13593 Assembleon Specboekje
Contents
1. Type of nozzles for X Type 71 Standard for the Opal X will Type 72 be delivered 1x nozzle 72 Type 73 1x nozzle 73 1x nozzle 76A Type 75 1x nozzle 77 Type 76A Melf nozzle Type 77 Nozzle exchange station 20 nozzle positions Optional No nozzles included Nozzle station can hold 4 x 71 4x 72 4x 73A 2x 75 4 x 77 1 x 76A and 1 special nozzles Component weight if certain conditions are met ines sommes O interdistance SOP 0 7mm or more Placement system With the use of Nozzle type 75 Pneumatic or servo controlled for component height compensation Placement force 24 gram mm for nozzles with buffer this value is different Pre tension is 200 gr spring loaded Number of feeders Pneumatic Tape Feeders 8mm 100 positions 12mm 48 positions 16mm 48 positions 24mm 32 positions 32mm 22 positions 44mm 21 positions 96mm 20 positions 72mm Tape feeders are available Stick feeders Depends on stick dimensions on special request Bulk feeders 100 x 8mm positions Component Packaging Tape according to IEC EIA J JEDEC 8 56mm Tape reel diameter max 380mm For larger tape feeders such as 15 6 OF 40 72mm please contact your local sales representative 13593 Assembleon Specboekje 25 02 2003 16 29 Pagina 7 D Opal X Manual Tray feeder Max tray size is board width dependent Max tray size 330mm x 300mm 12 8 x 11 7 Max tray size by max board width2. Non Mountable area Board Top side 3mm from rear side board edge 0 12 Omm from front side board edge Component height restrictions apply in the 10mm 0 40 area from front side edge depending on board thickness 4mm around reference holes 0 16 locate pins Board Bottom side 5mm from front and rear side board edge 0 2 PCB Material Phenolic FR4 Composite Materials Ceramic PCB transport is optional PCB weight Max 1 2 Kg without components Max 2 0 Kg with components 26 of 40 13593 Assembleon Specboekje 25 02 2003 16 30 Pagina 27 Table 7 BOARD HANDLING PCB positioning Locate pin fixation adjustable second pin Z servo controlled push up system software con trolled by PCB thickness Push up pins adjustable positions Optional Board clamping sandwich Sub stop PCB waiting buffer adjustable position Exit stop fixed position PCB Transport height 900mm 10mm 35 4 0 4 SMEMA 953mm 12 5mm 37 5 0 5 PCB Transport direction PCB Transport width Left to Right standard optional Right to Left Automatic PCB loading time PCB ratio width length Approximately 3 sec Max 1 3 27 OF 40 13593 Assembleon Specboekje 25 02 2003 16 30 Pagina 28 D BOARD HANDLING 3mm 0 12 A omm 0 2 5mm 0 2 Not mountable area Mounting is not possible within 3mm 0 12 of the periphery of the A pos
3. 13593 Assembleon Specboekje 25 02 2003 16 29 Pagina om2 D Assemblcon LEADERS IN ELECTRONIC MANUFACTURING TECHNOLOGY MARCH 2003 GEMLINE OPAL X SPECIFICATIONS 13593 Assembleon Specboekje 25 02 2003 16 29 Pagina om3 D PA 1314 03 Opal X Assembl on Netherlands BV 2003 All rights are reserved Reproduction in whole or in part is prohibited whitout the prior written consent of the copyright owner The information presented in this document does not form part of any quotation or contract is believed to be accurate and reliable and may be changed without notice No liability will be accepted by the publisher for any consequence of its use Publication thereof does not imply any licence under patent or other industrial or interlectual property rights Values are valid at specified conditions Printed in The Netherlands Date of release March 2003 9498 392 0020 1 13593 Assembleon Specboekje 25 02 2003 16 29 Pagina om4 P 13593 Assembleon Specboekje 25 02 2003 16 29 Pagina 1 D CONTENTS 1 0 2 0 3 0 4 0 5 0 6 0 7 0 8 0 9 0 CONTENTS Introducing the GEM Opal X series 2 eee ee eee 3 General SPENNE 5 Features Accessories and Options cece eee eee 10 PO RP E EEE 10 3 2 Accessories and ODUIONS x suueuwrsezesessesedecensscs 11 3 3 Machine configuration examples 0 13 Mounting Head Configuration 2 2ccgsrer
