Pick and place machine for LED
Generally speaking, the LED chip mounter is one of the surface mount technology (SMT) chip mounters. With the development of LED technology, the traditional SMT chip mounter can no longer meet the production needs of the LED industry. At this time, the LED chip mounter Came into being.
The LED placement machine is an SMT placement device specially designed and customized for the LED industry, which is used to realize the assembly of large-scale LED circuit boards. Equipment requires low accuracy but fast speed. LED dedicated placement machine reduces the cost of placement equipment and improves production efficiency. At present, there are many types of LED placement machines, but whether they are fully automatic high-speed placement machines or manual low-speed placement machines, their overall layout is similar.
The Full-automatic LED placement machine is computer-controlled, high-precision automation equipment that integrates light and electricity. It consists of a rack, a PCB transfer mechanism and a carrier organization, a drive and servo positioning system, a placement head, a feeder, and optical identification The system, sensor, and computer control system consist of suction, displacement, positioning, and placement to complete the fast and accurate placement of the SMD on the PCB.
1.Difference between LED mounter and traditional mounter
The LED placement machine mainly needs to meet the precision requirements of lamp beads placement of 3014, 2835, 3528, and 5050, 5630, and 5730. Compared with the processing accuracy of traditional placement machines, LED placement machines have lower requirements. However, the LED mounter pays more attention to performance, that is, the stability, speed, operability, and size requirements of the machine. Therefore, the LED mounter must have the following design ideas and rigid requirements.
1) The intelligent method is more maturely applied to the dedicated LED mounter. Various types of sensors with excellent performance can fully collect data for computer disposal during the implementation, ensuring the stability and reliability of the entire mounting process. At the same time, like other equipment, according to scientific methods and technical specifications, regular maintenance of the LED chip mounter, such as cleaning and washing of the surface area of the machine and the circuit board, can effectively prevent poor internal heat dissipation of the machine due to dust and dirt. It causes overheating and burn the device. LED mounter has good stability to maximize efficiency and generate benefits for the enterprise and reduce production costs.
2) The speed of the LED placement machine must be fast, with a minimum placement speed of more than 18 000 chips / h.
3) With simple and easy-to-learn humanized operation methods, it can extremely shorten the training time of personnel, and effectively reduce misoperation in the production process, and improve production efficiency and product quality.
4) The LED mounter must be able to mount a PCB with a length of 1 200 mm. Because a large part of the LED is to replace the traditional light pipe lighting, the length will greatly exceed the size of the traditional PCB. In addition to these, in order to ensure no color difference for a single LED lamp board, the entire batch of LED lamp beads to be mounted is required to have the same color temperature. BIN (BIN generally represents the range of some parameters of LED lamp beads. Different ranges can be used with different The number indicates that these parameters include voltage, color temperature, brightness, etc. Therefore, there will be terms such as voltage BIN, color temperature BIN, and brightness BIN, and BIN can be used to represent the product model).
2.Development Status of Domestic LED Mounter Technology
As the fourth-generation light source's huge market potential, coupled with the strong support of government policies, the domestic LED lighting industry is developing by leaps and bounds. From the popularity of early LED display screens to the current transition to LED commercial lighting, indoor lighting, outdoor lighting, lighting projects, etc., LED products have realized the transition from a single hot product to the application and popularization of LED in all fields.
The development of LED has driven the popularity of related equipment industries. Reflow soldering, wave soldering, printing machines, LED chip mounters and LED packaging equipment has developed rapidly. At present, most of the domestic LED equipment is small placement machines that can mount 1.2 m light boards. Basically, they use a platform-type movement structure, combined with a double swing arm movement, to achieve LED placement. There are few track-type LED mounters in China. This is also the next step, a direction for the development of many enterprises.
At present, domestic LED mounter technology is still in its infancy. The products developed can only meet the early needs of some small and medium enterprises. China is a large electronics manufacturing country and needs domestically produced LED placement machines of different grades. Therefore, it is necessary to optimize the model according to the actual situation, reduce the development difficulty of domestic LED chip mounters, and quickly enter the electronic equipment industry.
Second, the most critical technology of LED placement machine
2.1 Precision machine photoelectric integration technology
During the operation of the LED placement machine, this technology is embodied: the placement head picks out components from the feeder through precise mechanical movement and passes the calibration mechanism to accurately and quickly install the components on the PCB board. .
2.2 Vision Technology
Adopt non-stop rapid shooting and positioning technology to achieve optical image capture positioning and flight alignment.
