’s after-sales services are vital. Here’s a look at our process and how you can find confidence in our approach to After-Sales Services.

After Sales Service Plan:

  1. We arrange for your engineers to come to China and offer accommodationsincluding meals, and transportation while learning in our facilities.
  2. Installation –  your equipment is delivered and installed by our engineers
  3. We then send our engineers to your home factory
  4. We recommend 7-15 days of Training and Production for full quality control
  5. Our Engineers are responsible for training your team and work with you to produce your products
  6. Follow-up – our team follows-up to ensure things are running smoothly

SMThelp.com Get the Best in After-Sales Service

Our engineers are always here to make sure that your EMS Factory is always performing at top capacity. Here are some of the ways we ensure that you have everything you need to maintain top performing Equipment. We offer video trainings, Skype trainings, troubleshooting via Team Viewer, amongst other channels.

The future of After Installation Service with IoT:

With Industrial IoT, we look toward a future where all sensors will be extremely intelligent and collaborate to perform tasks via an entire network geared toward constant monitoring and improvement. Southern Machinery will continue to provide the customer service you are used to but will also have the capability to offer instant feedback with intelligent sensors that constantly read data and measure equipment output and quality. We look forward to this future with you.

Service Questions HERE!

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Service Engineers Built Southern Machinery

Higher Quality, Lower Costs, Most Knowledgeable and helpful Engineers

Service Engineer Built Southern Machinery

Service Engineer Built Southern Machinery

Did you know that Southern Machinery was founded by a Veteran Service Engineer? Founder, Jason Wu spent over 12 years as a service engineer. Jason’s mode of operation is tailored to the engineering needs of your manufacturing system. If you need guidance with design, CAD, equipment configuration, training, just ask! Southern Machinery is not just a place to buy machines, but also a place to get your technical questions answered. So ask us! We want to help you solve your PCBA problems.

Do you have a question you need answered and can’t seem to locate the information you need? Ask us and we will feature your Q&A!

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Ensuring the Best Design for Final PCB Production Stage with Testing!

Ensuring the Best Design for Final PCB Production Stage with Testing! Ensuring the Best Design for Final PCB Production Stage with Testing!

Avoiding Design Mistakes with Testing

Improve EMS Productivity by Testing Early

http://www.smthelp.com/product/high-speed-in-line-circuit-board-test-machine/

PC Board errors are a drain to EMS productivity. Through analysis and testing PCBs in the pilot stages, a smoother and more educated production set-up can be achieved. By performing automatic impedance measurements and testing of components (chip resistors and capacitors) early on, you can ensure the best design for production.

We recommend applying the best design logics when creating your PCB layout and Test, Test, Test for maximum efficiency and output. According to Circuits Assembly’s December 2016 Magazine, here is the list of 5 Most Common PCB Design Mistakes: “1. The components do not suit the production technology 2. Thermal imbalance 3. Incompatibility between fabrication and assembly technology 4. Component placement at PCB edge 5. Placing fiducials on the PCB’s edge.”

Once you have planned your PC Board with best practices, Southern Machinery’s High-Speed In-line Circuit Board Test Machine will help with testing by incorporating a visual inspection function which allows mounting status checks on each component (e.g.: typo descriptions in alphanumeric characters, orientation, size) on the operator’s monitor will serve to best analyze testing up close. As well as automatically generating test data from mounting data and component list.  

http://image.slidesharecdn.com/highspeedin-linecircuitboardtestmachine-fai-161223080028/95/high-speed-in-line-circuit-board-test-machinefai-14-638.jpg?cb=1482480094

http://image.slidesharecdn.com/highspeedin-linecircuitboardtestmachine-fai-161223080028/95/high-speed-in-line-circuit-board-test-machinefai-3-1024.jpg?cb=1482480094

http://www.smthelp.com/product/high-speed-in-line-circuit-board-test-machine/

S600-OF SERIES AUTO INSERT&SURFACE MOUNTING MACHINE

S600-OF SERIES

AUTO INSERT&SURFACE MOUNTING MACHINE

The s-600-of is a revolutionary new concept from southern machinery.
that allows the placement or insertion of both surface mount
and through-hole components.

