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How to design SMT factory layout for Smart EMS

 

 

How SMT workshop planning? It turned out to be so useful.

How SMT workshop planning!

And only after the plant began production found that some areas have not planned beforehand, need to be adjusted, resulting in a waste of human and financial resources and valuable production time.

Therefore, it is important to check in advance SMT factory layout, especially for new SMT factory business, because there is no experience in SMT plant layout, the need to pay attention to the elements is not very clear, if we find a problem in the layout after production point, will cause some unnecessary losses.

So, when doing layout SMT plant, what to pay attention to what matters in advance to do to prepare? Here actual cases where we work to and we explore this problem.

Case

planning SMT line configure

the client recent planning new on two identical SMT production line, specific device configuration (see FIG. 1) and the size of the apparatus is as follows: According to Figure 1 can be seen, the maximum width of the production line equipment is 1.71 m, the length of all devices sum is 13.6 meters, will add future planning a production line (line bulk on equipment configuration).

Situation Workshop

Workshop length 36 m, width of 12 m, an area of 432 m2, on the ground floor of the factory. Currently common ground for the shop floor, and no established anti-static system, can not meet the requirements of SMT antistatic workshop, but two conductive ground terminals, can establish subsequent workshops antistatic SMT system. Further, there is no air conditioning workshop and humidifiers, can not meet the requirements of SMT workshop temperature and humidity control. There workshop ventilation system, back to meet the requirements of the reflow furnace equipment. Workshop sufficient power to meet the electricity needs of all equipment in the workshop. There are two entrances whole plant, as are required to meet the equipment, raw materials and semi-finished channel. Special materials warehouse in another workshop, the need for planning. Good lighting conditions in the workshop, to meet the brightness of the SMT shop lighting requirements all stations. Whole plant layout situation shown in Figure 2.

Customer requirements

1, the current new move into production lines and related aids, regional positioning;

2, the whole plant to meet future erection and production requirements three production lines, without planning zone realignment;

3, each production line starting position as consistent as possible, so that the whole plant orderly arranged in three lines.

Subject  of

analysisthe customer’s request, we first analyzed how the production line positioning; and before locating the production line, we consider the following points:

1, SMT equipment should avoid column and they maintain a certain distance, the distance is equipment installed at least after a good feed material by a vehicle;

2, SMT crossing equipment required for frame division pitch, and the crossing equipment to extend outwardly after the device installed above the material 50 cm;

3, optimal spacing of the two lines spaced more than 1.2 meters between the outer frame;

4, check the wire tail is generally a repair plan area, quality control personnel can perform sampling line tail region.

Based on the above considerations, the length of each line should be at least 13.6 meters (without regard to the maintenance area and the tail, the case where the sampling area and the thread area kanban), the width should be 2.7 meters (SMT feeding both surfaces), specifically as shown in Figure 3.

Therefore, the production line is positioned in substantially considering plant shown in FIG. 4.

Some details of the requirements of SMT plant layout

after determining the approximate location of the production line, when the need to consider some details of SMT production line requirements, and then to determine the exact location and the location of other auxiliary equipment SMT line.

First, we analyzed the SMT line position and aids required for each area requirements: 1, fire extinguisher drop zone;

fire extinguishers to be placed around the side of the post and SMT plant, placed according to the requirements of fire regulations.

2, the car rack placement region; car rack replacement for SMT production line models and switching material, in order to facilitate production and to improve the efficiency of replacement materials, preferably the vehicle is placed near the rack placement machine.

3, stock units rest area;

stock table mainly used in the production process and dryer materials stock preparation before switching, therefore, to be placed near the preparation station placement machine, and the best car rack together, Preparation facilitates directly on the car frame after a good feed material.

4, the shelf rest area printing station;

printing station for positioning the shelf aids in the production of printing presses, such as wipes, paste, alcohol, etc., to be placed in the vicinity of the printing press to facilitate removal use, improve Productivity.

