Scribd
Upload
257 views44 pages

Topaz X

The GEM Topaz-X is a high-speed SMD pick and place machine capable of handling various components at speeds up to 18,000 SMDs per hour, featuring a rigid frame for accuracy and stability. It includes advanced vision systems for precise alignment and supports a wide range of feeders, allowing for efficient production. The machine is compatible with other models in the GemLine series and offers options for nozzle exchanges and program optimization.

Uploaded by

andyandrei241
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF or read online on Scribd
257 views44 pages

Topaz X

The GEM Topaz-X is a high-speed SMD pick and place machine capable of handling various components at speeds up to 18,000 SMDs per hour, featuring a rigid frame for accuracy and stability. It includes advanced vision systems for precise alignment and supports a wide range of feeders, allowing for efficient production. The machine is compatible with other models in the GemLine series and offers options for nozzle exchanges and program optimization.

Uploaded by

andyandrei241
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF or read online on Scribd
You are on page 1/ 44
Contents 1.0 2.0 3.0 4.0 5.0 6.0 7.0 Contents Introducing the GEM Topaz-X ... 0.2.0 c eee ved General Specifications ....... bev eetteeeee ners 5 Features, Accessories and Options .......-..00e.. 02-10 BAL Features 0... 00eeeeeeeeeeeeeeeeeeeeeeese ee 10 3.2 Accessories and Options . 13, Mounting Heads Configuration 17 Alignment ...... 5.1 Line Array Camera Alignment . 5.2. Single Area CCD Alignment... 5.3. Fiducial Alignment . . 5.4 Master, Bad Mark Sensing . Board Handling Component Handling .. TL Tape Feeding ......- 0000-00000 7.2 Double Shuttle Tray reder (PA. 2699/22) 7.3. ATS 20 Tray Feeder portrait (PA 2696/21) 74 Double ATS 20 Tray Feeder portrait (PA 2696/22) 7.5. ATS 20 Tray Feeder landscape (PA 2696/23) 7.6 Mountable Components & Required Nozzles GEM Topaz-X oo... cece cvees reece vee Al | of44 Contents 2of 4 Introducing the GEM Topaz-X Figure 1 Ineroducing the GEM Topaz-X "The Topaz-X, part of the GemLine (Modular High Speed Production Machines), is the newest addition to the top-of-the-line Philips’ SMD pick & place machines. The ‘Topaz-X is a High Speed flexible machine that can handle a wide range of components at speeds up t0 18,000 SMDs per hour. The machine is built around a very rigid, vibration-frce frame for improved accuracy and long-term stability and is perfectly suitable for round-the-clock production, 1850mm The GEM Topaz-X features a high precision single placement beam carrying 4 Flying Nozzle Change heads (each equipped with 3 nozzles) and 4 standard heads with exchangeable nozzles. The placement beam moves in X/Y and Z direction, while the board and component feeders are stationary. A flexible board transport system enables the Topaz-X to handle virtually any type of PCB, with or without tooling pins. Board conveyor width is automatically adjustable, allowing board dimensions up to 460 x 440mm (17.9" x 17.2") to be handled. The newly designed vision system with Line Array camera allows fast and accurate “on-the-fly” alignment of a wide range of components fom 0201 up co 32mm square PLCC, including 32mm square QFPs with lead pitches down to 0.5mm (20 mil). Dark background BGAs, #BGAs and CSPs with ball pitches down to 0.75mm (31 mil) and ball diameters down to 0.3mm (12 mil) can be recognized with the use of a new developed illumination unit which allows measurement of ball positions and dimensions. 3 of 44 Ineroducing che GEM Topaz-X ‘An optional single area CCD camera extends the component range to 32mm square ICs with lead pitches down to 0.4mm (16 mil). The vision system deteets missing, bent or irregular spaced leads or BGA balls; faulty components are rejected. A separate camera system monitors fiducial marks at the board, circuit and component level, using a combination of white-light and IR LEDs with multi-angle diffusers to provide optimal illumination. Just five nozzle shapes are required to cover the specified SMD range. High output levels are therefore achieved, as the need for nozzle exchanges is minimal. An optional 18 position nozzle exchange station enables additional special nozzles to be accommodated Up to 90 tape feeders can be loaded on the GEM Topaz-X. ‘The machine supports tape, stick, bulk and tray feeders. ‘The tape feeder design for the GEM Topaz-X allows simultancous picking from any mix of tape feeders ranging from 8 to 44mm, ‘An industrial PC controller, running Philips well proven and user-friendly software, allows the GEM Topar-X to be used stand-alone or in-line. The controller includes a Management Information System (MIS) that continuously gathers production data for management feedback. The unique bad mark sensing capabilities allow a multi- circuit panel to be run as one large board, thus maximizing placement speed while still using bad mark information. A laser-based verification system, which guarantees correct feeder latching, is standard. ‘The GEM Topaz-X is fully compatible with the Sapphire, Topaz, Emerald and Emerald-X, which use the same feeders, feederbars, software and controller. A basic program optimization function is also included in the machine as standard. For more advanced machine optimization