pick and place
Picking a Pick and Place
From Cogwheel Circuit Works
Overview
A key piece of equipment in electronic assembly is the Pick and Place machine or ‘PnP’ for short. A PnP places electronic components onto circuit boards. These days, the majority of components are about the size of a grain of rice and smaller, making hand assembly meticulous or impossible. Fully automated PnP machines with a basic set of features start at $35k. High volume, large capacity PnP machines can have price tags well north of $150k. This may seem steep, but since they are treated as something called ‘capital equipment’ by the bean-counters, you get to treat them as ‘Assets’ and ‘Depreciate’ them which, trust me, the bean-counters consider a Good Thing(tm) . The take-away is that their price tags shouldn’t give you as much sticker shock as you initially might think. For instance, if you are borrowing money from your Aunt Stella and she asks “What if you go under in a year ?”, after telling her that’s not ‘gonna happen, tell her that you can liquidate your assets and the PnP machine is likely to recover most of its value. Promise her some free assembly runs too :)
Feeder Requirements
Feeders are the parts of the PnP which supply(aka feed) components to be placed on the board. Feeders are designed for the packaging that the components are supplied in. There are many types of packaging – Loose, Tape, Tube and Tray are just a few.
Selecting a Pick and Place is driven by the size and type of components you intend to place. I analyzed some typical designs and determined my designs fit the following mix:
| Part Type | Footprint | Packaging | % of Total in Typical Design |
| Small Inductors, Resistors, Capacitors, Transistors, Diodes | 0603,0805,1206,SOT23 | 8mm wide tape | ~50% |
| Medium Inductors, Resistors, Capacitors, Transistors, Diodes, Small ICs | 2420, SMB,8-SOIC, 2010 | 12mm wide tape | ~25% |
| SMD Crystals, Medium ICs, | 16-SOIC, 14-SOIC, Medium BGA, Leadless, SOIC | 16mm wide tape | ~12.5% |
| Larger ICs, Small Connectors, Small Electrolytic Capacitors, | SOW-24, USB mini-b, Cap 10mm Radial, BGA, Small PLCC | 24mm wide tape | <~3% |
| Larger ICs, Connectors | Power Inductor | 32mm wide tape | <~3% |
| Other ICs, Modules, Connectors | TQFP, Large PLCC, BGA | Waffle Tray or Loose | <~3% |
| Certain SOICs | 16-SOIC, 14-SOIC, etc | Tube | <~3% |
It should be noted that determining the width of the tape and the specific packaging is usually buried deep in the component data sheet and typically a big pain in the tuckus to locate. Often, the packaging is driven by the distributor. Sometimes exact packaging cannot be predicted when ordering small quantities;
Armed with this general information our requirements for feeders are:
Waffle Tray – Highly desirable as an IC tray area can also be used for cut tape, or any part that can be laid out into a consistent X,Y array. Some parts arrive in waffle trays. Custom waffle trays can be easily laser cut. Some machines are sophisticated enough to be able to pick, align, and place parts placed randomly on the flat tray area, but this could slow down training and placement quite a bit.
Tape Feeders – As many lanes as possible. Order 8mm tape feeders in the largest number, w/some capability for 12mm. Larger 16mm, 24mm, and 32mm would be desirable but not mandatory to start off with as parts that large can be placed into trays
Tube Feeders – Desirable, but not mandatory as their functionality can be substituted by laser cutting custom waffle trays as previously mentioned.
Other Requirements
The machine should be able to place larger modules such as Wi-Fi or ZigBee radios, Leadless and BGA parts, and smaller parts below 0603 such as 0201
The Contenders
During my pre-purchase research in 4Q2012, Two machines made the shortlist (update 1Q2014: no new contenders in this price class):
Manncorp FVX
This machine is based off of the earlier Manncorp 7722FV machine, which originally designed and manufactured by Japanese company MDC. This model is used by Adafruit Industries and numerous others. It is the least expensive and generally highly capable, and meets all the basic requirements
Manncorp MC-400
This machine is actually designed by Autotronik of Germany and manufactured in Asia. It is sold in North America by Manncorp as the MC-400. It has a high degree of commonality with the Manncorp MC-385 series, and uses the same feeders. They are used by such companies as DIY Drones, Polulu, Spark Fun and many, many others. While more expensive than the FVX, it uses the same smart feeders as the MC-385 series which means a very easy upgrade path to the next level.