Nozzle: 6 PCS
⊙PCB Size:400*360mm
⊙Speed:12000-15000CPH

⊙Insert Object:Capacitor,Switch,
Connector, etc.
⊙Mounting Objet:Standard SMD
CLICK HERE TO SEND ME A EMAIL

7 pages make you know our professional package about machine

Our South Machinery Company is a professional supplier of
customized automotive insertion machine.Being endowed with more than 20 years of experience in electronic manufacturing ,our professional engineers/technical teams can provide you
excellent 7X24 hours service anywhere and anytime .

Know more about LED SMT whole line solution

What problem we can help you solve?

  1. How to build a LED assembly line?
  2. How to choose a cost-effective LED SMT line?
  3. What solution can reflect the quickest ROI (Return on Investment)?
  4. What’s the true one stop solution?
  5. What is the total cost for building a full LED SMT line?
  6. In what situation should you choose a semi auto solution?

We welcome any of your inquiries, questions or concerns. Contact us to find out how to greatly save  on your manufacturing costs, and increase your benefits.


chan@smthelp.com
CLICK HERE TO SEND ME A EMAIL

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OUR NEW MACHINE S-7000 IN THAILAND

Southern Machinery just finish a new project in Thailand.

We sale a new model S-7000 to a thai customer in Samut prakan,maybe it’s the first TE square pin auto-insert machine in the world .

we send a engineer to thai for install this machine and training customer.

At last,we reach customer’s production target & quality requirements successfully

s7000 in thai

s7000-2

s7000-4

s7000-5

s7000-1

pin insert

 

 

 

 


p10s2

Acceptability for Electronic Assemblies :Soldering Acceptability Requirements

Acceptability for Electronic Assemblies :Soldering Acceptability Requirements


Target-Class1,2,3
.Solder fillet appears generally smooth and exhibits good wetting of the solder to the parts being joined.
.Outline of the parts is easily determined.
.Solder at the part being joined creates a feathered edge.
.Fillet is concave in shape.



p1s1

See pic for examples of soldering anomalies.

Acceptable-Class1,2,3
.There are materials and processes,e.g.,lead free alloys and slow cooling with large mass PCBs, that may produce dull
matte,gray,or grainy appearing solders that are normal for the material or process involved.These solder connections
are acceptable.
.The solder connection wetting angle (solder to component and solder to PCB termination do not exceed 90°(Figure).
.As an exception,the solder connection to a termination may exhibit a wetting angle exceeding 90°(Figure)when it is 

created by the solder contour extending over the edge of the solder able termination area or solder resist.


p1s2


Figures below illustrate acceptable solder connections with various solder alloys and process conditions.

p2s1 p2s2

SnPb Solder; No Clean Process                                     SnAgCu Solder;No Clean Process

p2s3 p2s4

    SnPb Solder;Water Soluble Flux                                 SnAgCu Solder;Water Soluble Flux

p2s5 p2s6

   SnPb Solder; Water Soluble Flux                                 SnAgCu Solder;Water Soluble Flux

p3s1 p3s2

     SnAgCu Solder;No Clean Process,N2 Reflow                 SnAgCu Solder,No Clean Process;Air Reflow

p3s3 p3s4

      SnPb Solder;No Clean Process                                  SnAgCu Solder;No Clean Process

p3s5 p3s6

     SnPb Solder;No Clean Process                                   SnAgCu Solder;No Clean Process

p4s1 p4s2

                        SnPb Solder                                                      SnAgCu Solder

p4s3 p4s4

                     SnPb Solder                                                           SnAgCu Solder

p4s5 p4s6

         SnPb Solder ; OSP Finish                                                       SnAgCu Solder; OSP Finish

p5s1 p5s2

                     SnAg CuSolder                                                      SnAg CuSolder

p5s3 p5s4

                 SnAgCu  Solder                                                         SnAgCu Solder


       Soldering Anomalies-Exposed Basis Metal

Exposed basis metal on component leads,conductors or land surfaces from nicks,scratches,or other conditions cannot exceed
there quirements of 7.1.2.3 for leads and 10.2.9.1 for conductors and      lands.
Component leads,sides of land patterns,conductors,and use of liquid photo image able solder resist,can have exposed basis
metal per original designs.
Some printed circuit board and conductor finishes have different wetting characteristics and may exhibit solder wetting only to
specific areas. Exposed basis metal or surface finishes should be considered normal under these circumstances,provided the
achieved wetting characteristics of the solder connection areas are acceptable.