and/or line balancing, the new Production Preparation System for GemLine allows you to create and optimize SMD machine programs on a PC instead of using the SMD machine. This reduces line change-over time and prevents errors 4of44 2.0 General Specifications Tact tne ‘Optimal placement rate ‘Nominal placement rate ‘0.20sec/chip with line array camera {0.45 see/SO with line array camera 14 secIQFP with line array camera 3,7 secIQFP with area CCD camera 18,000 ph 12,000 - 14,000 «ph ‘General Specifications REMARKS ‘Simultaneous pick with 8 heads ‘Simultaneous pick with 4 heads ‘Sequential pick with 4 heads in fine mode with | head ‘Simultaneous pick with & heads ‘Applicable components Mounting accuracy: &y) 36 Mounting accuracy: @30 Mounting angle Mounting repeatabiley 30 Number of heads ‘Alignment system: 0201 - SOP, SO}, PLE Samm CAT 26 ‘6mm - QFP 32mm fl (1.26") with pin pitch down to 0.5mm (20 mi) Dark background BGA, y8GA, CSP with regular pitches; ‘6mm = 32mm: Min. ball pitch down to 0.75mm (3Imil, Min ball diameter down to 0.3mm (12m) “mm = OFP 32mm Fi (1-26") with pin pitch down to O-mm (16 mi) Dark background BGA, yBGA,CSP with regular pitches: ‘mm ~ 32mm: Min. ball pitch down to 0.75mm (3Imil, Min ball diameter down to 0.3mm (I2mil) £75u for chips and SOIC + 604 for QFPs (6mm - 32mm fl 1.26") with pin pitch down to {0.5mm (20 mil) +353 for OFPs (6mm = 52mm fA 126") with pin pltch down to mm (16 mil) For Chips and SOIC ths s Lead dependent +£0.° for QFPs (6mm ~ 32mm GZ |.26") with pin pitch down to 0.5mm (20 mil) + 0.09" for QFPs (Bmm = 32mm (2 1.2) with pin piech down 10 0-4 (18 mil) ‘0 up to 360 (programmable in steps of 001) , ¥ 30 for OFPs (Gm - 32mm (126°) pitch 04 Phi (009°) ‘One single beam with 4 Flying Nozzle change heads and 4 standard heads ‘One line aray camera with fore and side llumination system for Vision on the Fly using the VICS 2500 processing system ‘Area CCD camera for QFP 32mm (i (1.26) with pin pitch down t© 0.4mm (16 mil) Moving CCD camera for Fiducil alignment Tine array camera system ‘Optional 32mm area CCD camera system with fore and side illumination unit Line array camera system {all placement heads and al placement angles) ‘Optional area CCD camera system (in fine mode) Line array camera system {all placement heads and al placement angles) ‘Optional area CCD eamera system (in fine mode) “The Standard heads can exchange nozzles withthe use of the optional Nozzle Exchange Station Standard, second line array camera is optional ‘Optional Seandard Sof 44 ‘General Specifications REMARKS, Type of nozzles: Type TIF (on FNC head) ‘Standard willbe delivered ‘Type 72F (on FNC head) 4x nozzle 7IF, 4x nozzle 72F, ‘Type 73F (on FNC head) 4x nozzle 73F, 4x nozzle 72A Type TIA Type 72A Type A, Type 744, Type 76A (Melf nozzle) Nozale exchange station: | 18 nozzle positions ‘Optional (No nozzles included) Nozzle station can hold: 4X TIAAX TIAA TAA, 4 76 and 2 special nozzles Nozzle 73A does not fit in the nozzle station Component weight | Max 10 gr With the use of nozzle type 740 ‘Component height: Max: 40mm Max: 65mm depending on mount sequence. Placing of parts with a height of 6.5mm ~ 10mm is possible if certain conditions are met. ‘Component mounting | Chip: 0Smm or more inerdistance: SOP: 0.7mm or more Placement system: Pheuratic oF servo contrelled for component height compen: Placement force: 24 gramimm (for nozzles with bulfer this value is diferent) | Pre-tension i 200 gr. (spring loaded) Number of feeders Tapefeeders ‘inm: 90 positions (Tamm: 43 postions ——=SCS~“~*~*~“~*~*~*~*~‘“~“S*s~“~—*SSSSSSSSS*S [Témm:43 postions ——~=~*~*~“‘*‘“*~“‘“‘“*~*~‘“‘<“<~*;CS*‘“‘~“CSCSCSCSCStSS*S 24mm: 28 positions (Hamm: postions ——SCS~“~S~“—s*S*S*S*S*S~S~S~—~—~SsSsSSSSSSSSSS [Hmm2I postions ———=S~*~“~*~“—~*S*S*S*S*~—~—sSsSsSSSSSSS*Sd Stick feeders: Depends on stick dimensions 6 of44 ‘General Specifications REMARKS Component packaging: | Tape according to IECIEIA JJEDEC: 8-44mm Tape reel diameter max: 380mm For larger tape feeders such os Sémm, 72mm please contact your | (I5") local sales representative Manual Tray feeder: Max way size Is Board width dependent’ | Optional: Manual tray feeder Max era size: 330mm x 300mm (12.8" x 11.7") (Max. number of feeders 65, Max tray size by max board width of 440mm (I7.2"): 330mm x | Head number 8 can't pick 175mm (12.8" x 68°) components in an area of [4mm Min tray size SOmm x SOmm (2.0" x 2.0 fom the right side of the MTF ATS 20 Tray Feeder portrait: Max. tray size: 220mm x 350mm | Optional (factory bull in: ATS | @s"x 137) 20 Tray Feeder portrait (Max. Min tray size SOmm x SOmm (2.0" x 2.0") board wideh 250mm (9.8"), max. number of 8mm feeders 3 x 20, amount of pallets 20 with 2.5mm piteh) Double ATS 20 Tray Feeder portrait: ‘Optional (factory Bult i) Max. tray size: 220mm x 350mm (86° x 13.7" Double ATS 20 Tray Feeder Min tray size 50mm x 50mm (2.0" x 2.0") portrait (Max. board width 250mm (9.8"), max. number of ‘8mm feeders 2 x 20, amount of pallets 2x 20 with 25mm pitch, atthe left ATS 20 components can't be picked by all heads in an area of 36mm from the left side of the ATS 20) ‘ATS 20 Tray Feeder landscape ‘Optional (actory bul inj: ATS 20 Max. tray size: 350mm x 220mm (13.7" x 86 ‘Tray Feeder landscape (Max, board Min tray size 50mm x SOmm (2.0" x 2.0") width 380men (15.0°), max. umber of feeders 