Special-Shaped Plug-In Machines are mainly used in the electronics manufacturing, specially used for "automatic electronic assemble" process. It can multi-station and multi-head pick up electronic components from tapes or feeders according to the preset program, then automatically insert special-shaped components into PCB board's specified holes, such as resistors, capacitors, transistors, connectors, buttons, etc. In this way, it can greatly improve production efficiency and reduce costs.
Applications: 3C Consumer Electronics, Automotive Electronics, Medical Equipment, Industrial Control, Aerospace, etc.
Nowadays, requirements on smaller, more complex electronic elements are increased due to spreading and updating of electronic products, which means the market also needs high-speed and high-precision special-shaped plug-in machines. Because this kind of "Automatic Special-Shaped Plug-In Machine" can improve current production technology process, and remove those unstable factors in the production.
A. ❌ Traditional PCB Electronic Component Plug-In Solution
It needs "manual operation" & It is mainly for one single type of electronic component.
*Reasons of "Why Not Traditional One" *
a. Manual Plug-In: low efficiency, and problems of "plug-in error", "plug-in missed" can't be avoided well, then cause unstable product quality.
b. Dedicated Automatic Plug-In Machine: it can't suit to new type electronic components' production, it is not flexible, and technology upgrading needs to change the equipment or the production line, which means high-cost and time-consuming.
c. Complex Control System: it consists of "vision system", "motion control system", and "HMI", so the configuration is PC + machine vision + PLC, but interaction efficiency of PLC ethernet is not high, then the production capacity will be low also.
B. ✔ Zmotion Special-Shaped Plug-In Solution
According to this market needs, Zmotion develops "High-Speed Special-Shaped Plug-In Machine" based on "Ultra High-Speed PCIe EtherCAT Motion Control Card PCIE464".
*Advantages of "Why Zmotion Solution"*
a. PC Windows: easy and rapid to connect MES (data center)
b. Safe Program Mechanism: prevent control system downtime
c. Rich & Powerful Control Functions: high real-time, low delay, multi-axis synchronous control, high compatibility, high-speed IO, and other functions make sure some key steps in the plug-in technology are completed at high-speed and with high-precision, like, path planning, data interaction, electronic component insertion and clamping control.
d. System Configuration: match with the third party high-precision vision system, equipment's parameters can be adjusted quickly, that is, easy to change the material. All kinds of new types components can be compatible flexibility.
It can be known, Zmotion "Automatic Special-Shaped Plug-In Machine Solution" solves the problem of "untimely data interaction". Obviously, it improves data processing speed, simplifies production process, then achieves high-speed and high-precision production. Help you realize "Large Scale, Efficient, and Intelligent" production.
Zmotion PCIE464 motion control card has high-speed PCIe interface, and its EtherCAT period control can be up to 125us. In addition, it supports vision fly-shooting function and SS curve smoothing function, then it can be used for high-speed and soft motion control.
In the "special-shaped plug-in machine", when the plug head captured the component, XY linear motion platform will move to camera above and take photo, detect and positioning component pin, in this way, make it more precise, optimize the path, and ensure the XY platform running path be shortest (efficiency: 0.6s/pcs, repeated positioning precise: ±0.01mm).
Next, how to achieve high-speed and high-precision control in details.
--Machine Vision--
In the part of "machine vision", mainly used for detection, positioning and correction.
At first, detect and positioning electronic component's outer contour and pin, also check whether there is defect or deformation on the pin.
Then, do MARK positioning for round holes, square holes and irregular points on the PCB board to make sure the electronic component can be inserted in the PCB board specified holes.
--Motion Control--
18 bus drives can be controlled at the same time through connection of IPC and PCIE464 motion control card, it includes linear motors, rotary motors, remote IO, etc. And it can real-time switch drive's position, speed, and torque modes, then matches with vision fly shooting to trigger camera. In this whole process, it is rapid and precise.
--Configuration Process--
--Hardware Configuration--
Zmotion PCIE464 motion control card provides efficient industrial motion control solution. Insert PCIE464 into standard PC for high-performance EtherCAT motion control.
Under "PC + Motion Control Card" mode, it can achieve excellent multi-axis synchronous control, high-speed point motion, and complex motion control through PC efficient data processing and control card's high-speed PWM, multi-dimensional PSO (position synchronous output). That is, control card and PC can interact data in real-time, the whole motion control efficiency and precision are improved a lot.
Such powerful functions, wide fields are applied, 3C electronic manufacturing, semiconductors, assembly, precision processing, lithium batteries and photovoltaics, robots, etc.
If you want to know more information about PCIE464, please refer to here or manual, or directly contact us.
Let's conclude why choose Zmotion solution -- Core Technology Advantages
*several valid operation systems: support Windows XP/7/10/11, Linux
*general & open API function interfaces: develop easily, flexibly, and efficiently
*PCIe interface: faster transferring efficiency than PCI interface
*hybrid development: PC languages + ZBasic (RTBasic) scripting language develop, command execution efficiency can be enhanced
*C language compile: faster program execution efficiency and device running efficiency
*EtherCAT synchronous period: up to 125us, improve device production capacity
*1D/2D/3D PSO: support hardware position comparison output function to achieve vision fly-shooting, whole CT of device can be shortened
*inner RTBasic program execution: when Windows system appears "blue screen", program will not downtime.
