At this year’s SMT Hybrid Packaging in Nuremberg, Yamaha Motor unveiled the new YSM40 high performance modular assembly machine, which has a high degree of flexibility to provide the production line with versatility. We invite you to explore details of selected Yamaha product innovations.
The innovation of Yamaha’s technological equipment is seen in the marketplace primarily through the extensive process control that the manufacturer has achieved through advanced inspection and control systems such as the new YSi-X 3D/2D inspection machine combining X-ray, optical system, infrared inspection and laser scanner in one product. The second innovation of this type is the YSi-12, a linear AOI machine, which together with the breakthrough QA (Quality Assistant) software creates a market benchmark for quality control in production. Yamaha also stands out with its unique technical solutions, implemented in the new compact YC8 machine, which allow to place large, heavy and irregularly shaped components on PCBs in a standard SMT process. Yamaha’s innovations also include the new, highly efficient YSM40 surface mount machine.
100,000 COMPONENTS PER HOUR EFFICIENCY
The new Yamaha YSM40 high performance modular surface-mounting machine has 4 heads located on a small operating platform just 1 meter wide. It achieves the industry’s best assembly speed of over 100,000 cph (according to IPC 9850 standard) and establishes a record high performance per square meter of production area and assembly line length. The new YSM40 offers manufacturers versatility and configuration flexibility. It is designed to achieve a high level of productivity and the ability to handle a wide range of components on a single assembly platform. The YSM40 is the right solution for the high-speed SMT machine with parameters optimized for small and medium sized PCBs, such as those found in many modern consumer and industrial electronics products.
The YSM40 can be adapted to diverse applications, e.g. by equipping the machine with 2 or 4 mounting heads, three different head types and a single or dual-track conveyor system. In addition, several new solutions, including an innovative tray changer mounted instead of a component trolley, allowing all pallets to be changed at the same time, reduce set-up and changeover times. The efficiency of the device is also increased by the possibility of changing the feeders on the fly, which is made possible by the new electric „ZS“ belt feeders. The ZS feeder is 30 to 40 percent faster than its predecessor, and thanks to its compatibility with previous machines, it can be replaced during operation.
QUALITY ASSURED BY AN EXTENSIVE INSPECTION SYSTEM
The new YSi-X 3D/2D hybrid inspection device includes a unique laser height control sensor and vision system that takes optical and X-ray images of the operating field. It is the fastest and most efficient 3D inspection system on the market and the first on the market to take X-rays and perform an optical inspection at the same time. Images are created using Yamaha’s patented CL pulsed technique, which enables the acquisition of a three-dimensional image through horizontal and vertical sections, with very low X-ray exposure and in less than four seconds in total.
The sensitive detector minimises the necessary inspection time and reduces potential radiation damage to components. Thanks to its low radiation levels and pulsed operation, it significantly extends the life of the X-ray source and detection sensors to four years in 24/7 operation.
The camera used for the optical system is the same as in the AOI YSi-12 inline system and the AOI YSi-S offline system. It has a triangular setting and 3-color RGB imaging and works with infrared LEDs to ensure proper illumination of the area under examination. The YSi-X 3D/2D inspection device also includes a laser height sensor that estimates the position of the pads to component leads.
QA PROVIDES FEEDBACK IN DEFECT DETECTION
All the inspection systems available on the market identify a manufacturing defect, but few can indicate the cause of incorrect assembly. It is therefore worth noting that Yamaha’s SMT lines, working with this manufacturer’s AOI system, can use the QA software together and immediately warn operators of the problem, indicating the machines, components, feeder position, placing head and nozzle number that are causing the problem. This minimizes assembly errors, rather than simply marking faulty boards for repair.
WORKING WITH HEAVY, LARGE AND NON-STANDARD SMT COMPONENTS
Yamaha Motor’s new compact, modular YC8 surface-mounting machine allows you to place or push large components and custom shaped components up to 100x100x45 mm in size and weighing up to 1 kg.
The YC8 provides a high level of installation quality and ease of use that is standard with Yamaha machines, adding the ability to mount heavy power modules and power electronic components. It can also be used for the assembly of large-size elements, such as screens in smartphones and tablets, connectors and power connections requiring high pressure during assembly (adjustable pressure force). YC8 allows you to automate processes that until recently could not be performed by conventional surface-mounting machines. The unit includes mounting head with a 100 mm stroke, that can handle components up to 45 mm high and has additional functions such as an automatic nozzle station with the possibility of replacing large 25 mm nozzles and automatic tray delivery kit ATS15. These options provide excellent versatility.
SUMMARY
The above characteristics and descriptions of devices allow us to learn only little about the possibilities of new production equipment. Nevertheless, even a perfect knowledge of technical specifications and data sheets cannot be a decisive factor in the selection of specific devices. Such important decisions should be based on the comparison of machines in real production conditions (distributor’s demo-room, visit to the production floor), having learned the quality of warranty and post-warranty service, warranty conditions and similar factors.