AI, Auto Insertion : Axial Inserter; Radial Inserter; JW (Jumper Wire) Inserter; Odd form Inserter; PIN inserter; Eyelet Inserter; Terminal Inserter IM, Insertion Mount, MI,Manual Insertion,  DIP,  Wave soldering 
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How is the future Through Hole Technology in Electronic Manufacturing

Automatic component insertion provides the consistency required to
ensure the highest levels of circuit board quality, throughput, and
process control. When properly planned and implemented, automatic
component insertion provides significant cost savings in the
printed circuit board assembly process.
The benefits realized from automating circuit board assembly processes
span all areas of manufacturing. Ultimately, all of these
benefits result in improved products and reduced production costs.
Three key inputs affect the economics and logistics of PC board
assembly: (1) the circuit boards, (2) the equipment used to assemble
the boards, and (3) the components to be inserted. By precisely
understanding and standardizing these three primary elements,
manufacturers can improve the quality of the finished boards,
increase the throughput of the assembly equipment and the system,
and more precisely define the process control standards to provide a
basis for future applications. Standardizing these elements reduces
process variability, which leads to increased insertion reliability,
improved product quality, enhanced system price/performance and,
ultimately, reduced production costs.

 

LED SMT line after sales tape cutter S-1688 Pneumatic Stencil cleaner line SMT

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What is First Article Inspection

First Article Inspection overview

Before the manufacturing course begins, business necessities require an in depth verification and comparability of product design vs. manufacturing outcomes, often called First Article Inspection (FAI). Frequently used within the aerospace, medical electronics and automotive industries, FAI studies have gotten an ordinary course of to make sure high quality and consistency of the ultimate product is in order. Although conducting FAI could be advanced, technological developments and person pleasant software programs have allowed customers to implement and execute this course of shortly and precisely.

What is First Article Inspection?

As an official authentication technique for production, FAI intention is to overview and authorize dimensional studies. FAI stories make the most of dimensional properties of a manufacturing like design specs, to make sure of consistency or uncover any deviations. This inspection ensures reliability and repeatability of the manufacturing course, in addition to making certain the producer’s capability to provide elements in accordance with specifications.

 What is First Article Inspection

 

 

What is the aim of FAI?

The goal of a FAI report outlined below:

  1. The FAI report supplies a tenet for goal affirmation that every engineering design and specification is appropriately understood, accounted for, verified and documented.
  2. Ensure the manufacturing course of action is dependable, repeatable and constant
  3. Develops a transparent understanding and communication outlet between purchaser and provider.
  4. Verify the accuracy of drawings, making certain that each adjustments made to any part of the designs are accounted for.
  5. Validate all tooling used for production, guaranteeing the instruments’ capabilities to supply all required elements at defined and accepted speed.
  6. Ensure manufacturing course is succesful and might meets the entiretly of all manufacturing needs.

When is FAI report crucial?

FAI studies are crucial when any of the following occur:

  • A change in design which may probably have an effect on match, kind or operation
  • A change in manufacturing supply, course of action, inspection technique, location of producer, tooling or supplies
  • A change to a special media program that will likely have an effect on match, kind or performance
  • Production has not been executed for 2 years or more (or as specified by buyer)

FAI Benefits

Before proceeding with manufacturing elements, FAI studies will be helpful in figuring out whether or not a production course of action is able to deliver elements constantly within design parameters. Furthermore, FAI studies present construction between buyer and provider for understanding and verifying the final mission necessities. FAI additionally assists buyer and provider with communications and help to avoid future miscommunication. This course of action additionally ensures that you will be using the precise supplies and instruments, offering an efficient initiative for the anticipated outcomes for manufacturing.

Full FAI vs. Partial FAI

A full FAI requires that each field has been accounted for.  With a partial FAI report, any subject missed will affect the FAI sucess. In regards to any excellent fields, they might be crammed out at a later date or utilizing earlier knowledge, on condition that it applies to the precise traits of duplicate elements produced by the identical manufacturing course of action.

FAI Planning

Before the primary manufacturing beings to run elements, many components have to be accounted for with the intention to execute FAI planning, which generally embrace the following:

Records for the manufacturing course of action– manage actions to be executed all through FAI course of and accountable suppliers/organizations.