Acceptable-Class 1,2,3
.Exposed basis metal on:
.Vertical conductor edges.
.Cut ends of component leads or wires.
.Organic Solderability Preservative (OSP) coated lands.
.Exposed surface finishes that are not part of the required solder fillet  area.

p6s1 p7s1


Acceptable-Class 1

Process Indicator-Class 2,3

.Exposed basis metal on component leads,conductors or land surfaces from nicks or scratches provided conditions

do not exceed the requirements of7.1.2.3 for leads and 10.2.9.1 for conductors and lands.

p7s2


 Soldering Anomalies-Pin Holes/Blow Holes


Acceptable-Class1
ProcessIndicator-Class2,3

.Blowholes (Figures 1,2),pinholes (Figure 3),voids (Figures 4,5),etc.,providing the solder connection meets all other requirements.



p8s1 p8s2                           

                          1                                                                                2                                                                        

p8s3 p8s4

                             3                                                                                 4

 p8s5                     

                                  5

Defect-Class 2,3

Solder connections where pin holes,blowholes,voids,etc.
reduce the connections below minimum requirements(not shown).


Soldering Anomalies-Reflow of Solder Paste

 Defect-Class1,2,3
.Incomplete reflow of solder paste.


p9s1

 p9s2


Soldering Anomalies-Nonwetting

IPC-T-50 defines nonwetting as the inability of molten solder to form a metallic bond with the basis metal.In this Standard,that
includes surface finishes.

Defect-Class 1,2,3
.Solder has not wetted to the land or termination where solder is required.
.Solder coverage does not meet requirements for this termination type.

p10s1

p10s2

p10s3

p10s4

p10s5


Soldering Anomalies-Dewetting

Defect-Class 1,2,3
.Evidence of dewetting that causes the solder connection to not meet the SMT and thru-hole solder fillet requirements.



p11s1

p11s2

p11s3


                          Soldering Anomalies-Excess Solder-Solder Balls/Solder Fines

Solder balls are spheres of solder that remain after the soldering process.Solder fines are typically small balls of the original 

solder paste metal screen size that have splattered around the connection during there flow process.


Target-Class 1,2, 3
.No evidence of solder balls on the printed wiring assembly.

p12s1

Acceptable-Class 1,2,3
.Solder balls are entrapped/encapsulated and do not violate minimum electrical clearance.
 Note:Entrapped/encapsulated/attached is intended to mean that normal service environment of the product will not cause a solder ball to become dislodged.

p12s2


Defect- Class 1,2,3
.Solder balls violate minimum electrical clearance.
.Solder balls are not entrapped in no-clean residue or encapsulated with conformal coating,

or not attached(soldered)to a metal surface.

p13s1

p13s2

p13s3

p13s4


Soldering Anomalies-Excess Solder-Bridging


Defect-Class 1,2,3
.A solder connection across conductors that should not be joined.
.Solder has bridged to adjacent noncommon conductoror component.

p14s1

p14s2

p14s3

p14s4


Soldering Anomalies-Excess Solder-Solder Webbing/Splashes

Defect-Class 1,2,3
.Solder splashes/webbing.


p15s1

p15s2


Soldering Anomalies-Disturbed Solder

Surface appearance with cooling lines as shown in Acceptable pic is more likely to occur in lead free alloys and is not a disturbed solder condition.

p16s1


Defect-Class 1,2,3
Characterized by stress lines from movement in the connection (SnPb alloy).

p16s2

p16s3

p16s4

p16s5


Soldering Anomalies-Fractured Solder


Defect-Class 1,2,3
Fractured or cracked solder.


p17s1

p17s2


Soldering Anomalies-Solder Projections

Defect-Class 1,2,3
.Solder projection,figure 1,violates assembly maximum
height requirements or lead protrusion requirements.
.Projection,figure 2,violates minimum electrical clearance(1).


p18s1 p18s2

                       1                                                              2


p18s3


Soldering Anomalies-Lead Free Fillet Lift

Acceptable-Class 1,2.3
.Fillet lifting-separation of the bottom of the solder and the
top of the land(primary side of plated-through hold connection).

