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Quality Control for Auto Insertion machine manufacturing

   

Quality Control

 

 

Every Auto Insertionl machine
is subjected to a Quality Acceptance Test (QAT) before being shipped to
its customer. There are 4 phases to a QAT:

 

 

Phase I – Pre-Dry Cycle

 

The
appropriate pattern program is loaded and the machine performs a short
part run with all motions and mechanisms functioning to check setups and
speed. All data is recorded on the machine’s event log.

 

 

Phase II – Dry Cycle

 

Can
only occur after successful completion of the Pre-Dry Cycle. The
machine is run with all motions and mechanisms functioning but without
boards or inserting components for a pre-specified period of time. All
data is recorded on the machine’s event log.

 

 

Phase III – Integrity Run (Final Run)

 

Can
only occur after successful completion of the Dry Cycle. This is a
simulated production run to check insertion performance and speed.
Results are recorded on the machine’s event log.

 

 

 

Axial Inserter

S4000

Radial Inserter

S3000

Phase I

         

Parts Run

2000

2000

Insertion PPM *

0

0

Intrinsic Availability **

100%

100%

Phase II

         

Length of Run

12 hrs.

12 hrs.

Intrinsic Availability

95%

95%

Phase III

         

Minimum Parts Run

20000

20000

Allowable Insert Errors

10

20

Intrinsic Availability

95%

95%

Acceptable PPM Levels

500 – 1000

1000

Confidence Level

95%

95%

 

 

* (# of good insertions / total # of insertions)

** (# of hours the machine is ready to run / total # of hours machine planned to run)

 

 

Phase IV – Customer Acceptance (Optional)

 

Can
only occur after successful completion of the Integrity Run. The
customer visits the factory to watch verify the machine’s ability to
meet performance requirements. The customer’s production run is
simulated and all options are verified and explained. 

 

 

 For any further questions regarding the customer acceptance procedure, please  contact:

 

 Albert Wen

 Albert@smthelp.net

 

 

 

Phase V – Preproduction Acceptance (At customer site)

 

Service engineer installs the machine and assures it is setup
and running with the same degree of operational efficiency as at the
factory.

 

By SMThelp Article • THT • • • • • • • • • • 0 Comments

Auto Insertion machine Competitive Analysis – TDK AC7 vs Universal VCD

Axial Products Competitive Analysis

Competitor

Location

Key Weaknesses

Key Strengths

Comments

TDK 

(Rank 2)

Japan/U.S.

No Axial experience

No previous Axial machines in product mix, offering only a SH VCD (no Sequencer, DH, etc.)

Axial product offering is VERY similar to Dynapert V12000.  Possible patent infringements on Dynapert design.

Support infrastructure is inferior to UIC’s.

Low price machines

Field proven reliability of Radial Inserter

Large multi-national installed base for Radial Inserter

Japanese firm, thus strong JMA loyalty

Asian company, thus understands Asian business needs

Operates in Microsoft Windows interface, which provides immediate productivity feedback

Financially sound and stable

Offer a  SH VCD – Avisert AC-7

TDK Competitive Summary

 

AC-7 Avisert Features:

· Board offset correction

· Insertion hole correction

· Ammo or reel input packaging

· Push button control panel

· Microsoft Windows interface

· Intelligent operator message feedback

· Servo driven cam operated insertion head

· Servo motor driven rotary table

· Available Options: 

– Pass through capability

– Throughput optimizer

– Flexible work board holder

– Touch screen

  – Pattern repeat

– Multi tier security software

– Optical safety device

– Integrated machine enclosure

Key Sell Against Points:

Universal offers a complete Axial product line; Single Head, Dual Head, VCD Sequencer and Sequencers while TDK offers a single Axial machine.

Universal completes the IM product offering with Radials and Special Products which include Eyelet and Pin Inserting Machines, and 3-Span Radials.

We offer optional Universal board handling on most models.

Universal offers a superior training, service and support infrastructure.

