Yamaha YRM20DL SMT Assembly line

Placement Speed: 120, 000 CPH
Accuracy: ±0.015mm Cpk≧1.0
Applicable Part :0201mm to W12 x L12mm, Height 6.5mm or less
Applicable PCB :Single use : L50 x W50mm to L810 x W610mm Dual use : L50 x W50mm to L810 x W330mm

BASIC INFO

Yamaha YRM20DL SMT Assembly line

Yamaha YRM20DL SMT Assembly line configuration:

1.PCB Loader

2.SMT stencil Printer DEK NeoHorizon 03 iX

3.KOH YOUNG KY8030-3 3D SPI

4.NG buffer Conveyor

5.Yamaha YRM20DL Pick and place machine

6.Heller 2043 MK7 SMT reflow oven

7.KOH YOUNG ZENITH 3D AOI

8.NG/OK Unloader

Placement Speed: 120,000 CPH

Accuracy：±0.015mm Cpk≧1.0

Applicable Part :0201mm to W12 x L12mm, Height 6.5mm or less

PCB size(mm):Max. L810*W610

1. PCB loader

PCB frame loading machine is a kind of automatic loading equipment for electronic components PCB board. It is usually composed of a conveying system, a positioning system, and an upper plate manipulator.
The working principle is to place the PCB board and component material that need to be mounted on the board in the material frame, and send the material frame to the machine through the conveying system. Then, the positioning system is used to accurately locate the position of the PCB board, and then the components are removed from the material frame by the upper board manipulator and placed on the PCB board accurately.

2. SMT stencil Printer DEK NeoHorizon 03iX

DEK NeoHorizon Solder paste printer

Maximum flexibility for the integrated smart factory

With its modular and scalable configuration options, the DEK NeoHorizon printer meets any process requirements and offers best flexibility for any production volumes

DEK NeoHorizon Innovations

Best printing offering to cover all your needs

DEK NeoHorizon 03 iX:

Machine Alignment Capability: ±12.5 µm @ 2.0 cmk, (±6 Sigma)

System Alignment Capability: +/- 20μm @ 2.0 cmk, (±6 Sigma)

Wet Print Capability: ±25 µm @ 2.0 cpk, (±6 Sigma) - Certified by external system for every printer before delivery by standard

Core Cycle Time (CCT): 8 sec.

Perfect printing solution for best performance in high-mix production

DEK NeoHorizon 01 iX:

Machine Alignment Capability: ±12.5 µm @ 2.0 cmk, (±6 Sigma)

System Alignment Capability: +/- 15μm @ 2.0 cmk, (±6 Sigma)

Wet Print Capability: ±20 µm @ 2.0 cpk, (±6 Sigma) - Certified by external system for every printer before delivery by standard

Core Cycle Time (CCT): 6.5 sec.

Best printing quality with maximum throughput

DEK NeoHorizon Back-to-Back:

The DEK NeoHorizon Back-to-Back setup offers higher print performance in dual-lane assembly line.

DEK NeoHorizon Options

DEK provides the industry’s most powerful and flexible printing platforms. The following retrofittable DEK options help you further improve productivity and print quality on your DEK NeoHorizon printer:

1.Full flexible DEK All Purpose Clamping (APC) system

2.High flexibility and maximum cleaning performance with DEK Typhoon Cleaner

3.DEK Grid-Lok: the universal board support system

4.DEK Paste Management: the best combination of automated paste dispensing with paste roll height control

5.Closed loop to SPI systems with ProDEK

6.DEK Multiple Alignment of Singulated Substrates (MASS) offers a solution for individual optical alignment at a very high speed to boost your throughput

3.KOH YOUNG KY8030-3 3D SPI

World-Fastest Full 3D Solder Paste Inspection

The industry’s fastest full 3D measuring inspection solution- Solves shadow problems by utilizing 2-way projection- Full 3D foreign material inspection for the entire PCB- Provides accurate inspection data with real-time PCB warp compensation·Full 3D data-based process optimization solution: Realization of industry 4.0 / smart factory- Realizes real-time process optimization through powerful SPC analytics- Provides a powerful printing process optimization tool·Leading model for high-speed mass production line

4.SMT NG buffer Conveyor

● Exterior structure: plate gold structure and aluminum profile into the frame, the surface spray treatment and the color is wavy white.

● Microcomputer PLC control system works stably and reliably.

● Operating by touch screen, with automatic fault diagnosis function, convenient man-machine dialogue.

● Multiple sound and light and touch screen inside prompt alarm function.