Process Indicator-Class 2
Defect-Class3

.Fillet lifting-separation of the bottom of the solder and the top of the land(secondary side of plated-through hold connection)(not shown).
Defect-Class 1,2,3
.Fillet lifting damages the land attachment.

p19s1


Soldering Anomalies-Hot Tear/Shrink Hole

Acceptable-Class1,2,3
.For connections made with lead free alloys:
.The bottom of the tear is visible.
.The tear or shrink hole does not contact the lead,land or
barrel wall.


Defect-Class 1,2,3
.Shrink holes or hot tear in connections made with SnPb  
solder alloys:

.For connections made with lead free alloys:
.The bottom of the shrink hole or hot tear is not visible.
.The tear or shrink hole contacts the lead or land.

p20s1

                                   end

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Acceptability for Electronic Assemblies-connector pins

Acceptability for Electronic Assemblies : connector pins

Target-Class1,2,

.Pins are straight,not twisted and properly seated.

.No discernible damage         

      P1P1

      1.No discernible damage

      2.Land

      3.No discernible twist


       Acceptable-Class1,2,3

       .Pins are slightly bent off center by 50% pin thickness or less.
       .Pin height varies within tolerance.
       Note:
       Nominal height tolerance is per pin connector or master drawing specification.The connector pins and mating connector must havea good electrical contact. 

p1p2

1.Pin height tolerance
2.Less than 50% pin thickness


Acceptable-Class1,2
.Less than or equal to 75% of the width(W) of the annular ring is lifted.
.Damaged nonfunctional lands for single and double-sided boards are acceptable if firmly attached to board in unlifted areas.

 

P2P1

1.Land lifted 75% of annular ring or less
2.Land with conductor
3.Land not fractured
4.Land lifted,fractured but firmly attached land with out conductor (nonfunctional)

 

 

Defect-Class1,2
Any functional annular ring which is lifted more than 75% of the width(W).

Defect-Class3
Any lifted or fractured annular rings with press fit pins.

 p2p2

1.Land fractured
2.Functional land lifted greater than 75% of annular ring
3.Landlifted


Defect-Class1,2,3
Pin is bent out of alignment.(Pin is bent off center greater than 50% pin thickness.

 

p3p1

 


Defect-Class1,2,3
Pin visibly twisted.

 

p3p2


Defect-Class1,2,3
Pin height is out of tolerance as to specification.

p4p1


Defect-Class1,2,3
Damaged pin as a result of handling or insertion.
Mushroomed
Bent

 p4p2


Defect-Class1,2,3
Damaged pin (exposed basis metal).

Defect-Class2,3
Burr

 p4p3

1.Burr
2.Plating missing


                                                                                    Press Fit Pins-Soldering

The term “press fit pins” is generic in nature and many types of pressure inserted pins,e.g. connector,staked,etc.,are not intended to be soldered,if soldering is required the following criteria is applicable

 

 

Target-Class1,2,3
.A 360 solder fillet is evident on the secondary side of the assembly.
.Note:Solder fillet or fill on primary side is not required.

 p5p1

 

p5p2

1.Bottom view
2.Side view
3.Land
4.Top view
5.PCB

 

Acceptable-Class1,2
Solder fillet or cover age (secondaryside) is present on two adjacent sides of the pin.

 

p5p3

1.Bottom view
2.Side view
3.Land
4.Top view
5.PCB


 Acceptable-Class1
Solder wicking is permitted above 2.5mm\[0.0984in] on sides of pins provided there is no solder build up which interferes with subsequent attachments to the pin.

 

Acceptable-Class2,3
Solder wicking on sides of pins is less than 2.5mm\[0.0984in], provided the solder does not interfere with subsequent attachments to the pin.

 p6p1

 


Defect-Class1,2
Solder fillet or coverage is evident on less than two adjacent
sides of the pin on the secondary side.