4. 440mm 17 2 330mm x 175mm 12 8 x 6 8 Min tray size 50mm x 50mm 2 0 x 2 0 GENERAL SPECIFICATIONS REMARKS Optional Manual tray feeder Max number of feeders 75 Double shuttle LCS Tray Feeder Max tray size 350mm x 440mm 13 7 x 17 2 Min tray size 50mm x 50mm 2 0 x 2 0 Stick and bulk Optional Double shuttle LCS tray feeder no restrictions Max 120 Jedec trays Many solutions possible Maximum height pre mounted components 6 5mm on placement side 0 26 18mm on non placement side 0 7 Before transport PCB Dimensions x y PCB Weight PCB Thickness Min 50 x 50mm 2 0 x 2 0 Max 460 x 440mm 18 x 17 2 Special applications upon request Max 1 2 Kg Max 2 0 Kg Min 0 4mm 0 015 Max 4 0mm 0 15 Special applications upon request Using PCB pin fixation Without components With components Non mountable area Board top side 3mm from rear side board edge 0 12 Omm from front side board edge 4mm around reference holes 0 16 locate pins Board bottom side 5mm from front and rear side board edge 0 2 Component height restrictions apply in the 10mm 0 40 area from front side edge depending on board thickness Flat edge of 30mm 1 27 is required on bottom right corner for the use of the main stopper sub and exit stopper For Ceramic PCBs optional the non mountable area can be different PCB Material
5. Nozzle types 6 different shapes Encoder resolution X Y 0 0012mm pulse Phi 0 0146 pulse Z 0 00048mm pulse Head position accuracy X 0 010mm Y 0 010mm speed X 1500mm sec Y 1500mm sec Acceleration X 36600mm sec Y 2 000mm sec Table 3 17 oF 40 13593 Assembleon Specboekje 25 02 2003 16 30 Pagina 18 5 0 ALIGNMENT 5 1 LINE ARRAY head spindle encoder ALIGNMENT The high speed of the Opal 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 vision systems monitor While moving the beam over the camera the encoder triggers the camera to capture 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 SMD components are illuminated by a new developed multi angle side illumination unit which allows high speed recognition of CSP s uBGAS The leads of the components CAMERA ALIGNMENT camera picture gt Figure 3 Line sensor vision principle the heads are imaged on the line sensor 18 OF 40 13593 Assembleon Specboekje
6. a Feederbar Exchange System for the front and or rear side of the machine the 50 position feederbar will be replaced by two FES 20 position carts 13 OF 40 13593 Assembleon Specboekje 25 02 2003 16 29 Pagina 14 D FEATURES ACCESSORIES AND OPTIONS EXAMPLE 1 OPAL X Opal X ll 50 position Orr fixed side P 1 hd M foo 4 I 19081 iS tee 50 position Total available feeder number 100 PA 1314 03 Opal X with 4 SF heads PA 2505 26 Board clamping for Opal X PA 2699 24 Double shuttle LCS for Opal X PA 2932 40 Feeder lock verification svstem for Opal X front and rear PA 2963 27 Nozzle Exchange Svstem Opal X 18 positions no nozzles included PA 2969 85 Area CCD camera 32mm including lighting unit for series 14 oF 40 13593 Assembleon Specboekje 25 02 2003 16 30 Pagina 15 D FEATURES ACCESSORIES AND OPTIONS EXAMPLE 2 OPAL X PA 1314 03 PA 2505 58 PA 2505 26 PA 2699 24 PA 2932 40 PA 2963 27 PA 2969 85 Opal X Il 50 Bo position 1 side ada eh BAAN oeo Hat K PEREEEEEEEEE LA Za 9 T 20 position f 20 position 20 position Total available feeder number 90 Opal X with 4 SF heads Feederbar exchange system front side included FES 20 position carts serie Board clamping for Opal X Double shuttle LCS for Opal X Feeder lock verification system for Opal X front and rear Nozzle Exchange System Opal X 18 positions n
7. 25 02 2003 16 30 Pagina 19 D ALIGNMENT Specifications Line array camera CCD 1024 x 1 pixels Max component size 45mm z 1 77 Min lead pitch 0 5mm 20 mil Min lead width 0 2mm 0 008 Grev scale 256 levels Lighting Multi angle Fore side illumination red LED arrav Light intensitv is software controlled for each component separatelv Recognition Reflection Pattern recognition on all leads Max number of lead sides 4 Max number of lead groups 2 per side Check on Lead ball pitch Lead ball location Bent missing leads balls Total number of leads balls Cumulative lead ball pitch Table 4 19 of 40 13593 Assembleon Specboekje 25 02 2003 16 30 Pagina 20 D 5 2 SINGLE AREA CCD ALIGNMENT Figure 4 20 oF 40 ALIGNMENT An optional single area CCD camera extends the component range for the Opal X Component illumination is performed by means of fore reflective lighting and side illumination The lighting source reflects the lead of OFP 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 SNUS VIN INN N B M Yj SANG GEM Opal X working area 13593 Assembleon Specboekje 25 02 2003 16 30 Pagina 21 D ALIGNMENT Specifications Area CCD camera CCD 512 x 480 pixels Max component size 32mm z 1 26