2x 20+ 16, amount of pallets 20 with 125mm piech, atthe right side of ATS ‘components can be picked by all heads in an area of 18:2mm) Double shuttle LCS Tray Feeder: ‘Optional: Double shuttle LCS Max. tray size: 350mm x 440mm (13.7" x 17.2") ‘Tray Feeder (no restrictions) Min tray size SOmm x SOmm (2.0" x 2.0") Max: 120 Jedec trays Stick and bulk Many solutions possible Maximum height pre- | 40mm on placement side (0.16") mounted components: _| I8mm on non placement side (0.7") PCB Dimensions (xy): | Min: SOmm x SOmm (2.0" x 2.0°) Max: 460 x 440mm (18" x 17.2") Using PCB pin uation or edge Special applications upon request ctarmping system. PCB Weight Max. 12 Ke Without components Max. 2.0 Ke With components PCB Thickness Min: 0-4ram (0.015 Max: 4.0mm (0.15") Special opplicaions upon request 7 of 44 'Non-mountable area PCB Material PCB Positioning: Board top side 3mm (0.12") from rear side board edge mm from front side board edge |"Amam (0.16") around reference holes (locate pins) Flat edge of 30mm (2) | Board bottom side Smm from front and rear side board edge (0.2") PhenoliciFR4/Composite Materials Locate pin fivation Z servo controlled push up system Push up pins Edge clamping Sub stop (PCB waiting buffer) Exit stop ‘General Specifications ‘Component height restrictions apply in the 10mm (0.40") area from front side edge depending ‘on board thickness Fiat edge of 30mm (12) required on bottom right corner for the use of the main stopper, sub and exie stopper For ceramic PCBs (optional) the rnon-mountable area may be di ferent ‘Ceramic PCBs require special ‘conveyor sections (optional) ‘Adjustable second pin Sofeware controlled by PCB thickness ‘Adjustable positions ‘With adjustable push in ‘Adjustable position Fixed position PCB Transport height: 300mm + 1Oram 54" OA") [SMEMA 953mm # 125mm Q75°205) ——~S~SStandard ——SSSSS~*& ‘Standard ‘Seandard PCB Transport direction: PCB Transport width PCB Loading ie: PCE Ratio widthength ‘Control system Left to Righe ‘Automatic ‘Approximately 3 se Max 13 MCX controller 486-100 40 Mb flash disk [44 Mb floppy drive 3.5" [RS232Seralinerace==S=S*~*~“‘*‘“‘*“‘“‘“‘~*~*SS*S*S*C‘“VIOS MIS data gathering Data teaching Data tracing ‘Component database Mark database 'SMEMA electrical interfacs ‘On line calibration ‘On ne help functions Feeder lock verifier Lengch: 1450mm (54) Height: 1850mm (6.1 ) ‘Width: 1408mm (4.5 ®) ‘Weight: 1570 kg (3460 Lbs) EN 292, EN 294, EN 349, EN 614, EN 1050, EN $5011, EN '50082-1, EN 60204-1 Electrical safety according IEC 204 ‘White: Emergency stop, safety cover interlock Blue: Pick up error, out of components, Green: in automatic operation ‘General Specifications REMARKS Max. 2560 components per PCB "3000 Component packages; user sn define and teach vision files 300 Mark shapes Width including feeders i= 224mm (7.36 f) CE-safety is part of system design, Safety measurements are tested on each product in the factory. Electric power: Air supply: ‘Operating temperature Humidity Noise: Voltage AC: 200/208/230/240/380/400/416 V + 10%, 3 Phase Frequency: 50/60 Hz ‘Consumption: 4 KVA max Pressure: > 5.5.10 Pa (5.5 bar, 80 PSI) ‘Quality: dust and oil free ‘Consumption: 350 Nimin 15:35" C (69"- 95°F) 20-90% (no dew) < 7adBa More than 25mm? cables are needed Specification guaranteed: 20° 28" C (68" - 82° F) Table 1 9 0f 44 3.0 3 Features, Accessories and Options Features ‘The standard GI Features, Accessories and Options IM Topaz-X includes the following features: (On the fly alignment using a vision system with a Line Array camera standard equipped with a side illumination unit for BGAs, hBGA, CSP components Placement beam with 4 Flying Nozzle Change heads (cach head standard equipped with 3 nozzles) and 4 standard heads Simultaneous picking is possible by all 8 heads fom any mix of tape feeders (except for 0201 components). This allows a much higher nominal placement rate and board throughput. ‘Complete component range can be handled with only 5 nozzles shapes. Fiducial alignment camera with improved software controlled illumination unit (white + IR’ Leds), that also can be used as teaching/tracing device and for Bad Mark sensing. Automatic width adjustment. The PCB dimension is included in your PCB data. PCB pin-positioning. Second pin is easily adjustable for fast changeover. PCB edge clamping system, for PCBs without tooling holes. PCB push up plate (Z. servo controlled) with 12 push up pins, for PCB support thickness is included in the PCB daca Substopper, allowing a second PCB to enter the machine for reducing transport time. Exit Substopper, allowing a new PCB to enter the work area of the machine while the downstream machine is still not ready to accept a new PCB. Feeder lock verification system to avoid damage to the machine due to incorrectly latched feeders 3.5" FDD for backup purposes. Component dump box. Operator manual, available in different languages User manual Service manual. ‘Two empty tape bins Toolset. 