1. SMT Manufacturing Machines Information
1.1 The basic information
Full SMT production line
SMT manufacturing equipment is for assembling the PCB (printed circuit boards) that apply the SMT (surface mount technology).
Generally, SMT machines are including PCB linkage machines, solder paste printing machines, soldering machines, ovens, component placement and paste depositors, which we called the SMT Line, you could refer to the below link for more info of SMT LINE.
7 Layouts Of SMT Line | Teach You How To Start In Success
SMT machine helps PCB manufacturers to place more features on smaller PCBs without having to fix components with through-hole wire leads.
SMT machine fixes components directly onto a printed circuit board surface by using soldering and adhesive equipment to
Also, the SMT producing machine enables both sides of a PCB to be printed with circuits and fitted with components.
Technically, SMT production starts with an SMT machine that prints a thin layer of solder paste onto the surface of a PCB guided by the use of a stencil.
The pick and place machine will place each SMT component on the solder paste, which consists of flux particles and solder particles.
Then, the printed circuit board will pass through a series of SMT machines like reflow ovens which melt the solder paste and burns off the flux particles.
Surface tension in the liquid solder keeps the chips to stay in place on the solder pads attached to the printed circuit board assembly while the solder cools.
PCBs have both sides printed may use adhesive dots to fix the chips on the remaining side. The adhesive is cured by applying low heat ovens or ultraviolet (UV) radiation.
SMT producing machines offer easy SMT assembly by eliminating issues and applying smaller components with inductance and lead resistance, as well as upgrading the performance in high-frequency applications.
It may also include hot gases or infrared lamps to reflow solder for adding additional components.
Besides, the operator can solder any components that are irregularly shaped or heat-sensitive on the PCB by hand.
1.2 The global SMT Machines market
7 Billion within the year 2020, is projected to succeed in a revised size of US$5.5 Billion by 2027, growing at a CAGR of 5.7% over the analysis period 2020-2027.
High-Speed Placement Equipment, one among the segments analyzed within the report, is projected to grow at a 6.5% CAGR to succeed in US$2.7 Billion by the top of the analysis period.
After an early analysis of the business implications of the pandemic and its induced depression, growth within the Medium-Speed Placement Equipment segment is readjusted to a revised 5.1% CAGR for the subsequent 7-year period.
This segment currently accounts for a 17.1% share of the worldwide Surface Mount Technology (SMT) Equipment market.
Placement Equipment with low-speed Segment Corners takes up an 11.2% market Share in 2020 within the worldwide low-Speed Placement Equipment segment, such as Canada, Japan, USA, China, and Europe will drive the 3.6% CAGR forecasted in this segment.
These regional markets taking up a combined market size of US$333.6 Million in the year 2020 will reach an expected scope of US$428.3 Million. Furthermore, China will keep among the fastest-growing during this cluster of regional markets.
1.3 The development history of SMT Machine
The history of the event of SMT equipment may be a short one, and it had been only first introduced within the 1960s.
During this point, however, only a couple of players within the industry took advantage of the chances that surface mounting provided.
It took almost 20 years for SMT to become a widely used operation with performing much of the foundational groundwork for the event of surface mount technology.
By mechanically changing the structure of the components and circuitry on computer circuit boards, parts might be soldered directly onto the board.
This led to the event of smaller components overall that would be attached to each side of the board. the utilization of adhesives and other sorts of mounting beyond soldering was developed to be used specifically for computer circuit boards.
During the 1980s and 90s, the event of SMT placement equipment began to automate the method of surface mounting.
Initial placement equipment was integrated into the surface mount production line as two sequential operations.
First, the empty circuit card was run through fast placement machines that applied simple components including resistors and capacitors.
Then the board was skilled in a precision placer that attached all remaining components with accuracy inside a 0.02” error margin.
This two placement equipment were combined into one in the early 2000s, speeding up the surface mounting procedure.
Since 2010, the multiple machine heads that performed the placing were also combined into one highly advanced head which will perform every placement procedure. a number of the fastest automated SMT machines can place 200,000 components per hour.