2.3 Magnetic levitation technology
Can solve the application of high-speed and placement precision motion control technology magnetic levitation linear motor drive, improved the original servo rotary motor screw rod mother has the disadvantages of low speed and high noise. The linear motor uses magnetic levitation technology, which has no friction, no resistance during movement, high speed, and long service life.
2.4 Efficient Intelligent Software Technology
With the increasing complexity and diversification of the placement machine's composition and structure, the importance of the software technology of the placement machine has been increasingly reflected. Efficient real-time multi-tasking parallel processing operating systems, intelligent placement program optimization, and automatic diagnosis technology is bound to greatly improve production efficiency and product quality.
2.5 Modularization and System Integration Technology
The purpose of modularization and system integration technology is to propose optimized and improved solutions for the three basic requirements of speed, accuracy, and flexibility of LED chip mounters. Flexible modular technology emphasizes the portability, interoperability, scalability, and configurability of the device, and provides the reconfigurability and openness of the control requirements of the device control platform so that it can simply and efficiently construct and complete specific requirements. Surface mount equipment improves assembly productivity.
2.6 Lightweight Design Concept for Motors
It can greatly reduce the weight of the moving part of the machine, thereby reducing the power consumption of the machine to only 1/4 of the ordinary placement machine, and the power consumption can reach 1/4 of the ordinary placement machine; LED placement machine The placement accuracy is not high, but the speed is fast. At present, there are several professional placement machines for LEDs in China, which can be divided into 4 heads, 6 heads, and 8 heads according to different speeds. You can refer to the LED special stickers of Tamray LED640, LED660 V, and LED680 V. Tablet machine actually understands. The middle number represents the number of heads. The higher the number, the higher the speed. The mainstream application of the LED chip mounter should be a PCB that can be mounted on a large area. It must meet the online requirements to ensure speed.
Third, the development trend of the LED placement machine
LED chip mounter plays a very important role in the manufacturing process. It is the equipment with the largest investment and the most advanced technology in the mainstream electronic assembly technology production equipment, which has the greatest impact on the production capacity and production efficiency of SMT production lines. In fact, the most failures and speed bottlenecks are largely from the placement process, so the development of placement machine equipment is the most noticeable. With the number and advanced level of placement machines, it has become a key indicator of the electronics manufacturing capabilities of an enterprise, region or country. The development trend of the current placement machine is described below.
3.1 LED mounter is developing towards higher precision
The accuracy of the placement machine refers to the mechanical accuracy of the X and Y axes of the placement machine and the rotation accuracy of the Z-axis. The placement machine adopts precise electromechanical integration technology to control the mechanical movement to grab the components from the feeder and align them accurately and reliably on the circuit board after being aligned by the calibration mechanism. In order to produce products with higher performance, one of the first major challenges is to improve the placement accuracy of the placement machine. From the beginning of the LED manufacturing process, the following describes the LED chip mounter with higher accuracy that may have a revolutionary impact on the future production of LED.
In ordinary LED packaging technology, the connection between the chip electrode and the pin of the bracket is usually achieved by means of gold wire interconnection, but gold wire breakage has always been one of the common causes of failure. The anomaly of the gold wire in LED lighting applications is the culprit for common problems such as deadlights and large light decay. The dead lamp can be roughly divided into two situations, one is completely off, and the other is hot off and cold on, or flickering. The main reason for not lighting is that the electrical circuit is open, and the reason for flicker is because the gold wire is soldered or the contact is bad.
With the introduction of flip-chip welding technology, the connection of the two can be connected by more stable metal bump solder balls, saving costs and greatly improving reliability and heat dissipation capabilities. LED has the advantages of long life and other advantages. With flip-chip bonding technology, it can give full play to the advantages of LED compared with traditional packaging technology using gold wire interconnection. LED flip-chip bonding technology achieves gold-free, Solid crystal packaging has many advantages such as high brightness, high light efficiency, high reliability, low thermal resistance, and good color consistency.
LED gold-free packaging is commonly known in the industry as "no packaging" or "package-free." This process uses direct SMT bonding of flip-chips and circuit boards, omits the SMD packaging process, and directly attaches flip-chips to circuit boards or carriers using the SMT method. Because the chip area is much smaller than SMD devices, so This process requires a very sophisticated design.
In the future, the LED chip mounter will be directly applied to the flip-chip package less process on the basis of improving accuracy. This will be a small revolution in the LED process, which can save a lot of packaging costs, and greatly increase production costs and shorten production cycles. Making LED products really enter the general lighting market with high performance and low price. Applying the LED mounter directly to the LED manufacturing process has great potential to become the trend of future technology.
