Based on the World Semiconductor Trade Statistics, the semiconductor industry has been growing since 2020 despite the Covid-19 situation. The increment of semiconductor usage shows that it has become significant in the electronic industry. As a result, Printed Circuit Board (PCB) plays an important role in this industry where it is used to mechanically support and electrically connect electronic components using a certain pathways, tracks and signal traces etched from copper sheets laminated onto a non-conductive substrate.

The PCB process includes 3 different sections, namely the Inspection stage, Manufacturing Burn-in (MB) testing and In-Circuit Testing (ICT) to ensure that the end-product will be in good condition.

These days, the process is merged into one system to increase automated application by adding a conveyor and robotic arms. This procedure increases the productivity of testing and inspection whilst having a structured process in the manufacturing production line.

Customer challenges:

Accuracy and precision are important in the PCB production and the lack of skilled workers become one of the obstacles in the production line. There is little room for human error in a PCB production line; therefore, consistent training is required for every new worker to ensure a smooth operation.

Default systems have three different sections including inspection, MB testing and In-Circuit Testing that are separated from each other. The production line becomes unstructured as each station is placed at different areas. Misplacing the PCB or repeating inspection and testing might happen and this can affect the production output.

When workers are required to work long hours without breaks, human error occurs and as a result, accidents and injuries might happen. Moreover, the time used for breaks will impact productivity because the inspection and testing will now take a longer time to complete. Consequently, the demand from the end-users cannot be fulfilled.

XD Solutions: Robotics, Automation & Vision System

In order to merge the three sections of inspection, MB testing and ICT testing into one system, a conveyor belt plays an important role. It helps to commute the PCBs from one section to another.

An XYZ gantry is a 3-axis robot that is suitable for a variety of automated tasks such as pick and place applications, 3D printing or laser machining precision handling and electronics applications that will be installed in the first segment to automate the inspection section. It also comes with a smart vision sensor mounted on the robot to detect faults such as misalignment, misorientation, wrong assembly part or code reading in the PCB.

KUKA Robotic Arm will be used in this system to ease the process of picking up and placing down the PCB from the conveyor belt to the tester and vice versa.  KUKA Robotic also comes with new technology - Ready2_Pilot, allowing the user to control the robot without using the teach pendant. The new technology is installed at the robot and used to move and program the robot easily, freely and precisely.

The PanelView Plus is a standard terminal that comes with a 6.5 inch touch screen, TFT Colour, Single Ethernet, 24V DC, Windows CE OS License and Standard Model. It helps to build applications and simplify configurations as well as strengthen the Integrated Architecture solution. Besides that, it monitors and controls the devices that are attached to the CompactLogix controller which is the main processor that controls the whole system.

Benefit

Having a structured and automated process system by merging 3 sections into 1 can speed up the process and reduce the production time while reducing the traveling time and human error. Operators would not need to send the PCB from one section to another and any mistakes or repeated steps are avoided.

The installation of smart vision sensor system in all sections help to detect and inspect the PCB at an earlier stage and this will help ensure the accuracy and precision of the product. By minimizing defective items, the production loss can be reduced significantly.

In addition, the speed of the robot can be 10 times faster than the average human worker in which it can boost the productivity and improve the product quality.

KUKA robots with low payloads demonstrate unique strengths in bonding, sealing, foaming and all tasks requiring a high path accuracy. In arc welding, KUKA robots for low payloads boast the best acceleration values on the market. Even light work such as component testing, small-part assembly or grinding, polishing, assembly as well as machine loading and unloading is in the best of hands when performed by KUKA robots of the low payload category. With optimal reach and payload coverage, this range of robots offers a level of performance that is hard to beat. Entrust your automation to high-performance professionals: the KR CYBERTECH robots. Worldwide, no other portfolio offers a comparable combination of high power density, compact masses and application-relavant specialization in the low payload category.

A vision system that have high frame rates, exceptional image quality and easy integration. Its robust design has a long-term stability and precise image analysis in any application. It includes CMOS-based matrix camera and colour and monochrome versions with resolutions ranging from VGA to 65 megapixels.

Our Bulletin 1769 CompactLogix™ 5370 Controllers are part of the Integrated Architecture® system. These controllers include integrated safety, and use the same programming software, network protocol, and information capabilities as all Logix controllers. This provides a common development environment for all control disciplines. Consistent tools and features help users to lower engineering investment costs, ease diagnostics and troubleshooting, and speed up time to market for small to mid-size applications.

Stratix 2000™ industrial-grade unmanaged switches require no configuration, which helps you set up and install your switch quickly. The Stratix 2000 line has flexible power requirements and can be used with AC or DC power. The switches connect easily with Logix controllers and have features to autonegotiate for speed and duplex per port. Stratix 2000 switches are ideal for small, isolated networks.

The PanelView™ Plus 7 Standard terminals are operator interface devices. They monitor and control devices that are attached to ControlLogix® 5570 and CompactLogix™ 5370 controllers on an EtherNet/IP network. Animated graphic and text displays provide operators a view into the operating state of a machine or process. Operators interact with the control system by using touch screen input.

Our Kinetix® TL-Series™ servo motors represent an economy solution for machine designers with a wide range of application needs. The Kinetix TLP Plus servo motors expand the offering up to 15 kW and include a 24-bit high-resolution absolute feedback option. The Kinetix TLP multi-purpose servo motors offer a broad power range and optimization with the Kinetix 5100 servo drive platform. The Kinetix TL and TLY compact servo motors are ideal for low-power applications.

PowerFlex® 520-Series AC drive delivers an innovative design that is remarkably versatile and can accommodate systems ranging from standalone machines to simple system integration. The PowerFlex 523 drive provides general purpose control for applications ranging up to 30 HP and 22 kW. The PowerFlex 525 drive provides maximum flexibility and performance ranging up to 30 HP and 22 kW. By combining a variety of motor control options, communications, energy savings and standard safety features in a costeffective drive, the PowerFlex 520-Series drive is suitable for a wide array of applications.