Ensure authorized  materials sources, laboratory and relevant manufacturing, planning, routing and buying are in accordance with the specifications.

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Helps the Environment — S1688 stencil cleaner machine

Waste Streams from Printed Circuit Board Manufacturing
Waste Stream Waste Stream
Waste Source Description Composition
Cleaning/Surface preparation 1. Airborne particulates
2. Acid fumes/organic vapors
3. Spent acid/alkaline solution
4. Spent halogenated solvents
5. Waste rinse water
Catalyst application/
Electroless plating
1. Spent electroless copper bath
2. Spent catalyst solution
3. Spent acid solution
4. Waste rinse water
Pattern printing/masking 1. Spent developing solution
2. Spent resist removal solution
3. Spent acid solution
4. Waste rinse water
Electroplating 1. Spent plating bath
2. Waste rinse water
Etching 1. Spent etchant
2. Waste rinse water
Board materials,
sanding materials,
metals, fluoride,
acids, halogenated
solvents, alkali.
Acids, stannic
oxide, palladium,
complexed metals,
chelating agents.
Vinyl polymers,
chlorinated
hydrocarbons, organic
solvents, alkali.
Copper, nickel, tin,
tin/lead, gold,
fluoride, cyanide, sulfate.
Ammonia, chromium,
copper, iron, acids.

 

 

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AI/SMT spare parts

Profesional in AI/SMT machine and spare parts of AI/SMT .
1.We have original drawing ,what we can make is almost  the same quality with original spare parts.
2.All the process when manufactured ,our engineer would give guide and test the quality.
3.Only when the qulity is passed will we let the parts into our store.
4.Also we can control our spare parts in a very low price, when control it on a good quality.

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Do you want to build a LED SMT line ?

We are especially good at designing special-purpose equipment according to the customer’s requirements. With our effort and hard work, we are becoming one of the experienced and powerful electronic equipment suppliers in China.
The product range covers computer lead-free reflow soldering, computer lead-free wave soldering, complete set of illuminating lamps (Their aging, a dry thread on the light wave spreading t4 t5, t8, tube, ballast aging and led the aging of the inspection and etc), SMT relevant equipment, factory product line, and all kinds of large assembly lines.
PCB assembly LED SMT line LED SMT line

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Comparison between Pneumatic stencil cleaner and Ultrasonic stencil cleaner

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One key point to consider Radial machine spare parts design and manufacturing

Reels or ammo packs of radial leaded components are loaded on the sequencer module, dispensed, and inserted in the PCB following the programmed sequence. Component dispensing heads remove components from the carrier tape and place them in component carrier clips located on the sequencer chain assembly. The sequencer chain assembly transports the components to the insertion area. While the components are on the sequencer chain assembly, the carrier tape is removed. The component transfer assembly transfers components from the sequencer chain assembly into the insertion head tooling. The insertion tooling guides the leads through the holes in the PC board. The cut and clinch unit cuts and then forms the leads, securing the component in the PC board.

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How does SMT electronics assembly work?

Electronics manufacturing using surface-mount technology (SMT) simply means that electronic components are assembled with automated machines that place components on the surface of a board (printed circuit board, PCB).

SMT车间

Electronics manufacturing using surface-mount technology (SMT) simply means that electronic components are assembled with automated machines that place components on the surface of a board (printed circuit board, PCB). In contrast to conventional through-hole technology (THT) processes, SMT components are placed directly on the surface of a PCB instead of being soldered to a wire lead. When it comes to electronic assembly, SMT is the most frequently used process in the industry.

Electronic assembly encompasses not only placing and soldering components to the PCB, but also the following production steps:

  • Applying soldering paste, which is made of tin particles and flux, to the PCB
  • Placing SMT components to the soldering paste on the PCB
  • Soldering the boards with a reflow process.

Applying Soldering Paste

Applying soldering paste is one of the first steps in the SMT assembly process. Soldering paste is “printed” on the boards using the silk-screen method. Depending on the design of the board, different stainless-steel stencils for “printing” the paste onto the board and various product-specific pastes are used. Using a laser cut stainless-steel stencil custom made for the project, the soldering paste to be applied only to the areas where components will be soldered. After the soldering paste is on the boards, a 2D-soldering paste inspection is performed to ensure that the paste is evenly and correctly applied. Once the accuracy of the soldering paste application has been confirmed, the boards are transferred to the SMT assembly line, where the components will be soldered.

