https://www.rocketscream.com/blog//07/04/picking-the-right-or-wrong-pick-and-place-machine/
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I would like to set the record straight and ask my clients to comment on their experiences.
If everything went good mostly no customer writing about this.
Unfortunately, Lim Phang Mo (Rocketscream) has been experiencing some problems that we are not happy with and are sorry for.
This was an old case from where we were trying to resolve the issue.
We have sold more than 160 machines with mostly good feedback.
Dissatisfied customers are always not good, but I am glad to read that he is happy with his new solution.
Main board went kaput – The very moment we installed the vibration feeder that comes with the machine, it started to make a loud noise and that is when we knew something was not right. It turns out that the driver of the vibration feeder located on the main board is damaged and is driving the motor on the vibration feeder well beyond it’s maximum rating. SmallSMT told us it was due to the short circuit caused by the vibration feeder metallic body. We find this rather absurd because there was isolation between the vibration feeder electronics and the chassis of the pick and place machine. Anyhow, they sent us a replacement main board albeit it sure looks like a board that has been used before and repaired judging from the amount of flux residue from hand soldering on the new main board.
Sometimes shit happened and our customer produced a short of motor PCB against machine chassis. His message „motor on the vibration feeder well beyond it’s maximum rating“ is totally wrong because the failure of the main board driver caused by shortage. Why does the replaced mainboard work if the motor was the problem??
We have a lot of vibration feeder working under same conditions and received no problems.
Even the actual owner of this machine is operating it without problems.
What is the truth? This was an early machine construction and in a small space there was not enough distance between PCB and machine plate. Under some conditions and without isolation it could cause a short between machine plate. We changed construction and it never happened again.
Even the mainboard received additional fuse in vibration feeder line to prevent these kind of damages
We sent out the spare parts in a short time and after installation everything was ok.
North feeder working inconsistently – A bulk of our time spent on the machine was on configuring the push feeder. It is at best described as “fiddly” and “inconsistent”. It would work perfectly during the setup process, but would then fail to accurately advance the tape of reels during normal operation. This resulted in countless halted job anytime in a pick and place job. But, what baffled us was why it would run almost perfectly on the west feeder but not on the north feeder? We tried every tricks and method suggested by SmallSMT but most of the time it would work fine for a short while before going back to it’s old self. We desperately need the north feeder because there is where our components that comes in 12 mm, 16 mm and 24 mm tape width reels can be installed. Even more shocking, SmallSMT told us the 24 mm feeder is actually not supported! Why sold it to us at the first place?
“what baffled us was why it would run almost perfectly on the west feeder but not on the north feeder”
Really easy to explain that 8mm feeder lines work more reliable using push feeder than wide 12 / 16 / 24mm plastic tapes. Mostly parts heavier so the tape may slide back if top springs not adjusted strong enough to keep a better friction. But it is always comparing apples with pears a CL feeder 12 /16/24mm is a better solution. That is the reason we focussed on these kinds of feeders and added these even to our smallest machine we are selling now. All other machines using drag feeders have the same problems.
North feeder location not accessible by the head – this is one of the most shocking issue we faced on the machine. When we try to move the head to any of the 8 mm tape width feeder on the north side, the software will complain it is not reachable. A solution given by SmallSMT was to shave off a portion of the y-axis limit end stop. We reluctantly shaved off 2 mm from the y-axis limit end stop metal piece. Even though this solved the problem, we start asking our self, isn’t the machine calibrated and tested at the factory to detect such issues? Or it was not even calibrated? After the fix, the top camera will no longer park at the machine origin (indicated by a engraved mark on the machine bed) when the homing function is executed. An offset of 2 mm was also needed on the software to tell the machine everything has been moved by 2 mm on the y-axis.
This was a real issue caused by a manufacturing problem. The machine head could not move back enough caused by a light barrier switch not installed well. After reducing the length of the metal finger moving inside the light barrier switch the machine worked.
We improved our manufacturing process and documented several QE steps by videos since .
So, it should be impossible to receive a machine where not all feeder locations tested anymore.
Reel cover tape snapping way too often – The machine uses a push feeder (instead of a drag feeder) to advance the component reels. A mechanical cover tape peeling mechanism will pull the cover tape towards the back to expose the component to the pick and place head. How tight or lose the tension on the cover tape can be adjusted to one of the 3 settings on the machine. However, even at the least tight setting, the cover tape on our component reels snap way too often. Again, this resulted in countless stop on the pick and place job.
In his case this was our simplest machine he could buy and I told him before he needs a different type of machine but he wanted to buy exactly the simplest one. The funny thing is finally he bought exactly what I introduced a cassette feeder machine.
Push feeder are a much better solution than drag feeder because head is not involved in pulling parts tape. There is no mechanical wear out for the head.
Drag feeder machines use mostly common winder for a feeder bank so all tapes receive mechanical treatment during feeding process if line addressed or not.
Especially this case we tell our customers in any case. So, he knows the limitations of this feeder type. The push feeders are working more reliable than drag feeders and they offer a higher feeder count in smaller space at low price. So, it is ok to accept some limitations.