2. How to Buy Specialized SMT Machines With Custom Design or Operation Features
Modern-Day-Buyers-Journey – PHOTO SOURCE
2.1 When to Consider A Specialized SMT Machines
Let’s say you’ve got a special product configuration, a singular space requirement, an unorthodox handling system, or an application completely unrelated to the printed circuit board or SMT assembly business, and you can not find a typical machine provider which will deal with your demands. So now it is the requirement for you to seek for the specify SMT machine.
2.2 To begin, what kinds of challenges you will meet?
- Special soldering requirements
A company that required a reflow oven with a long dwell time within the chamber, which might normally require a 40-foot tunnel, but needed to suit it into a foot-print only 6 feet long.
The solution was to style and build a serpentine conveyor within the length of a brief tunnel that achieved the dwell time dictated by the method and footprint.
- Particular placement process
A user trying to find a completely integrated inline component placement process from a reel of the blank substrate at the start to a populated reel at the top.
The customer received a self-contained system that precisely attaches miniature medical devices onto a strip for the seamless downstream procedure.
A custom pick and place application that selects a component, dips it into one or more materials at different stations, like paste or epoxy, then accurately centers and mounts it on a substrate.
An off-the-shelf chip mounter was modified for this application with customized jaws and positioning software. this instance also demands two different reservoirs for a “double-dip” function.
A process to put multiple microchip lasers onto a block to aggregate a high-intensity beam into one point for a steel laser cutter.
For the reason fo the accuracy demanded in this project, the pattern layout was essential. A machine was custom-engineered including unique LED lighting configured to handle special gold plating.
Unique sequencing operations and processes for assembly machines conducting operations on multiple stations that need custom software programming.
- Customized programming demands
SMT Machine Programming
In addition to putting an inline system together, one must confirm the programming is often customized also.
An example of this was a production line that needed to dispense paste, inspect, accurately place the components, index through a cutter assembly,
provide a feed system over to an accumulation loop, input that feeds into the reflow oven procedure by the visual inspection of final assembly.
Material handling systems with special line functionality, like reverse feeding or a capability to manage large or odd-shaped parts.
One customer already had an inline system, that required their new reflow oven to maneuver right to left, in reverse of the norm.
There are some worthwhile goals which may drive you to think about getting to the difficulty and expense of a non-standard machine,
Like reducing labor and improving predictable quality by integrating multiple processes and reducing dependence on non-skilled labor.
While the upfront investment is going to be considerably above that of a typical machine, the ROI – counting on the appliance and volume – might be short and significant.
2.3 how do you look for a SMT machine manufacturer that supports customization?
Start by asking the sellers of kit what – if any – customization they will do. If they will, then describe your objectives and constraints, but don’t tell them the way to do it; allow them to revisit to you with a recommended solution.
If you plan to dictate the way to build a machine instead of describing its functional purpose, you’ll be responsible for taking delivery of something that does what you’ve asked but fails to measure up to your performance expectations.
Companies that provide customized assembly service should be equipped with the following abilities:
- In-house design for both software and mechanical integration ² Practical engineering and quality procedures to offer optimal performance with maintenance
- Ability to create prototype parts and/or entire machines
- Machining, electrical design/assembly, PCBs assembly
- Sheet metal fabrication, assembly, and welding
- Testing and inspection, including processes for validating the design and checking potential failure points in a customized machines
- Capability to design and make any special tooling demanded to produce small desktop machines to large assembly/process machines.
3. What does Surface Mount Technology offer OEMs?
Surface Mount Technology
Surface Mount Technology (SMT) has become a core construction technology in current industrial electronic product designs.
Although there is still a considerable amount of conventional or Pin-Through-Hole (PTH) parts, especially on more rugged designs,
SMT has become a fundamental method of assembly within modern electronics manufacturing and has helped expand and improve the capabilities of the industry.