10 of 44 Features, Accessories and Options + First aid spare parts kit. + CE safety. + ESD safery + Electrical and Mechanical SMEMA. Standard Software Features: + Variable XY axis speed per component (neu). + Datum angle functionality (especially for stick components, there is no pick angle necessary to recognize the component which results in higher output). (new) * User Friendly Human interface VIOS (Visual-Integrated-Operating, System). + An Online help funetion allows display of detailed descriptions of operations and functions on screen. + Management Information System (MIS) to gather production history data. * 4 point fiducial correction, to maintain accuracy for stretched/distorted boards. + Template (pattern) matching for PCBs that have no fiducials, + Different mark shapes for fiducial pair possible. * Box teaching to recover fiducial recognition error. + Data editing functions with the use of the fiducial camera (teaching, tracing). + A Component database, that can hold up to 3000 component packages, with the most frequently used components already predefined. + A Mark database, that can hold up to 300 mark shapes, with the most frequently used mark shapes already predefined. + Precede pick-up, allowing to pick up components before the PCB is fixed, reducing cycle time. + Alternative feeder function, reducing operator intervention (empty feeder switching), + Automatic program change over for family boards (self production contol). + Automatic rework cycle to improve operator efficiency and on-line optimization, to keep mounting speed during production in case of empty feeders. Detected empty feeders are automatically skipped until end off programs, to allow one time replenishment. * Product preparation can be done on the machine including basic optimization of the mount program. (nozzle and feeder set-up) 1 of 44 Features, Accessories and Options + Multi-section PCBs can be either be mounted block-by-block or the block daca can be combined to achieve the fastest mounting sequence. In the latter ease, block badmatks still remain in effect 3.2 Accessories snd Opn PA 1912/00) CSMIGEM Glass Adjustment Kit PA 2695/12 ‘Manual Tray Feeder Topaz-X/Emerald-X PA 2696/21 ‘ATS 20 Tray Feeder portrait for GEM PA 2696/22 Double ATS 20 Tray Feeder portrait for GEM PA 2696/23 ATS 20 Tray Feeder landscape for GEM PA 269922 Double shuttle Tray Feeder (LCS) for Topar-X/Emerald-X PA 2903/20 Timm Tape Feeder, 15 inch reelholder FVIGEM PA 2903/25 llgmm Tape Feeder, 15 inch reelholder FV/GEM PSA PA 2903/30 24mm Tape Feeder, 15 inch reelholder FV/GEM PA 2903/35 ‘2amnm Tape Feeder, 15 inch reelholder FVIGEM PSA PA 2903/40 32mm Tape Feeder, 15 inch reelholder FV/GEM PA 2903/45 32mm Tape Feeder, 15 inch reelholder FVIGEM PSA PA 2903/50 ‘44mom Tape Feeder, 15 inch reeiholder FV/GEM PA 2903/55 ‘44mm Tape Feeder, 15 inch reelholder FVIGEM PSA PA 2903/73 ‘8mm Tape Feeder for 0201, 2mm pitch, 7 inch reelholder FV GEM (PSA) PA 2903/74 ‘8mm Tape Feeder, 2mm pitch, 7 inch reelholder FVIGEM (PSA) PA 2903/75 ‘Sm Tape Feeder, 4mm pitch, 7 inch reelholder FVIGEM (PSA) PA 2903/76 ‘8mm Tape Feeder, 4mm pitch, 15 inch reelholder FVIGEM (PSA) PA 2903/85 2mm Tape Feeder, 7 inch reelholder FVIGEM PSA PA 2903/86 mm Tape Feeder, 15 inch reelholder FVIGEM PSA PA 2906/10 Reject conveyor for Topaz-X and Emerald: PA 2923/00 Set of 20 dummy feeders PA 2962/41 Nozzle Type 71A (0201-0420/0603-1005) PA 2962/42 Nozzle Type 72A (0603-1206/1608-3216) PA 2962/43 Nozzle Type 73A (1812-SOPI4532-SOP) PA 2962/44 Nozzle Type 74A (Middle size QFP) Inota4 33 Table 2 Machine configuration examples Features, Accessories and Options PA 2962/46 Nozzle Type 76A Cylindrical chip (MELF) PA 2963/16 Nozzle Exchange System Topaz-X (18 position no nozzles included) PA 2969/51 Second Line Array camera for Topa-X PA 2969/53 Second Line Array camera in combination with ATS (factory bull in only) PA 2969/91 ‘Area CCD camera 32mm (including fore and side ilunination unit) for Topaz-X PA 2981/15 Pallet for LCS Tray Feeder FVIGEM (PA 2699/22) PA 2981/35 Pallet for PA 2696/21 and PA 2696/22 (ATS 20 portrait) PA 2981/36 Pallet for PA 2696/23 (ATS 20 landscape) On the following pages you can find some machine configuration examples for the Topar-X. Remark: In the examples the dotted line pictures indicate the physical position of the second line array camera, area CCD camera and nozzle exchange station. These can be ardered as an option. 1, Second line array camera 2, Area CCD camera Topaz-X. 3, Nozzle exchange station for Topaz-X. 13 of 44 Features, Accessories and Options Example |: Topaz-X — Pa 01201 pax ms 12098 scandy ease + veteu rh “| Ci Example 2: Topaz-X with double shuttle LCS spi PA 269912. Double shat LCS —— PA 296314. Nose Exchange Sytem Topas X (18 pstionsino none neue) resmucle PA 2968191. Area CCD camer 32m Gluing lihting un for Top Figure 2 Machine configuration examples I to 5 (sce alo next pages) M4 of 44 Features, Accessories and Options Example 3: Topaz-X with ATS-20 portrait zee] tty som Li Ld fam A 1201 Topaex A 2696721 ATS-20 tray feederporrat A 2963/16 Nowale Ehange System ToparX (18 poionine nous included) #4 2969153 Second be aay carers ni facory baler) 42969931 Area CCD camera 32mm (lung ihn un or Tapa Example 4: Topaz-X with double ATS-20 portrait #4 269622 Dovble ATS-20 ty feeder portrait A 2963/16: Norse Exchange Sytem ToparX IB postonsno nemies need) A 2969153 Second ie array camera (on factory butt) A 2969191 Area CCD camera Sim Gling iping uke) for Topas X 15 of 44 Example 5: Features, Accessories and Options Topaz-X with ATS-20 landscape L PA 1312001 Topaz-x Le a 26903 £15209 er oi t 6 of 44 4.0 Mounting Heads Configuration Figure 3 Mounting Heads Configuration ‘The GEM Topaz-X features a high precision single placement beam carrying 4 Flying Nozzle Change heads (each equipped with 3 nozzles) and 4 standard heads with exchangeable nozzles and a separate camera system that monitors fiducial marks at the board, circuit and component level, using white + IR light LEDs and multi-angle diffusers to provide optimal illumination. High placement rates are achieved by simultancous component picking which reduces head beam travel and thus shortens the mounting cycle. Configuration of head section The high-precision dual Y drive Topaz-X features four-axis (X.Y,Z,R) servo control for accurate, stress-free component mounting. Direct drive, brushless AC motors controlling heavy duty lead screws allow optimal accuracy and high reliability. 