Insertion Machine Research Articles

Collision-free insertion of components on PCBs using spatial representation technique

This paper presents the technique for checking collision of through-hole components during the machine insertion process on a printed circuit board (PCB). The spatial representation technique is used to represent the components and the mounting head of an insertion machine. An algorithm that simulates the insertion process is written to detect any collision of component and mounting head during the insertion process. When a collision is detected, the algorithm will attempt to avoid the collision by re-sequencing the components concerned. If resequencing does not avoid the collision, the algorithm will compute a minimum safe distance for the affected component. The algorithm can also detect component collision due to components' space overlapping each other and subsequently can provide the minimum safe distance. The required safe spacing is based on the type of mounting head or machine used. The algorithm is a useful and efficient tool that could be used during the PCB design stage. The effectiveness of the spatial representation technique has been demonstrated using the TDK VC-544R/AR insertion machine.

Cell formation in PCB assembly based on production quantitative data

In this paper an application of Group Technology (GT) and Cellular Manufacturing concepts to scheduling printed circuit boards (PCB) assembly is discussed. The objective of the study is to design and test a procedure capable of grouping the PCBs in a number of cells with minimized setup and maximized workload balance that satisfy such quantitative constraints as the number of available inserter machines at each assembly stage, the capacity of each available machine and the maximum number of component types that can be simultaneously equipped on board each machine. A completely new heuristic is proposed for assigning sequentially the PCBs of a given mix to PCB cells in such a way that: setups are minimized; the workload balance among different machines is maximized; the PCB cells are less or equal in number to the available insertion machines; the insertion machines are utilized between user defined upper and lower utilization rates thresholds. The designed heuristic, implemented on a PC, is tested by means of a simulation model, using data coming from a real PCB assembly system, yielding interesting results.

Just‐in‐Time (JIT)

Initial Planning or Revision of Electronics Manufacturing Areas: Automation and just‐in‐time (JIT) manufacturing are the crucial suppositions of economical electronics manufacturing in the future. Surface mount technology (SMT), automated through‐hole component insertion machines and in‐line assembly systems are the basic solutions to implement highly automated electronics manufacturing systems (see photograph).

Annealing method for PCB assembly scheduling on two sequential machines

Abstract Modern electronic printed circuit board assembly (PCB) typically employs specialized component insertion machines, in a flow-shop-type facility. Since the mix of boards on production utilizes more component types than the machines contain, there is a sequence-dependent set up time between the board types. The setup time is very significant relative to the fast insertion operation. This paper demonstrates the simulated annealing approach as a tool for sequencing the boards on two sequential insertion machines, in order to minimize the average flow time of the boards. This approach is experimented on a real industrial problem and its results and computation times are presented.

Part assignment to electronic insertion machines: two machine case

SUMMARY Modern electronic circuit board production typically uses computerized insertion machines to insert electronic components into circuit boards in a flow shop type of production line. This paper studies the problem of assigning components to insertion machines with the aim of maximizing output. The paper initially examines the two machine assignment case, identifying requirements sufficient to ensure an optimal solution for two technological scenarios. Moreover, it is noted that the sequencing issue of different board types in a production cycle is immaterial, given large machine capacity. Solution procedures for this components assignment problem are described and tested on data obtained from a real life industrial setting. The resulting solutions are within 0-5% from optimality.

A Max-Min Allocation Problem: Its Solutions and Applications

This paper describes a max-min allocation problem that has M constraints and N nonnegative integer variables. By exploring the structure of the optimal solution to this max-min allocation problem, we develop a nonsimplex-based algorithm that finds an optimal solution within O(MN2) operations. In addition, we show that a space allocation problem for a flexible component insertion machine can be formulated as a special case of this max-min allocation problem with one constraint. Furthermore, we present some manufacturing and production problems that can he formulated as max-min allocation problems, and hence, can be solved efficiently.

An automated card assembly line using robots

Electronic card assembles, also known as printed circuit boards, are being produced in the computer products industry in much greater volumes then in the past. This is due to the increased consumer demand for low cost/high volume products such as personal computers, printers and other related hardware. Manual build and test of the electronic card assemblies is being replacecd by automation which can be easily justified at these increased volumes. This paper presents an automated electronic card assembly line. This line does not currently exist: it is a combination of existing equipment, such as automatic insertion machines and automatic wave solder machines, and new technology such as robotic component insertion and automated test stations. The overall line is first presented and then the details of the line are given. Special emphasis has been placed on automated test because this is a very important part of the line which has been neglected in the past

An integer programming application to solve sequencer mix problems in printed circuit board production

The production of printed circuit board in the electronics industry requires that the taped components at the insertion machines input be in a predetermined order or sequence. The sequencing operation is performed on a microcomputer-controlled sequencing machine which represents a substantial proportion of both the initial capital and direct costs. The sequencing costs are affected by two sequential decisions: sequencer mix or the size and the number of sequencers required to meet the production requirements, and the processing schedule at each sequencer. An integer programming approach is presented for determining the optimum sequencer mix and is illustrated by means of an industrial case study example.

Accommodating a turnkey CAD/CAM system to organizational needs

This paper describes an integrated PCB CAD/CAM system which utilizes turnkey CAD/CAM systems as design stations. The Implementation of the system is based on the practical experience that turnkey systems do not support all possible design work. Typical design routines in effect in a service bureau type environment are assisted by user-written software in the realized system. User written software provides integrated parts data base, one phase user-friendly data input, intensive input data checking, support for part and document numbering, user definable document formats and languages, and a fully automatic generation of N.C. programs for insertion machines, and input data for test equipment. User-written software is run in a separate host computer, to which all the turnkey design stations are linked.