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Component  Placement and Assembly

The electronic components to be assembled come in trays or reels, which are then loaded into the SMT machine. During the loading process, intelligent software systems ensure that components are not inadvertently switched or misloaded. The SMT assembly machine then automatically removes each component with a vacuum pipette from its tray or reel and places it on its correct position on the board using precise pre-programmed X-Y coordinates. Our machines are capable of assembling up to 25,000 components per hour. After the SMT assembly is completed, the boards are moved on to the Reflow ovens for soldering, which affixes the components to the board.

S-320 pick&place machine

SMT line

Component Soldering

To solder electronic components, we use two different methods, each of which has distinct advantages depending on the order quantity. For series production orders, the Reflow-soldering process is used. During this process, boards are put in a nitrogen atmosphere and are gradually warmed up with heated air until the soldering paste melts and the flux vaporizes, which fuses the components to the PCB. After this stage, the boards are cooled off. As the tin in the soldering paste hardens, the components become permanently affixed to the board and the SMT assembly process is completed.

For prototypes or highly sensitive components, we have a specialized vapor-phase soldering process. In this process, boards are heated until the specific melting point (Galden) of the soldering paste is reached. This allows us to solder at lower temperatures or solder different SMT components at different temperatures depending on their individual soldering temperature profiles.

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AOI and Visual Check

Soldering is the second-to-last step of the SMT assembly process. In order to ensure the quality of the assembled boards, or to catch and correct a mistake, AOI visual inspections are performed for almost all series production orders. Using several cameras, the AOI system automatically checks each board and compares the appearance of each board with the correct, pre-defined reference image. If there are any deviations, the operator of the machine is informed of the potential problem, who then corrects the mistake or pulls the board from the machine for further inspection. The AOI visual check ensures consistency and accuracy in the SMT assembly production process.

Dimensons_floor _layout - A_cmyk

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Pay more attention to safety hazard during operating auto machine！

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Automation technique is applied to the development of mechanical manufacturing industry ，which  can greatly improve productivity, in other hands, the machinery manufacturing automation technology is currently one of the most valuable in the world of science and technology, it is to promote the development of social productivity and also make people’s life become more quickly, play an important role in improving people’s living standard.

But with the development of mechanical processing manufacturing, also can not avoid artificial operating machinery and equipment, and always heard the sad news, such as workers injury or death when operating the machine.On May 29, a factory ‘s worker body is stuck to the machine unfortunately when operating the machine， while firefighters rushed to the rescue, the women were taken to a hospital successful, but the last，the woman died of his wounds.This let us deep thinking.

So in our SMT/AI industry，every workers must to know the machine security issues and safety guidelines，it‘s very important，we must ensure the safety of workers！

SMT车间

 

 

 

 

 

 Security issues and  safety guidelines：

1 Tooling cuff requirements beam, work shoes should be prevented slippery, and can’t wear high heels.

2 When  working alongside the material stack， must press the STOP button bright women scarves.

3 The woman should on long hair to disk, and the men tie to close firmly, prevent into the machine at work.

4 Single machine operation, it is strictly prohibited to many people at the same time.

5 Hands in upper and lower, inside the machine components to use pliers or tweezers (axial element), hands, hands after leaving the plug-in area, then operate the control panel.

6  Must sure to remove all tools sundry machine worktable when start to operate the machine.

7 Work in it is prohibited to put any goods on the worktable, so as not to damage the machine.

8 In the work such as unexplained machine stopped suddenly, may not be reached below the plug-in head.

9 Plug-in mistakes in normal production, may not be reached to the head.

10 For the automatic machine, the machine in normal production, it is forbidden to reach into to send slab bridge.

11 To understand the mesa machine movement area, not collision.

Maybe there are more things we should care，safety is the basis of the production.So please every factory ’s leader pay more attention to the Security issues and the workers must be more care.

 

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35000 CPH ! High Speed SMT pick&Place machine

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