1.0 Introducing the GEM Topaz-X - philips
Contents
1. Grey 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 ball pitch 23 of 44 5 3 Fiducial Alignment Table 6 Alignment The GEM Topaz 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 teaching device for PCB data if CAD data is not available automatic calibration and inspection purposes Specifications Fiducial camera CCD2. Features Features Accessories and Options The standard GEM 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 uBGA CSP components Placement beam with 4 Flying Nozzle Change heads each head standard equipped with 3 nozzles and 4 standard heads Simultaneous picking is possible by all 8 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 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 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 Feeder lock verification system to avoid damage to the machine due to incorrectly latched feeders 3 5 F
3. Line Array camera CCD 2048 x pixels Max component size 32mm 1 26 Min component size 0201 Min lead pitch 0 5mm 20 mil Min lead width 0 2mm 0 008 Grey scale 256 levels Lighting Multi angle Fore side illumination Light intensity is software controlled for each component separately 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 21 of 44 5 2 Single Area CCD Alignment Figure 6 Alignment An optional single area CCD camera extends the component range for the GEM Topaz X Component illumination is performed by means of fore reflective lighting and side illumination The lighting source reflects the lead of QFP 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 GEM Topaz X working area 22 of 44 Table 5 Area CCD Camera Alignment Specifications CCD 512 x 480 pixels Max component size 32mm Zl 1 26 Min component size 6mm AZ 0 24 Min lead pitch 0 4mm 16 mil Min lead width 0 2mm 0 008
4. XY 3o 75y for chips and SOIC 60u for QFPs 6mm 32mm 1 26 with pin pitch down to 0 5mm 20 mil Line array camera system all placement heads and all placement angles 35y for QFPs 6mm 32mm 1 26 with pin pitch down to 0 4mm 16 mil Optional area CCD camera system in fine mode Mounting accuracy 9 30 For Chips and SOIC this is Lead dependent 0 6 for QFPs 6mm 32mm f 1 26 with pin pitch down to 0 5mm 20 mil Line array camera system all placement heads and all placement angles 0 09 for QFPs 6mm 32mm to 0 4mm 16 mil 1 26 with pin pitch down Optional area CCD camera system in fine mode Mounting angle 0 up to 360 programmable in steps of 0 01 Mounting repeatability 3c X Y 30u for QFPs 6mm 32mm 1 26 pitch 0 4 Phi 0 09 Number of heads One single beam with 4 Flying Nozzle change heads and 4 standard heads The Standard heads can exchange nozzles with the use of the optional Nozzle Exchange Station Alignment system One line array camera with fore and side illumination system for Vision on the Fly using the VICS 2500 processing system Standard second line array camera is optional Area CCD camera for QFP 32mm 1 26 with pin pitch Optional down to 0 4mm 16 mil Moving CCD camera for Fiducial alignment Standard 5 of 44 General Specifications
5. 5mm 0 2 0 2 Not mountable area Mounting is not possible within 3mm 0 12 of the periphery of the A positioning 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 Mountable area Max 0 5mm 0 02 Max 1 0mm 0 04 Warp of fixed PCB 30 of 44 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 Pd from front edge depending on board thickness f 5 mm 0 2 Figure 15 Mountable area 31 of 44 7 0 7 1 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 achieve 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 Feeding pitch PAH mm Tape Feeder 8mm 7 for 0603 0201 component PSA 2 PA 2903 73 Tape Feeder 8mm 7 for 1005 040