● Using stepper motor to transmission.

● The bad board can be stored 10 pcs by rising and the good boards can be directly transported to the next machine.

● Applicable behind AOI and SPI devices.

● Double line number to distinguish NG\OK.

5. Yamaha YRM20DL Pick and Place Machine

The 1 head solution has reached an ultimate stage. A dual-lane surface mounter delivering great productivity, flexibility and ability to take on PCB.
- 1 head solution provides broad-range production capability
- Solution for variable-mix, variable volume production
- High accuracy mounting and steady production of micro components
- High-efficiency production with various features
Function and Feature
- 2-beam 2-head Dual-lane class 120,000CPH

- 1 head covers 0201mm to large-size components

- Dual-lane transfers PCB Max.W330mm

- Low-impact, High mounting accuracy ±15um

For customers who want to achieve the highest productivity in a limited floor space
Various Yamaha original features realize full dual lane lines with twice the productivity in the same floor space
The Yamaha 1 head solution provides both high speed mounting for chip components and flexibility for mid-to-large components
- RM head：A newly developed head that realizes both high-speed chip mounting and flexibility for mid-sized components up to 12mm, T6.5mm.
Rotary head boosts component mountability of tiny components. This maintains high speed production since head replacements are no longer needed. This is technology that helps carry on the 1 head solution concept. This head can handle components ranging from super-tiny 0201mm components on up to medium-sized odd-shaped components of 12 x 12mm dimensions with heights of 6.5mm

- HM head：Realizes large component high-speed mounting and flexibility via 10 fully proven inline heads + scan camera.
The flexible “all-around” head not only has high-speed, but also has the versatility essential for mounting super-tiny 0201mm components all the way up to large-size components of 55 x 100mm and heights up to 15mm.

- FM head: is a high-precision high-efficiency head that holds up to 5 nozzles while also handling large-size-tall and odd-shaped component. The FM head also has a force control function.
The ultra-wide-range head fully handles components ranging from super-tiny 03015mm chips on up to ultra-large components of 55 x 100mm and heights of 30mm. Force control is also available.

Supports various dual-lane surface mounting with high efficiency
- Parallel Mode : Production of different types (same type is also possible) on two lanes. For PCBs with a small number of component types, and for situations where you want to increase production capacity as much as possible.
- Alternate Mode : Two lanes produce the same board. For PCBs with a large number of component types and with a short cycle time.
- Hybrid Mode : By combining parallel mode and alternate mode on the same line, productivity can be maximized while maintaining the number of feeder slots.
High-efficiency production with various features
- ALF: Applies a unique center-open method to successfully realize non-skilled operation + labor-saving by tape and reel presetting + improved pickup rate.
- Side-view camera function monitors nozzle tip images to detect the component pickup position (attitude) and detects such as missing components, vertical mounting errors, and reversed components.
- Relative height of the mounting surface and component bottom controlled by measuring PCB height to control mounting height, which minimizes impact on micro components togeter with a low static-loaded nozzle.
- IT option - Production Setup Verify ensures quality via barcode checks during component changeovers and refills. It also handles Material Time Limit Management & Bin Code Management tasks.
- IT option traceability function utilizes ID information during component verification to identify the range of the defective lot.
- All Image Tracer Plus saves images during component recognition and applies factor analysis to them when a defect occurs. Images from the side-view camera can also be saved.
- Dashboard analyzes the operating rate and mounting quality to support better productivity and quality. N-point collation function linked to the YSi-V and All Image Tracer help to swiftly identify the cause of defects.
Various features that enable operation with less man-hours
- Auto Loading Feeder realize non-skilled operation + labor-saving by tape and reel presetting.
- ZSR feeder: Light-weight single feeder that can be carried in one hand with reel attached allows external setups/changeovers of reel-setting tasks. This vastly reduces the load on the operator.
- IT Option- Components Remain Counter：Gives pre-warning of component shortage (stockout) to allow preparing spare tape and reels and splicing the tape before the machine stops.
- Automatic changeovers: Prevents changeover errors and reduces machine switchover downtime on multi-connected lines by sequentially carrying out the “next changeover’ when the next PCB lot arrives. Automatic push-up pin changerover is also available.
- Dashboard and All Image Tracer Plus can reduce man-hours from checking the matter to investigating the cause and taking countermeasures.
Various features that realize automatic maintenance inside the machine
- Maintenance made easy: Yamaha’s mounter head
- Automatic cleaning of nozzles and shafts within the machine Shaft blow / Side blow
- Nozzle ID management enables maintenance optimization based on the total number of shots.The nozzle holder can be exchanged with a single touch which makes setup and maintenance easy.
- Nozzle and feeder maintenance warnings:Self-diagnosis and self-recovery functions continuously maintain nozzles and feeders in a clean state for continuous high-quality production.
- Maintenance support with the dashboard

