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2005 Product Review
December 31, 1969 |Estimated reading time: 9 minutes
ASSEMBLY TOOLS & EQUIPMENTProcess Development Tool
A profiler and process development tool designed to optimize the lead-free thermal process is available. The SlimKIC 2000-LF kit incorporates 9-12 thermocouples and has real-time and datalogging operations. The system features a stainless-steel thermal shield and thermocouples rated to handle higher reflow temperatures. The kit also features Navigator and Auto-Focus to ease the lead-free reflow process setup. KIC, San Diego, Calif.
PCB Handling System
The Model 80 Karry-All system can store and transport up to 450 circuit boards in less than 6 sq. ft. of floor space, making it suitable for active manufacturing environments. The system consists of a vertical transport cart with side wire-slide assemblies. The cart measures 72" high and comes in three widths, depending on rack size. Carts feature 5"-diameter polyurethane casters and a grounding chain for ESD protection. Constructed of two conductive, injection-molded side panels with reinforced ribbing to prevent flexing, the panels also have 75 slots measuring 0.110" × 0.155" on a 0.210"-pitch with thumbscrews for adjustment. Fancort Industries Inc., West Caldwell, N.J.
CLEANING MATERIALS & EQUIPMENTStencil Cleaner
The Model 1550 Ultrasonic Stencil Cleaner safely cleans PCBs using low-power-density technology. The cleaners have been rated to 10 W/l or less and are said to clean any type of solder paste from a fine-pitch stencil by combining 440-R SMT Detergent with ultrasonic transducers. SmartSonic, Canoga Park, Calif.
Batch Washer
Using a combination of wash methods focusing solution into smaller areas, the FocusWash features a spray system with a 15°-spray angle to improve flow rate. A spray arm using ten nozzles arranged to create ten concentric spray patterns also is included. An oscillating board rack eliminates blind spots by creating infinite impingement angles. Aqueous Technologies Corp., Rancho Cucamonga, Calif.
COMPONENTSThin Array Plastic Package
A thin array plastic package (TAPP) features high I/O capabilities, single and multiple rows, 0.4-mm thickness for some applications and an exposed die-attach pad for thermal performance. When soldered onto a PCB, the exposed die pad provides a direct thermal path from the chip down to the copper planed on the PCB, which acts as a heat sink. This is said to halve thermal-package resistance. Package designs offer suitable power/ground ring options for high electrical performance. The package is available in lead-free and environmentally friendly options. Because of its process flow and chemically milled processing, the package also offers high yields. ASAT, Inc., Pleasanton, Calif.
CONTRACT SERVICESOutsourced Cleaning Process
The Outsourced Cleaning Process is a contract cleaning service involving all phases of cleaning - from parts washing to water defluxing. With operating facilities in Manchester, N.H., and Nashville, Tenn., the service is capable of either aqueous, semi-aqueous or vapor-phase cleaning technologies. The facilities also offer experienced staff to help customers decide which cleaning process best suits their needs. The service is said to eliminate customer concerns regarding hazardous waste issues or EPA compliance, as well as operating, cleaning maintenance and labor or equipment costs. Kyzen Corp., Nashville, Tenn.
Machine Capability Analysis Testing
Machine Capability Analysis (MCA) testing is a third party, objective evaluation method in which special vision algorithms, accurate glass plates and components are used to measure Cp and Cpk indices on production equipment. Designed to help pick-and-place and equipment manufacturers and users meet the IPC-9850 performance standard. The testing can validate all brands and models of SMT printers and dispensers, as well as placement and semiconductor machines. Software operates the measurement equipment and provides statistical specifications-based results for machine performance. CeTaQ Americas, Hudson, N.H.
DISPENSING EQUIPMENTMicroprocessor-controlled Dispenser
The DX-300 series includes the DX-300, a microprocessor-controlled dispenser with an operating pressure of 0-100 psi for general dispensing applications and the DX-315 with 0-15 psi for specific, low-viscosity fluid applications. Each system provides ten programmable memories to store dispensing cycle timing, facilitating uniform sequence dispensing of bead and dot sizes required in repeatable, high-speed production environments. To control material waste and ensure precise bead and dot sizes, the series offers an adjustable vacuum and post-dispense vacuum. Both systems have a footprint of 9.25" 8.5" 2.5", and include a 100-230 VAC power supply at 50/60 Hz. OK International, Menlo Park, Calif.