Defect-Class3
Solder fillet is evident on less than four sides of the pin on
the secondary side.

Defect-Class1,2,3
Solder build up interferes with subsequent attachments to the pin.

Defect-Class2,3
Solder wicking exceeds 2.5mm\[0.0984in].

 p6p2

1.Bottom view
2.Side view
3.Land
4.Top view
5.PCB


Backplanes

Acceptable-Class1,2,3
.Chip on nonmating surface of separable connector pin
.Burnish on mating surface of separable connector pin,providing that plating has not been removed.
.Chip that encroaches the mating surface of separable connector pin which will not be in the mating connector contact
wear path.

 

 

 

p7p1

A.Sheared/nonmating surface of connector pin
B.Coined/mating surface of connector pin

 

Defect-Class1,2,3
Chipped pin on mating surface of separable connector
Scratched pin that exposes nonprecious plating or base metal.
Missing plated on required areas.
Burr on pin
Cracked PCB substrate.
Pushed out barrel as indicated by copper protruding from bottom side of PCB.

 

p7p3

HIGH SPEED DISPENSING OF SURFACE MOUNT ADHESIVE BETWEEN SOLDER PASTED PADS

HIGH SPEED DISPENSING OF SURFACE MOUNT ADHESIVE BETWEEN SOLDER PASTED PADS

 

Introduction

 

Surface mount
adhesive has been a part of electronics manufacturing applications from
the beginning of SMT. It has been used, in conjunction with wave
soldering processes, to successfully solder millions of components to
the bottom sides of printed circuit boards. In an effort to make the
manufacturing processes more robust and to improve the quality of the
assemblies, a solder paste printing step and a reflow soldering step
have been added to many traditional bottom side assembly lines. These
operations are added in order to decrease defects such as missing
components and insufficient solder joints. Both SMT (double sided
reflow) and Through hole (mixed SMT/THT) processes can benefit from this
process utilizing adhesive and solder paste. Some of the process
considerations are nozzle design, pad design, PCB layout, stencil
design, and adhesive properties. This article will deal with the
characteristics that must be considered in setting up this process, how
it can be implemented successfully, and typical line configurations
associated with this process. The major foundation of traditional
bottom side assembly processes is the adhesive.

 

Adhesive Selection

 

 When selecting an
adhesive for applications involving the dispensing of surface mount
adhesives between solder pasted pads, it is important to choose an
adhesive that is formulated to give very specific rheological, or flow
properties. The adhesive selected should be formulated to allow for a
higher profile dot that exhibits very little slump. This will allow the
glue to contact the component, above the height of the solder paste
deposition, when the component is placed. Dots dispensed for this type
of application should have a tall, cylindrical shape as opposed to the
typical triangular Hershey kiss dot profile. The typical profile may
not allow the glue to properly adhere to the component prior to curing
and then hold the component through wave soldering. This will cause a
large number of missing component errors to be seen following the wave
soldering operation. Excessive missing components following manual
assembly may also be seen because the glue joint is not large enough to
provide the strength needed to hold the components in place.

 The surface mount
adhesive chosen for these applications must also have a high green
strength in order to hold the component prior to the curing process. It
is this green strength that also helps the adhesive to maintain the
tall cylindrical dot shape needed when dispensing between solder pasted
pads. Without it the adhesive deposit will slump, losing contact area
with the component, and causing a decrease in the strength of the
adhesive joints.

SMT,THT,PCB,PCBA,AI,wave soldering,reflow oven,nozzle,feeder,wave soldering,PCB Assembly, LED, LED lamp, LED display,

 

 

 

 

 In adhesive
dispensing processes utilizing heat, it is difficult to achieve the
necessary dot height. By applying heat to the adhesive, the material’s
viscosity is lowered, allowing it to flow more easily. This type of
flow characteristic will cause the adhesive dot to slump after
dispensing. Problems related to the adhesive not contacting the
component (missing components after wave soldering, etc.) will increase
in frequency, as well as the number of opportunities for defects such as
pad contamination to occur.