5, placing solder paste regions;

region comprising placing solder paste storage refrigerator, solder paste mixer, paste warmed cabinets, can be placed next to the plant as required or uprights placed around a fixed area of the plant, However, to facilitate the operator to take place.

6, visual inspection after the furnace area, maintenance area;

in order to facilitate visual inspection after reflow and rework semifinished product, a shelf generally placed in the furnace, designed for the visual inspection of the furnace and rework.

7, screen placement area;

drop zone comprises a mesh screen plate was placed cabinet, stencil cleaning machine, inspection tools, screen, stencil for storing, cleaning and inspection screen tension, etc., while in the region as much as possible to facilitate the production screen to take place.

8, garbage drop zone;

Production waste mainly from two parts, wipes and the like used in one printing operation, the second is to replace the waste tray and waste material produced with the like. Garbage two parts is generated to be placed separately, specialized recycling, in particular waste presses used. Thus, waste area may be placed next to the press machine or patch, or set beside the column region refuse placed separately placed.

9, kanban placement region;

kanban including the SMT billboards and other signage quality management, may be centrally located on the entrance into the shop, and also set up the production line Kanban state in which each head of the line, in order to view the producers and managers, promptly understand the current state of production status and quality SMT workshop and so on.

10, product placement area;

include products produced finished products in two parts, to separate the two partial regions divided out, strictly distinguished, in order to avoid confusion.

11, SMT placement of spare areas;

Nozzle including the SMT spare parts, a motor, a belt, cylinder or the like, to be placed in a special area, to facilitate the production of access.

12, location area temperature and humidity;

temperature and humidity conditions in order to better understand the SMT plant, depending on the size of the workshop area, several appropriately set the temperature and humidity measurement area, generally placed on the production line next to the column or wall.

13, SMT workshop office area;

let engineers and technicians and management personnel in office SMT shop floor, which can solve the problem on technology and management encountered in the production, to ensure the smooth operation of the SMT production lines.

14, anti-static protection area;

entry into SMT workshop area must have good anti-static measures. You may delineate the area in front of the plant, including the replacement of static clothing, shoes, hats and so on each employee’s locker. Also, the establishment of regional designed to test the static ring in SMT workshop at the entrance, so that each employee to do static loop testing and record test results before going to work. Based on the above analysis, the results of this SMT plant layout is shown in Figure 5.

In addition, SMT workshop also meet other requirements: 1, anti-static processing;

shop floor must be anti-static treatment, a common anti-static conductive flooring and paint and other ordinary places, customers can choose according to the actual situation. In addition, anti-static system must be set up in the workshop, to meet the requirements of the entire anti-static SMT workshop.

2, air-conditioning and a humidifier; SMT workshop to meet the requirements of temperature and humidity control.

3, the material management requirements;

in the warehouse, with particular attention to the way the material is stored, reel packaging methods, the use of hook-type place, wetting elements employed Cabinets for placement shelves to be treated with anti-static manner.

4, patch equipment gas and electrical circuitry;

preferably introduced directly from the production line at the down side of the roof, is arranged below the gas passage in the device and circuit wrapped with wire groove.

5, the ventilation system requirements;

needs to be installed to meet the requirements of the three power lines of the blower, and the third exhaust port reserved line.

Results

1, according to the size of production line and the size of the entire plant SMT, completed the reasonable position of the production line; and

2, for aids, regions, etc. SMT production lines need to make the corresponding position location; 3, according to the SMT the characteristics of the plant, some of the necessary factors to consider in planning, in particular, anti-static; 4, in accordance with the requirements of the current situation and future development of the factory has been take into consideration, unified planning.

Summary

For SMT plant layout, but also requires a combination of size and product requirements and other plants to consider a number of factors, but to stimulate here.