6.HELLER 2043 MK7 SMT Reflow Soldering Oven

The 2043 MK7 reflow oven machine is an ultra-high volume reflow oven with 13 heated zones and belt speeds up to 1.88m/min. The 2043 offers the lowest delta T’s, reduced nitrogen and electrical consumption and advanced flux management options. The 12” wide heater modules offer profile compatibility with competitor systems.

- Built-in Thermal Monitoring

- Nitrogen Capable to < 100 ppm

- Energy Management System

- Virtually No Maintenance

- 12” Wide Heater Modules

Oven Length	723cm (285”)
Process Gas Options	Air, Nitrogen
Heated Zones	Convection: 13 Top / 13 Bottom
Heated Length	449 cm (177”)
Cool Zones	3 Top (Bottom Option)
Max Working Temperature	Standard: 350°C (Option: 400°C)
Maximum PCB Width	55.9cm (22”)
Cleanroom Option	Down to Class 1000

7. KOH YOUNG ZENITH 3D AOI

Ultimate Solution for Inspection Challenges

Circuit boards are becoming more complex with new products. An AOI machine is becoming even more crucial to the electronics manufacturing lines. The industry has many2D, 2.5D and pseudo-3D inspection options that only compound issues with false calls and escapes. The Zenith AOI Series is the only machine that delivers True 3D Inspection to address solutions caused by highly specular packages and shadows from adjacent parts.

Incomparable True 3D Inspection Performance

The Zenith AOI Series is the only solution in the industry to base its inspection criteria according to IPC-610 standards for electronic assembly acceptability requirements. It provides clear and precise AOI measurements to accurately identify multiple defects such as missing solder, offset, polarity, upside down, OCV/OCR, solder fillet, billboarding, lifted lead, lifted body, tombstone, bridging, and more. Because it uses a quantitative True 3D measurement-based approach, the system delivers exceptional accuracy and repeatability.

IPC-based Solder Joint Inspection

Through Koh Young’s proprietary vison algorithms, the Zenith Series can quantify the exact height of a solder joint. Despite shadows or interreflection challenges, the Zenith accurately inspects and measures according to IPC-610 standards for electronic assembly acceptability requirements.

AI-Powered Auto Programming (KAP)

Industry-leading 3D profilometry technology converges with Koh Young’s proprietary AI technology to deliver true automatic programming. The innovative geometry-based Koh Young Auto Programming (KAP) software solution reduces the programming process to minimizes time to production and reduces costs.

KSMART Solutions: True 3D Measurement-based Process Control System

Koh Young pioneered True 3D measurement technology 20 years ago to create a zero-defect

8.NGOK Unloader Machine

According to signal recognition, NG board and OK board are automatically collected into two lifting turnover boxes respectively; The NG\OK receiver is connected with AOI, after AOI detection to determine the good (OK) and bad (NG) output different signals, the signal is transmitted to the next NG\OK receiver, the NG\OK receiver receives the signal sent by AOI for judgment, and the PCB is automatically classified and stored in the OK and NG material frame; Such as: AOI output OK signal through NG\OK judgment into the moving trolley directly into the OK lifting trolley material frame; The AOI output NG signal is judged by NG\OK into the moving car and transferred to the material frame of the NG lifting car at the back.

Appearance structure :3mm thick sheet metal structure and aluminum profiles into the frame, surface spray treatment, color is corrugated white.
Microcomputer original Panasonic PLC control system, stable and reliable work.
Touch screen display operation, with automatic fault diagnosis function, man-machine dialogue is convenient.
Multiple sound, light and touch screen prompt alarm function.
The lifting step of the rack can be set according to the PCB thickness.
With automatic counting function, convenient production statistics.
Humanized design ensures that the PCB board is not broken and improves the output capacity
The bottom connecting PCB board uses a motor to push the board into the material frame
Stepper motor push plate, strength, speed can be set on the touch screen,
The push-plate device uses the Omron groove sensor to protect the PCB board from being pushed out
Push the PCB board can set the push distance in the touch screen
The OK plate is loaded into the front material frame, and the NG plate is loaded into the fabric frame.
Double line number distinguish NG\OK