Machine Comparison
| FEATURE | Manncorp FVX | Manncorp MC-400 |
| Tape Feeder Lanes | 54 | 64 |
| Waffle Tray Area | Yes | Yes |
| Tube Feeder | Yes | Yes |
| Max PCB/Panel Size | 390 x 310mm (Shared with Waffle Tray Area) |
415×320 (Shared with Waffle Tray Area) |
| Placement Speed | 2200 placements per hour | 3000 placements per hour |
| Minimum Component Size | 0201 | 01005(ridiculously tiny, BTW) |
| Placement accuracy | +/- .1mm | +/- .05mm |
| Min Lead Pitch | .4mm | .4mm |
| BGA, Leadless (Bottom Vision) | Yes | Yes |
| Feeder commonality with higher capacity machines | No | Yes |
| Software commonality with higher capacity machines | No | Yes |
The Selection
While both machines met all of the basic requirements, the MC-400 was chosen over the FVX mainly because it provided an upgrade path to larger machines with respect to software and feeders. These features come at a higher cost, but my capital equipment budget allowed for it. That said, the FVX would also be an excellent pick for organizations on tighter budgets, and with their advanced vision capabilities, I expect both machines to postpone their obsolesence for many years to come.
Manncorp MC-385V2V Pick and Place Machine
Posted by Manncorp
Pan Delta Controls Pte Ltd is pleased to announce the recent acquisition of a brand new Manncorp MC-385V2V Pick and Place Machine. The MC-385V2V was selected as it is ideal for the high-mix jobs that they are engaged in. With their new high-speed equipment, they are capable of placing up to 8,000 parts per hour with greater accuracy.
The video shows the production of their NAV1560DC-V3.06 Current Sensor Module which is used in their DC Navigation Light Control Panels.
High-Precision, High-Mix, Print-Place-Reflow Package Under $47K
From Manncorp
SMT turnkey assembly systems, reconfigured and expanded to accommodate a wider range of production levels and budgets.
The cornerstone of the 2500-MV is the MC-400 pick and place system, featuring Cognex® on-the-fly and bottom vision alignment, for high-accuracy, 2500 CPH placement of a wide range of advanced SMDs—from 0201 chip components to BGAs and 15 mil ultra-fine-pitch devices. The MC-400 has the capacity for up to 64 automatic “smart” tape feeders and can also accept a wide variety of stick, cut-strip, and IC tray holders. Built upon the same architecture as Manncorp’s popular MC Series of SMT pick and place machines, MC-400 feeders and software are compatible with all other MC series equipment.
The 2500-MV includes the heavy-duty MC-110 stencil printer —the industry’s most robust, highest-precision, manual printer with a repeatability of ±0.02 mm (less than 1 mil). Its universal mounting bracket allows clamping or screw mounting of frames up to 740 mm x 740 mm (29” x 29”) and tool-free, self-locking, X-Y-Z and theta axis adjustments provide quick and easy stencil to pad alignment.
The profilable MC-301 batch reflow oven rounds out the 2500-MV and simulates the performance of an inline system in a compact benchtop design. Through its innovative user interface and Android operating system, preheat, soak, reflow, and cooling stages are easily programmed to conform to component and paste manufacturer’s precise specifications. For process control and traceability, solder profiles are easily saved and distributed via built-in WiFi.
To learn more about the 2500-MV or other SMT turnkey systems available from Manncorp, please go to www.manncorp.com/turnkeys.
MC-388 4-Head SMT Pick and Place
Posted by Manncorp
MC-388 4-head SMT Pick and Place: Huge feeder capacity plus speed (10,500 cph) and large placement area for maximum flexibility.
Features
- Speed, Accuracy and Precision
- 30 µm, 3 Sigma placement accuracy thanks to high-precision ball screw X-Y drive and closed-loop servo control system
- Heavy-duty welded, uni-body steel frame provides stability for precision placements even at high speeds
- Four heads for placement rates to 10,500 parts per hour (8,000 pph, IPC-9850)
- Two-head configuration available, with placement speeds to 6,400 pph
- Huge Placement Area
- Large placement area of 408 mm x 1200 mm (16" x 48") allows plenty of room for waffle trays
- 3-stage, single-lane SMEMA-compatible conveyor with automatic width adjustment allows machine to be used inline or connected to board loader/unloader for work cell operation
- Adapter for extra-large LED boards (to 408 mm x 1200 mm/16" x 48") included
- Can alternately be configured with a single-stage or dual-stage conveyor, a dual-lane conveyor, or no conveyor at all (batch/standalone operation).
- Dual stage conveyor handles PCBs to 1500 mm long.