6. Contents Contents 1 0 Introducing the GEM Topaz X 0 00 00 0006 3 2 0 General Specifications aos Gore ped de ere pennen 5 3 0 Features Accessories and Options lessen 10 ad Parese cete t BAe athe ene xen ens ax 10 3 2 Accessories and Options 00 ee ee eee 13 4 0 Mounting Heads Configuration 00 17 5 0 Mennenes eee odde 20 5 1 Line Array Camera Alignment 20 5 2 Single Area CCD Alignment 2er mre 22 5 3 Fiducial Alignment Ss pi car uda ee 24 5 4 Master Bad Mark Sensing eeu ees sans vemos en 26 60 Bardal esse eue ee sobre eet asse 27 7 0 Component Handling ccnp ass osetia cae eee EST 32 Tal Typene er be 32 7 2 Double Shuttle Tray Feeder PA 2699 22 33 7 3 ATS 20 Tray Feeder portrait PA 2696 21 25 7 4 Double ATS 20 Tray Feeder portrait PA 2696 22 37 7 5 ATS 20 Tray Feeder landscape PA 2696 23 39 7 6 Mountable Components amp Required Nozzles GEM Topaz X SEE ETE 4 of 44 Contents 2 of 44 1 0 Introducing the GEM Topaz X Figure I Introducing 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 amp place machines The Topaz X is a High Speed flexible machine that can handle a wide range of components at speeds up to 18 000 SMDs per hour The machine is built around a very rigid vibration free
7. REMARKS Type of nozzles Type 71F on FNC head Type 72F on FNC head Type 73F on FNC head Type 71A Type 72A Type 73A Type 74A Type 76A Melf nozzle Standard will be delivered 4x nozzle 71F 4x nozzle 72F 4x nozzle 73F 4x nozzle 72A Nozzle exchange station 18 nozzle positions Optional No nozzles included Nozzle station can hold 4 x 71A 4 x 72A 4 x 74A 4 x 76A and 2 special nozzles Nozzle 73A does not fit in the nozzle station Component weight Max 10 gr With the use of nozzle type 74A Component height Max 4 0mm Max 6 5mm depending on mount sequence Placing of parts with a height of 6 5mm 10mm is possible if certain conditions are met Component mounting interdistance Chip 0 5mm or more SOP 0 7mm or more Placement system Pneumatic or servo controlled for component height compen sation Placement force 24 gram mm for nozzles with buffer this value is different Pre tension is 200 gr spring loaded Number of feeders Tapefeeders 8mm 90 positions 12mm 43 positions I 6mm 43 positions 24mm 28 positions 32mm 22 positions 44mm 21 positions Stick feeders Depends on stick dimensions 6 of 44 General Specifications REMARKS Component packaging Tape according to IEC EIA EDEC 8 44mm For larger tape feeders such as 5 mm 72mm please contact your local
8. 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 simultaneous 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 ATS 20 Tray Feeder portrait PA 2696 21 specifications GENERAL Max Tray size L x W 220mm x 350mm 8 6 x 13 7 Min Tray size L x W 50mm x 50mm 2 0 x 2 0 Pallet exchange time Changing from pallet to 20 5 6 seconds Weight 80 Kg 176 Lbs Power and air supply Supplied by Topaz X Topaz X ATS 20 Tray feeder dimensions Length 1650mm 5 5 ft Height 1850mm 6 2 ft Width 1870mm 6 2 ft with ATS 20 door open 2220mm 7 4 ft Maximum board size Topaz X 250mm 9 8 Maximum amount of feeders on Topaz X 60 APPLICABLE COMPONENTS Max Tray height included component height 8 5mm 0 33 from pallets at pitch of 12 5mm 0 49 total 20 pallets possible 16mm 0 63 from pallets at pitch o
9. 0 00048mm pulse Speed X 1500mm sec Y 1500mm sec Acceleration X 36600mm sec Y 27000mm sec 18 of 44 Mounting Heads Configuration Figure 4 Head section detail 19 of 44 5 0 5 1 Alignment Line Array Camera Alignment picture gt E components Alignment 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 with a second Line Array camera which reduces head beam travel and thus shortens the mounting cycle encoder PE monitor Figure 5 Line sensor vision principle 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 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 of 44 Table 4 Alignment Specifications
