Smarter production systems for surface mounting allow production lines to
production lines to run longer without unplanned interventions or interruptions
Enabling pick and place machines to monitor their own performance and detect
and detect anomalies in real time enables production to deal efficiently
to deal with errors and unexpected events. By preventing
minor problems from escalating into costly downtime, production can be
production can be carried out without interruption. Technicians can
can then analyze and resolve the underlying problems at an appropriate
analyze and resolve them. This can help to reduce operational interruptions
interruptions and increase the overall effectiveness of the systems, which
ultimately leading to higher productivity.
Increased adaptability
Both software and hardware-based systems have their place when it comes to
when it comes to enabling production systems to adapt autonomously to recognized
to recognized problems in order to ensure continuous production and high productivity.
and high productivity. For systems such as high-speed pick and place machines that already have
already have integrated inspection cameras and motion controls,
new self-test functions can be added via a software update.
can be added via a software update. On the other hand, new hardware may be required for additional tests
if additional sensors or actuators are required.
Problems with nozzles, which are often caused by blockages, are a common
are a common phenomenon that production teams have to deal with.
have to deal with. The nozzles are loaded and unloaded by the loading head and stored in a
stored temporarily in a nozzle station when not in use. The position of each
station is assigned during set-up and usually remains fixed until the machine is next used.
fixed until the machine is reprogrammed at the next product change.
is reprogrammed.
In Yamahas neuesten YRM-Bestückern ermöglicht die neue Nozzles-Free-LayoutSoftware ( Bild 1), dass die Maschine die Nozzles nach ihrer Identität und nicht
nach ihrer Position in der Nozzlestation verwaltet. Jede Nozzle hat eine
eindeutige Identität, die mit einem 2D-Code versehen ist. Beim Nozzles-Free-Layout bringt die Maschine die Nozzles zur Ablage in jede beliebige, freie
Position der Nozzlestation.
Nozzles-Free-Layout-Software
The use of this software enables the machine to avoid problems with a
problems with a poorly functioning nozzle by taking another nozzle of the same
of the same type from a different position in the Nozzle Station. The
production continues without interruption so that the faulty nozzle can be
can be examined to rectify the fault. The ‘Nozzles-FreeLayout’ option helps to minimize operator errors after cleaning or maintenance and enables production
minimize operator errors after cleaning or maintenance and allows production teams to closely
of the nozzle performance.
This example shows how a software change can improve fault-tolerant operation.
can improve fault-tolerant operation. On the other hand, a new option for measuring the
force for spring-loaded nozzles requires the installation of new hardware. With
this function, the placement machine can regularly check whether problems with the
occur with the nozzle. The new hardware includes a load cell that is used by
evaluated by the special software for controlling the nozzle test sequence.
Measurement of the nozzle contact force using a load cell
The hardware upgrade is attached to the feeder rail of the pick-and-place machine
and can be installed during the construction of a new machine or retrofitted to
existing machines in the field. The measurements
verify whether the force at the nozzle tip is within the usual range
between 0.5 N and 0.8 N. An abnormal force indicates a problem such as a blockage.
e.g. a blockage. Such a problem can occur when deposits impair the
impair the spring function. By measuring the component loading force with a resolution of up to 0.1 N, this system provides an early warning before spring problems occur.
early warning before spring problems lead to assembly errors. The results
The results of the nozzle placement force measurement also help with troubleshooting, so that the
so that the cause of the fault can be found and rectified quickly. The
software supports calibration as soon as the load cell is installed.
is installed. It then guides the operator during normal
operator through the measurement process with menu-driven instructions during normal operation.
Simple hardware expansion
Alternatively, the LCR unit, which has been specially developed for Yamaha
an example of a hardware-based upgrade that can be carried out without modifying the
changes to the pick and place machine. This LCR unit contains a
digital multimeter in a standard feeder format and is extremely easy to install.
to install. After a component is picked up, the multimeter measures its
its value before the part is placed on the PCB. It is capable of
measure inductive, capacitive and resistive components and can be used at specific
at specific times, e.g. immediately after changing a component roll.
component roll. Checking the component values with this device confirms that
the new roll contains components with the same nominal value and tolerance
as specified on the label. Defective components are
sorted out immediately.
The LCR unit is easy to install and measures component values automatically
An assembler equipped with the LCR unit can detect problems such as
feeding errors, roll defects or defective components before they are placed. This helps to maximize production yield and avoid rework.
avoid rework. The unit occupies two 8 mm feeder positions and can be
be plugged into any Yamaha placer during operation – as easy as changing a feeder.
as changing a feeder. No special software is required, and production
production does not have to be interrupted. The LCR test
supports quality assurance and is particularly valuable when
components are used or to ensure traceability in the automotive, medical or aerospace industries.
the automotive, medical or aerospace industries.