 

 

Board Design

SMT,THT,PCB,PCBA,AI,wave soldering,reflow oven,nozzle,feeder,wave soldering,PCB Assembly, LED, LED lamp, LED display,

 

 

 Typically,
surface mount component pads are designed for either adhesive deposition
or the screening of solderpaste. The pad spacing is generally smaller
for solderpaste application as opposed to that of adhesive deposition.
For example, the component pad spacing between the pads of a 0603 chip
cap/resistor is typically 0.020”, if the board was designed to be screen
printed with solderpaste. The pad spacing for the same board can be
0.040” if adhesive deposition was to be utilized. A 0.030” diameter dot
of adhesive would easily be recommended for use if the component pads
on the board were indeed designed for adhesive deposition. However, if
the pad design for the same board was originally designed for
utilization of solderpaste, as a method of adhering the component to the
board, obviously, an 0.030” diameter dot of adhesive would be too
large, as the spacing between the pads is now 0.020”. A 0.015” to 0.018”
diameter dot is required for this particular application.

 In designing pad
spacing and component spacing, the height of the pad and the solder
paste deposition must also be taken into consideration. Typically, the
height of an adhesive dot is one half the diameter of the dot.
Depending upon the material used for the pads, it would be possible
design a board which would be impossible to print and dispense adhesive
on. If the typical dot size for a 0603 component were 0.015” to 0.018”,
the height would be approximately 0.0075” to 0.009”. If the thickness
of the stencil utilized to print the solder paste was 0.006” to 0.007”
this might not allow the glue dot to contact the component body on some
types of board finishes. For example, a typical HASL finish is
approximately 0.003” thick. If the thickness of the stencil utilized
were 0.007”, the adhesive dot would have to be at least 0.011” to 0.012”
tall to properly contact the component. This would require
approximately a 0.022” diameter dot. This is why the rheology of the
adhesive is so important. If the adhesive slumps at all after
dispensing, it may not properly contact the component. The nozzle
design also plays a part in the development of the correct dot for each
application.

 

Nozzle Design

 

When selecting a nozzle for use in dispensing adhesives the main characteristics that must be considered are nozzle
design, standoff size and placement, and nozzle ID. A relationship
exists between these characteristics and the adhesive dot diameter.
When the adhesive volume is dispensed, the surface tension of the
adhesive on the board, should be twice that of the surface area of the
adhesive at the nozzle tip. If this condition exists, as the nozzle
retracts, the adhesive will snap off clean from the nozzle and leave a
well-defined dot of constant volume on the board. The nozzle must be
chosen based upon the size dot that is required by the application.

SMT,THT,PCB,PCBA,AI,wave soldering,reflow oven,nozzle,feeder,wave soldering,PCB Assembly, LED, LED lamp, LED display,

 

 

 

Nozzle selection
refers in this case to specific nozzle specifications for a known dot
size requirement. The dot size requirements can be derived from the
board design being utilized or specifically the pad spacing of
components. Reference pad spacing previously discussed in this paper. It
is not uncommon for Manufacturing Engineer personnel or Quality
Engineering personnel of a printed circuit board manufacturing facility,
to inquire what a recommended adhesive dot diameter should be for a
particular component type. Much has been written in regards to
recommended surface mount component pad designs and layouts for bottom
side applications. Topside pad designs are also used on bottom side PCB
fabrication. However these guidelines are rarely utilized. The pad
spacing for a particular component for each individual customer product
is unique.

Because the pad
spacing for most typical surface mount components is not standardized
from one customer product to another, it becomes a challenging task when
recommending what tooling should be utilized to satisfy a particular
customers’ adhesive deposition requirement for a particular component.

Note that the
volume of adhesive needed to maintain the component in place during the
high speed placement or wave solder process may be larger than possible
for some specific pad designs.