17 of 44 Table 3 Number of axis: Axis configuration: |Z axis sequence: R axis sequence: Mounting Heads Configuration X axis AC servo Double Y axis AC servo Z.Raxis AC servo W (aucomatie width) axis AC servo Push up plate AC servo Air and AC servo motor AC servo motor Pick-up error detection: Mounting angle: ‘Vacuum check (256 level digital setng) 0° - 360° (0.01° step) ‘Number of mounting head! Nozzle types: Encoder resolution: B inline mult head 5 diferene shapes XY = 0.00122mmipulse Phi= 0.0146" /pulse Z= 0,00048mmipulse Speed: Acceleration: X= 1500mmisec Y= 1500mmisee X = 36600mmisec? Y= 27000mmisec? IB of 44 Mounting Heads Configuration Figure 4 Head section detail 19 of 44 5.0 Alignment 5.1 Line Array Camera Alignment Figure 5 ‘Alipument ‘The high speed of the GEM Topaz-X is achieved by fast on-the-fly component alignment using a revolutionary Line Array camera system, equipped with a newly developed multi angle illumination unit, that is four times faster than conventional systems, For ultimate speed, the machine can be equipped wich a second Line Array camera which reduces head beam travel and thus shortens the mounting cycle. encoder i motor , head €_» spindle ¥ 4— components camera a monitor Line sensor vision principle. ‘While moving the beam over the camera, the encoder triggers the camera to caprure consecutive lines of pixels. All these lines form the total picture of the components ‘This picture is processed by a sophisticated vision system. The vision system algorithms inspect the components and calculate position and orientation of the components on the heads. ‘The SMD components are illuminated by a new developed multi angle side illumination unit which allows high speed recognition of CSPs, uBGAs. The leads of the components are imaged on the line sensor. 20 0f 44 Table 4 Alignment cations Line Array camera: CCD 2048 x 1 piel Max, component size 3mm (126°) in, components 201 in, ea pitch Oram 0 mip Min. lead widch: 0.2mm (0.008") Grey sale: 256 levels Lighting Mut angle Forelside ilmination Light ncensiyssofeware controled foreach component separately Recognition Reflection Pattern recognition on al leads Max. number of lead sides Max. number of lead groups ‘Cheek on: 4 2 per side Leadbal pitch eadiball location Bent/missing leadsibals Total number of leads/balls ‘Cumulative lead/bal pitch 2I of 44 Alignment 5.2 Single Area An optional single area CCD camera extends the component range for the GEM cb “Topar-X. Alignment ‘Component illumination is performed by means of fore/teflecive lighting and side illumination. The lighting source reflects the lead of QF and the balls of BGA components on the CCD camera. The single area CCD camera grabs the image of the component in one frame and presents it to the vision system for recognition and measurements purposes Figure 6 GEM Topaz-X working area of 44 Table 5 Alignment JArea CCD Camera! CCD 512 x 480 pixels Max. component size: 32mm (126°) Min, component size mm 2 (0.24") Min, lead piteh (4mm (16 mi) Min, lead wide: (0.2mm (0.008") Grey scale: 256 levels Lighting Forelside lighting illumination Recognition: Reflection, Pattern recognition on al leads Max, number of lead sides Max. number of lead groups (Check on: a 2 per side Leadiball pitch Leadball location ‘Bene/missng leadsibals ‘Total number of leads/balls ‘Cumulative leadbal pitch 23 of 44 Alignment 5.3 Fiducial “The GEM 'Topaz-x is standard equipped with a fiducial camera. ‘This camera is used Alignment to compensate for variations in the position of the cireuit pattern relative to the expected position. ‘The fiducial alignment system is an opto-electronic system which performs geometric measurements of fiducial marks on the PCB in order to calculate the deviations from their expected positions. The system can use two or four fiducials per board. Fach sub-circuit can also be aligned using two fiducials. For placement of fine-pitch components two local fiducials per component may be used. ‘The individual shapes of a fiducial pair ean be different to allow for maximum application flexibility. Also pattern recognition algorithms can be used on traces or pads on the PCB board for cases where fiducials are not available. ‘The fiducial camera can also be used as a high accurate teaching device for PCB data GE CAD data is not available), automatic calibration and inspection purposes. Fiducial camera ccD Fiducial eamera functionality Fiducial detection, Bad Mark detection, teaching device (2 or 4 point teaching) Fiducial Mumination ‘White + IR LEDs in conjunction with a mule angle illumination ‘Compensation for Translation (with cwo fiducial) Rotation Linear stretch and shrink ‘Compensation for: Non-linear stretch and shrink (with 3 or 4 fducials) “Type of compensation: PCB, Biock, Local Fiducial size: Max. 3.0mm (0.12) Min, 0.8mm (0.03") Fiducial material ‘Copper Gold Leadstin Fiducial clearance area 2x Fiducial size PCB warpage at fiducial Max. 0.5mm (0.027) Pattern offset Max. Imm (0.04") ‘Number of diferent Fiducial pairs per PCB: | 128 Number of fiducial shapes in Mark Database: | 300 Examples of fiducial: Solid cirele (preferred) Square Triangle Donut Binary cross Bow-tie (connected) Template matching (art work) Fiducial definition ‘According CAD data Table 6 24 of 44 Figure 7 Figure 8 Figure 9 Alignment Fiducial fee space. @O/a\+\0\O "| m/# Examples of fiducial. Examples of PCB, block and local fiducials 25 of 44 5.4 Master, Bad Mark Sensing Alignment IF the PCB contains subcircuits, one or more of these subcircuits can be skipped for placement by giving them a “Bad Mark” on a designated position on the subcircuit. No parts will be placed on a circuie that has a Bad Mark. Bad Mark sensing, with the use of the fiducial camera, is based on recognition of a difference in contrast in a certain area. This area can be defined in the machine software (position and area- dimensions). This gives maximum freedom in choosing the process or technique to add Bad Marks, for example: *+ white or light colored labels of any dimension, + white paint, cor any other material that can be fixed as long as it contrasts with the PCB surface. Before checking the Bad Marks on all circuits, the Master Mark may be checked first. Presence of a Master Mark means that one or more Bad Marks are present on the circuits. This allows the machine to skip the Bad Mark sensing process for all circuits if no Bad Marks are located on the circuits, therefore saving valuable production time. 26 of 44 Board Handling 6.0 Board PCB boards can be located in the machine by cither tooling pins or edge clamping if Handling tooling holes are not available. With pin location, one location pin is fixed on the machine while the other locate pin is easily adjustable when the board length changes. Change over to a different board size is just a matter of seconds by using the automatic adjustment (servo controlled) of the conveyor width and the PCB thickness. Figure 10 Pin fixation system PCB support plate PCB — Spring loaded pin Conveyor. Pin shat frame Magnes—> Figure 1 Push up system. 27 of 44 Figure 12 Board Handling “The Edge Clamping system is as easy to adjust as che locate pin fixation. Both these systems use Push-up pins to support the PCB. GEM Topaz-X Edge Clamping stem. A sub-stop enables an additional PCB to enter the machine while the current board is being populated. This reduces time loss during transport and is very useful when ‘operating the machine in a flowline. An exit sub-stop, which can be seen as a transport buffer function, links the entrance sub-stop and main stopper, shortening the PCB transport time and reducing loss from inefficient operation. ‘When using the machine ina flowline, ic communicates with the unit upstream and downstream over a SMEMA-connection. 28 of 44 Table 7 IPCB Dimensions (xy) Board Handling ations Min, 50mm x SOmm (2.0" x 2.0°) Max. 460mm x 440mm (18" x 17.2) using PCB pin fixation or PCB edge clamping systern PCB Thickness Min, 0mm (0.0157) Max. 4.0mm (0.15") Reference hole position: Reference hole diameter: [@ 2Omm-@ 4.0mm (0.08" - 0.157%) ‘Smm (02°) in X and Y from lower right corner| PCB Maximum warpage: Max. height pre-mounted components: ‘4mm on placement side (0.16) ‘05mm up (00) |.omm down (0.04") 8mm on non placement side (0.7") INon- Mountable area: PCB Material PCB weight! PCB positioning: PCB Transport height: PCB Transport direction: PCB Transport width: PCB loading time: PCB ratio widthilength "PhenoliciFRA/Composite Materials ‘Max. 1.2 Ke without components 700mm # 10mm (354° = 04%) Board Top side: ‘3mm from rear side board edge (0.12") ‘mm from front side board edge (Component height restrictions apply in the |Omm (0.40") area from front side edge depending on board thickness) 4mm around reference holes (0.16°) (locate pins) Board Bottom side ‘Smm from front and rear side board edge (02) ‘Ceramic PCB transport is optional Max. 2.0 Ke with components Locate pin fixation (adjustable second pin) Z servo controlled push up system (sofeware controlled by PCB thickness) Push up pins (adjustable positions) Edge clamping (with adjustable push in) ‘Sub stop (PCB waiting buffer) adjustable position Exit stop (fixed position) SMEMA 953mm * 125mm (37.5" + 05") Lefe to Right standard, optional Right to Lefe ‘Automatic Approximately 3 sec. Max. 13 29 of 4 Board Handling sm (0.42%) w ‘onm ony ee At | gL Lenmioz sn se (0.29 whan ene pectin So) She be Song hae) and tom eu slo Bord Edge [Ey -Locat pin esticton. Component hight rstctions apply inthe {Beem bate om Figure 13, Mountable area | Figure 14 Warp of fixed PCB. 30 0f 44 Board Handling t . 