If you’re assembling prototypes of SMD boards on your own, placing the parts accurately can be a pain. Of course, it’d be nice to have a full pick and place machine, but those are rather expensive and time consuming to set up, especially for a small run of boards. Instead, a vacuum pickup tool can help you place the parts quickly and accurately by hand.
The folks over at Ohmnilabs have put together their own DIY pickup tool for about $75, and it’s become part of their in-house prototyping process. They grew tired of placing components with tweezers, which require you to remove parts from the tape before lifting them, and have a tendency to flip parts over at the worst time.
The build consists of a couple parts that can be bought from Amazon. An electric vacuum pump does the sucking, and the vacuum level is regulated with an adjustable buck converter. A solid foot switch keeps your hands free, and syringe tips are used to pick the parts up.
This looks like a simple afternoon build, but if you’re prototyping, it could save you tons of time. To see it in action, check out the video after the break.
Three things that I love about participating in Maker Faires are seeing all the awesome stuff people have done over the past year, spending time with all my maker friends in one big room over two days and the reactions to what I made. The 2016 Ottawa Maker Faire had all this in spades.
There’s just something about BB-8 that touches people. I once heard of a study that showed that when buying kid’s toys, adults were attracted to circles, that that’s the reason teddy bears often have round heads with big round eyes. Similar reactions seem to happen with BB-8, the droid from last year’s Star Wars movie. Adults and kids alike pet him, talk baby-talk to him, and call to him with delight in their voice. I got those reactions all throughout the Maker Faire.
But my favorite reaction happened every time I removed the head and lifted the top hemisphere of the ball to expose the electronics inside. Without fail the reaction of adults was one of surprise. I don’t know if it was because of the complexity of the mechanism that was revealed or because it was just more than they expected. To those whom I thought would understand, I gave the same speech:
“This is the remote control receiver taken from a toy truck, which puts out negative and positive voltages for the different directions. That goes to this ugly hack of a board I came up with that converts it all to positive voltages for the Arduino. The Arduino then does pulse width modulation to these H-bridge driver boards, for speed control, which then talk to these two drill motors.”
Those I wasn’t sure would understand were given a simpler overview. Mine’s a hamster drive (we previously covered all the possible ways to drive a BB-8) and so I showed how it sits on two Rollerblade wheels inside the ball. I then flipped it over to show the heavy drill batteries underneath, and then explained how the magnets at the top of the drive mechanism attracted the magnets under the head, which got another look of revelation. All went away satisfied.
But BB-8 sometimes needs a break from human interaction and seeks out its own kind, like Bowie which you can read about below along with more awesome Maker Faire exhibits.
This weekend at Maker Faire, Chipsetter showed off their pick and place machine. It is, in my opinion, the first pick and place machine designed for hackerspaces, design labs, engineering departments, and prototypers in mind. It’s not designed to do everything, but it is designed to everything these places would need, and is much more affordable than the standard, low-end Chinese pick and place machine.
Inexpensive and DIY pick and place machines are familiar territory for us. A few years ago, we saw the Carbide Labs pick and place machine, a machine that allows you to put a board anywhere, pull chips out of tape, and place them on pasted pads. The Retro Populator is a pick and place machine that retrofits onto a 3d printer. The Firepick Delta, another Hackaday Prize project, takes a mini-factory to its logical conclusion and is capable of 3D printing, populating boards, dispensing paste, and creating its own circuit boards. All of these machines have one peculiarity: they are entirely unlike normal, standard, industrial pick and place machines.
The idea of any startup is to build a minimum product, and the idea behind Chipsetter is to build a minimally viable tool. For their market, that means being able to place 0402 components (although it can do 0201, the team says the reliability of very small packages isn’t up to their standards), it means being able to shoot 1250 components per hour, and it must have inexpensive feeders to accept standard tape.
This is a complete departure from the spec sheet of a machine from Manncorp. For the ‘professional’ machines, a single feeder can cost hundreds of dollars. According to Chipsetter founder Alan Sawula, the feeders for this machine will hopefully, eventually cost about $50. That’s almost cheap enough to keep your parts on the feeder. A pro machine can handle 01005 components, but 0402 is good enough for most projects and products.
This is the closest I’ve seen to a pick and place machine designed to bridge the gap between contract manufacturers and hackerspaces. Most of the audience of Hackaday – at least as far as we’re aware – doesn’t have the funds to outsource all their manufacturing to a contract manufacturer. Most of the audience of Hackaday, though, or any hackerspace, could conceivably buy a Chipsetter. The Chipsetter isn’t designed to be the best, but when it comes to placing parts on paste, the best is overkill by a large margin.
