NEWS + HIGHLIGHTS High level demand for production equipment From depanelizing to highly efficient automation lines Panel cutter, router, depaneler – whatever the machines that separate the individual board assemblies that are manufactured in differently sized panels are called- they are a central stage in electronics manufacturing environments. For over 20 years now, IPTE, headquartered in Belgium, has been successful in this industry with its families of routers, as well as, automation solutions for the electronics and machinery industries. Sales Director Rainer Krohmann and Dr. Jörg Handke, Business Unit Manager Systems, from the company’s German office in Heroldsberg, discuss the success and benefits of the systems. “Our market position has become clear by the matter of fact that customers often come to us with demand for an efficient depaneling machine. And then as further discussions and questions on application, handling, functionality and automation reveal, they are going to order a comprehensive automation solution, including the router, for their electronics production, because our highly flexible and efficient range of equipment has convinced them.” Solutions with flexibility It is important, as the managers make clear, that as a supplier of such system solutions, the company has always actively and cooperatively taken up the requirements of the market and then, on a case-by-case basis, implemented promptly the relevant options requested. In this case, they are also a competent partner for users resolving such projects. After all, these system solutions have to exhibit their performance in daily operation. “The feedback from our customers in the field, with whom we generally maintain long-term and trustful relationships, including the exchange of special knowhow, is very important for such further developments,“ emphasizes Rainer Krohmann. This also applies to upcoming manufacturing con- Modular machine concepts enable a wide range of applications IPTE offers a total of four different depaneling machine families in its portfolio. The systems EasyRouter and TopRouter for off-line operation originate from the headquarters in Genk, Belgium. On the other hand, FlexRouter II and SpeedRouter in-line machines are developed and manufactured in Heroldsberg, Germany. Continuous improvements have made these systems very efficient. For more than 20 years, the in-line capable and flexible SpeedRouter for the depaneling processes sawing and milling or a combination of these has been continuously further improved. Designed for high-speed requirements, it is characterized by high reliability, robustness and speed. The modular concept allows for a variety of different tools, grippers and in-feed and out-feed transport mechanisms for in-line and off-line applications. Integration in manufacturing lines is supported by a wide range of different cells and modules. The system is also ideally suited for requirements demanding very narrow tolerance limits and short cycle times. The FlexRouter II has been developed for medium to high production throughput with a high product mix. It now also works with framelessrouting technology. Despite the small space requirement of only onemeter width, panels up to 330 mm x 500 mm can be processed. Four of the seven axes are designed as linear drives. The panel is loaded, clamped and measured in position by means of a width-adjustable belt conveyor. A freely programmable servo gripper on a Cartesian 3-axis system with rotary axis holds the panel during the cutting process, thus basically eliminating PCB-specific tooling costs. The milling spindle under the PCB is also positioned with a Cartesian 3-axis system and can be equipped with different spindle types to realize even complex applications without difficulties. The automated change of gripper fingers allows simple and fast product changes. Various options are available for positioning and moving the panels: such as belt conveyor (also double beam), tray magazines up to a size of 600 x 400 mm, work-piece holder, linear shuttle and turntable. As an option, it is possible to check the singularized board assemblies by means of optical inspection. Separation programs can be created with camera support or with the integrated DXF converter for the transfer of CAD data. The machine is intuitive and easy to operate. Features, such as the use of several milling cutter sections for cost reduction, automatic milling bit change and detection of bit breakage, are standard. The EasyRouter II is a low-cost off-line depaneler for operations from the top of the panel at a speed of up to 60 mm/sec. Among other features, the accuracy, user guidance and noise level have been optimized. The complete process sequence of the milling tool can be displayed in 3D real-time positions or simulated using industry-specific parameters to determine the cycle time from the original product data. Loading and unloading take place alternately during the cutting process via a turntable with an integrated work-piece carrier. Handling is carried out manually, and robot support (Cobot) can also be implemented. X and Y axes of the milling machine feature fast and precise spindle drives. Automatic change of the milling tool with bit recognition and diameter inspection are also provided for. The bit position can be learned to use a camera; ESD monitoring of the milling tool is possible. Programming can be provided via DXF files or codes. 6 EPP EUROPE November 2019
Dr. Jörg Handke and Rainer Krohmann (from left) during a tour at the manufacturing floor of the IPTE in-line depaneler machines: “The demand for our solutions is particularly high.” Source: IPTE Dr. Handke: “Frameless routing allows a further increase in efficiency and cost reduction, as panel waste is significantly reduced.“ Source: IPTE cepts, such as Industry 4.0/Smart Factory and their implementation. In addition, there are user requests for easy program generation and CAD import of product data, high flexibility and functions, such as the optimization of the edge-cut procedure, detailed system monitoring and ergonomics, as well as application-specific customization and user aids. As Dr. Handke states, “operation, programming and maintenance must be practically intuitive and self-explaining. Straightforward and machine-aided troubleshooting, as well as preventive maintenance and statistical process control (SPC), are inherited elements of our machine concept. Of course, also a reduction of downtime is very important, because shutdowns in lines are always very costly. The system also includes so-called software wizards for providing user assistance. It is not exaggerated to say that our software has now become a unique selling point in the equipment design.“ Transparent cost and quality situation “To set up a cutting process, the operator has to only follow the carving process on the panel with the aid of the machine. The result, including possible optimization, is thus immediately available. The transfer of CAD data to a cutting program is likewise convenient. Because the trend towards smaller boards is increasing, panels with 256 single assemblies are already a reality in production, high precision and cutting speed are essential. Also, we have further optimized the management of dust generation and extraction as well as the reduction of operating noise. And, of course, the exact monitoring of tool wear or tool breakage as well as statistical evaluation and traceability are included in the performance machine package. And for production monitoring, users can extract the data from the running process and prepare it immediately,“ Dr. Handke further explains. Therefore, not only the costs for the separation of a single board assembly are transparent for the user, but also the quality of process and product. No wonder that besides the outstanding hardware design, the company also gives high priority to software development. Rainer Krohmann underlines the current development in this topic of interest in the industry and its impact on the company: “For some time now, we have been hiring an above-average number of employees in the software area, in order to meet the increasing demands in the application, optional enhancement, functionality and user-friendliness. The software‘s proportion of added value in our machines is thus constantly increasing.“ Frameless routing increases efficiency and profitability As well as on the hardware side, highly innovative solutions continue to be developed. As Dr. Handke, responsible for the design of the SpeedRouter and FlexRouter II product families, points out: “With the new frameless routing (option), we are now increasing the efficiency of the FlexRouter II. Because with frameless routing, i.e. without the use of frames, there are only very few circuit board leftovers.“ This is also interesting from both, an ecological and a cost-related point-of-view, because it reduces the amount of nonrecyclable material and therefore reduces the amount of waste that has to be disposed of. This solution also features a transport mechanism without any edges, which enables fast, stress-free and pre- EPP EUROPE November 2019 7
