Tour A PCB Assembly Line From Your Armchair

Those of us who build our own electronics should have some idea of the process used to assemble modern surface-mount printed circuit boards. Whether we hand-solder, apply paste with a syringe, use a hotplate, or go the whole hog with stencil and oven, the process of putting components on boards and soldering them is fairly straightforward. It’s the same in an industrial setting, though perhaps fewer of us will have seen an industrial pick-and-place line in action. [Martina] looks at just such a line for us, giving a very accessible introduction to the machines and how they are used. Have a look, in the video below the break.

It’s particularly interesting as someone used to the home-made versions of these machines, to see the optical self-alignment and the multiple pick-and-place tools which are beyond the simpler pick-and-place machines you’ll find in a hackerspace. Multiple machines in a line are also beyond hackerspaces, so the revelation that the first machine is deliberately run slowly to avoid the line backing up is a valuable one.

At the end of the line is the reflow oven itself, through which the boards pass on a belt through carefully graded hot air zones. Certainly a step up from a toaster oven with an Arduino controller!

Sadly not all of us will be lucky enough to have such a line at our disposal, but pick-and-place projects come up here quite often. We did a teardown on the feeders from a Siemens machine a couple of years ago.

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A Ploopy Pick And Place

A fair number of hackers reach that awkward age in their careers – too old for manual pick and place, but too young for a full-fledged PnP machine. The obvious solution is to build your own PnP, which can be as simple as putting a suction cup on the Z-axis of an old 3D-printer. Feeding parts into the pick and place, though, can be a thorny problem.

Or not, if you think your way through it like [Phil Lam] did and build these semi-automated SMD tape feeders. Built for 8-mm plastic or paper tapes, the feeders are 3D-printed assemblies that fit into a rack that’s just inside the work envelope of a pick and place machine. Each feeder has a slot in the top for the tape, which is advanced by using the Z-axis of the PnP to depress a lever on the front of the case. A long tongue in the tape slot gradually peels back the tape’s cover to expose a part, which is then picked up by the PnP suction cup. Any machine should work; [Phil] uses his with a LitePlacer. We like the idea that parts stay protected until they’re needed; the satisfyingly clicky lever action is pretty cool too. See it briefly in action in the video below.

It looks like [Phil] built this in support of his popular Ploopy trackball, which is available both as a kit and fully assembled. We think the feeder design is great whether you’re using PnP or not, although here’s a simpler cassette design for purely manual SMD work.

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A Pick-And-Place That Is A Work Of Art

It’s a Holy Grail among hackerspaces, the possession of a pick-and-place machine. These robotic helpers for placing surface-mount components on PCBs are something of a gateway to electronic production, but they can carry a fearsome cost. Happily for the cash-strapped would-be electronic manufacturer, it is possible to build a pick-and-place for yourself. [Mcuoneclipse] has demonstrated this with a rather impressive build that works with the freely available OpenPnP software.

Superficially it shares much with what you might expect from a small CNC mill, in that it has a frame made from extruded aluminium that carries rails that trace an X and a Y axis supporting a tool head. But instead of a blade it has a box made from laser-cut ply that contains a camera and a vacuum pick-up tool that can collect a component from the tapes and deposit it in the correct point on the board. At the machine’s heart is a Smoothieboard, and the work is done by an assortment of solenoid valves and actuators. A huge amount of attention to detail has been paid to this build, with a holder for all the interchangeable nozzles for different component sizes, laser-cut mountings for all the motorised components, and automatic feeders for the SMD tapes all being carefully designed and built. Several iterations of the design are presented, in particular around the head itself which has passed through more than one form to remove as much vibration as possible. But don’t take it from us, have a look at the video we’ve pasted in below the break.

This isn’t the first pick-and-place machine we’ve brought you here at Hackaday. If you already have a 3D printer, would you consider this upgrade?

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Make A Better, Spring-Loaded SMT Tape Strip Holder

Every so often, a project is worth some extra work to see if the idea can go any further. [JohnSL] has been busy doing exactly that with his spring-loaded SMT tape holder project. Having done the original with 3D printing, he has been working on designing for injection molding. This isn’t a motorized feeder, it’s still a manual tool but it is an improvement over the usual workshop expedient method of just sticking segments of tape down to the desktop. Tape is fed into the holders from one end and spring tension holds the tape firm while a small slot allows the cover tape to be guided backward after peeling. As anyone who has used cut segments of tape to manually deal with SMT parts knows, small vibrations — like those that come from peeling off the clear cover — can cause the smaller components to jump around and out of their pockets, and any length of peeled cover gets awkward quickly.

The design allows for multiple holders to mount side-by-side.

In [JohnSL]’s design, all SMT tapes sit at an even height regardless of size or tape thickness. A central support pushes up from the bottom with tension coming from a spring pulling sideways; the central support is forced upward by cams and presses against the bottom surface of the tape. As a result, the SMT tape gets supported from below with even tension and the whole assembly maintains a narrow profile suitable for stacking multiple holders side by side. The CAD files are available online along with a McMaster-Carr part number for the specific spring he used.

After working out the kinks on 3D printed prototypes, [JohnSL] decided to see if it would be feasible to design an injection molded version and made a video outlining the process, embedded below.

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DIY Pick And Place Builds Boards, Is Awesome

In what can probably be attributed to the pains of placing a lot of SMD components, [gravelrash] built his own home-made pick and place machine.

Instead of being frustrated with tweezers, stereo microscopes, and having an inordinate amount of concentration, [gravelrash] built a pick and place machine from a Chinese CNC router. The build doesn’t use automated feeders for its reels of parts. Instead,[gravelrash] picked up five manual feeders from eBay, allowing his pick and place to hold 25 different reels of components.

There is, of course, a vacuum pump for sucking up SMD parts and a two-axis gantry capable of moving components from reel to board. The software is Mach3, a program normally used with spinning cutters to mill away wood, metal and plastic. [gravelrash] replaced this motor with a few vacuum controlled needles to pick up, move, and drop components onto the board.

While the build may not be as fast as some other pick and place machines we’ve seen, it’s almost as fast as hand-placing components with the added bonus of not tearing your hair out over very tiny parts.

Tip ‘o the hat to [Alexander] for sending this one in.

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