PCB + ASSEMBLY The
PCB + ASSEMBLY The CX2030 embedded PC (left) that serves as the main controller for the automated production line. Source: CYGIA, China The master CX2030 runs both the PLC program and the motion control and HMI software. It also sends data bidirectionally at high speed between the control system and the MES over TwinCAT TCP/ IP (TF6310), and controls the printing, surface mounting and reflow welding processes. Here, TwinCAT PLC/NC PTP 10/NC I (TC1260) provides full motion control functionality that can dynamically position 20 EtherCAT servo axes per machine. The NC I interpolation function serves to achieve smooth, steady, coupled movements on two axes and to control the arc-welding process. The second CX2030 embedded PC runs PLCs, motion control and HMI software, handles communication over TCP/IP, and exchanges data with the ALC line control system. It also receives instructions from the MES over TCP/IP to run tests and execute packing and unpacking processes. It can flexibly configure ten EtherCAT servo axes through a synchronization device that can switch quickly and efficiently between specific test environments for different products. The third CX2030 handles PLCs, motion control and HMI software, and in addition controls a high-resolution TCP/IP camera for optical inspection. Zusammenfassung Eine Smart-Factory-Plattform stellt im Rahmen eines flexiblen Fertigungskonzepts für Elektronikprodukte einheitliche Schnittstellen und Protokolle bereit, so dass ein vollständiger Automatisierungsprozess, vom Auftragseingang bis zum Transport, realisiert wird. Résumé Une plate-forme Smart Factory fournit des interfaces et des protocoles uniformes dans le cadre d’un concept de fabrication flexible pour des produits électroniques, ce qui permet de réaliser un processus d’automatisation complet, depuis la réception des commandes jusqu’au transport. Резюме «Умная фабрика» предоставляет для электронных устройств в рамках гибкой производственной концепции унифицированные интерфейсы и протоколы, позволяющие реализовать полный автоматизированный процесс со стадии поступления заказов до доставки. EtherCAT technology boosts system performance CYGIA chose EtherCAT as a high-speed communication system to ensure fast, precise transmission of sensor signals. The company runs master communication on its automated production line over EtherCAT in a star topology. Slave devices are easy to connect, which simplifies management, maintenance and expansion. A line topology is used at sub-station level to keep the wiring as simple as possible. Says Jianming Huang, a senior electrical engineer: “The EL1809 and EL2809 HD EtherCAT terminals are not just highly compact and inexpensive, they operate on multiple channels and can be configured flexibly for different topologies. They also support offline configuration and hot connect groups, which makes them much easier to set up. In addition, EtherCAT provides a wide range of useful information, such as diagnostic codes, diagnostic types, text IDs and time stamps. This helps to locate and fix master-slave communication outages potentially caused by EMC disturbance, cable damage or equipment faults. This makes maintenance much more efficient.” Future development potential The company’s aim with its smart factory solution is to integrate assembly and manufacturing units for discrete electronic components within a unified production system. Other goals are to connect production plants, to visualize production data, to make production processes transparent, and to create fully automated production sites. Given the broader trend toward Industry 4.0, CYGIA also needed smart factory software that would enable access to a wide range of data resources, including cloud computing, big data, and IoT. With TwinCAT 3, Joshua Wang has found the right solution and is now looking forward to the new production model the company has lined up: “We’ll gradually incorporate TwinCAT 3 functionality to support big data analysis, IoT advancements, and machine vision in future upgrades. Going forward, this will further enhance the setup of this hybrid control system to fully exploit the benefits of cloud data storage and distributed data interaction.” www.beckhoff.com; www.cygia.com 44 EPP EUROPE November 2020
PRODUCT UPDATES PCB + ASSEMBLY Introducing flexible laser marking solution The miniaturization of the printed circuit board with simultaneous high assembly density increases the requirement to apply codes in the smallest possible space. Asys has the answer: the laser marking system Insignum 6000 uses a CO2 laser and a positioning accuracy of ± 100 μm@5Sigma to mark codes smaller than 1 mm. Therefore, module sizes of < 3 mil (0.08 mm) are possible. A product becomes a unique specimen by providing it with a unique code. Traceability is the big keyword here. In times of electromobility and 5G technology, high performance electronics are applied to a smaller PCB area. Accordingly, the markings must also shrink. This requires a new type of technology in the field of laser marking. Laser marking with CO2 The company’s laser experts have taken up the challenge. They have succeeded in guiding the laser beam through optics in such a way that a small spot is created with which 3 mil codes can be generated. This technology is integrated in the new laser marking system Insignum 6000 3 mil. The system uses a CO2 laser and a positioning accuracy of ± 100 μm@5Sigma to mark codes smaller than 1mm. Therefore, module sizes of < 3 mil (0,08 mm) are possible. Flexible platform – Configuring the machine With this flexible solution, it is possible to realize any requirements in the field of laser marking. In addition to the realization of module sizes smaller than 3 mil, model variants for double-track solutions, the processing of large format printed circuit boards and the marking of e.g. ceramics, plastics and DBC substrates are also possible. Transport system and laser types are individually adapted to the process requirements. Different laser sources such as CO2, fiber, green and UV can be used in the system to meet any special requirements. In the basic version, the plant is equipped with a 10-Watt CO2 laser, X/Y linear axis and transport system. The benefits: • Miniature markings: codes smaller than 1 mm with module sizes < 3 mil • High-precision marking: with a positioning accuracy of ± 100 μm @ 5 sigma • Flexible: different laser sources can be integrated www.asys-group.com PanaCIM-EE Gen2 - Smart Factory solutions for today and tomorrow Shorter cycle times and optimized line productivity thanks to production planning at line level Digitization of all production steps and cross-plant inventory management thanks to systems for maintenance and asset management The laser marking system Insignum 6000 uses a CO2 laser to make markings smaller than 1mm. Source: Asys industry.panasonic.eu EPP EUROPE November 2020 45