 

Welcome inquiry

 

1,Please visit : www.smthelp.com

 

2, Find us more: https://www.facebook.com/autoinsertion

 

3, Know more our team: https://cn.linkedin.com/in/smtsupplier

 

4, Welcome to our factory in Shenzhen China

 

5, See more machine working video, please Youtube: Auto Insertion

 

6, Google: Auto+insertion, to get more informations

 

7,Looking forward to your email: info@smthelp.com

 

 

https://docs.google.com/document/d/e/2PACX-1vSFUaow2vtLCQbtVShngWxA2uiLkcv6i4BKn4ORhsatobh8Ah_ONk2bFfjkAOSsZf3yKfBrj2hULMi0/pub

How SMT magazine installed? And how to use it

How  SMT magazine installed? And how to use it?

ESD SMT magazine 10ESD SMT magazine 13 ESD SMT magazine 12

ESD SMT magazine 14ESD SMT magazine 15ESD SMT magazine 16ESD SMT magazine 17ESD SMT magazine 19ESD SMT magazine 22ESD SMT magazine 21ESD SMT magazine 20

ESD SMT magazine
ESD SMT magazine

ESD SMT magazine 2ESD SMT magazine 3ESD SMT magazine 4ESD SMT magazine 5ESD SMT magazine 6ESD SMT magazine 7ESD SMT magazine 8ESD SMT magazine 18ESD SMT magazine 9ESD SMT magazine 14ESD SMT magazine 25ESD SMT magazine 24

Learn more spare parts:

1, Find us more: https://www.facebook.com/autoinsertion

2, Know more our team: https://cn.linkedin.com/in/smtsupplier

3, Welcome to our factory in Shenzhen China

4, See more machine working video, please Youtube: Auto Insertion

5, Google: Auto+insertion, to get more informations

6,Looking forward to your email: info@smthelp.com

 

3D Viewing SMT spare parts in THT PCB Machine

       

      We  Provide different spare parts and wearing parts of different brands and models.(UIC,TDK,Panasonic,Samsung,Fuji,Juki,SIMMENS……) Only need to tell us your parts‘ machine model and P/N. Fuji TDK Juki Samsung YAMAHA  UIC Panasonic

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      Why Choice Us?

      • We owning 10 years experience in providing SMT/EMS services.
      • Familiar design and engineering capability both on Hardware and software.
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      How to maintain Auto Insertion and SMT machine — ESD Cleaning and Testing Procedures

      Procedures and Adjustments

      CAUTION

      The following procedures explain how to properly clean and test an ESD surface.

      Clean an ESD Surface

      Do not use abrasive or highly alkaline cleaners on polycarbonate. Never scrape polycarbonate with squeegees, razor blades, or other sharp instruments. Benzene, gasoline, acetone, or carbon tetra chloride should never be used on polycarbonate. Do not clean polycarbonate in the hot sun or at elevated temperatures.

      1. Using a sponge or soft cloth, wash the ESD-protected surface with either a mild detergent or Windex product and lukewarm water.
      2. After washing, rinse with water and dry thoroughly with a chamois or moist cellulose sponge to prevent water spots.
      3. To protect the ESD surface after rinsing and drying,  recommends applying Kleenmaster Brillianize®. This application helps to maintain the static dissipative coating and reduce the accumulation of dust.

      Test Static Dissipative Covers

      Periodically and after maintenance, check the machine covers to determine if the dissipative qualities of the cover have changed. The following procedure ensures that static dissipative covers are in fact dissipative.

      Tooling

      Surface resistance meter (such as 3M 701 Surface Resistance meter and probe).

      Comments

      The surface resistance should be less than 109 ohms in all areas. If the cover package is no longer dissipative, contact you Universal Instruments Corporation sales representative.

      Procedure

      1. Clean the static dissipative covers using the Clean ESD Surface procedure to ensure the accuracy of the test.
      2. Using the surface resistance meter, follow the instructions provided by the manufacturer to measure the surface resistance of both the inside and outside of the covers. Measure the resistance at all four corners and at several areas in the middle of the cover. This test checks the integrity of the ESD coating.
      3. Connect the ground path resistance probe to the meter and chassis ground.