3.2 LED mounter is developing towards high-efficiency production
One of the most important characteristics of today's society is competition. It is this kind of competition that motivates people to strive for innovation; it is this kind of competition that promotes the rapid development of science and technology. Driven by the booming LED lighting market, the high-efficiency work of LED chip mounters is bound to become its core competitiveness. High efficiency is to improve production efficiency, reduce working hours, increase production capacity, and create economic benefits. The main methods for improving efficiency based on the current basis are: strengthening the automation performance of LED placement machines and improving the equipment structure and working mode.
3.2.1 Enhance the automation performance of LED placement machine
The development and improvement of today's information science and technology have greatly promoted the level of automation, from the original automatic control, automatic adjustment, automatic compensation, automatic discrimination, etc. to the higher level of automation such as self-learning, self-organization, self-maintenance, and self-repair. become possible. At the same time, the efficiency of software programming is also very important to improve the efficiency of equipment such as chip mounters. The development of a more powerful software function system, reducing manual programming time, can greatly reduce invalid working time and improve production efficiency.
3.2.2 Improve equipment structure and working mode
When the placement machine gradually reaches the bottleneck in improving the placement speed, it is a good idea to improve the structure of the LED placement machine. For example, the dual-channel LED placement machine has designed the PCB transportation, positioning, inspection, and placement into a dual-channel structure while retaining the performance of a traditional single-channel LED placement machine. This two-way structure can work synchronously and asynchronously. The synchronous method is to send two PCBs of the same size to the mounting area for simultaneous placement from the dual-track, and the asynchronous method is to send different size PCBs to the mounting area. Both of these working methods can improve the productivity of the machine. Another example is the multi-cantilever and multi-mount head structure of the placement machine, which are all effective methods.
3.3 LED placement machine is developing towards the flexible and modular structure
The development of the times has promoted people's living standards and cognition. Personalized demand is an important strategic means for the future market. The opening of the first year of e-commerce has given us more enlightenment. The traditional business model of physical stores is more toward the development and transformation of product experience stores. In the future, in order to meet the personalized needs of the market, electronic product manufacturing will face challenges such as variety, fewer batches, shorter cycles, etc. An effective method to adapt to this trend is the flexibility of placement equipment.
For example, the main unit of the LED chip mounter is made into standard equipment and equipped with a unified base platform and a universal user interface, and the various functions of the dispensing chip are made into functional module groups. The module group has different functions. According to the mounting requirements of different components, it can be mounted at different accuracy and speed to achieve higher efficiency. When users have new requirements, new functions can be added according to needs. Modular machine.
The flexibility of the LED placement machine is the flexibility of placement in actual production. It includes the ability to adapt to different PCBA products, can take into account placement accuracy and speed, can quickly perform production conversion, and can upgrade. Flexibility is a solution that can maximize the use of existing resources to create the best economic benefits, so softening is a conceptual, dynamic, and relative device characteristic description.
3.4 LED placement machine is developing towards intelligence
With the rapid development of Internet technology, the explosive growth of mobile smart terminals and the youth of consumer groups, intelligence is inevitable in the development of the electronics industry, especially the home appliance industry. The concept of intelligence has appeared in our lives very frequently. In China, product intelligence is the most promising future market. Similarly, in manufacturing, intelligent manufacturing equipment is the most promising development of manufacturing technology.
The Intelligent LED placement machine has the following characteristics: human-machine integration, self-learning, self-organization, self-maintenance, self-repair, ultra-flexible, etc., which has greatly improved the level of mental labor automation and reduced errors in the production process. Thus improving efficiency and productivity. The future LED placement machine is based on computer intelligence technology, which enables him to have a more advanced human-like thinking ability. It can analyze, judge, reason, conceive and make decisions about the placement process, and can collect, store, share, and Inherit the intelligence of human experts to provide the most suitable and flexible solution quickly. The precision and intelligence of the LED mounter will inevitably have a huge impact on the future production and technology of LEDs.
3.5 LED placement machine is developing towards green
In recent years, new concepts have been added to the concepts of greening and environmental protection. The so-called environmental protection is broad and includes not only the protection of the natural environment but also the social and production environment, as well as the physical and mental environment of producers. The development of human society will inevitably lead to the harmony between man and man, man and machine, man and society, man and nature. In the future, the whole process of LED chip mounters from design to recycling and manufacturing must consider the impact on the environment. From the beginning, it has been fully considered to maximize the utilization of materials as much as possible, so as to maximize user investment benefits.
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