sony smt machine

Types of SMT machines

SMT machines are critical equipment used in the surface mount technology process of electronically assembling products. Entertainment, automotive, and smartphone industries are just a few examples of where these machines are important. There are five main kinds of SMT machines, among them is the Sony SMT machine, which is a staple in Sony's line of industrial machines for crafting circuit boards.

• A placer: This device puts the components on the paste-covered areas of the PCB precisely.
• Print machines: They apply solder paste to the PCB. The print machines have to be precise in line with the components' needs and frequently include high-level verification and examination capabilities.
• Sony SMT machines: These are high-density, high-speed industrial machines for making circuit boards. They are usually uniquely designed to cater to the different features of the varied kinds of surface-mounted components. When it comes to efficiency, speed, and precision placement of components, SMT machines from Sony are without a rival. They are designed to meet the needs of the whole process of surface mount technology, from solder paste printing to component placement and reflow soldering.
• Offline Inspection Machines: The placed components are checked for errors by the inspection devices. Before the PCB goes further in the production process, any mistakes need to be detected and corrected.
• Final Setup and Shared Reflow Machines: Assembling surface-mounted components and through-hole components that are all together is what these machines are for. The SMT machines are generally shared reflow setups. After the reflow process, they might have a mixed or single-stage reflow set up, which is mostly a conveyor that goes through a heated chamber.

Specification and Maintenance

Generally, the specifications of SMT Sony machines vary with models. However, below are some standard specifications and their meanings.

• Placement Accuracy

  Placement accuracy is the ability of SMT machines to position components precisely on printed circuit boards. It is usually expressed in millimeters or inches. For instance, a machine with a standard accuracy of +/- 0.01 mm would place components with the specified precision.

• Max Component Size

  The maximum component size refers to the largest electronic component an SMT machine can handle. Usually, it is measured in millimeters or inches. For example, a machine with a maximum component size of 10 mm x 10 mm is capable of managing components with those dimension.

• Max PCB Size

  The maximum PCB size is the biggest dimensions of a printed circuit board that an SMT machine can work on. It is generally expressed in millimeters or inches. For instance, a particular SMT machine may have a max PCB size of 400 mm x 300 mm. This means the machine can only work with PCB of dimensions 400 mm by 300 mm.

• Speed (CPH)

  The speed of SMT machines is usually expressed in “Components per Hour” (CPH). This measures the quantity of electronic components the machine can place on a PCB in one hour. For instance, one may come across an SMT machine that operates at a speed of 5,000 CPH. This means the machine can place up to 5,000 electronic components on boards within one hour.

• Vacuum Nozzle

  Vacuum nozzles of an SMT machine are used to pick and place different electronic components. Each of the nozzles is designed to handle particular shapes and sizes. For example, a SMT machine might have a vacuum nozzle with a 0.5 mm tip designed to handle small capacitors and resistors diameter.

Maintenance

Maintenance of an SMT machine is essential for efficient functioning as well as for prolonging its lifespan. Here are some crucial SMT machine maintenance tips:

• Regular Cleaning: SMT machines should be cleaned regularly to remove any residue and dirt from the boards or solder paste. For instance, cleaning of critical parts, such as the feeder, nozzles, and conveyor belts, can significantly enhance their performance.
• Lubrication: Lubrication of moving parts of the SMT machine enhances their smooth operation. Lubrication also helps to reduce wear and tear. This eventually prolongs the life of the machine.
• Calibration: Regularly calibrating the SMT machine ensures that it maintains proper placement accuracy. This enhances the quality of the board assemblies. During calibration, it is important to follow the manufacturer guidelines. This enables the machine to maintain specified tolerances and settings.

Usage scenarios of Sony SMT machines

Sony SMT machines are the backbone of real-time production lines. They efficiently place parts on printed circuit boards (PCBs), which serve as the foundation for electronic devices. SMT machines can be used in some general scenarios on assembly lines.