      The path to the ground should not be higher than the surface resistance. If it is, clean the frame connections, repair loose or corroded fasteners and ground straps, and check tracks for dirt and/or corrosion.

      4. Measure the ground path from the covers to the chassis ground. Take this measurement from both surfaces and all four corners of each cover.

      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

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      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.  

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      LED Manufacturing 💡🔦

      Bright Idea! Stop importing from China and Invest in LED Assembly Equipment

      MARKET DEMAND FOR LED MANUFACTURING

      Today, LEDs are used for bulbs and tubes but increasingly they are being used in the many lighting components necessary for automobiles, airplanes, appliances, computers, electronics, televisions and more. LEDs use a whopping 80% less energy than old Incandescent Lighting and 50% less than Compact Fluorescent Lighting. Soon, international mandates to deal with climate change, like the Paris Agreement, will make an already huge market, topple over with growth and opportunity.

      LEDs offer a promising solution to deal with energy agendas set forth by conventional international treaties and local environmental policies that seek to gain quantifiable reductions in fossil fuel usage. LEDs are a simple, yet integral solution to improving energy efficiency and helping to solve the issue of climate change. Are you keeping up with the Paris Agreement and what that means for a BOOMING LED Market?

      Souther Machinery provides full-service equipment for LED Manufacturing Solutions. Please call us at 0755-83203237 if you would like more information about our LED SMT Manufacturing Technologies and to discuss how we can help you participate in this expanding global market.

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      SMT,PEC,UIC,Camera,Balser

      UIC SMT machine PEC Camera Assembly – T50319001 Rev

      Beam 2 FW PEC Camera Assembly – T50319001 Rev. K
      This Document Supports Assembly 50319001 Rev. G


      Replace the PEC Camera Assembly

      If the PEC Camera Assembly is damaged or experiences an electrical or optical failure, the camera must be replaced.

      CAUTION
      Use caution when handling the PEC Camera and Lighting Assemblies. These assemblies are very sensitive to sudden shock. Also use ESD precautionary measures when handling the PEC Camera and Lighting Assemblies. A properly grounded ESD wrist strap is recommended.

      Prerequisites

      Make sure that the following items are available before beginning the procedure:

      • A new PEC Camera Assembly
      • A calibration kit and a new PEC gray card

      Remove the PEC Camera Assembly

      To remove the faulty PEC Camera Assembly from the head cage, perform the following procedure:

      1. Power down the machine and perform Lockout/Tagout according to local procedures.

      WARNING – LOCKOUT/TAGOUT
      The machine must be powered down and your site’s Lockout/Tagout procedure executed during this procedure to ensure personal safety.
      1. Open the access cover.
      2. Move the beam to a location where the PEC camera can be easily accessed.
      3. Disconnect the PEC_VIDEO/PWRPL and PEC_LED_CTRPL cables from the Head Cage Interface PCA.
      4. Remove all cable ties securing the PEC camera cables to the head cage.
      5. Remove the PEC camera cables from the cable clamps on the bottom of the head cage.
      6. Remove the screws that secure the PEC lighting to the PEC camera. Let the lighting hang loose from the hole in the carriage plate.

      7. Disconnect the PEC lighting cable from the PEC lighting. Set aside the PEC lighting.
      8. Remove the screws that secure the PEC camera to the carriage plate.
      9. Lift the PEC camera out of the head cage and discard.


      Remove/Install the PEC Camera Assembly

      If the PEC Camera Assembly is damaged or experiences an electrical or optical failure, the camera must be replaced.

      CAUTION
      Use caution when handling the PEC Camera and Lighting Assemblies. These assemblies are very sensitive to sudden shock. Also use ESD precautionary measures when handling the PEC Camera and Lighting Assemblies. A properly grounded ESD wrist strap is recommended.