8. 37 oF 40 13593 Assembleon Specboekje 25 02 2003 16 30 Pagina 38 D COMPONENT FEEDING Components Dimension mm Required nozzle type SOJ 20 42 pin TSOP 20 32 pin Table 12 For your information on CSP uBGA bare chip and other types of components please consult your local sales representative 38 oF 40 13593 Assembleon Specboekje 25 02 2003 16 30 Pagina 39 D 9 0 OPAL X SUMMARY Table 13 e Standard o Optional Special order OPAL X SUMMARY Model Opal XII IPanumber 1 OPAS O Super Fine head 4 x SF i Nozzle Exchange station 20 position Special order nozzles Line Array camera 44mm L LL O Area CCD camera 32mm including illumination unit Fiducial camera L 11 ma Bulk Feeder Stick Feeder 11100 Double Shuttle Tray Feeder LCS 10 Reject station Manual Tray Feeder Feeder Exchange System FES 20 s o Main Stopper Locate Pin PG Board Clamp System Z servo controlled Push Up Plate Entrance Sub Stopper Feeding Exit Sub Stopper Automatic Width Adjustment High Speed soft stop conveyor Reverse transfer Right to Left PCB positioning transport Special sized PCBs x Conveyor Entrance Exit covers Safety specifications according CE standards Spare parts kit tools SMEMA kit Front and rear anti static covers Signal tower warning buzzer Windows NT Graphical User interface Multipl
9. 5 02 2003 16 30 Pagina 35 D Table 11 COMPONENT FEEDING LCS Tray feeder specifications GENERAL Max Tray size L x W 350mm x 468mm 13 7 x 18 4 which can hold 3 Jedec trays Min Tray size L x W Component feeding time 50mm x 50mm 2 0 x 2 0 3 5 sec for 2 parts picking from pallet 1 8 5 sec for 2 parts picking one from pallet 1 and one from pallet 40 Power and air supply LCS Tray feeder dimensions Delivered by Opal X Length 826mm 2 8 ft Height 1165mm 3 8 ft with top cover open 1545mm 5 2 ft Width 1650mm 5 2 ft with door open 2292mm 7 6 ft Opal X Tray feeder dimensions Length 24 6mm 8 3 ft Height 1850mm 6 1 ft Width 1898mm 6 3 ft with LCS door open and feeders on Opal X 2942mm 9 8 ft Min Component dimension Max Component dimension 280 kg 617 Lbs APPLICABLE COMPONENTS 8mm x 8mm 0 31 x 0 31 Mold size 45mm x 45mm 1 8 x 1 8 Max Tray height included component height 8 5mm 0 33 from pallets at pitch of 12 5mm 0 5 total 40 pallets possible 20mm 0 8 from pallets at pitch of 25mm 0 98 total 20 pallets possible Number of pallets Standard 40 pallets included additional pallets available PA 2981 15 35 oF 40 13593 Assembleon Specboekje 25 02 2003 16 30 Pagina 36 8 3 COMPONENT FEEDING COMPONENT FEEDING Just six nozzle shapes are required to cover the
10. 6mm 45mm J with pin pitch down to 0 5mm 20 mil 40y for QFP s 6mm 32mm z 1 26 with pin pitch down to 0 4mm 16 mil For Chips and SOIC this is Lead dependent 0 2 for QFP s 6mm 32mm 1 26 with pin pitch down to 0 5mm 20 mil Optional 32mm area CCD camera system with fore and Side illumination unit Line array camera system all placement heads and all placement angles Optional 32mm area CCD camera system in fine mode Line array camera system all placement heads and all placement angles 0 10 for QFP s 6mm 32mm ZI 1 26 with pin pitch down to 0 4mm 16 mil Optional area CCD camera system in fine mode Mounting repeatability 3 o Mounting angle X Y 30u for QFPs 6mm 32mm JA 1 26 pitch 0 4 Phi 0 075 0 up to 360 progammable in steps of 0 01 Optional 32mm area CCD camera Number of heads One single beam with 4 standard heads The Standard heads can exchange nozzles with the use of the optional Nozzle Exchange Station 5 oF 40 LP 13593 Assembleon Specboekje 25 02 2003 16 29 Pagina 6 P Alignment system GENERAL SPECIFICATIONS Opal X REMARKS One line arrav camera with fore and side illumination svstem for Standard Vision on the FIv using the VICS 3200 processing svstem Area CCD camera for QFP 32mm J 1 26 with pin pitch Optional down to 0 4mm 16 mil Moving CCD camera for Fiducial alignment standard
11. Min component size 6mm ZI 0 24 Min lead pitch 0 4mm 16 mil Min lead width 0 2mm 0 008 Grev scale 256 levels Lighting Fore side lighting illumination Recognition Reflection Pattern recognition on all leads Max number of lead sides 4 Max number of lead groups 2 per side Check on Lead ball pitch Lead ball location Bent missing leads balls Total number of leads balls Cumulative lead balls pitch Table 5 210F 40 13593 Assembleon Specboekje 25 02 2003 16 30 Pagina 22 D 5 3 FIDUCIAL ALIGNMENT Table 6 22 OF 40 ALIGNMENT The Opal X is standard equipped with a fiducial camera This camera is used to compensate for variations in the position of the circuit 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 Each 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 can 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 teachin