3.1 What benefits does SMT have vs. other processes?
SMT has significant benefits compared to standard PTH processes. So let’s have a glance at the foremost obvious advantages of SMT:
Reduced footprint: taking over less valuable PCBA area
Smaller mass: resulting in lower power consumption (hence less use of energy, materials, and warmth dissipation measures)
Lower component cost: SMT devices often are available at a tenth of the value of a PTH variant.
Although PTH tends to possess better mechanical rigidity, this is often generally not a priority unless related to bulky connectors and high-power devices, so SMT satisfies diverse requirements.
However, SMT also can lower costs through less apparent benefits like innovative machine-storage and component kitting processes. These techniques reduce the labor costs involved in manually retrieving components from storage as a part of the kitting operation.
Automating these processes also lessens the prospect of human error, eradicating costs related to the reworking recovery of those mistakes.
Also, SMT automates the location of components onto boards, through using innovative kitting technology.
3.2 Ensuring component reliability
SMT machine placement also can provide superior product yield and reliability in leadless devices, like Ball Grid Arrays (BGAs),
and more currently micro-BGAs, and chip-scale devices that require precise control during assembly but have the advantage of being a repeatable process.
SMT also offers improved shock and vibration resistance as a result of the lower mass of components, further driving up reliability and increasing the product’s lifecycle.
3.3 The importance of kitting speed
A popular misconception within the mid-tier global manufacturing environment is that component placement speed is that the primary hindrance to cost. this is often not the case.
Whilst almost every Electronics Manufacturing Services (EMS) company will have some sort of SMT capability, our specialize in automation and process governance helps to drive significant benefits in terms of quality and price.
- Kitting speeds: pulling stock from storage
- Setting-up component feeders
- De-kitting: returning the components to storage.
Whilst almost every Electronics Manufacturing Services (EMS) company will have some form of SMT capability, our focus on automation and process governance help to drive significant benefits in terms of quality and cost.
We boast an array of assets:
- SMT conversion design services, converting existing PTH designs to SMT.
- Automated kitting infrastructure, such as a JUKI system, to speed up the assembly process whilst maintaining material control.
- RFID tracking codes stock usage with superior accuracy.
- Automated component storage, removing the need for specific component bins. The system manages everything automatically.
- SMT job clustering that minimizes or even eliminates changeover times between jobs.
- Intrusive re-flow options, allowing for boards to be retrofitted.
4. The Major SMT Machines
4.1 Pick and place machines
Electronicstalk pick and place – Check Here
The pick and place segment is during a state of constant development. Though this equipment is now able to mount on different levels, and also it is the core SMT machine depends the productivity throughout the smt production line.
Quality nozzles and feeders are at the core of the pick and place process. If the pick and place machine fails to select parts consistently or hold on to the components while transporting from the feeder to the PCB, defects will occur. So proper feeder and nozzle selection are critical.
Many SMT manufacturers also are creating customed pick and place trays to permit more accurate picking and transport processes.
This equipment has customized nozzles that allow LEDs to be picked, vision center, and mounted at a high speed.
4.2 Printer system
Solder Paste Printer
SMT machinery requires the solder paste to be screen printed onto the PCB before placing the surface mount components. the standard of a PCB depends on the standard of the initial solder paste deposits.
Today, the smaller lead pitches and components make it harder to realize accurate, unflawed, and perfectly printed PCBs. this needs top quality, a precise printer that will handle small, mid-sized, and high volumes.
Additionally, a component pitch size of < 0.3 mm would require higher accuracy machines print fast and accurately.
Electronics today is a high mix, high density, varied substrate oriented then high accuracy prints for both fine and standard deposits adjacent on an equivalent land, are going to be what future printers will be got to address.
Printers in the future will have special squeegee technologies, different process stencils, and work on top quality paste.
Also, printers will presumably accommodate a good sort of substrates, have smartphones like MMIs, integrated paste and PCB surface analysis, intelligent response to substrate and printing variations directed at the highest productivity, yield ad efficiency, reducing operator dependence.
4.3 Reflow ovens
Electronicstalk air convention oven
Reflow ovens are applied for reflow soldering of the surface-mounted electronic components onto printed circuit boards. These are usually two types—infrared and convection ovens.