      Prerequisites

      Make sure that the following items are available before beginning the procedure:

      • A new PEC Camera Assembly
      • A calibration kit and a clean, undamaged PEC gray card

      Remove the PEC Camera Assembly

      To remove the faulty PEC Camera Assembly from the head cage, perform the following procedure:

      1. Power down the machine and perform Lockout/Tagout according to local procedures.

      WARNING – LOCKOUT/TAGOUT
      The machine must be powered down and your site’s Lockout/Tagout procedure executed during this procedure to ensure personal safety.
      1. Open the access cover.
      2. Move the beam to a location where the PEC camera can be easily accessed.
      3. Disconnect the camera control/interface cables from the Head Cage Interface PCA.
      4. Remove all cable ties securing the PEC camera cables to the head cage.
      5. Remove the PEC camera cables from the cable clamps on the bottom of the head cage.
      6. Remove the screws that secure the PEC lighting to the PEC camera. Let the lighting hang loose from the hole in the carriage plate.

        (Typical PEC Camera and old-style mount shown below)


        (New-style PEC mount shown below)


      7. Disconnect the PEC lighting cable from the PEC lighting. Set aside the PEC lighting.
      8. Remove the screws that secure the PEC camera to the carriage plate or mounting block.
      9. Carefully remove the PEC from the head cage.
      10. If installing a camera with a different magnification, remove the 6 frame fiducial inserts on the feeder uprights and the 4 nozzle changer fiducials on the nozzle changer. Retain for use with the .4 MPP PEC camera.

        For UPS+ 7.5SC and higher with a .4 MPP PEC camera: Remove the 6 frame fiducial inserts on the feeder uprights; they will not be re-installed.

      Install the PEC Camera Assembly

      To install the PEC Camera Assembly, perform the following procedure:

      1. Carefully move the PEC camera into the head cage and position on the alignment pins.
      2. Apply Loctite 222 to the PEC camera mounting screws.
      3. Install the PEC camera mounting screws and torque to 1,36 Nm (12.0 in-lb.).
      4. Connect the PEC lighting cable to the PEC lighting.
      5. Install the PEC lighting to the new PEC camera and secure with the screws removed earlier.
      6. Route the PEC cables through the cable clamps on the bottom of the head cage.
      7. Connect the camera control/interface cables to the Head Cage Interface PCA.
      8. Install new cable ties to secure the PEC cables to the head cage. Do not over-tighten the cable ties.
      9. If installing a .4 MPP PEC camera where one did not exist previously, install the 6 frame fiducial inserts on the feeder uprights and the 4 nozzle changer fiducials on the nozzle changer. Install over the existing fiducials.

        For UPS+ 7.5SC and higher with a .4 MPP PEC camera:  Do not install the 6 frame fiducial inserts on the feeder uprights.

      10. Close the access cover.
      11. Power up the machine.
      12. Determine if the machine is equipped with the Cognex Vision system:
        1. Open Diagnostics II.
        2. Select Version Information > Hardware Options > Vision Systems.

      If Cognex Vision is…

      Then…

      On the machine Continue with the next step.
      Not on the machine Do the following:

      1. Update the camera drivers. For instructions, see the Update the Camera Drivers help topic in Voyager.
      2. Continue with the next step after the drivers are updated.
      1. Calibrate the PEC camera and lighting. For instructions, see the PEC Calibration: Camera and Lighting (Multifunction Machines) help topic in Voyager.

      PEC Camera Polarizing Components

      The PEC camera consists of two elements: a rotating polarizer that covers four of the eight illumination petals and a sliding polarizer. The sliding polarizer is located in the camera aperture. The axis of this polarizer, frequently referred to as the “analyzer”, is orthogonal to that of the rotating polarizer. The combination of these polarizers on the module results in cross-polarized illumination.