The Chipsetter has a Kickstarter going right now. They’re about halfway funded, with a little more than three weeks to go. Right now, if you’re looking at pick and place machines, I’d highly suggest checking out the Chipsetter. It works, and with forty feeders it’s cheaper and more capable than the lowest priced ‘pro’ machines.
A SCARA (Selective Compliance Assembly Robot Arm) is a type of articulated robot arm first developed in the early ’80s for use in industrial assembly and production applications. All robotics designs have their strengths and their weaknesses, and the SCARA layout was designed to be rigid in the Z axis, while allowing for flexibility in the X and Y axes. This design lends itself well to tasks where quick and flexible horizontal movement is needed, but vertical strength and rigidity is also necessary.
This is in contrast to other designs, such as fully articulated arms (which need to rotate to reach into tight spots) and cartesian overhead-gantry types (like in a CNC mill), which require a lot of rigidity in every axis. SCARA robots are particularly useful for pick-and-place tasks, as well as a wide range of fabrication jobs that aren’t subjected to the stress of side-loading, like plasma cutting or welding. Unfortunately, industrial-quality SCARA arms aren’t exactly cheap or readily available to the hobbyist; but, that might just be changing soon with the Creo Arm. Continue reading “Creo Arm Might be the SCARA You’re Looking For”→
Recently we started a series on the components used to assemble a circuit board. The first issue was on dispensing solder paste. Moving down the assembly line, with the paste already on the board, the next step is getting the components onto the PCB. We’re just going to address SMT components in this issue, because the through hole assembly doesn’t take place until after the SMT components have gone through the process to affix them to the board.
SMT components will come in reels. These reels are paper or plastic with a clear plastic strip on top, and a reel typically has a few thousand components on it. Economies of scale really kick in with reels, especially passives. If you order SMT resistors in quantities of 1-10, they’re usually $.10 each. If you order a reel of 5000, it’s usually about $5 for the reel. It is cheaper to purchase a reel of 10 kOhm 0603 resistors and never have to order them again in your life than it is to order a few at a time. Plus the reel can be used on many pick-and-place machines, but the cut tape is often too short to use in automated processes.
In the 80s and 90s, building a professional quality PCB was an expensive proposition. Even if you could afford a few panels of your latest board, putting components on it was another expensive process. Now, we have cheap PCBs, toaster-based solder ovens, and everything else to make cheap finished boards except for pick and place machines. ProtoVoltaics’ semifinalist entry for the Hackaday Prize is the answer to this problem. They’re taking a cheap, off-the-shelf CNC machine and turning it into a pick and place machine that would be a welcome addition to any hackerspace or well-equipped garage workshop.
Instead of building their own Cartesian robot, ProtoVoltaics is building their pick and place around an X-Carve, a CNC router that can be built for about $1000 USD. To this platform, ProtoVoltaics is adding all the mechanics and intelligence to turn a few webcams and a CNC machine into a proper pick and place machine.
Among the additions to the X-Carve is a new tool head that is able to suck parts out of a reel and spit them down on a blob of solder paste. The webcams are monitored by software which includes CUDA-accelerated computer vision.
Of course a pick and place machine isn’t that useful without feeders, and for that, ProtoVoltaics built their own open source feeders. Put all of these elements together, and you have a machine that’s capable of placing up to 1000 components per hour; more than enough for any small-scale production, and enough for some fairly large runs of real products.
You can check out some of the videos for the project below.
Jigsaw puzzles are a fun and interactive way to spend an afternoon or twelve, depending on the piece count and your skill level. It’s exciting to find the pieces you need to complete a section or link two areas together, but if you have poor dexterity, excitement can turn to frustration when you move to pick them up. [thomasgruwez] had the disabled and otherwise fumble-fingered in mind when he created this pick and place jigsaw puzzle aid, which uses suction to pick up and transport puzzle pieces.
The suction comes from an aquarium pump running in reverse, a hack we’ve seen often which [thomasgruwez] explains in a separate Instructable. A large, inviting push button is wired in line to turn the pump on and off. An equally large and inviting momentary switch turns off the vacuum temporarily so the piece can be placed.
At the business end of this hack is the tiny suction-cupped tip from a cheap vacuum pen. To interface the pen head with the pump, [thomasgruwez] designed and printed a rigid straw to bridge the gap. With utility already in mind, [thomasgruwez] also designed a ring that can be bolted to the straw to house a steadying finger of your choice, like the pinkie hook on a pair of barbers’ shears.
Our favorite part of this hack has to be the optional accessory—a tiny platform for quickly flipping pieces without cutting the vacuum. Check it out after the break.