12. Phenolic FR4 Composite Materials Ceramic PCB s requires special conveyor section optional PCB positioning Locate pin fixation Adjustable second pin Z servo controlled push up system Push up pins software controlled by PCB thickness Adjustable positions 7 OF 40 13593 Assembleon Specboekje 25 02 2003 16 29 Pagina 8 P GENERAL SPECIFICATIONS Opal X REMARKS Board clamping Sub stop PCB waiting buffer PCB Transport height 900mm 10mm 35 4 0 4 Standard SMEMA 953mm 12 5mm 37 5 0 5 PCB Transport direction Left to Right Right to Left is optional Rear rail moving picking and alignment Optional Adjustable position Control system Celeron 566 MHz controller 128Mb intern memory E TOT M 256 Mb flash disk mam CD ROM Sone eras Montor Rini 15 Color User Interface Monitor 12 Flat touch screen optional Comnena rew a Communication protocol TCP IP NetBEUI il User Interface VGOS Visual Graphical Operating Svstem Enhanced PC AT keyboard for data editing functions Control system functions Max 127 PCBs 12 800 Components per PCB Backup and restoring data using floppy Data conversion Text lt gt VIOS MIS data gathering Ne Data teaching Data tracing can define and teach vision files SMEMA electrical interface nine i tng e On line help functions Feeder lock verifier Optional 8 OF 40 13593 Assemble
13. dceyeecnneenenacee hs 16 ANIME eet ae 18 5 1 Line Array Camera Aligments 002 eee eee 18 5 2 Single Area CCD Aligment 22 eee 20 5 3 FN 22 5 4 Master Bas Mark Sensing eee eee ee eee 24 Board Handing EEE 25 Feederbar Exchange Ne 30 T11 PAD 30 Component Feeding EE 4s poo 44685 32 8 1 Pneumatic Tape Feeders sssrssreszzjnottossseknta ani 32 8 2 Double Shuttle Tray Feeder PA 2699 24 34 8 3 Mountable Components amp Required Nozzles GENLODAE ki i EE A E A EEN 36 GJEN SNAP EEE a E E E 39 1 oF 40 13593 Assembleon Specboekje 25 02 2003 16 29 Pagina 2 b CONTENTS 2 OF 40 13593 Assembleon Specboekje 25 02 2003 16 29 Pagina 3 D 1 0 INTRODUCING THE GEM OPAL X Figure 1 INTRODUCING THE GEM OPAL X The new Opal X part of the Modular High Speed Production Machines belongs to the top of the line Assembl on SMD pick amp place machines Front view GEM Opal X The Opal X is a High Speed flexible machine that can handle a wide range of components at speeds up to 12 500 SMDs per hour The machine is built around a very rigid vibration free frame for improved accuracy and long term stability and is perfectly suitable for round the clock production The Opal X features a high precision single placement beam carrying 4 Super Fine heads with exchangeable nozzles The placement beam moves in X Y and Z direction while the board and comp
14. delivered with each FES cart FES 20 specifications PA 2505 59 FES change over time lt 60 sec FES repeatability Pick position lt 0 05mm Applicable feeders Tape stick bulk feeders 13593 Assembleon Specboekje 25 02 2003 16 30 Pagina 31 D Table 8 Figure 14 FEEDERBAR EXCHANGE SYSTEM Number of feeders on FES carriage omm 20 positions 12 16mm 9 positions 24mm 6 positions 32mm 6 positions 44mm 4 positions 56mm 4 positions Stick depends on stick dimensions Air and Electrical interface Electrical power Quick coupling one action Supplied by main system Air supply FES 20 dimensions stand alone without feeders Supplied by main system Length 750mm 2 5 ft Width 460mm 1 5 ft Height 1000mm 3 3 ft Weight without feeders Tape waste bin 65 kg 143 Lbs Included Compatibility Min component size X serie machines 0402 1 0mm x 0 5mm Smaller components should be used with pick up teaching function Clamping system 31 OF 40 13593 Assembleon Specboekje 25 02 2003 16 30 Pagina 32 P 8 0 COMPONENT FEEDING 8 1 PNEUMATIC TAPE FEEDERS Figure 15 Table 9 32 OF 40 COMPONENT FEEDING The Opal X has a fully compatible feeder platform with all GEM machines Depending on the machine configuration up to 100 tape feeders 8mm can be loaded The tape feeder design allows simultaneous picking from a