Non-stop productivity
There are further software upgrades for Yamaha assemblers, including
automatic support of components from different manufacturers and the
delay-free evaluation of component fixtures. The multi-supplier feature helps operators avoid problems that can arise when the company’s
problems that can arise when the company’s purchasers source a part type from multiple
suppliers. The supplied components can be aligned differently in the belt pockets
differently in the belt pockets, the distance between the components (pitch)
may be different, or there may be other visible differences.
may exist. These could lead to the machine detecting a component fault
and interrupt production unnecessarily. By using the
automatic multi-supplier support software upgrade, the part database can be
the component database can be adapted to such differences so that production
production can continue.
The component pick-up evaluation uses the picker’s standard built-in side camera
built-in side camera of the pick-and-place machine to check the alignment of the components after
after the pick-up. It offers a quick way to check the stability of
important parameters of the pick-and-place machine such as pick-up height, XY movement and component vision recognition. This option generates
optimized component pick-up data, which helps to minimize the setup time per component
minimize setup time per part when introducing new products and optimize part information
during production. By activating automatic settings and
settings and assessments, this software can help to quickly optimize the
quickly determine the compatibility of the nozzles, optimize the traversing speed
of the pick-and-place head and assess the component pick-up information
information, reducing operator decision time to a few seconds.
is reduced to a few seconds.
In addition, Auto Teach extends the offline editing software’s ability to fine-tune library and Gerber data
data, helping to identify corrections that should be made before the start of production.
the start of production. In this way
manufacturing teams can avoid the production of sample assemblies that would otherwise
would otherwise be required to verify correct component alignment. An
additional, powerful software tool automatically supports the removal of unused feeders. Production teams are often confronted with
often face problems when changing products if additional component feeders are
additional component feeders are required for the new product, although the feeder positions of the
feeder positions are already occupied. Identifying unused feeders through manual
manual inspection can be difficult and requires time-consuming cross-referencing
cross-referencing between programs. Yamaha’s unused feeder removal software
unused feeders has automated this analysis and quickly identifies those feeder
those feeder positions that can be replaced. This means that the
changeover can be completed quickly and production resumed
to maintain productivity.
Another upgrade that is now available introduces an option for large
printed circuit board assemblies. A reinforced conveyor belt (image 4) is
suitable for PCBs weighing up to 10 kg and up to 10 mm thick.
of up to 10 mm. The transport system is compatible with the single-traverse pick-and-place machines
YRM20 and can process PCBs with a length of up to 1.5 meters.
can be processed. It is ideal for products such as particularly large LED lighting assemblies made of heavy, insulated copper or aluminum metal substrates.
Transport system upgrade for handling large, heavy PCBs
Conclusion
Optional hardware and software upgrades can be integrated into SMT assembly systems
and enable problems to be anticipated, recognized, diagnosed and
recognize, diagnose and react to problems independently. Through the
intelligence and resilience, failures due to minor problems can be easily
problems, which can be easily avoided or rectified, can be avoided.
Productivity is increased and operators are given the freedom to focus on
concentrate on those problems that require human intervention.
About Yamaha Robotics SMT Division
The Yamaha Surface Mount Technology (SMT) Section, a subdivision of the
Yamaha Motor Robotics Business Unit of Yamaha Motor Corporation, produces a comprehensive
a comprehensive range of systems for high-speed in-line electronics assembly. This 1 STOP SMART SOLUTION includes solder paste printers,
placement machines, 3D solder paste inspection machines, 3D assembly inspection machines, dispensers, and management software.
These systems, which bring the Yamaha approach to electronics manufacturing, emphasize
focus on intuitive operator guidance, efficient coordination between all inline processes
between all inline processes and a modularity that enables users to
to meet the latest manufacturing requirements. The Group’s expertise in
servo motor control and camera-based vision systems ensure extreme accuracy at high speed.
The current product line includes the latest generation of YR machines with advanced automation features for programming, setup and changeover, as well as the new YSUP management software with state-of-the-art graphics.
changeover and the new YSUP management software with state-of-the-art graphics and
and integrated data analysis.
By bundling expertise in the areas of design and technology,
manufacturing, sales and service, the Yamaha SMT Section ensures operational efficiency
efficiency and easy support access for customers and partners. With regional
offices in Japan, China, Southeast Asia, Europe and North America, the company offers a truly
company offers a truly global presence.
https://smt.yamaha-motor-robotics.de/