Some feeder pick up locations are not reachable by the top camera – In order to configure the pick up location, we need to move the head manually to the pick up location without vision assistant. This process needs trial & error and we spent a lot of time here. The vibration feeder is one of the location not accessible by the camera on top of few other push feeders.
You will get efficient and thoughtful service from Ling Yueyang.
This was small machine and push feeder locations on the front side but camera behind the head.
It is logically that we cannot move above the vibration feeder pickup point using the top camera.
And it is not a real problem to use the pickup head to move to this position for teach in.
In retrospect, these first machines are no longer in the program and our current machines are better thought out and adapted to the application of prototype production. Where, in addition to a large number of feeders, high precision is also required.
Compared to the Huawei Guochang machine used, we are miles away from their production quality and are much more innovative too!
We use high-quality imported linear guides and ball screws. The same applies to our servo motors and drivers.
We focus on a wide range of applications, which also requires complex software solutions. The whole process from setting up a project to operating the machine is covered here.
I also believe that an europe based support is an advantage not to be neglected.
We also run a support forum, which none of the other manufacturers mentioned does.
And if you need a modular and durable machine that can also be set up in tight office environments, then you've come to the right place.
Each machine fits through a standard office door and can be placed there without any problems, as there is no need to plan for a machine weight of 200 to 400 kg.
Finally, I can only say that our customers place and 0.35mm pin pitch components and we know that the machines can do it!
Pick and place automation machines have numerous applications, from building complicated prototypes, to mass-producing consumer products, to assembling complex medical and military electronics. However, a pick and place machine is just one example of robotic part handling machines and processes available in automated manufacturing.
When the focus is narrowed to a single function or area of operation, there is not a simple one-size-fits-all solution. Before investing in a pick and place robot, conduct a full-scale professional analysis of production requirements and bills of materials. If that sounds overwhelming or intimidating, our project management experts can guide you through the process.
The main reason for investing in assembly (line) automation is efficiency. The argument for automation is made succinctly in Min Zhou and Renjie Jiang’s paper on automation strategy:
“a 1% improvement in efficiency over a long period of operation can lead to more economic benefits and a lower average cost expenditure.”
Although it may be clear WHY you would consider automation, the question of WHERE to improve efficiency may not be as explicit. Here are three questions to help contextualize how pick and place automation can increase your particular warehouse or factory throughput.
For many years, those watching and analyzing the development of automation have predicted the increased use of and reliance on machines for production. When many of these original projections were made, the cost to automate was prohibitively expensive for small or average-sized manufacturing assembly lines.
However, as industrial robot integrators have progressively optimized their own processes, automation in manufacturing has become more accessible, which comes at a time of absolute necessity. Companies have considered pick and place machines to enhance material handling coordination for a long time.
Recently, rising employment costs have made it increasingly necessary to automate manufacturing processes. In , Reuters reported that “Labor costs surged 5.1% on a year-on-year basis, the largest rise since the current series started in , after rising 4.5% in the first quarter.” Clearly, now is the time for automating processes to reduce the dependence on human labor.
It may seem contradictory to include this point since we just mentioned the reduction in human labor. However, the human component of manufacturing is never going to be zero (at least, not anytime soon). Instead, the trend suggests an increased collaboration between robots and humans rather than outright replacement. Consequently, pick and place automation should highlight improving the working conditions for the humans involved in the process.
Measures like digital twin technology are already integrated into many assembly lines to raise safety and production standards in manufacturing. Digital twinning itself is part of a broader practice called virtual commissioning, which has proven to be immensely beneficial on the factory floor, and can contribute to “avoiding the risk of damaging [a] device during commissioning while ensuring the safety of the personnel.”
In the broader conversion of pick and place automation—how to use it and how to benefit from it—allocate time for discussing vision system inspection. This technique is good for your workers and your bottom line. While moving physical products down the assembly line more quickly and efficiently, investments in doing this as safely as possible provide an undisputed benefit to companies and their employees. When thinking about automation, think about safety, too.
Under the general heading of “efficiency” fall the objectives of boosting inventory control and maximizing existing square footage usage. Both directly and indirectly, a pick and place machine can help by moving products more quickly and effectively. This helps keep excess inventory at a minimum, which in turn improves customer satisfaction, completes product lines, and alleviates lead time uncertainty.
While a pick and place machine’s placement speed can positively impact production volume, look closely at a machine’s components per hour (CPH) or parts per hour (PPH). Machines may be able to handle the necessary components for your assembly line, but you must also determine how quickly they can process them.
Additionally, to get the most benefit out of a pick and place system, examine the method used to determine the order in which the objects are picked up. Machines are only able to do what they are built and programmed to do. If there is a restriction on the capability of how a machine maneuvers, it’s best to know that ahead of time. It may not be the best solution for your particular manufacturing assembly line.
+Vantage is a global company with offices and support centers worldwide. If you are ready to implement pick and place machines in your manufacturing line, we are an automation company you can trust.
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