15. e Accuracy Compensation System Fiducial Recovery function Bad Mark Master Mark Sensing On line teaching Alternative Feeder Function Automatic program change Variable XY axis speed per component On line Help function Management Information System Template pattern matching Automatic rework cycle On line data generator 39 oF 40 13593 Assembleon Specboekje 25 02 2003 16 30 Pagina 40 b OPAL X SUMMARY 40 of 40
16. et sequencer feeding parts from a tray This feeder can be equipped with maximum 40 pallets each being able to hold different trays Double shuttle 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 part is 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 simultaneous operation of Tray sequencer and Opal 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 e A tray container is fixed and separated into two sections with each 20 pallets This allows tray replenishment while the machine is running e A buffer conveyor is standard equipped so a reflow oven can be connected without additional conveyors 13593 Assembleon Specboekje 2
17. g device for PCB data if CAD data is not available automatic calibration and inspection purposes Specifications Fiducial camera CCD Fiducial camera functionality Fiducial detection Bad mark detection teaching device 2 or 4 point teaching Fiducial illumination White IR LEDs in conjunction with a wide angle diffuser Compensation for Translation Rotation with two fiducials Linear stretch and shrink Compensation for Non linear stretch and shrink with 3 or 4 fiducials Type of compensation PCB Block Local Fiducial size Max 3 0mm 0 12 Min 0 8mm 0 03 Fiducial material Copper Gold Lead tin Fiducial clearance area 2 x Fiducial size PCB warpage at fiducial Max 0 5mm 0 02 Pattern offset Max imm 0 04 Number of Fiducial shapes in Mark Database 300 Examples of Fiducials Solid circle preferred Square Triangle Donut Binarv Cross Bow tie connected Template matching Fiducial definition According CAD data 13593 Assembleon Specboekje 25 02 2003 16 30 Pagina 23 D e ml Ww Figure 5 Fiducial free space eqarovsosm Preferred others possible but not preferred ALIGNMENT Figure 6 Fiducials Figure 7 Examples of PCB block and local fiducials 23 OF 40 13593 Assembleon Specboekje 25 02 2003 16 30 Pagina 24 D 5 4 MASTER BAD MARK SENSING 24 oF 40 ALIGNMENT If the PCB contains sub circuits one or more of these subcircuits can be sk
18. holder CL PA 2903 78 8mm Tape Feeder 2mm pitch 15 inch reelholder CL PA 2903 88 12mm Tape Feeder 15 inch reelholder CL 9466 920 10921 Reject belt feeder GEM Set of 20 dummy feeders PA 2930 15 Empty tape waste bin front and rear Feeder Floating detection Opal X front and rear PA 2962 45 Nozzle Type 73 1812 SOP 4532 SOP Nozzle Type 76A Cylindrical chip MELF PA 2962 47 Nozzle Type 71 0201 0402 0603 1005 Nozzle Type 72 0603 1206 1608 3216 P 2962 49 Nozzle Type 75 Large size QFP PA 2962 50 Nozzle Type 77 Middle size QFP P 2963 27 Nozzle Exchange System Opal X 20 position no nozzles included factory built in only PA 2969 85 Area CCD camera 32mm including fore and side illumination unit for series PA 2981 15 Pallet for LCS Tray Feeder FV GEM PA 2699 22 23 24 Table 2 12 OF 40 13593 Assembleon Specboekje 25 02 2003 16 29 Pagina 13 D 3 3 MACHINE CONFIGURATION EXAMPLES FEATURES ACCESSORIES AND OPTIONS On the following page you can find a machine configuration example for the Opal X II Remark 1 In the example the dotted lines pictures indicate the physical position of the area CCD camera large component sequencer nozzle exchange station and FES 20 These can be ordered as an option I 20 position f 1 32mm Area CCD camera Opal X 2 Nozzle exchange station for Opal X 3 Feederbar Exchange System 20 position Remark 2 By ordering
19. ipped for placement by giving them a Bad Mark on a designated position on the subcircuit No parts will be placed on a circuit 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 e white or light colored labels of any dimension e white paint or any other material that can be fixed as long as it contrast 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 13593 Assembleon Specboekje 25 02 2003 16 30 Pagina 25 D 6 0 BOARD HANDLING Figure 8 Figure 9 BOARD HANDLING PCB boards can be located in the machine by either tooling pins or board clamping if 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