We offer industry leading cost per insertion and the highest throughput per square foot of floor space.

UIC Strengths and Proof Points:

UIC Strengths

Benefit

For the Customer:

Machine designs allow flexibility in the production environment.

Universal offers a complete IM product line of Axial inserters, Sequencers and combination machines, as well as Radial product offerings.

Universal board handling is optional for machine integration.

Discuss customer need for  factory integration.

Possible future need for increased automation.

High value for the price, and  fastest inserters in the industry.

Dual Head machines provide  the highest throughput in the industry, 32,000 cph, a cost effective approach for high volume applications.

Ask the customer to compare cost per insertion.

Superior service, support and training.

Excellent investment protection.

UIC is a respected and secure provider of insertion equipment.

Pre and post sale assistance with specific applications and systems integration.

Ask the customer to compare UIC’s support infrastructure (tech. specialists, spare parts, FE response time) to Panasonic.  Also discuss unique value benefits – Uptime 100 and Tech Advisor.

TDK Strengths and Counter Points:

Competitor Strength

The Facts

For the Customer:

Perceived high throughput (16,000 CPH).

The throughput Nepcon Tokyo 觀appeared closer to 10,000 CPH.

Noisy.

Demonstrate UIC’s commitment to reducing customer costs by: 

1.  Comparing cost per insertion.

Single insertion head provides better stability and less maintenance and setup.

Dual head machine is the  highest throughput inserter in the industry with exceptional reliability and insertion performance.

Single head machine offers competitive cost per insertion with all the other values of UIC.

Demonstrate UIC commitment to customer support with:

1. Service and support, including PM schedules and maintenance manuals.

2. Uptime 100 program.

3. Tech Advisor.

4. Superior training program.  

Priced competitively in the 80K – 106K range.

Targeting existing Dynapert accounts where support requirements are minimal.

Demonstrate UIC’s commitment to reducing customer costs by: 

1.  Comparing cost per insertion.

Financial backing from a major IM provider.

Very similar to Dynapert V12000 machine 

Possible patent infringements on Dynapert design.

Not a complete product line, no complementary Sequencer available to date or board handling.  

May not have devoted TDK backing for service and support.

Determine if customer is will to obtain investment protection:

1. From a supplier that may not remain in business due to legal problems.

2. Has revived very old designs.

3. Discuss Broome Engineering products for low cost entry and their ability to allow trade-up. 

Appendix – Reference Accounts and Testimonials:

Account Name

Salesman to contact

Comments

AT&T Monterey, Mexico

Michael Lewis 

TDK offered AT&T accepted an all expenses paid trip to Boston to evaluate the AC-7 but still prefers the UIC Dual Head machines.

SMT spare parts, such as SMT nozzle, SMT feeder, SMT feeder parts, SMT filter, SMT cutter, SMT consumbles, (2)
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How to analyze common failure case of reflow soldering

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

              A common fault handling of reflow soldering is analysed

Reflow soldering heat alarm prompt temperature difference is too big or too small, in the process of computer tip ‘communication failure can’t start the machine, according to the two kind of phenomena, we had a lot of test and analysis work, draw the following conclusions:

1, in the process of reflow soldering heat suddenly alarm prompt “temperature range of a certain temperature too low or a certain temperature and set temperature difference is too large”.
Aiming at this phenomenon, we can preliminary judgment fault will occur in the heating or part overheating protection, and so will all overheat protection switch sub let its failure, and start the machine, found that seems to be normal.After further analysis, under the condition of the overheating protection switch sub machine can work, but in the event of heating, the temperature rise too high a less protection of defense, will bring more serious consequences.In order to solve this problem, we must put 16 from heating unit to find out one or several thermal protection switch failure, we will each heating unit with this problem apart, examine its overheating protection switch, found problems the second heating unit overheating protection switch, with a moving contact bimetallic strip fixed weak, cause the moving contact and the static contact point contact is not good, or not at all contact (normally two contacts should be contact together and conduction).Because there is no the second heating unit of the spare parts to replace we will switch sub to ensure production run smoothly.To this can solve the problem, but as soon as possible to the broken overheating protection switch is off, so as to achieve the purpose of protecting the second heating unit.