• In the initial phase of PCB assembly, Sony SMT machines can accurately position the majority of surface-mount components, including tiny resistors, capacitors, integrated circuits, and complex parts like chip-scale packages and ball grid arrays, onto PCBs. This is especially useful for boards requiring high-density component placement.
• An efficient pick-and-place function is typically incorporated into SMT machines. They are designed to quickly and accurately pick up previously prepared electronic parts (usually mounted on tape, reels, or strips) and place them on PCBs in predetermined locations and orientations. This helps to streamline the assembly process.
• A machine's ability to adapt to various scales of production is a crucial feature. Sony SMT machines can be used for large-scale production runs requiring frequent or near-constant component changes and small-scale production requiring uncommon or limited part quantities.
• For products indicating multiple PCBs are to be connected, including, for example, a daisy chain configuration, SMT devices placed SMT connectors can be utilized to facilitate connection via connectors.
• For boards indicating the necessity for ruggedness, in which not only performance but also survival under more demanding conditions will be required, some SMT devices may show reinforced connectors to be used, including those requiring a greater number of mating cycles and higher connector bandwidths. In these situations, select connectors specified as "field rated" or "high mating cycles" will be indicated.
• As connector technology evolves, boards may involve "board-to-board" SMT connectors that link one part of a circuit to another. These connectors are generally designed for high pin counts and minimal signal loss. They frequently incorporate features to facilitate the incorporation of the connector and improve the quality of the connection in the direction of signal transfer.
• Because projects require a small number of boards, some may indicate a through-hole solder technique. In this situation, an SMT connector will be used to assess how to use it correctly. An example of a possible solution is to include a connector with through-hole solder posts in addition to SMT solder.

How to choose Sony SMT machines

Choosing the right SMT machine requires a consideration of many factors. The needs of the business will have to be matched with the capabilities of the SMT machines in order to make a successful choice.

• Production requirements and scale:

  It is important to identify the production volume in order to meet the assembly needs of certain types of products. A desktop pick and place machine may be sufficient for a low-volume contract manufacturer or one that does production runs of less than 500 units. An inline SMT machine will be better suited for high-volume production lines.

• Flexibility:

  A flexible pick and place machine will be suitable if a variety of product models are to be assembled. Changeover times should be short, and the machine should be able to accommodate different kinds of PCBs and components.

• Accuracy and speed:

  Higher levels of accuracy and speed are necessary if complex and large-scale assemblies are to be produced. Consider the scanning resolution, camera system, and placement accuracy of the machine. The speed (tact time) of the machine should also be considered. This will determine how many components can be picked and placed per hour.

• Automation level:

  Low production volumes, where less than 1000 boards are made per day, can benefit from having some automation. A semi-automated machine can save costs while improving production efficiency. Fully automated SMT machines will be required on production lines where more than 1000 boards are made each day.

• Machine size:

  A line that has a large footprint will not be suitable for small contract manufacturers or startups. A benchtop or small inline machine will have to be chosen to fit into the manufacturing space.

• Budget constraints:

  It is important to determine how much budget is available and to consider the total cost of owning the machine. This includes initial purchase cost, installation, training, maintenance, and any extra costs that will be required over the life of the machine.

After choosing the right SMT machine to meet these requirements, it is still essential to select a reliable supplier. The reputation and track record of the manufacturer will have to be researched and considered in deciding to buy the machine. Once bought, the machine will need to be properly supported with training, technical help, and spares to ensure it continues to function well over time.

Q&A

Q1: What are the benefits of using a Sony pick and place machine for SMT assembly?

A1: The benefits include improving assembly accuracy, enhancing productivity, enabling flexible processing, and ensuring reliable quality control.

Q2: What is the role of a feeder in a Sony SMT machine?

A2: A feeder in an SMT machine is used to transport surface mount components from the stationary location to the pickup nozzle

Q3: How does the vision system in a Sony SMT machine work?

A3: The vision system in an SMT machine works by taking images of the components and PCB. Then, it analyzes these images for alignment, placement accuracy, and verification of the quality of the assembly.

Q4: What is the difference between automatic and manual SMT machines?

A4: An SMT machine automatically places components on a PCB. In contrast, the manual type assists in placing components with manual intervention. The automatic type is more efficient than the manual type.