These ovens have multiple zones, each of which can be controlled individually for different temperatures. Generally, there are many heating zones as well as one or more cooling zones.
The PCB passes through the oven on a conveyer belt and is subjected to a controlled time-temperature profile. Reflow ovens are now available with many advanced features.
4.4 Inspection systems
Solder paste inspection (SPI) systems and automated optical inspection (AOI) systems are becoming critical tools in PCB assembly lines at present, especially in industries where tough quality and safety standards apply.
It is not just the increasing board density and therefore the miniaturization of components that are driving this trend—the use of AOI and SPI systems within the overall process control and test strategy has proved to be an unmatched return on investment.
Over the years, makers of those machines have technically enhanced the features to satisfy all the challenges of today’s complex PCB assembly.
4.5 Soldering systems
SMT soldering machines constitute an important part of the manufacturing process as they assist in evaluating the consistency within the soldering quality of a product.
SMT soldering machines cover an array of kit including SMT reflow soldering (reflow ovens) which we already mentioned above, SMT/BGA soldering stations (used for single component placement/removal and also referred to as SMT/BGA rework stations),
and SMT discrete soldering equipment like soldering stations, hot tweezers, infra-red guns (predominantly utilized in low volume/prototype development), etc.
By applying SMT soldering machines, manufacturers can increase thermal conductivity and reduce assembly costs, because of the lower labor involvement and therefore the use of less solder paste.
Today, these smt machines are more technologically advanced and use the newest soldering technology, which may reliably solder surface mount components, particularly those with very fine pitch leads.
In BGA, the pads are under the device and aren’t visible.
Today, BGA solder techniques are tried and tested and are proved to be very reliable. These machines are now available with advanced technologies.
4.6 Dispensing systems
The adhesive dispensing procedure deliveries adhesives onto the solder mask of the printed circuit board within a position appropriate for holding the components until the printed circuit board is wave soldered.
This smt machine used for adhesive dispensing is often inline or offline. Choosing an inline or offline system depends on the actual job at hand.
If the method is for little production batches, an offline dispenser unit is going to be adequate, except for high output placement lines, where the merchandise cycle time is brief, an inline system is important.
For both offline and inline systems, three different dispensing solutions are applied: auger pump time/pressure, and the piston pump.
4.7 Rework stations
Defective surface-mount components are often repaired by using soldering irons or a non-contact rework system.
A rework system may be a more sensible choice because SMD work with a hand tool requires considerable skill, and in many cases isn’t feasible in the least.
There are generally two non-contact soldering/desoldering ways—soldering with hot gas and infrared soldering.
With infrared soldering, the energy for heating the solder joint is transmitted by long or radio wave infrared electromagnetic waves.
With the present technological achievements, one system combines all crucial process steps, providing manual to automatic soldering, de-soldering, and placement, demanding only little action from the machine operator.
5. SMT machine programming
SMT machine programming
To enable the SMT line to work well automatically, one critical thing that the SMT operator needs to do is prepare the production programming for the SMT machines, such as the solder paste printer, pick and place machine, and reflow oven.
In the following contents, you can find some programming information about SMT machines respectively.
5.1 The Importance of XY Data in PCB Assembly
PCB assembly may be a precise and sophisticated job. Over the years, boards have gotten smaller and smaller — meaning that where once they might be assembled by hand, now they require the assistance of machinery to put the microscopic components.
Automated pick and place equipment is employed to line surface mount components onto PCBs. To try to do this, the machines got to know the precise coordinates or position of every component which will be assembled on the PCB.
Pick and place machines are often programmed manually, but this will take an extended time for sophisticated boards and cause errors. to help with the programming of those machines, an XY file is required.
Applying a file to program the pick and place machine will help reduce the production time and improve the precision. As well as XY data, the file can be known as the following:
- a centroid file;
- a pick and place file;
- or an SMT placement file.
During the design process of the printed circuit board, design software has different outputs — one example being Gerber data that also contains the XY data.