10. 5 6 seconds Pick up restrictions At the left ATS 20 components can t be picked by all heads in an area of 36mm 1 4 from the left side of the pallet Power and air supply Supplied by Topaz X Weight 160 Kg 342 Lbs Topaz X double ATS 20 Tray feeder dimen sions Length 1650mm 5 5 ft Height 1850mm 6 2 ft Width 1870mm 6 2 ft with ATS 20 door open 2220mm 7 4 ft Maximum board size Topaz X 250mm 9 8 Maximum amount of feeders on Topaz X 40 APPLICABLE COMPONENTS Max Tray height included component height 8 5mm 0 33 from pallets at pitch of 12 5mm 0 49 total 20 pallets possible 16mm 0 63 from pallets at pitch of 25mm 0 98 total 10 pallets possible Min Component dimension 6mm x 6mm 0 24 x 0 24 mold size Max Component dimension 32mm x 32mm 1 3 x 1 3 STANDARD COMPONENT CAPACITY Max number of component types Number of pallets 40 40 x Jedec tray Standard 2 x 20 pallets included additional pallets available PA 2981 35 38 of 44 7 5 Component Handling ATS 20 Tray The ATS 20 Tray Feeder landscape is a new additional internal pallet sequencer Feeder allowing high speed feeding of tray components This feeder can 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 p
11. Fiducial camera functionality Fiducial detection Bad Mark detection teaching device 2 or 4 point teaching Fiducial illumination White IR LEDs in conjunction with a multi angle illumination Compensation for Translation with two fiducials Rotation 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 different Fiducial pairs per PCB 128 Number of fiducial shapes in Mark Database 300 Examples of fiducials Solid circle preferred Square Triangle Donut Binary cross Bow tie connected Template matching art work Fiducial definition According CAD data 24 of 44 Figure 7 Figure 8 Figure 9 Fiducial free space 2A 2 Examples of fiducials Examples of PCB block and local fiducials Alignment 25 of 44 5 4 Master Bad Mark Sensing Alignment If the PCB contains subcircuits one or more of
12. Component feeding time 3 5 sec for 2 parts picking from pallet 1 8 5 sec for 2 parts picking one from pallet and one from pallet 40 Power and air supply Delivered by Topaz X LCS Tray feeder dimensions Length 826mm 2 8 ft Height I 165mm 3 8 ft with top cover open 1545mm 5 2 ft Width 1650mm 5 2 ft with door open 2292mm 7 6 ft Topaz X Tray feeder dimensions Length 2476mm 8 3 ft Height 1850mm 6 1 ft Width 1842mm 6 1 ft with LCS door open and feeders on Topaz X 2942mm 9 8 ft Weight 280 kg 617 Lbs Power supply air supply Supplied from main machine APPLICABLE COMPONENTS Min Component dimension 8mm x 8mm 0 31 x 0 31 Mold size Max Component dimension 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 78 from pallets at pitch of 25mm 0 98 total 20 pallets possible FEED CAPACITY Number of shuttles 2 Number of pads on each shuttle 2 with a pitch of 48mm STANDARD COMPONENT CAPACITY Max number of component types 120 3 x 40 Jedec Number of pallets Standard 30 pallets included additional pallets available PA 2981 15 34 of 44 7 3 Component Handling ATS 20 The ATS 20 Tray Feeder is a new additional internal pallet sequencer allowing high