40 mm (@015*-0.153) No component should be inthis area 5mm (025 ~ Locate pin restriction, component height ~ OF) restrietion apply in the 10 mm (0) area from front edge depending on board thickness Figure 15 Mountable area 31 of 44 7.0 mA ‘Component Handling Tape feeding Table 8 Table 9 ‘Component Handling The GEM Topaz-X has a fully compatible feeder platform with all GemLine machines, Sapphire, Topaz, Emerald, and Emerald-X. Depending on the machine configuration up to 90 feeders (8mm) can be loaded. The tape feeder design for the GemLine allows simultaneous picking from any mix of tape feeders ranging from 8 to 44mm. To achive high speed feeding all feeder types are air driven. To prevent incorrect feeder latching, a laser-based verification system is used. ‘Available tape feeders Tape Feeder Tape Feeder 8mm 7° for 0603 (0201) component (PSA) | 2 PA 2903/73 Tape Feeder Simm 7" for 1005 (0402) 24 PA 2903/74 “Tape Feeder 8mm 7° (PSA) 4 PA 2903/75 ‘Tape Feeder 8mm 15" (PSA) 4 PA 2903/76 Tape Feeder [2mm 7" (PSA) 48 PA 2903/85 Tape Feeder |2mm 15" (PSA) 48 PA 2903/86 Tape Feeder 6mm 15 4.8,12,16 | PA2903/20 Tape Feeder Iémm 15° (PSA) 4.8,12,16 | PA2903725 Tape Feeder 24mm Tape Feeder 24mm Tape Feeder 32mm 4.8, 12, 16,20 PA 2903/30 4.8, 12, 16,20 | PA 2903735 12, 16,24, 32 PA 2903/40 Tape Feeder 32mm 12,16, 24,32 | PA 2903/45, Tape Feeder 44mm 12, 16,24, 32 | PA 2903/50 Tape Feeder 4mm 15 (PSA) 12, 16,2432 | PA 2903155 The feeding pitch can be adjusted on the feeder side. Sar Required feeder position Feeder type ‘equivalent to tape feeder 8mm Tape Feeder 8mm T Tape Feeder [2mm, 16mm, 24mm 3 Tape Feeder 32mm 4 Tape Feeder 4mm 5 The above feeder conversion number may differ according to the installation combination. For larger and special tape feeders such as 56mm, 72mm please contact your local sales representative 320f 44 72 Double Shuttle Tray Feeder (PA 2699/22) Figure 16 ‘Component Handling ‘The double shuttle Tray feeder is an additional pallet sequencer feeding parts from a tray, This feeder can be equipped with maximum 40 pallets, each being able to hold different trays. Double shutele Tray Feeder. ‘Two components are picked up from the tray with a double head, and placed simultaneously on a shuttle. ‘This shuttle then moves into the machine where the components are picked by the placement head. The partis then aligned by vision and placed on the PCB. At the same moment when the components are picked by the placement head a second shuttle will be supplied with the next components which minimize the feeding time. The component feeding time of the double shuttle ‘Tray feeder is 3.5 seconds for 2 parts when using the same tray (pallet 1) and 8.5 seconds when changing the tray (pallet 40). However, in practice no time is lost because of the simultancous operation of Tray sequencer and Topaz-X: while the machine is picking from on- board feeders, the shuttle brings in new components. A part that is rejected by vision will be placed back on the reject conveyor which means no loss of expensive parts. The PCB conveyor on the double shuttle Tray feeder offers the possibility for visual PCB inspection. + Atray container is fixed and separated into two sections with each 20 pallets. This allows tray replenishment while the machine is running, 33 of 4 Table 10 ‘Component Handling + A buffer conveyor is standard equipped, so a reflow oven can be connected without additional conveyors. LCS Tray Feeder specifications GENERAL Max. Tray size (Lx W) Min Tay size (Lx W} [Component feeding time Power and air supply LCS Tray feeder dimensions Topaz-X + Tray feeder dimensions: Weigh Power supply. air supply APPLICABLE COMPONENTS Min. Component dimension: Max. Component dimension Max. Try height incladed component height 50mm x SOmm (20° x 2.0) 13.5 sec. for 2 part (picking from pallet 1) | Delivered by Topar-X | Length: €26mm (2.8 f) | Length: 2476mm (23) | 200 kg (617 Ub 350mm x 468ram (13.7 18. 3 Jedec trays which can hold 85 sec. for 2 parts (picking one from pallet | and one from pallet 40) Heighe 1 165mm (3.8 f); with top cover open Us45mmn (5.2 f) Width: 1650mm (52); with door open 2292mn (76 R) Height: 1850mm (6.1 &) Width: 1842mm (6.1 Rj; with LCS door open and feeders on Topar-X 2942mm (98 f) Supplied from main machine ram x Sm (031" x 031") Mold size 45mm x 45mm (18x 18") £8 Sm (0.33) from pallets at pitch of 125mm (0.5, total 40 pallets possible 20mm (0.78) from pallets at pitch of 25mm (0.98°), coal 20 pallets possible FEED CAPACITY Number of shuts: 2 Number of pads on each shut [STANDARD COMPONENT CAPACITY Max. number of component types 2 (witha pitch of 48>) 120 (3x 40 Jedec) Number of pallets Standard 30 pallets included (additional pallets avallable PA 2981/15) 34 of 44 13 ‘Component Handling ATS 20 “The ATS 20 Tray Feeder is a new additional internal pallet sequencer, allowing high- Tray Feeder speed feeding of tray components. This feeder can be equipped with a maximum of portrait 20 pallets, each being able to hold different trays. (PA 2696/21) Figure 17 ATS 20 Tray Feeder portrait. The maximum pallet exchange time for the ATS 20 Tray feeder is 5.6 seconds. However, in practice no time is lost because of the simultancous operation of the ATS 20 Tray feeder and ‘Topaz-X; while the machine is picking from on-board feeders, the pallet brings in new components. ‘A part rejected by vision will be placed back in its original tray position; this means no loss of expensive parts. 35 of 44 Table 11 ‘Component Handling Crete dda kiana GENERAL Max, Tray size (Lx Wi) Min, Tray size (Lx Wy 220mm x 350mm (8.6° x 13.7). 