20. itioning hole and the B long hole and from rear side Board Edge Locate pin restriction Component height restrictions apply in the 10mm 0 4 area from side edge depending on Board thickness Figure 10 Mountable area Max 0 5mm 0 02 Max 1 0mm 0 04 Figure 11 Warp of fixed PCB 28 OF 40 13593 Assembleon Specboekje 25 02 2003 16 30 Pagina 29 D BOARD HANDLING No component should be in this area T 0 4 4 0 mm 0 015 0 15 mm 0 2 Locate pin restriction component height restriction apply in the 10 mm 0 4 area we from front edge depending on board thickness l mm 0 27 Figure 12 Mountable area 29 oF 40 13593 Assembleon Specboekje 25 02 2003 16 30 Pagina 30 P 7 0 FEEDERBAR EXCHANGE SYSTEM 7 1 PA 2505 59 Figure 13 30 oF 40 FEEDERBAR EXCHANGE SYSTEM The Feederbar Exchange System FES allows fast change over by switching the complete 20 position feederbar on an Opal X FES cart X Feederbars are mounted on carts to off line feeder Set up These carts are easily moved from set up area to the mounting machines and back This option is available for the front PA 2505 57 and rear side PA 2505 58 of the machine At the front and rear side of the machine the standard 50 position feederbar will be replaced by two FES 20 position carts The Opal X FES carts are compatible with those of the X serie machines An empty tape bin will be
21. l An optional 20 position nozzle exchange station enables additional special nozzles to be accommodated Up to 100 tape feeders can be loaded on the Opal X The machine supports tape stick bulk and tray feeders The tape feeder design for the Opal X allows simultaneous picking from any mix of tape feeders ranging from 8 to 56mm A Windows NT based controller running an user friendly Graphical User Interface allows the Opal 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 Opal X is fully compatible with the other X serie machines which use the same feeders feederbars software and controller Off line feeder changeover can be achieved by using a 20 position Feederbar Exchange System FES An entire feederbar can be conveniently loaded off line minimizing change over time A basic program optimization function is also included in the machine as standard which can be used during production For more advanced machine optimization and or line balancing the new Production Preparation System allows you to create and optimize SMD machine programs on a PC instead of
22. n unit for BGAs uBGA CSP components Placement beam with 4 Super Fine heads Simultaneous picking is possible by all 4 heads from 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 6 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 push up plate Z servo controlled with 12 push up pins for PCB support PCB thickness is included in the PCB data 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 3 5 FDD for backup purposes CD ROM drive for software installation Operation panel with push buttons Component dump box Operator manual available in different languages User manual Service manual Toolset First aid spare parts kit CE safety ESD safety Electrical and Mechanical SMEMA 13593 Assembleon Specboekje 25 02 2003 16 29 Pagina 11 D 3 2 ACCESSORIES AND OPTIONS FEATURES ACCESSORIES AND OPTIONS Standard S
23. ny mix of tape feeders ranging from 8 to 56mm To achieve high speed feeding all feeder types are air driven To prevent incorrect feeder latching a laser based verification system is used Pneumatic tape feeder Available tapefeeders Tape Feeder Feeding pitch PA mm Tape Feeder 8mm 15 for 0603 0201 component CL Tape Feeder 8mm 15 for 1005 0402 CL Tape Feeder 8mm 15 CL 4 PA 2903 79 Tape Feeder 12mm 15 CL 4 8 12 PA 2903 88 Tape Feeder 16mm 15 CL 4 8 12 16 PA 2903 27 Tape Feeder 24mm 15 CL 4 8 12 16 20 24 PA 2903 38 Tape Feeder 32mm 15 PSA 8 12 16 24 32 PA 2903 41 Tape Feeder 44mm 15 PSA 8 12 16 24 32 36 PA 2903 51 Tape Feeder 56mm 15 CL 4 8 12 16 24 32 36 PA 2903 68 For larger and special tape feeders such as 72mm please contact your local sales representative The feeding pitch can be adjusted on the feeder side 13593 Assembleon Specboekje 25 02 2003 16 30 Pagina 33 D COMPONENT FEEDING Feeder occupation Feeder type Required feeder position equivalent to tape feeder 8mm Tape feeder 8mm Tape feeder 32mm Tape feeder 44mm Tape feeder 56mm Table 10 The above feeder conversion number may differ according to the installation combination 33 oF 40 13593 Assembleon Specboekje 25 02 2003 16 30 Pagina 34 D 8 2 DOUBLE SHUTTLE TRAY FEEDER PA 2699 24 Figure 16 34 oF 40 COMPONENT FEEDING The double shuttle Tray feeder is an additional pall