13. Text gt VIOS MIS data gathering Data teaching Data tracing Component database 3000 Component packages user can define and teach vision files Mark database 300 Mark shapes SMEMA electrical interface On line calibration On line help functions Feeder lock verifier Machine dimensions and weight Length 1650mm 5 4 ft Height 1850mm 6 1 ft Width 1408mm 4 5 ft Width including feeders is 2244mm 7 36 ft Weight 1570 kg 3460 Lbs Safety standards EN 292 EN 294 EN 349 EN 614 EN 1050 EN 55011 EN 50082 1 EN 60204 1 Electrical safety according IEC 204 CE safety is part of system design Safety measurements are tested on each product in the factory Warning lights Electric power White Emergency stop safety cover interlock Blue Pick up error out of components Green in automatic operation Voltage AC 200 208 230 240 380 400 416 V 10 3 Phase More than 2 5mm cables are needed Frequency 50 60 Hz Consumption 4 kVA max Air supply Pressure gt 5 5 10 Pa 5 5 bar 80 PSI Quality dust and oil free Consumption 350 NI min Operating temperature 15 35 C 59 95 F Specification guaranteed 20 28 C 68 82 F Humidity 20 90 no dew Noise Table 1 lt 78dBa 9 of 44 3 0 3 1 Features Accessories and Options
14. frame for improved accuracy and long term stability and is perfectly suitable for round the clock production A NN q NN A QD xm c d Sy M 2244mm 1650mm Front view GEM Topaz X 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 from 0201 up to 32mm square PLCC including 32mm square QFPs with lead pitches down to 0 5mm 20 mil Dark background BGAs uBGAs 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 Introducing the 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 detects missing bent or irregular spaced le
15. 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 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 white or light colored labels of any dimension white paint or 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 either 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 Sub stopper
16. 0 Type 72A 72F capacitor 3 80 2 90 1 60 Type 73A 73F 4 70 2 60 2 10 Type 73A 73F 6 00 3 20 2 50 Type 73A 73F 7 30 4 30 2 80 Type 73A 73F Aluminium electrolytic 4 3 4 3 5 7 Type 73A 73F capacitor 6 6 6 6 57 Type 73A 73F 10 10 10 5 Type 74A 41 of 44 Component Handling Components Dimension mm Required nozzle L W T Chip film capacitor 7 3 5 3 3 25 Type 73A 73F Chip inductor 3 2 2 5 2 0 Type 73A 73F 4 5 3 2 3 2 Type 73A 73F Semi variable 4 5 3 8 2 4 Type 73A 73F resistor Transistor SOT 2 90 1 5 1 10 Type 72A 72F 4 0 3 1 8 Type 73A 73F ED Power transistor 4 6 2 6 1 6 Type 73A 73F f i i T TE yA Uf j w L SOP 6 28 pin 5 00 4 50 1 50 Type 73A 73F 7 60 4 50 1 50 Type 73A 73F 10 10 4 50 1 50 Type 73A 73F 12 60 5 70 1 50 Type 73A 73F 15 30 7 50 2 00 Type 74A 17 80 7 50 2 00 Type 74A PLCC 5 16 Type 73A 73F 15 20 Type 74A 15 32 Type 74A QFP Z 5 16 Type 74A 15 20 Type 74A Zi 15 32 Type 74A BGA Zl 10 26 Type 74A Z 10 30 Type 74A 42 of 44 Component Handling Components Dimension mm Required nozzle SOJ 20 42 pin 10 20 Type 73A 73F 15 30 Type 74A TSOP 20 32 pin 10 20 Type 73A 73F 15 30 Type 74A Table 13 For information on CSP uBGA bare chip and other types of components please consult your
17. 15 inch reelholder FV GEM PA 2903 45 32mm Tape Feeder 15 inch reelholder FV GEM PSA PA 2903 50 44mm Tape Feeder 15 inch reelholder FV GEM PA 2903 55 44mm Tape Feeder 15 inch reelholder FV GEM 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 FV GEM PSA PA 2903 75 8mm Tape Feeder 4mm pitch 7 inch reelholder FV GEM PSA PA 2903 76 8mm Tape Feeder 4mm pitch 15 inch reelholder FV GEM PSA PA 2903 85 12mm Tape Feeder 7 inch reelholder FV GEM PSA PA 2903 86 12mm Tape Feeder 15 inch reelholder FV GEM PSA PA 2906 10 Reject conveyor for Topaz X and Emerald X 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 SOP 4532 SOP PA 2962 44 Nozzle Type 74A Middle size QFP 12 of 44 3 3 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 5 Second Line Array camera for Topaz X PA 2969 53 Second Line Array camera in combination with ATS factory built in only PA 2969 9 Area CCD camera 32mm including fore and side illumination unit for Topaz X PA 2981 15 Pallet for L