Vision system aligns leads for automatic component insertion

Two solid state cameras and a newly developed image processor have been used to measure the positional deviation of the two leads of a component and control adjustment of the X‐Y table. The system allows the insertion machine to operate without mechanical guides for the leads, allowing insertion of components with different lead pitches and at high density. Application results are reported in this article.

Automatic Production System for Circuit Boards With Universal HybridIntegrated Circuits

In the 1970′s, much development occurred in monolithic IC′s and automatic insertion machines, which brought about extensive changes among mass producers of electronic consumer products and greatly influenced the improvement of quality and the saving of labor in production. The challenges of the next era are the achievement of the following four objectives in addition to the quality improvement and labor saving objectives involved in the recent decade. 1) The efficient use of material resources to eliminate waste, 2) elevation of reliability, 3) striving for uniform specifications for components on a worldwide basis to achieve more rational and efficient operations, and 4) the creation of unique products through new mounting and assembly techniques. Towards these objectives, a unique technology has been developed which has been named ‘universal hybrid integrated circuits’ (UHIC), for which the automatic production system has been put into practical use. The various components used in assembling through this system are cylindrical in shape and entirely new in concept. They are called ‘metal electrode facebonding’ (MELF) type components. The new production system has the capacity of mounting 600 components simultaneously and can handle circuit boards up to a size of 330 millimeters per side. This means that a stereo unit or a color television set can easily be assembled on one circuit board, which could be called “all‐in‐one UHIC”.

Some Thoughts on Crossovers

In order to improve packing density and make fuller use of standard DIL insertion machines, a range of inexpensive multiple crossover networks in DIL packages is proposed.

Future Component Parts for Mechanization

The author introduces Philco's TV middle-of-the-road philosophy for component parts. Basic ground rules are laid down, such as: machines must be simple and specialized; parts must be uniform and easy to handle. A considerable Philco experience with component insertion is indicated. It is pointed out that "universal" insertion machines are always more costly than specialized capital equipment. Component parts with a rectangular form factor and special leads are proposed, and the advantages of these parts are listed. The state-of-the-art is considered in order to assess the specific ease of conversion to such modular parts. Modular dimensions for multiple component parts are also suggested. It is emphasized that 60-40 solder coated--not solder plated--parts have always, in Philco's experience, surpassed all other types to some degree. Higher temperatures and shorter time cycles are recommended. The coordinate grid system is briefly discussed from the TV manufacturer's point of view. It is concluded that the industry has much to gain from a reliable mechanization program, and it is stressed that even the smallest detail is important when tooling for new parts. The rectangular component part is suggested as one solution to those conditions which have yet failed to yield reliable results to the machine de- signer.

Increased Reliability and Better Quality Control through Mechanized Assembly and Test

It is pointed out that the electronics industry long a heavy contributor to automation in other industries, has until recently been in the role, one might say, of the cobbler's son who goes barefoot. Bast and future expansion of the electronics industry is charted, as it is estimated that an all-out national emergency would demand an output of 10 times our present production rate. Automation is posed as a solution to this dilemma; as well as an aid to uniformity, miniaturization, conservation, quality, and reliability. Changing production requirements are cited. It is also emphasized that the product, the process, or both must be completly changed in order to make automatic production feasible. Two automation approaches are discussed: that of the component-parts manufacturer, and that of the equipment assembler. Three machines are described: a simple bench-type individual-insertion machine, a fully-automatic in-line insertion machine, and an automatic forced-area dip-soldering machine. Assembly efficiency of the in-line machine is charted in detail (for early 1956 operation). A 7½ % rework rate is quoted without insertion inspection, and a 0.07 % rate with insertion inspection. The need for greater reliability is stressed, and attainment of this greater reliability through automatic assembly anti automatic test is treated at some length. In conclusion, the author admits that the present state of the art leaves much to be desired, as we build new machines and modify our products for mass-production suitability. Yet high hopes are expressed that much simpler quality-control procedures and ranch more uniform products will give considerably more reliable equipment in the field-- and this, in the not too distant future.

The Problem of Compatibility Between Military Equipment Design and Commercial Automation Techniques

The thesis is presented that standardization is the key to compatibility between military equipment design and commercial automation techniques. The definition of automation, as authorized by the Electronic Industries Assn. (formerly RETMA) is given. The cognizant standardization organization, Panel within EIA on Automation and Computers is described as consisting of seven main committees with most made up of several subcommittees. It is stated that technical representatives of non-member companies are invited to participate fully in the workS and coordination with IRE headquarters is noted. The first national standard for the Baudot Code is mentioned, and A-3's proposed specification STANDARD DIMENSIONAL SYSTEM FOR AUTOMATION REQUIrEmeNTS (covering modular hole spacing) is reproduced in its entirety. A few of the new attacks,, on automation that Remington Rand has been developing, are pictured. A single drill head, a multiple drill head, and a componentparts insertion machine are shown, which operate on the template principle, using a pantograph-type mechanism. It is mentioned that the principle is adaptable to automatic programming if economically warranted. Reliability of both insertion and the product is discussed, and 99.6% is labeled as too low. An admonition is given to KEEP IT SIMPLE, and emphasis is placed upon the importance of military feed-back from operational units in the field.