The nozzle standoff
can be defined as the distance from the tip of the dispensing surface
to the end of the mechanical standoff. The nozzle standoff is used to
maintain the distance between the PCB and the dispensing tip. Most
dispensers in use today are designed to utilize some sort of mechanical
standoff with the nozzles. The standoff usually dictates, to some
degree, the height of the dispensed dot

Typical designs for
nozzle standoffs are the castle design, the post design, or a dual post
design. For applications utilizing surface mount adhesive between pads
that have had solder paste applied to them, a single post design nozzle
is the most appropriate. In this type of application the standoff
should be set at 45
° , 135 ° , 215 ° , or 315 ° around the pad circuitry.

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When selecting the
correct nozzle ID a rule of thumb is that the nozzle ID should be one
half of the required dot diameter. This will allow for the correct dot
diameter to be dispensed so that the glue snaps away from the nozzle
without contamination. By beginning with this guideline, the
approximate nozzle diameter can be determined, and then adjusted based
upon the material utilized.

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Stencil Printing Considerations

 

 When printing
solder paste prior to dispensing surface mount adhesive, there are some
stencil design considerations that must be taken into account. The
thickness of the stencil is important because it will determine the
height of the solder paste depositions. This also determines the
minimum height of the dot that must be dispensed in order to properly
contact and hold the component. In applications where wave soldering
will follow manual assembly, a smaller stencil thickness may be used
because the ultimate solder joint quality will be determined by the wave
soldering operation. It may also be beneficial, on pads with very
tight pads spacing, to undercut the stencil so that as much space as
possible is available for adhesive deposition.

 

Adhesive Curing

 

    When printing
solder paste and dispensing epoxy between solder pasted pads a
specialized cure cycle is required. Curing epoxy at 150º C is a
bondline temperature that should be verified with thermocouples at
various locations. Curing epoxy at temperatures above 160º C can cause
the adhesive to become brittle, leading to possible component loss
during the solder wave process. The solution for this is that the epoxy
must be cured at 150º C for about 90 seconds prior to ramping to the
reflow temp. This type of reflow takes into account the adhesive cure
as well as the solder paste reflow. Care should be taken to check the
quality of the solder joints achieved with this profile. The graph
below is a sample of what the cure cycle should look like. The final
profile should take into account the recommended profiles from both the
adhesive and from the solder paste manufacturers.

 

 

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Placement Machine Considerations

 

 When selecting a
placement machine for use in a process utilizing the dispensing of
surface mount adhesives between solder pasted pads, it is important to
consider the accuracy and the repeatability of the placement machine
down line. In typical top side applications utilizing solder paste
printing, when the solder paste is reflowed, the forces associated with
the solder, automatically center the component, within reason, on its
pads. When glue is added to the process this does not occur because the
glue resists these forces since it is cured prior to the reflowing of
the solder paste. It is important to consider all of the machines in
the line when developing this type of process.

 

 

Typical Manufacturing Line Configurations

 

Traditional Bottom Side Line

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  GDM Adhesive Dispenser

  Vitronics Reflow Oven

  HSP Chipshooter

 

 

 

 

 

Typically, a
traditional bottom side manufacturing line includes an adhesive
dispenser, a chipshooter to place the bottom side components, and an
oven to cure the adhesive. This line will be followed by a wave solder
machine, which will in turn be followed by an inspection and/or rework
station.

The first thing
that must be considered when setting up any manufacturing line is the
type of components and assemblies that are going to be used or built on
it. A traditional bottom side line can be used simply to apply glue to a
printed circuit board, place components on the board, and then cure the
glue in order to hold the parts onto the board prior and during wave
soldering and manual assembly. In this type of application the green
strength of the material determines whether components stay in place
during placement operation on the chipshooter. The post cure strength
of the adhesive determines whether or not the components will stay on
the board during manual assembly and handling. This makes the choice of
glue very important. After wave solder, using this type of line, parts
may be missing due to missing or unacceptable adhesive dots or some may
have be knocked off the board during manual assembly or handling. Care
should be taken to control the forces that these assemblies are
subjected to. This line is very basic in its functionality but can
reliably build products when implemented correctly.

 

Bottom Side Line With Solder Paste Application

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  HSP Chipshooter

  DEK Stencil Printer

  Vitronics Reflow Oven

  GDM Adhesive Dispenser

 

 

 

 

 

A bottom side line,
that includes solder paste application, incorporates a system for
applying the solder paste (stencil printer or high speed dispenser), an
adhesive dispenser, a chipshooter for the bottom side components, and an
oven to cure the adhesive and reflow the solder paste. A wave solder
machine and an inspection and/or rework station will then follow this
line.