18. 2 2 4 PA 2903 74 Tape Feeder 8mm 7 PSA 4 PA 2903 75 Tape Feeder 8mm 15 PSA 4 PA 2903 76 Tape Feeder 12mm 7 PSA 4 8 PA 2903 85 Tape Feeder 12mm 15 PSA 4 8 PA 2903 86 Tape Feeder 16mm 15 4 8 12 16 PA 2903 20 Tape Feeder l6mm 15 PSA 4 8 12 16 PA 2903 25 Tape Feeder 24mm 15 4 8 12 16 20 PA 2903 30 Tape Feeder 24mm 15 PSA 4 8 12 16 20 PA 2903 35 Tape Feeder 32mm 15 12 16 24 32 PA 2903 40 Tape Feeder 32mm 15 PSA 12 16 24 32 PA 2903 45 Tape Feeder 44mm 15 12 16 24 32 PA 2903 50 Tape Feeder 44mm 15 PSA 12 16 24 32 PA 2903 55 The feeding pitch can be adjusted on the feeder side Feeder occupation Feeder type Required feeder position equivalent to tape feeder 8mm Tape Feeder 8mm I Tape Feeder 12mm l6mm 24mm 3 Tape Feeder 32mm 4 Tape Feeder 44mm 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 32 of 44 7 2 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 shuttle Tray Feeder Two components are picked up from the tray
19. 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 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 I I of 44 Features Accessories and Options 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 badmarks still remain in effect 3 2 Accessories and Options Accessories and options Topaz X PA 1912 00 CSM GEM 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 2699 22 Double shuttle Tray Feeder LCS for Topaz X Emerald X PA 2903 20 16mm Tape Feeder 15 inch reelholder FV GEM PA 2903 25 16mm Tape Feeder 15 inch reelholder FV GEM PSA PA 2903 30 24mm Tape Feeder 15 inch reelholder FV GEM PA 2903 35 24mm Tape Feeder 15 inch reelholder FV GEM PSA PA 2903 40 32mm Tape Feeder
20. CS Tray Feeder FV GEM 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 Topaz 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 ordered as an option I 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 1312 01 Topaz X Topaz X main body PA 2963 16 Nozzle Exchange System Topaz X 18 positions no nozzles include 50 position PA 2969 5 Second line array camera Topaz X PA 2969 9 Area CCD camera 32mm including lighting unit for Topaz X fixed side ue JA eo Total available feeder number 90 Example 2 Topaz X with double shuttle LCS Topaz X main body 4 PA 1312 01 Topaz X PA 2699 22 Double shuttle LCS PA 2963 16 Nozzle Exchange System Topaz X 18 positions no nozzles included PA 2969 5 Second line array camera Topaz X PA 2969 9 Area CCD camera 32mm including lighting unit for Topaz X fixed side Total available feeder number 90 Figure 2 Machine configuration examples 1 to 5 see also next pages 14 of 44 Features Accessories and Options Example 3 Topaz X wi
21. DD 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 safety Electrical and Mechanical SMEMA Standard Software features Variable XY axis speed per component new 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 On line help function allows display of detailed descriptions of operations and functions on screen Management Information System MIS to gather production history data 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
22. M 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 simultaneous component picking which reduces head beam travel and thus shortens the mounting cycle HL dle Lo dle dL dL dL Y NAA AGUA AG GGA TY HHHHHHBH 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 Mounting Heads Configuration Specifications 7 Axis configuration X axis AC servo Double Y axis AC servo Z Raxis 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 8 in line multi head Nozzle types 5 different shapes Encoder resolution XY 0 00122mm pulse Phi 0 0146 pulse Z