Gerber data describes the computer circuit board images: copper layers, solder mask, drill data than on.
The XY file is then basically an inventory of all the components on the planning and their respective x-y coordinates and rotation.
Most PCB design software can extract the component location and orientation directly from the board layout file to form the centroid file.
These files are essential to the smt machine of pick and place procedure because of these two major reasons: efficiency and quality.
5.2 Importing the programming file to the SMT machine
PCB files importing
- Reducing the errors caused by human
Having a file allows a manufacturer to import the info without having to manually enter the knowledge — which could easily end in an error.
A simple human error typo could mean components being fitted within the wrong position. Additionally, the import data also will cover off any issues regarding the orientation of devices.
What’s more, silkscreens contained within the Gerber data aren’t always as clear as a manufacturer would like them to be — or in some cases, not even present.
With silkscreens normally being of a square print, it can make the numbers zero, six, eight, and nine all look very similar if it’s not 100% clear.
In some instances, silkscreens aren’t always correct either, with references swapped over or within the wrong place. XY data files are far more accurate.
- Increasing the assembly efficiency
Manually entering all the info takes time. So, not having a file to import means adding engineering time interval before employment is released to production — thus causing delays and pressure on final delivery dates.
Plus, if there are any discrepancies with an assembly thanks to silkscreen errors, the manufacturer will need to seek clarification on any queries.
As timely responses aren’t always received, the result may be a potential delay to the discharge of any kit to production.
The ideal file would be within the sort of a ‘.CSV file and would contain every location, even people who aren’t fitted.
As standard, there would be four columns: reference, X centroid, Y centroid, and side of PCB.
6. SMT Machine Operator Salary
Usually, the salary is different in different areas across the world. Also, the salary is dependent on the skills of the operator, the higher skill, the higher. Salary. So this is the basic philosophy also on the segment of SMT machine.
In the following is the average salary in the United States, this data is from a recruiter website called ZipRecruiter, please have a look:
Operator salary from the data of ZipRecruiter – PHOTO SOURCE
As of Jul 16, 2020, the typical annual buy an SMT Machine Operator within us is $32,987 a year.
While ZipRecruiter is seeing annual salaries as high as $42,500 and as low as $20,500, the bulk of SMT Machine Operator salaries currently range between $28,500 (25th percentile) to $37,000 (75th percentile) across us.
The average salary range for an SMT equipment operator varies little (approx. $8,500), which suggests that no matter the location,
there are not so many opportunities for increased salary or advancement, even with many years of working experience.
Based on recent job postings on ZipRecruiter, the SMT Machine Operator job market in both Tsuen Wan, CN, and therefore the surrounding area is extremely active.
People working as an SMT Machine Operator in your area are making on the average $32,987 per annum or an equivalent because of the national average annual salary of $32,987. ranks no 1 out of fifty states nationwide for SMT Machine Operator salaries.
Conclusion for SMT Machine
Smaller, cheaper, and faster are the features that the electronics manufacturing industry is trying to find today. So most of smt machine manufacturer also do the upgrade based on these trends.
The present industry is currently undergoing very fast development in technology, placing increasing requirements on production equipment such as surface mount technology (SMT) machine to effectively increase manufacturing outputs and reduce defects.
The requirements for SMT types of equipment are coming from emerging fields such as automotive, telecom, strategic electronics, and healthcare.
SMT machines must, therefore, be capable of placing components with a high level of accuracy, to deal with an ever-increasing variety and complexity of components,
such as smaller ball grid array (BGAs), tiny flip-chips (where the electrical connections are made on to the chip’s silicon), etc, with the added need for high-quality standards.
Hence, the SMT industry is expanding its manufacturing capabilities to satisfy these demands. An SMT machine is an upscale piece of kit.
So buyers got to plan very strategically before making a sale of these smt machines, as there are many choices offered by various companies.
So you need to evaluate the advanced technologies and new equipment available within the various SMT machine categories.
It will assists electronics manufacturers to produce highly complex products during shorter periods of your time, increasing the general production rates while reducing production costs.