This type of
manufacturing line is more flexible than the previously discussed line.
For bottom side applications, this configuration provides greater torque
strength due to the adhesive being combined with solder paste. This
will assist in reducing the number of missing part defects present in
the assembly. This type of line also helps to reduce problems related
to the wave soldering operation (insufficient solder). In this type of
application, the dot height is important to consider because the dot
must be tall enough to contact the component even above the solder paste
deposit. Consideration also must be given to the design of the stencil
used to print the solder paste and the design of the nozzle used for
high speed dispensing operations. Both of these points can turn into
problems later if not considered properly.

 

 

 

 

 

Mixed Technology Top/Bottom Assembly with Solder Paste Application

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      Vitronics Reflow Oven

  HSP Chipshooter

  GDM Adhesive Dispenser

  DEK Stencil Printer

  GSM Flexible Placement

 

 

 

 

 

A mixed technology
line for assembling top and bottom side products includes a system for
applying the solder paste (stencil printer or high speed dispenser), an
adhesive dispenser, a chipshooter to place the bottom side components, a
flexible placement machine to place top and bottom side components, and
an oven to cure the adhesive and reflow the solder paste. A wave
solder machine and an inspection station will then follow this line.
The inspection station however, should see limited use because of the
robustness of this process.

This manufacturing
line is more flexible than either of the previously discussed lines.
Like the bottom side manufacturing line with solder paste, on bottom
side applications, this configuration provides greater torque strength
due to the adhesive being combined with solder paste. This assists in
reducing the number of missing parts present in the assembly. This
also helps to reduce problems related to the wave soldering operation
(insufficient solder). In this type of application, the dot height is
important to consider because the dot must be tall enough to contact the
component over and above the solder paste deposit. Consideration also
must be given to the design of the stencil used to print the solder
paste and the design of the nozzle used for high speed dispensing
operations. This line also can be used for topside applications
including the deposition of solder paste, chip placement and flexible
placement (QFPs and BGAs for example). This type of flexible
manufacturing line has become the choice for contract electronics
manufacturers because it offers a simple, total assembly solution.

 

Conclusion

 

 The dispensing of
surface mount adhesives has been a part of electronics manufacturing
since the development of surface mount components. In an effort to make
the processes involved more robust, solder paste has been added to many
manufacturing line configurations. This configuration helps to
eliminate defects such as missing components and insufficient solder
joints following wave soldering.

 In order to
implement this process there are a lot of considerations that must be
taken into account. The type of adhesive used must have rheological
properties that allow for a tall, cylindrical dot versus the typical
Hershey kiss shaped dot. This type of dot is required to properly
adhere to the component when it is placed on top of the solder paste
deposits. In order to obtain the correct dot height, the board design
must be considered carefully. By designing in the correct pad spacing,
implementation of this process is much simpler. The volume of solder
paste required must then be determined as well as the design of the
stencil. The required adhesive dot size must be considered when
designing the stencil. After the board is designed and the volume of
solder paste required has been determined, a nozzle must be designed to
provide the correct dot diameter with standoffs that will not become
contaminated with solder paste. After the adhesive is deposited and the
chips have been placed, the glue must be cured and the solder paste
must be reflowed. The profile used for this process must be developed
from the adhesive and the solder paste manufacturers’ recommended
profiles. Finally, the type of assemblies that are going to be built
must be considered when developing a manufacturing line that will meet
your needs now and in the future.

 By carefully
considering all aspects of your manufacturing process, the dispensing of
surface mount adhesives between solder pasted pads can help eliminate
defects associated with typical electronics manufacturing processes.
This process helps to eliminate problems such as insufficient solder
joints. In applications where only glue was previously utilized, this
type of process can help eliminate defects such as missing components,
that can occur as a result of handling and manual assembly. By taking
time to consider the characteristics of your manufacturing process, the
correct line configuration and process parameters can be developed to
build the highest quality assemblies possible.