2, if the downtime is longer, when it turns switched on again reflow computer tip ‘communication failure and can’t start the machine for a long time to let the heat.
Aiming at this phenomenon, we preliminary suspect as the communication line fault, then replaced the telecommunication lines, the question remains, so denied this conjecture.After further observed, when the communication is not successful, the lights on the status of the controller is not normal, orange lights should be flashing, and should not go out.Based on manual measuring line 1001 and line voltage between 1007 found that the voltage is not constant for the + 5 VDC, about + 2 VDC when communication is not successful, the problem is out of here, why the voltage is too low, the original control panel in the end of the machine here are two simulated load resistance, resistance ought to be ‘5’R , but actual value only two ‘2’R, but I have measured the value to change it into ‘5’ R problem is resolved.


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SMT,THT,PCB,PCBA,AI,wave soldering,reflow oven,nozzle,feeder,wave soldering,PCB Assembly, LED, LED lamp, LED display,
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3 points development trend of SMT LED machine

                        

                THE DEVELOPMENT TREND OF THE LED MACHINE

  


The LED pick and place machine play an important role in manufacturing process, is the contemporary mainstream electronic assembly technology investment the largest and the most advanced production equipment, the production ability of SMT production line, and the greatest influence the efficiency of production equipment. In fact, the most fault, speed bottleneck largely from patch the process, so the development of the placement machine equipment is the most conspicuous. Currently has the number of SMT machine and advanced level, has become a corporate, regional, or national key symbol of electronic manufacturing capacity. Facing the current development trend of the placement machine under declare as follows.

1? the LED pick and place machine is developing toward the higher precision

Placement machine precision is refers to the placement machine X, Y axis navigation movement of the mechanical precision and Z axis rotation accuracy. SMT machine adopts precision mechanical and electrical integration technology control the mechanical movement components will crawl out from the feeder and after calibration institutions for the precise and reliable loaded on the circuit board. In order to produce the products with higher performance, first of all, facing a major challenge is more likely to improve placement accuracy of SMT machine. Below from the LED process began to speak with a higher accuracy of the LED placement machine could have LED the revolutionary impact of production in the future.

With the launch of the flip chip bonded technology, both are linked together by more stable metal convex welding ball to connect, saves the cost and greatly improves the reliability and the cooling capacity. Leads have the advantages of long service life, cooperate with the flip chip bonded technology is better than the traditional packaging technology of gold wire interconnection can play the advantages of LED, LED inversion welding technology, to realize the single chip and multichip module without gold line, solid crystal gel encapsulation, high brightness, high luminous efficiency, high reliability, low thermal resistance, good color uniformity, and many other advantages.

LED no gold wire packaging industry commonly known as the “packaging” encapsulation “free”. This process is to use the flip chip and PCB SMT joint directly, SMD encapsulation process is omitted, the flip chip directly with SMT method on the joint to the circuit board or bearer, because the chip http://www.onlinepharmacytabs.com area is far less than the SMD components, so the process need to be very sophisticated design.

LED placement machine in improving accuracy of future conditions on the basis of applied directly to the flip chip packaging process, it will be little revolution LED process, can save a lot of packaging costs, and greatly improves the production cost and shorten the production cycle, really high performance LED products to enter the general lighting market at low price. Will the LED placement machine directly applied to the LED process, very has the potential to become future technology trends.

2? the LED pick and place machine is developing toward the high efficiency production

Today, however, one of the most important characteristics of competition. It’s this competition, inspire people to explore innovation; It’s this competition, promote the development of science and technology with each passing day. In the course LED lighting market in full swing, the LED placement machine of high efficiency work must become its core competitiveness. High efficiency is to raise the production efficiency, reduce working time, increase production, create economic benefits. On the basis of the current main methods of improving efficiency are: strengthening the LED placement machine, automatic performance and improving the device structure and working mode.