24. o nozzles included Area CCD camera 32mm including lighting unit for series 15 oF 40 13593 Assembleon Specboekje 25 02 2003 16 30 Pagina 16 D MOUNTING HEADS CONFIGURATION 4 0 MOUNTING The Opal X features a high precision single placement beam carrying 4 Super Fine HEADS heads with exchangeable nozzles On the head a separate camera system is attached CONFIGURATION 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 simultaneous component picking which reduces head beam travel and thus shortens the mounting cycle Figure 2 Configuration of head section The high precision dual Y drive Opal 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 16 oF 40 13593 Assembleon Specboekje 25 02 2003 16 30 Pagina 17 D MOUNTING HEADS CONFIGURATION Specifications Axis configuration X axis AC servo Double Y axis AC servo Z R axis AC servo W automatic width axis AC servo Push up plate AC servo Z axis sequence Air and AC servo motor R axis sequence AC servo motor Pick up error detection Vacuum check 256 level digital setting Mounting angle 0 360 0 01 step Number of mounting head 4 in line multi head
25. oftware features Variable XY axis speed per component Datum angle functionality especially for stick components there is no pick angle necessary to recognize the component which results in higher output User Friendly Graphical Human interface VGOS Visual Graphical Operating System with touch screen capability An On line help function 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 control Automatic rework cycle to improve operator efficiency and online optimization to keep mounting speed during production in case of empty feeder
26. on Specboekje 25 02 2003 16 29 Pagina 9 D GENERAL SPECIFICATIONS REMARKS Machine dimensions Length 1650mm 5 4 ft and weight Height 1850mm 6 1 ft Width 1408mm 4 5 ft Width including feeders pneumatic feeders 2244mm 7 36 ft Weight 1600 kg 3526 Lbs Safety standards EN 292 EN 294 EN 349 EN 614 EN 1050 EN 55011 CE safety is part of system design EN 50082 1 EN 60204 1 Safety measurements are tested Electrical safety according IEC 204 on each product in the factory Warning lights White Emergency stop safety cover interlock Blue Error made e g pick up error out of components Green In automatic operation Audio warning signal Operational errors Electric Power Voltage AC 200 208 220 240 380 400 416 V 10 3 Phase More than 3 5mm cables are needed Freguencv 50 60 Hz Consumption 4 4 kVA max Air supply Pressure gt 5 5 10 Pa 5 5 bar 80 PSI Tr min 350 NI min 15 35 C 59 95 F Specification guaranteed 20 28 C 68 82 F Humidity 20 90 no dew Noise lt 8dba Class 10 000 10 K Table 1 9 oF 40 13593 Assembleon Specboekje 25 02 2003 16 29 Pagina 10 P 3 0 FEATURES ACCESSORIES AND OPTIONS 3 1 FEATURES 10 of 40 FEATURES ACCESSORIES AND OPTIONS The standard GEM Opal X includes the following features On the fly alignment using a vision system with a Line Array Camera standard equipped with a side illuminatio
27. onent feeders are stationary A flexible board transport system enables the Opal 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 from 0201 up to 45Mm sguare PLCC including 45mm square OFPs with lead pitches down to 0 5mm 20 mil Dark background BGAs UBGAs and CSPs with ball pitches down to 0 5mm 20 mil and ball diameters down to 0 3mm 12 mil can be recognized with the use of new developed illumination unit which allows measurement of ball positions and dimensions 3 oF 40 13593 Assembleon Specboekje 25 02 2003 16 29 Pagina 4 D 4 oF 40 INTRODUCING THE GEM OPAL 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 detects 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 six nozzle shapes are required to cover the specified SMD range High output levels are therefore achieved as the need for nozzle exchanges is minima
