In the electronics industry, maximizing production profitability is a constant concern for manufacturers, regardless of their size or degree of automation. One area where significant gains can be made is in the automation of post-AOI processes. In this article, we will discuss the options available for optimizing post-AOI automation processes and their potential benefits.
The first and most important step in improving post-AOI automation is moving from batch AOI to inline AOI. While batch systems may be cheaper initially, the costs of a skilled operator’s wages over the lifetime of the machine are much higher than an inline system, which requires far less human intervention.
Once the inline AOI system is in place, there are several options available for post-AOI automation:
NG Conveyor and NG Workstation:
The most common method for separating NG (non-good) PCBAs from good PCBAs is the NG Conveyor. These conveyors have a pin lift mechanism that moves NG PCBAs from the good transfer conveyor to the NG position above. NG Conveyors can be equipped with up to three NG positions, and alarms can be set to signal line operators to remove the NG PCBAs for processing.
NG Workstations provide additional automation by bringing the review station to the SMT line. The workstation is equipped with a review station screen and PC, a mounted optical camera, and a screen on a floating X, Y gantry, allowing for all processing and reviews to take place on the line.
NG Buffer:
The NG Magazine Buffer is popular among OEM manufacturers and CEMs with high automation or throughput ambitions. This unit offloads perpendicular to the SMT line and provides the highest level of automation and efficiency, allowing full magazine racks to be taken to the review station and reviewed in bulk for processing. Alarms can be set to reduce unwanted scrap, which will pause production.
Split End of Line Unloader:
This option is great for those who want the functionality of the NG Buffer but do not have the floor space or budget to invest in one. With a PLC modification to an unloader immediately downstream from AOI, certain magazine positions can be allocated to NG products, which can be separated from GD (good) products and sent to review. If there are more NG PCBAs than slots, the unloader moves to the next empty rack to avoid human error on separation.
In conclusion, as boards become more complex, the inspection process’s accuracy and automation become increasingly important to ensure electronic components’ longevity. The limitations of optical inspection systems cannot be overlooked, as they can cause false calls and escapes. 3D AOI systems are the answer, but it is crucial to look for systems that combine technologies with superior hardware to provide true 3D optical inspection solutions and help guarantee that the inspection process is faultless. By optimising post-AOI automation, manufacturers can increase their profitability while ensuring high-quality electronic components.