3.  the LED pick and place machine intelligent direction development

With the rapid development of Internet technology, the explosive growth of mobile intelligent terminal and consumer groups of young, intelligent is inevitable in the development of electronic industry especially in home appliance industry, the concept of intelligence has been frequently appear in our life, intelligent product is the most promising market in the future. Similarly, in the manufacturing, intelligent manufacturing equipment is the most promising manufacturing technology development.

Intelligent LED SMT machine has the following characteristics: man-machine integration, self-study, self-organization, maintenance, such as self-healing, super flexible, high automation level, improves the mental Labour to reduce the error in the process of production, so as to promote efficiency increase production capacity. Future LED placement machine is on the basis of computer intelligence technology makes his classes with more advanced thinking ability, to stick to the whole process of loading analysis, judgment, reasoning, and decision making, and can through the collection, storage, sharing and inherit the human experts’ intelligent and efficient to quickly provide the most suitable for flexible scheme. LED placement machine, motors and intelligent is bound to the LED production and technology have a great effect in the future.


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Zuckerberg Responds To Critics, Explains How He’s Spending $45B

Zuckerberg Responds To Critics, Explains How He’s Spending $45B


 by Katie Roof 

On Tuesday, Facebook co-founder and CEO Mark Zuckerberg posted a powerful announcement — not only did he reveal the birth of his daughter, Max, but he shared plans to give up 99% of his personal Facebook shares over the course of his lifetime and use them to fund projects and causes through a newly formed entity called Chan Zuckerberg LLC.

The announcement generated a lot of attention, much of it due to the sheer volume of Zuckerberg’s net worth — $45 billion! While many people, including Bill Gates and Michael Bloomberg, praised him for his generosity, others expressed confusion and even questioned his motives for giving his money away.

Looking to alleviate some of those concerns, in a post Thursday,  Zuckerberg further explained how he and his wife Priscilla Chan, plan to delineate their funds.

“Our initial focus areas are personalized learning, curing disease, connecting people and building strong communities. We’ve already made many investments over the past five years in these areas — education, science, health, internet access and inclusion — and you can see a summary of our investments on the Chan Zuckerberg Initiative page timeline.”

Zuckerberg further addressed the allegations that this organization was a way to avoid taxes, and explained that by structuring the Chan Zuckerberg entity as an LLC, that their shares will still be taxed.

“By using an LLC instead of a traditional foundation, we receive no tax benefit from transferring our shares to the Chan Zuckerberg Initiative, but we gain flexibility to execute our mission more effectively. In fact, if we transferred our shares to a traditional foundation, then we would have received an immediate tax benefit, but by using an LLC we do not. And just like everyone else, we will pay capital gains taxes when our shares are sold by the LLC.”

He also says that this “for profit” structure allows them to make investments that will continue to fuel their objectives.

“This enables us to pursue our mission by funding non-profit organizations, making private investments and participating in policy debates — in each case with the goal of generating a positive impact in areas of great need. Any net profits from investments will also be used to advance this mission….For example, our education work has been funded through a non-profit organization,Startup:Education, the recently announced Breakthrough Energy Coalition will make private investments in clean energy, and we also fund public government efforts, like the CDC Ebola response and San Francisco General Hospital.”

Some of Zuckerberg’s early attempts at philanthropy were also met with controversy, particularly his $100 million gift to Newark schools.  But with $45 billion to experiment with, let’s hope that much of this money ends up doing a lot of good.

Zuckerberg previously signed The Giving Pledge, promising to give away over half his fortune, along with Richard Branson, Warren Buffett and other billionaires.

By timing the latest announcement with the birth of his baby, it seems that Zuckerberg is trying to send a message that he’s not hoarding his personal fortune for the next 100 generations of Zucks.