28. s Detected empty feeders are automatically skipped until end off programs to allow one time replen ishment Product preparation can be done on the machine including basic optimization of the mount program nozzle and feeder set up during production Multi section PCBs can be either be mounted block by block or the block data can be combined to achieve the fastest mounting sequence In the latter case block bad marks still remain in effect ACCESSORIES AND OPTIONS Opal X PA 1912 00 CSM GEM Glass Adjustment Kit PA 2505 26 Board Clamping system Opal X PA 2505 57 Feederbar exchange system front side including two FES 20 position cart for FV GEM series PA 2505 58 Feederbar exchange system rear side including two FES 20 position cart for FV GEM series PA 2505 59 FES feeder bar exchange cart 20 positions for series PA 2506 30 Rear site CRT monitor keyboard and mouse PA 2506 31 Flat touch screen monitor front side PA 2506 33 Flat touch screen monitor front and rear side PA 2506 35 Operation panel rear side PA 2506 40 Maintenance lamp 11 oF 40 13593 Assembleon Specboekje 25 02 2003 16 29 Pagina 12 P FEATURES ACCESSORIES AND OPTIONS PA 2695 12 Manual Tray Feeder Topaz X Emerald X Double shuttle Tray Feeder LCS for Opal X PA 2903 27 16mm Tape Feeder 15 inch reelholder CL PA 2903 41 32mm Tape Feeder 15 inch reelholder FV GEM PSA PA 2903 68 56mm Tape Feeder 15 inch reel
29. specified SMD range High output levels are therefore achieved as the need for nozzle exchanges is minimal An optional 20 position nozzle exchange station enables additional special nozzles to be accommodated Components Dimension mm Set i i Solid resistor Solid resistor Multi Lavered ceramic capacitor 0 60 Required nozzle type T 1 00 1 60 0 30 0 25 0 50 0 50 2 00 3 20 2 00 1 25 3 45 1 35 5 9 0 6 1 0 1 50 2 00 1 25 1 25 3 20 1 60 1 25 3 20 4 50 2 00 3 20 1 50 1 90 MELF ceramic capacitor Tantalium electrolytic capacitor Aluminium electrolytic capacitor ee ss 71 12 2 2 2 2 2 71 71 12 12 2 13 13 13 76A 12 73 13 13 3 13 9 13 10 5 36 of 40 13593 Assembleon Specboekje 25 02 2003 16 30 Pagina 37 Components Chip film capacitor Chip inductor Dimension mm COMPONENT FEEDING Required nozzle type j DR TI N C o CO NO OT IQ CI Semi variable resistor Transistor SOT Power transistor l 5 00 4 50 1 50 73 7 60 4 50 1 50 73 12 60 5 70 1 50 73 15 30 7 50 2 00 77 2 00 77 B 5 16 73 A 15 20 77 A 15 32 77 B 15 45 75 B 5 16 77 A 15 20 77 A 15 32 77 A 10 26 77 A 10 30 77 p 10 45 75
30. using the SMD machine 13593 Assembleon Specboekje 25 02 2003 16 29 Pagina 5 2 0 GENERAL SPECIFICATIONS Tact time 0 30 sec chip with line array camera GENERAL SPECIFICATIONS REMARKS Simultaneous pick with 4 heads 0 36 sec SO with line array camera 1 4 sec QFP with line array camera simultaneous pick with 4 heads sequential pick with 4 heads 1 7 sec QFP with line array camera 3 7 sec QFP with area CCD camera With 1 head In fine mode with 1 head Optimal placement rate 11 600 cph simultaneous pick with 4 heads at best conditions IPC 9850 placement rate Nominal placement rate 9 600 cph 8 000 9 000 cph C0603 all heads all angles Real mounting time Applicable Components Mounting accuracy X Y 3 o Mounting accuracy p 3 o 0201 SOP SOJ PLCC 45mm square 1 77 6mm QFP 20mm 7 0 78 with pin pitch down to 0 4mm 16 mil 20mm QFP 45mm 1 77 with pin pitch down to 0 5mm 20 mil Dark background BGA uBGA CSP with regular pitches 6mm 45mm Min ball pitch down to 0 50mm 20 mil Min ball diameter down to 0 3mm 12 mil Line array camera system 45mm 6mm QFP 32mm JZ 1 26 with pin pitch down to 0 4mm 16 mil Dark background BGA with regular pitches 6mm 32mm ff Min ball pitch down to 0 50mm 20 mil Min ball diameter down to 0 3mm 12 mil 50u for chips 0201 0402 75u for chips SOIC 60u for QFP s
31. width and the PCB thickness Sub stopper Moveable Fixed Fixed main stopper locate pin locate n k 4 MOVEABLE Pin fixation system PCB support plate PCB Conveyor 4 Pin shaft frame yy 4 Wing nut Magnet s II W SCM COMO GENUS Maule DELE Push up system 25 of 40 13593 Assembleon Specboekje 25 02 2003 16 30 Pagina 26 D BOARD HANDLING 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 in a flowline it communicates with the unit upstream and downstream over a SMEMA connection PCB Dimensions x y Specifications Min 50 x 50mm 2 0 x 2 0 Max 460 x 440mm 18 x 17 2 using PCB pin fixation or PCB board clamping system PCB Thickness Min 0 4mm 0 015 Max 4 0mm 0 15 Reference hole position Reference hole diameter omm 0 2 in X and Y from lower right corner 2 0mm 4 0mm 0 08 0 157 PCB Maximum warpage 0 5mm up 0 02 1 0mm down 0 04 Maximum height pre mounted components 6 5mm on placement side 0 26 18mm on non placement side 0 7
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