- Huge Component Range
- Dual vision alignment combines on-the-fly with bottom stationary systems for fast, efficient placement of 0201s through 100 x 150 mm SMDs
- 01005 placement capability available as option
- Full ball inspection and missing ball detection, with nonstandard ball patterns programmable and inspectable
- 15-position automatic tool holder/changer
- Feeder Capacity and Flexibility
- Total feeder capacity: 192 ports w/inline conveyor; 256 w/batch configuration
- With inline conveyor, MC-388 holds four 48-port feeder racks
- Batch configuration allows two 32-port feeder racks to be added
- Feeder racks accommodate a mix of tape feeders and IC tube/stick feeders
- Waffle trays and cut strip feeder holders can be used in placement area (one waffle tray included with machine)
- Easy Programming & Operation
- UCAD® universal CAD import and conversion for direct transfer of PCB data from ASCII, AutoCAD and Excel data formats
- Teaching/fiducial recognition camera
- Virtual PCB Simulator offers assembly preview for component, coordinates and orientation verification prior to running production
- Smart tape and IC tube/stick feeders for fast set-up and changeover and feeder placement optimization
- Additonal Touches
- Computer controller with flat-screen LCD display, keyboard and mouse included
- Included vision inspection capability allows camera to be used to selectively check solder paste printing or component placement accuracy
- Optional bar code reader scans component value, lot code, date and component quanities directly from component packaging for inventory management
- Optional offline Smart feeder programmer allows Smart tape and stick feeders to be programmed offline while the machine runs other jobs
- Optional temperature-controlled ATP digital dispensing system for solder paste and adhesive dispensing
- Fully Supported by Manncorp
- 2-year parts warranty
- Multi-language support in English, Spanish, German, French, Chinese, Italian and Turkish
- Remote service support software & network adapter for fast troubleshooting by Manncorp techs
- Installation and on-site training available
SMT Source June News
Posted by Manncorp
MC Series Pick and Place
Posted by Manncorp
Manncorp MC Series pick and place with flying vision cover the full range of surface mount PCB assembly, with SMD placement rates ranging from 3,000 to 13,000 cph
For more information, please visit the website: Manncorp MC Series Pick and Place Machines
At Less Than $40K, New Pick Place Machine Brings Advanced Capability To Prototyping & Pilot Production
Posted by Manncorp
Manncorp's new MC-400 which is specially designed for startups, product development labs, and contract manufacturers that need to build prototypes or short runs in-house, with high-precision and quick turn-around times. The MC-400 can also be viewed as a long-term investment in pick and place capability for when volumes increase, as feeders, software, and accessories are fully compatible with the other members of the MC family
Utilizing both flying and bottom vision, the MC-400 aligns and places 0201 chips, BGAs, CSPs, and 15 mil fine-pitch QFPs with ±0.05 mm placement accuracy at speeds up to 3000 cph (2500 IPC-9850). Key to the MC-400’s exceptional precision are its rugged, heavy-duty construction, for which the MC Series is well known, and closed-loop, servo-driven, X, Y, Z, and theta axes, complemented by high-resolution digital encoders.
Even at its full capacity for 64 individual smart tape or stick feeders, the MC-400 maintains a maximum placement area of 415 mm x 320 mm (16.3" x 12.5"). A wide variety of feeder options are also available for waffle trays, cut strips of tape, and other components used in small quantities, and a semi-automatic mode even allows pick-up and placement from loose component feeders.
Windows®-based software features programming via CAD data import or dual teaching cameras, and virtual PCB simulation for program verification. A vast library of component and vision data includes all common package types and sizes, and links to smart feeder data and optimization tools for easy setup and inventory control. Patterns of dots or lines for solder paste or adhesive are also linked to the component library for use with an optional dispensing head. As the need for greater throughput increases, valuable program data is directly transportable to all other MC Series equipment.
With the addition of the MC-400, Manncorp’s MC Series, with hundreds of systems in operation worldwide, now spans the full range of SMT placement equipment capability—from entry-level to high-speed systems over 10,000 CPH. All MC Series systems include remote diagnostics and tech support, along with a two-year limited warranty. On-site installation and training are also available. For pricing, details, and videos, go to: http://www.manncorp.com/smt/prod-181/pick-and-place-med-high-volume-mc400.html?tabshow=3.
15,000 CPH Pick and Place Machine for Dedicated LED Assembly
Posted by Manncorp
Manncorp's MC-LEDV4 pick and place machine for dedicated LED assembly
Manncorp's MC-LEDV4 series of LED pick and place machines are specially designed to place surface-mounted LED components using four pick-and-place heads and 'on-the-fly' vision for fast, accurate alignment. With a high-precision, ball-screw-driven gantry providing multiple, simultaneous pickups, MC-LEDV4 machines are capable of placement rates up to 15,000 LEDs per hour (IPC-9850).