50mm x 50mm (2.0° x 2.0") Pallet exchange time: (Changing from pallet | to 20; 5.6 seconds Weight: Power and alr supply | Supplied by Topaz x +80 Kg (I76 Lbs) FTopaz-X + ATS 20 Tray feeder dimensions Maximum board size Topaz-X: [250mm (28°) Lengeh: 1650mm (55) Height: 1850mm (6.28) ‘With: 1870mm (62 49; ‘with ATS 20 door open: 2220mm (7.4 #) Maximum amount of feeders on Topaz-X: APPLICABLE COMPONENTS. Max. Tray height included component height: Min. Component dimension: Témnm (0.63") from pallets at pitch of 25mm [lemm x 6mm (0.24" x 0.24") mold size 0 8.5mm (0.33") from pallets a pitch of 125mm (0.49; otal 20 pallets possible. ‘otal 10 pallets possible Max. Component dimension: [STANDARD COMPONENT CAPACITY Max. number of component types 32mm x F2mm (13"x 13°) 20 20 | Jedec tray) Number of pallets ‘Standard 20 pallets included (additional pallets available PA 2981/35) 36 0f 44 14 ‘Component Handling Double ‘The Double ATS 20 ‘Tray Feeder porteait is a new additional internal pallet ATS 20 sequencer, allowing high-speed feeding of tray components. This feeder can be Tray Feeder equipped with a maximum of 2 x 20 pallets, each being able co hold different trays. portrait (PA 2696/22) Figure 18 Double ATS 20 Tray Feeder portmait. ‘The maximum pallet exchange time for the Double ATS 20 Tray feeder is 5.6 seconds. However, in practice no time is lost because of the simultancous operation of the Double ATS 20 ‘Tray feeder and Topaz-X: while the machine is picking from on-board feeders, the pallet brings in new components A part rejected by vision will be placed back in its original tray position; this means no loss of expensive parts. 37 of 4 Table 12 Perce ns GENERAL eon ‘Component Handling Max, Tray size (Lx Wi) Min, Tray size (Lx Wy 220mm x 350mm (8.6° x 13.7). 50mm x 50mm (2.0° x 2.0") Pallet exchange time: (Changing from pallet | to 20; 5.6 seconds Pick up restricions Power and air supply Weight: FTopaz-X + double ATS 20 Tray feeder dimen- Maximum board size Topsz-X: Maximum amount of feeders on Topaz-X: ‘At the left ATS 20 components can't be picked by all heads in an area of 36mm (14°Vfrom the lft side ofthe pallet. Supplied by Topaz-X. 160 Kg (342 Lbs) | Length: 1650%mm (5.5 A) Height: 1850mm (6.2) ‘Width: 1870mm (6.2 £9; ‘with ATS 20 door open: 2220mm (7.4 #) 250mm (9.8) 0 [APPLICABLE COMPONENTS: Max. Tray height included component height: Min. Component dimension: Max. Component dimension: Tlemm x 6mm (02 [32mm x 32mm (13" x 13" 8.5mm (0.33") from pallets ac pitch of 12.5rmm (0.49; total 20 pallets possible. Térnm (0.63") from pallets at pitch of 25mm (0.98"; total 10 pallets possible 024") mold size [STANDARD COMPONENT CAPACITY Max. number of component types -40 (40 * | jedec tray) Number of pallets ‘Standard 2 x 20 pallets included (additional pallets available PA 2981/35) 38 of 44 1s ‘Component Handling ATS 20 Tray The AT'S 20 ‘Tray Feeder landscape is a new additional internal pallet sequencer, Feeder allowing high-speed feeding of tray components, This feeder ean be equipped with a landscape ‘maximum of 20 pallets, each being able to hold different trays (PA 2696/23) Figure 19 ATS 20 Tray Feeder landscape. The maximum pallet exchange time for the ATS 20 Tray Feeder landscape is 5.6 seconds, However, in practice no time is lost because of the simultancous operation of the ATS 20 Tray Feeder landscape and ‘Topaz-X; while the machine is picking from on-board feeders, the pallet brings in new components. ‘A part rejected by vision will be placed back in its original tray position; this means no loss of expensive parts. 39 of 4 re aa een errr GENERAL ‘Component Handling Max, Tray size (Lx Wi) Min, Tray size (Lx Wy 350mm x 220mm (13.7" x 86°) 50mm x 50mm (2.0° x 2.0") Pallet exchange time: (Changing from pallet | to 20; 5.6 seconds Pick up restrictions Power and air supply Weight: FTopaz-X + Landscape ATS 20 Tray feeder dimensions: Maximum board size Topsz-X: Maximum amount of feeders on Topaz-X: | Length: 1650%mm (5.5 A) ‘Ac the right side of the ATS 20 landscape paler components can't be picked by all heads in an area of 182mm (0.72") Supplied by Topaz-X. +80 Kg (I76 Lbs) Height: 1850mm (6.2 2) ‘Width: 1783mm (5:99; ‘with ATS 20 door open: 228%mm (7.6 #) 380mm (15.0") 56 [APPLICABLE COMPONENTS: Max. Tray height included component height: Min. Component dimension: Max. Component dimension: Térnm (0.63") from pallets at pitch of 25mm Tlemm x 6mm (02 [32mm x 32mm (13" x 13" 8.5mm (0.33") from pallets ac pitch of 12.5rmm (0.49; total 20 pallets possible. (0.98"; total 10 pallets possible 024") mold size [STANDARD COMPONENT CAPACITY Max. number of component types 20 (20 x | Jedec tray) Number of pallets ‘Standard 2 x 20 pallets included (additional pallets available PA 2981/36) 40 of 44 7.6 Mountable ‘Components & Required Nozzles GEM Topaz-X. ‘Component, Handling Just five nozzle shapes are required to cover the specified SMD range. High output levels are therefore achieved, as the need for nozzle exchanges is minimal. An optional 18 position nozzle exchange station enables additional special nozzles to be accommodated. Solid resistor ogo [030025 Type 7IATIF ao [050/050 Type 7IAMIF ia [080050 Type TRAITAF 200 [125/050 Type ATIF 320 [160/040 Type ATIF Seid restr 200 [6125 Tipe DATE 345 [0138 Tipe RAT 33 222 Type RATE uléLayered ceramic 08 03 03 Type TIAMIF epscter ‘a as as Type TIAMIF

You might also like