23. Moveable Fixed Fixed main stopper locate pin locate pin Figure 10 Pin fixation system PCB support plate PCB Spring loaded pin Conveyor lt Pin shaft frame Magnet gt E Servo comarolleePusnup plate Figure 11 Push up system 27 of 44 Board Handling The Edge Clamping system is as easy to adjust as the locate pin fixation Both these systems use Push up pins to support the PCB Figure 12 GEM Topaz X Edge Clamping system 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 28 of 44 Table 7 PCB Dimensions x y Board Handling Specifications Min 50mm x 50mm 2 0 x 2 0 Max 460mm x 440mm 18 x 17 2 using PCB pin fixation or PCB edge clamping system PCB Thickness Min 0 4mm 0 015 Max 4 0mm 0 15 Reference hole position 5mm 0 2 in X and Y from lower right corner Reference hole diameter 2 0mm 4 0mm 0 08 0 157 PCB Maximum warpage 0 5mm up 0 02 1 0m
24. ads 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 simultaneous 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 Topaz 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 fun
25. allet exchange time for the ATS 20 Tray Feeder landscape is 5 6 seconds However in practice no time is lost because of the simultaneous 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 44 Component Handling ATS 20 Tray Feeder landscape PA 2696 23 specifications GENERAL Max Tray size L x W 350mm x 220mm 13 7 x 8 6 Min Tray size L x W 50mm x 50mm 2 0 x 2 0 Pallet exchange time Changing from pallet to 20 5 6 seconds Pick up restrictions At the right side of the ATS 20 landscape pallet components can t be picked by all heads in an area of 18 2mm 0 72 Power and air supply Supplied by Topaz X Weight 80 Kg 176 Lbs Topaz X Landscape ATS 20 Tray feeder dimensions Length 1650mm 5 5 ft Height 1850mm 6 2 ft Width 1783mm 5 9 ft with ATS 20 door open 2283mm 7 6 ft Maximum board size Topaz X 380mm 15 0 Maximum amount of feeders on Topaz X 56 APPLICABLE COMPONENTS Max Tray height included component height 8 5mm 0 33 from pallets at pitch of 12 5mm 0 49 total 20 pallets possible 16mm 0 63 from pallets at pitch of 25mm 0 98 total 10 pallets possible Min Comp
26. components can t be picked by all heads in an area of 18 2mm 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 Optional Double shuttle LCS Tray Feeder no restrictions Max 120 Jedec trays Stick and bulk Many solutions possible Maximum height pre mounted components 4 0mm on placement side 0 16 18mm on non placement side 0 7 PCB Dimensions x y Min 50mm x 50mm 2 0 x 2 0 Max 460 x 440mm 18 x 17 2 Special applications upon request Using PCB pin fixation or edge clamping system PCB Weight Max 1 2 Kg Without components Max 2 0 Kg With components PCB Thickness Min 0 4mm 0 015 Max 4 0mm 0 15 Special applications upon request 7 of 44 General Specifications REMARKS Non mountable area Board top side 3mm 0 12 from rear side board edge 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 0 16 around reference holes locate pins Flat edge of 30mm 1 2 is required on bottom right corner for the use of the main stopper sub and exit stopper Board bottom side 5mm from front and rear side board edge 0 2 For ceramic PCBs optional the non mountable area may be dif ferent PCB Material Phenolic FR4 Composite Materials Ceramic PCBs require s
27. ction 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 4 of 44 2 0 General Specifications General Specifications REMARKS Tact time 0 20sec chip with line array camera Simultaneous pick with 8 heads 0 45 sec SO with line array camera Simultaneous pick with 4 heads 1 4 sec QFP with line array camera Sequential pick with 4 heads 3 7 sec QFP with area CCD camera In fine mode with head Optimal placement rate 18 000 cph Simultaneous pick with 8 heads Nominal placement rate 12 000 14 000 cph Applicable components 0201 SOP SOJ PLCC 32mm l 1 26 6mm QFP 32mm 1 26 with pin pitch down to 0 5mm 20 mil Dark background BGA BGA CSP with regular pitches 6mm 32mm Min ball pitch down to 0 75mm 3 I mil Min ball diameter down to 0 3mm 1 2mil Line array camera system 6mm QFP 32mm 1 26 with pin pitch down to 0 4mm 16 mil Dark background BGA uBGA CSP with regular pitches 6mm 32mm Min ball pitch down to 0 75mm 3 I mil Min ball diameter down to 0 3mm 12mil Optional 32mm area CCD camera system with fore and side illumination unit Mounting accuracy