Unlike SMT pick-and-place equipment that has merely been adapted for LED assembly, the MC-LEDV4 series is exclusively designed to be the ideal solution for long LED tubes, flexible strips, and panelized LED boards. Three models are available for either 600 mm (24"), 1200 mm (47"), or 1800 mm (71") substrates. All models can be purchased as stand-alone or inline systems.
The machines place both standard and domed LEDs from 0.6 x 0.3 mm to 8 x 8 mm, with Teflon®-coated nozzles and positive air pressure actuation to prevent component sticking. Component range can be expanded to 20 x 20 mm with a bottom vision option.
MC-LEDV4 series tape feeders have also been designed specifically for high-volume LED assembly. Brushless servo-driven tape feeder motors ensure years of reliable service, even through 24/7 production. The ability to automatically switch to a different pickup location when a feeder runs empty allows the MC-LEDV4 to run continuously, shift after shift.
The MC-LEDV4 is backed by a 2-year warranty and supported by Manncorp's experienced technical team. For details, pricing, and a 2-minute video, visit http://www.manncorp.com/smt/prod-638/pick-and-place-led-mc-ledv4-12.html?tabshow=2.
The Most Advanced Pick and Place Machine Under $40K
Posted by Manncorp
MC-400 Automatic Pick and Place Machine Advanced Capability for Prototyping & Pilot Production for Under $40K
For more information, please visit the website: Manncorp MC-400 pick and place machine
Check Out Our FVX Benchtop Pick and Place Machine Video
Posted by Manncorp
For more information, please visit the website: Manncorp FVX Benchtop Pick and Place Machine
MC-LEDV3 High-Speed Dedicated LED Pick & Place Machine
Posted by Manncorp
Assemble LED tubes, flexible LED strips and circular LED light bulb boards at rates reaching 10,000 LEDs per hour with the new high-speed, dedicated MC-LEDV3 SMT placement equipment.
| High-speed, high-efficiency design The three pick-and-place heads mounted on the MC-LEDV3's high precision, ball-screw-driven gantry perform simultaneous pick-up to achieve rates to 10,000 LEDs per hour (per IPC-9850 standard). True "vision on the fly" alignment, with upward-looking cameras located on the placement heads, aligns components while the head is in motion, saving time over fixed-camera systems where the component has to brought over the camera for alignment before it can move to the placement area. Thanks to the included software, feeder locations are also optimized prior to placement to minimize head travel and tool changes. |
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| Specifically designed for LED Unlike standard pick and place machines that have been adapted to LED assembly, the MC-LEDV3 LED pick and place machine is purpose-built, allowing it to do its one thing—building LED boards—really well, starting with the types of boards it can handle. Whether the machine is purchased with the worktable and magnetic board fixture or an inline conveyor, the MC-LEDV3 can assemble long LED boards, such as those used for tube lights, up to 47.2" (1200 mm) in a single pass. (For jobs that need even more length, the system can also be purchased with a max board length of 70.9" (1800 mm).) Flexible PCBs, circular boards for LED light bulbs and even irregularly shaped boards can also be assembled, quickly, accurately and reliably. Each of the MC-LEDV3's three placement heads features positive air pressure to release 'sticky' LED components. Non-stick, Teflon®-coated nozzles—including custom nozzle designs—are also available. The MC-LEDV3 places LED components from 0402 to 0505 (max LED size is 8 mm x 8 mm x 8 mm), including both standard and irregularly shaped LEDs. Domed LEDs can be safely placed using placement nozzles designed to not come in contact with the optical lens during pick-up and placement, protecting the component's overall light performance and reliability. |
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| 24/7 workhorse The MC-LEDV3 pick and place offers nonstop production. Its ability to automatically switch to a different feeder when an in-use feeder runs out of components allows the operator to refill and replace the empty feeder without taking production offline at all. MC-LEDV3 holds up to 16 tape feeders. These special feeders use brushless motors for longer feeder life under around-the-clock production conditions. With these feeders, it is also possible to splice a new reel onto an old one to minimize production interruption. |
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| Software simplifies production Several powerful software tools are included with the MC-LEDV3 SMT pick and place machine, including the UCAD® universal CAD import and conversion utility to simplify placement programming, a feeder arrangement optimizer to minimize head travel and tool changes, and real-time monitoring of production, which displays a virtual view of the progress of current product under assembly along with placement rate, placement time and production count. Companies that already have one or more MC series SMT pick and place machines in their facility will find the MC-LEDV3's software interface immediately familiar, which means a zero learning curve when it comes to programming and operating this machine. |
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For more information, please visit the website: Manncorp MC-LEDV3 pick and place machine for LED assembly