With the assembly of printed circuit boards (PCB) becoming automated, the whole process of PCB manufacturing has become more efficient. To achieve higher productivity along with quality, the need of the hour is to have efficient loader/unloader machines. In this article, we run you through the latest developments in this domain and look at what parameters you need to keep in mind when investing in these machines
By Gunjan Piplani
With the miniaturisation of PCBs and their components, the whole assembly process now requires minute details to be looked into. This can only be achieved with automated machines that offer a high yield.
“Primarily, PCB loaders, unloaders and a set of inspection conveyors comprise the main line of equipment in an SMT set-up,” says Amit Madan, country manager – India, TransTechnology India Pvt Ltd.
A faster process
Loader/unloader machines minimise the risk of errors that might occur when there is human intervention and have quickened the process of PCB loading and unloading.
According to Shailendra Mathur, general manager, India, ASYS Group, “Unloader/loader machines are also known to reduce the operational costs, as the state-of-the-art monitoring systems reduce the number of operators needed to administer the PCB assembly process.”
Ensuring high productivity
Loader machines are used to load the PCBs for the next stage of assembly, where it moves to the printer. Loader machines ensure that the PCBs are loaded without any misalignment, and a regular check is maintained when it comes to orientation and contamination, thus ensuring high productivity and yields.
Mathur adds, “Due to increased pressure on productivity and yields, customers are now choosing more feature-rich systems. So, increasingly, the Indian market is moving from being price-sensitive to one in which features that translate to yield and productivity take the centre stage.”
The latest in the market
SMT loader/unloader machines are available in two variants—machines that can both load and unload, or machines that can perform either of the functions. The current upgradation phase that these SMT machines are going through is in the increasing number of PCB magazines which can be loaded onto the machines. Earlier, the number was limited to one or two but has now grown to as high as five.
One of the latest launches is YJ Link’s ALD-12 S/Y/L/X (loader) and AUD-12S/Y/L/X (unloader) machines. According to Nitesh Srivastava of NMTronics, the Indian distributor of YJ Link, these machines are superior to their predecessors and offer a double base plate, which makes it an efficient board handling solution. With a magazine capacity of three and five, respectively, both the machines come with a Surface Mount Equipment Manufacturers Association (SMEMA) interface and have an LED display to make them more user- friendly. SMEMA has set certain specifications for single board transfer systems with conveyors as the transporters. Its specifications state that the boards should be moving from left to right, although the same standard also applies to board transfers going right to left. For proper sequencing of boards, two signal lines should be used—‘Board Available’ and ‘Machine Ready’, while the signal ‘Failed Board Available’ is optional.
These machines are available in four PCB sizes, namely, 330mm × 250mm, 440mm × 330mm, 530 mm× 375mm and 530mm × 460mm.
Another player, Nuteck Private Limited of Singapore, has introduced the MCF0100UM – an automated unloader with two levels of conveyors. The upper conveyor has a capacity of two magazines and the lower conveyor has a capacity of three magazines. The machine has a maximum power consumption of 350VA, and weighs about 180kg.
What is new in these machines is that the liquid crystal displays (LCD) have been replaced by LED displays, offering better and clearer details of what is running during the assembly process. Nuteck sells in India through TransTechnology India Pvt Ltd.
The third offering is from ASYS Group, the AMS 04 magazine loader with magazine buffer and automatic magazine change. This is equipped with automated magazine loaders. The unit consists of two loading and two unloading conveyors for magazines, a lifting axle with a magazine platform, a receiving conveyor for the previous unit and an electrically driven pusher.
A smart move
SMT machines comprise that part of the electronic components assembly line for which investments are made once in 5-10 years, depending on the technological advancements. This means that when a company plans to purchase a particular machine, it should have a long-term goal with clear plans on how to use it.
When making a purchase decision, some of the parameters that a customer should keep in mind include the technology (which must not become obsolete for at least a few years); an understanding that these machines are an investment rather than a purchase; the quality and compliance that the machines carry, which ensures that the machines will have a better life, are safe to use and are not harming the environment; the number of magazines that can be loaded at one time; and most importantly, the availability of local customer support, which ensures immediate help in case of any failure.
Sharing a larger perspective, Mathur opines, “Most importantly, we feel the buyer’s perspective has to shift from looking at loader/unloader systems in isolation. Rather, these should be looked at as a part of a set of other handling systems — as part of the productivity chain, and not just tools to fill the gaps in an assembly line. If the assembly line is not planned in the right way, it can prove to be the weakest link in the system. So, this necessitates more attention to be paid to the salient features of these tools. Additionally, as more and more systems are installed and a diverse workforce with different capabilities is used in the manufacturing process, safety compliance is critical.”
These machines are moving towards higher efficiency, offering better productivity with minimal or no errors.
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Newly Launched Machines
Model: ALD-12 S/Y/L/X- Loader, Brand: YJ Link, Manufacturer: YJ Link Co. Ltd
- PLC control
- SMEMA interface
- Buzzer, SMEMA interface LED display
- Compact design
- Durable structure with double base plate
- Consumes minimal power: 0.5kVA
Contact details: Dan Kim, sales manager, Asia, +82 53 592 1723, [email protected], www.yjlink.com
Indian distributor: NMTronics India Pvt Ltd
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Model: MFC0100UM – Automated Unloader, Brand: Nutek, Manufacturer: Nuteck Private Limited
- Includes pusher conveyor
- Adjustable pusher position
- Pneumatic pusher’s pressure is regulated
- Sturdy and stable design
- User-friendly ‘soft touch’ LED membrane control panel
- Pneumatic clamps provided for magazine alignment
- High throughput with short magazine changeover time
- SMEMA compatible
Contact details: +65 6862 0255, [email protected], www.nutek-sg.com
Indian distributor: TransTechnology India Pvt Ltd
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Model: AMS 04 magazine loader with magazine buffer and automatic magazine change, Brand: ASYS Manufacturer: ASYS, Automatisierungssysteme GmbH
- Automatic magazine changer with magazine clamps at the top and the bottom
- Loading and unloading conveyors situated directly one above the other
- Safety switch on input of PCB into magazine
- Double lift axle model
- Power consumption: 0.75kW
- LED interface: Siemens, SMEMA, SMPI, Panasonic, Fuji, Sanyo
Contact details: +49 7348 9855 0, [email protected], www.asys.de
Indian distributor: ASYS Group India
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CHECKLIST
√ Look for technology that can last for long
√ Look at these machines as an investment
√ Look for quality and compliance
√ Check the number of magazine loaders needed
√ Focus on features
√ Check availability of Indian distributors for quick customer support
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TYPES OF LOADER/UNLOADER MACHINES
- Bareboard loaders
- De-stackers
- De-stackers with buffer
- Single and multiple magazine loaders
- Multi-function buffer load and unload system
- Dual lane loaders and unloaders