28. f 25mm 0 98 total 10 pallets possible Min Component dimension 6mm x 6mm 0 24 x 0 24 mold size Max Component dimension 32mm x 32mm 1 3 x 1 3 STANDARD COMPONENT CAPACITY Max number of component types Number of pallets 20 20 x I Jedec tray Standard 20 pallets included additional pallets available PA 2981 35 36 of 44 7 4 Component Handling Double The Double ATS 20 Tray Feeder portrait 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 to hold different trays portrait PA 2696 22 Figure 18 Double ATS 20 Tray Feeder portrait 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 simultaneous 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 44 Table 12 Component Handling Double ATS 20 Tray Feeder portrait PA 2696 22 specifications GENERAL Max Tray size L x W 220mm x 350mm 8 6 x 13 7 Min Tray size L x W 50mm x 50mm 2 0 x 2 0 Pallet exchange time Changing from pallet to 20
29. local sales representative 43 of 44 Component Handling 44 of 44
30. m down 0 04 Max height pre mounted components 4mm on placement side 0 16 18mm on non placement side 0 7 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 PCB positioning Locate pin fixation adjustable second pin Z servo controlled push up system software 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 PCB Transport height 900mm 10mm 35 4 0 4 SMEMA 953mm 12 5mm 37 5 0 5 PCB Transport direction Left to Right standard optional Right to Left PCB Transport width Automatic PCB loading time Approximately 3 sec PCB ratio width length Max 1 3 29 of 44 Figure 13 Figure 14 Board Handling L ie gt 3mm 0 12 y A A W 10mm 0 4 B A m T A ra 5mm 0 2 5mm
31. onent dimension 6mm x 6mm 0 24 x 0 24 mold size Max Component dimension 32mm x 32mm 1 3 x 1 3 STANDARD COMPONENT CAPACITY Max number of component types Number of pallets 20 20 x I Jedec tray Standard 2 x 20 pallets included additional pallets available PA 2981 36 40 of 44 7 6 Mountable Component Handling Just five nozzle shapes are required to cover the specified SMD range High output Components levels are therefore achieved as the need for nozzle exchanges is minimal An amp Required optional 18 position nozzle exchange station enables additional special nozzles to be Nozzles GEM accommodated Topaz X Components Dimension mm Required nozzle L Ww T Solid resistor 0 60 0 30 0 25 Type 71A 7IF 1 00 0 50 0 50 Type 71A 7IF T gt 1 60 0 80 0 50 Type 72A 72F TORIS NETS 2 00 1 25 0 50 Type 72A 72F 3 20 1 60 0 60 Type 72A 72F i Solid resistor 2 00 1 25 Type 72A 72F A 3 45 1 35 Type 72A 72F y 5 9 2 2 Type 72A 72F Multi Layered ceramic 0 6 0 3 0 3 Type 71A 7IF capacitor 1 0 0 5 0 5 Type 7IA 7IF 1 50 0 80 0 80 Type 72A 72F 2 00 1 25 1 25 Type 72A 72F 3 20 1 60 1 25 Type 72A 72F 3 20 4 50 2 50 3 20 1 50 1 90 Type 73A 73F 5 60 5 00 1 90 Type 73A 73F L MELF ceramic 3 40 1 50 Type 72A 72F capacitor 5 9 2 2 Type 76A Tantalium electrolytic 2 90 1 60 1 6