      (Typical PEC Camera shown)

      The rotating polarizer ensures that the substrate is illuminated with linear polarized light. The metal features and ceramic background reflect polarized light differently. The light reflected from the metal has no net change in polarization. Because the orientation of the sliding polarizer located in the camera aperture is orthogonal to that of the rotating polarizer, most of the light reflected from metal features is blocked. Therefore, metal features appear dark on the camera.

      In contrast, the ceramic surrounding the metal features randomizes the polarization upon reflection. Because the polarization is randomized, a portion of the reflected light can pass through the central polarizer and reach the camera. Therefore, the ceramic background appears as a shade of gray.

      The following table summarizes the polarization effects on metals and ceramics:

      Material

      Incident Polarization

      Reflected Polarization

      Central Polarizer Orientation

      Intensity at Camera

      Metal

      Ceramic

      Polarized Lighting Zones

      The PEC Lighting Assembly has two lighting zones. Which zones are used for imaging depends on the type of substrate being imaged. The two lighting zones are shown in the table below.

      Lighting Zone

      LED Color

      Graphic

      Zone I

      Blue

      Zone II

      Red

      Petal Zones I and II each contain four illumination petals positioned at 90 degrees to each other. The illustration below shows how the Red (R) and Blue (B) LEDs are oriented.


      Selectable Polarizer Positions

      The PEC Lighting Assembly is equipped with a rotating polarizing filter and high intensity LEDs. The PEC camera has a polarizing film mounted within a rotating ring and a second polarizer mounted on a slide above the lighting module. Certain classes of flexible circuits image well with cross-polarized illumination. For the polarized option, it is recommended that the central polarizer be left in place.

      • The blue lighting zone of the PEC Lighting Assembly is designed to image flexible circuits.
      • The red lighting zone of the PEC Lighting Assembly is designed to image ceramic circuits.

      The following table summarizes the available Polarized lighting options:

      Lighting Zone

      Graphic

      Function

      Zone I

      Orienting the rotating polarizer above the blue LEDs allows non-polarized illumination from the Red LEDs. This lighting type is effective on dark-colored ceramics.

      Zone II

      Orienting the rotating polarizer located above the red LEDs allows polarized illumination from the Red LEDs. This lighting type is effective on white or light-colored ceramics.


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      How to use Solder Preforms to improve your Electronic Product Quality

       

      Solder Preforms are used in a variety of applications that require precise amounts of solder. Preforms come in standard shapes such as squares, rectangles, washers and discs. Typical sizes range from .010″ (.254mm) up to 2″ (50.8mm). Smaller and larger sizes, as well as custom shapes, are also available. Dimensions can be held to tight tolerances to assure volume accuracy.

       

      • Increased solder volume
      • Improved drop test results
      • Fewer issues with flux residue
      • Reduced rework
      • Improved fillet shape and volume

       

       

       

       

       

       

      What is the NEXT of Through Hole Technology in Electronic Manufacturing

      
      
      We designed and manufactured Auto Insertion machine in Shenzhen China,  -- Decreasing labor cost  -- Easier manufacturing and operations management  -- Predictable Product Quality – Less repairs  -- No wrong parts nor wrong polarity  -- Less risk of damage due to human contact (contamination, ESD, physical damage to components)  -- Better clinching, less risk of solder issues.  -- Smaller factory space required to produce same volume of product
      
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      Insert radial components by a chip mounter, how to realize?

      How to realize inserting radial components in a chip mounter?

      Normally , chip mounters are used to pick and place SMD components . But if you want to use your chip mounter to insert the radial components ,it is allowed also.

      S-RF1001 The through-hole feeder for mounter *The S-RF1001 is a revolutionary new concept from Southern Machinery that allow the placement or insertion of both surface mount and through-hole components. Can adaptive most of mounter.

      *We use the special way to modify feeder, can achieve Fuji, Juki, YAMAHA, MYDATA and other machine brands to insert the radial components.
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