32. pecial conveyor sections optional PCB Positioning Locate pin fixation Adjustable second pin Z servo controlled push up system Software 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 PCB Transport height 900mm 10mm 35 4 0 4 Standard SMEMA 953mm 12 5mm 37 5 0 5 Standard PCB Transport direction Left to Right Right to Left is optional PCB Transport width Automatic Front rail fixed Rear rail adjustable PCB Loading time Approximately 3 sec PCB loading concurrent to SMD picking and alignment PCB Ratio width length Max 1 3 Control system MCX controller 486 100 100 MHz 16 Mb intern memory 40 Mb flash disk Optional 85 Mb 1 44 Mb floppy drive 3 5 RS 232 Serial Interface 15 Color Monitor 9 Black White vision monitor User interface VIOS Visual Integrated Operating System Hand held keyboard for all operator functions Enhanced PC AT keyboard for data editing functions 8 of 44 GEM Topaz X General Specifications REMARKS Control system functions Max 127 PCBs Max 2560 components per PCB Backup and restoring data using RS232 serial line or floppy Data conversion UFOSVIOS Data conversion
33. sales representative Tape reel diameter max 380mm 15 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 width of 440mm 17 2 330mm x 175mm 12 8 x 6 8 Min tray size 50mm x 50mm 2 0 x 2 0 Optional Manual tray feeder Max number of feeders 65 Head number 8 can t pick components in an area of 14mm from the right side of the MTF ATS 20 Tray Feeder portrait Max tray size 220mm x 350mm 8 6 x 13 7 Min tray size 50mm x 50mm 2 0 x 2 0 Optional factory built in ATS 20 Tray Feeder portrait Max board width 250mm 9 8 max number of 8mm feeders 3 x 20 amount of pallets 20 with 12 5mm pitch Double ATS 20 Tray Feeder portrait Max tray size 220mm x 350mm 8 6 x 13 7 Min tray size 50mm x 50mm 2 0 x 2 0 Optional factory built in Double ATS 20 Tray Feeder portrait Max board width 250mm 9 8 max number of 8mm feeders 2 x 20 amount of pallets 2 x 20 with 12 5mm pitch at the 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 Max tray size 350mm x 220mm 13 7 x 8 6 Min tray size 50mm x 50mm 2 0 x 2 0 Optional factory built in ATS 20 Tray Feeder landscape Max board width 380mm 15 0 max number of feeders 2 x 20 16 amount of pallets 20 with 12 5mm pitch at the right side of ATS
34. th ATS 20 portrait Topaz X main body PCB NE 460 fixed side Total available feeder number 60 PA 1312 01 Topaz X PA 2696 21 ATS 20 tray feeder portrait PA 2963 16 Nozzle Exchange System Topaz X 18 positions no nozzles included PA 2969 53 Second line array camera only factory built in PA 2969 91 Area CCD camera 32mm including lighting unit for Topaz X Example 4 Topaz X with double ATS 20 portrait ppypea eq 3ouut5 SPEdY SWS I Topaz X main body fixed side Total available feeder number 40 PA 1312 01 Topaz X PA 2696 22 Double ATS 20 tray feeder portrait PA 2963 16 Nozzle Exchange System Topaz X 18 positions no nozzles included PA 2969 53 Second line array camera only factory built in PA 2969 91 Area CCD camera 32mm including lighting unit for Topaz X 15 of 44 Features Accessories and Options Example 5 Topaz X with ATS 20 landscape landscape i Topaz X main body fixed side e A Total available feeder number 56 PA 1312 01 Topaz X PA 2696 23 ATS 20 tray feeder portrait PA 2963 16 Nozzle Exchange System Topaz X 18 positions no nozzles includec PA 2969 53 Second line array camera only factory built in or PA 2969 91 Area CCD camera 32mm including lighting unit for Topaz X 16 of 44 4 0 Mounting Heads Configuration Figure 3 Mounting Heads Configuration The GE
35. 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 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 A tray container is fixed and separated into two sections with each 20 pallets This allows tray replenishment while the machine is running 33 of 44 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 L x W 350mm x 468mm 13 7 x 18 4 which can hold 3 Jedec trays Min Tray size L x W 50mm x 50mm 2 0 x 2 0
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