Dispensing Unit
The C-Pour reaction injection molding (RIM) gun and metering/tempering unit dispenses flexible or rigid polyurethane into molds or onto parts for filter applications requiring low flow rates. The unit features a mechanical, solventless, self-cleaning, L-type impinge mix gun that circulates two-component chemicals through the impingement rod and back to supply reservoirs. Other features include continuous flow, precision metering pumps with impingement pressures up to 3,000 psi and combined flow rates from 20-60 cc/sec. Flow meters or wet-calibration stations maintain ratio and flow rate. Liquid Control Decker, a business unit of Liquid Control Corp., Palm City, Fla.
ENVIRONMENTAL PROTECTIONRecirculation and Filtration System
The RFS-20 recirculation and filtration system recycles rinse water from stencil and batch cleaners. The system uses a four-stage filtration system to clean and recycle rinse water. A stainless-steel pump draws fluids from the cleaner’s rinse tank into the recycler. A stainless-steel, in-line solder trap and flow sensor protects the pump. The filtration system consists of an in-line solder trap, a 10-mm polypropylene filter that eliminates coarse particulates, an activated carbon powder filter to remove organics and a 5-mm polypropylene filter for fine particulates and organics. JNJ Industries Inc., Franklin, Mass.
HARDWARE/ACCESSORIESLead-free Switches
Elum illuminated pushbutton switches have a 6-mm height and a right-angle actuator with an integral central LED, removing the need for a separate LED, right-angle LED holder or light pipe. The switches mechanical design prevents misalignment; and custom caps or actuator extensions may be added to meet aesthetic requirements. The single-pole, double-throw contact allows for normally closed and open configurations. ITT Industries Cannon, White Plains, N.Y.
SMT Filter
Featuring a footprint of 0.442" × 184" and a thickness of 0.030", the S Band planar, low-pass SMT filter targets RF/microwave circuit designs. Passband reaches 2,500 MHz with passband ripple of 0.01 dB. Second and third harmonic rejection is a minimum of 25 dB and filter VSWR is a 1.1:1 ratio. The filter incorporates five sections with a 50-W I/O. Target applications include WLANs, microwave communication links, radar systems and wireless sensors and controls. International Manufacturing Services, Inc., Portsmouth, R.I.
INSPECTION EQUIPMENTMiniature Imager
The Quadrus MINI mega-pixel imager reads linear bar codes and 2-D codes on boards and components. Measuring 1.8" × 2.10" × 1" and weighing less than 2 oz., its hi-res optics provide a wide scan window for reading code at close range or in tight spaces. The reader can be embedded inside pick-and-place robotic equipment, or mounted at the entrance and exit points of work cells for process verification. Featuring a mega-pixel sensor with an extra-wide field of view and proprietary algorithms, it can read long bar codes omni-directionally, as well as high-density 2-D symbols. Microscan Systems, Inc., Renton, Wash.
X-ray Inspection
The SMT version of the COUGAR-VXP addresses advanced inspection requirements specific to SMT production, such as BGA, microBGA and wafer-level chip scale packages. COUGAR-VXP includes a microfocus X-ray tube up to 160 kV, a standard 5-axes manipulator with Auto Isocentric Motion (AIM) technology for oblique viewing, CNC capabilities, HDX-ray real-time 16-bit image processing, a CMOS digital flat panel detector and a hardware-driven anti-collision system. The system provides feature recognition down to 1 µm with a total magnification of up to 6,000× and True X-ray Intensity (TXI) control for stable, permanent image quality. A small, 1 × 1-m footprint and front- and side-door service access make the system suitable for multiple assembly environments. FEINFOCUS, a COMET business unit, Garbsen, Germany.
MATERIALSLead-free Wave Solder Flux
The 1075-EXR 44 wave solder flux targets lead-free wave soldering of surface mount, mixed-technology and thru-hole electronic assemblies. This water-based, non-flammable flux eliminates special storage requirements and is said to reduce VOC emissions. It provides suitable surface wetting, eliminates cleaning and reduces solder balling for improved solderability on difficult assemblies. The 1075-EXR 44 is also suitable for Sn/Pb assemblies. Indium Corporation of America, Clinton, N.Y.
Conformal Coatings
Conformal coatings with Parylene diX films can be used as a chemical barrier, electrical insulation or to protect against humidity and corrosion. The coatings are biocompatible and offer high levels of elasticity and transparency. Suitable for PCBs, sensors, piezoceramics, medical electronics, probes and elastomers, the coatings feature high flexibility and mechanical properties at low temperatures with no measurable out-gassing. Kishimoto Sangyo (KISKO) GmbH, Duesseldorf, Germany.
PCB/SUBSTRATES/LAMINATESRoHS-compliant PCBs
Two RoHS-compliant PCBs produced using a base material that can withstand higher lead-free process temperatures are available with ENIG or immersion silver surface coatings. The boards feature verification of compliance for all base materials and additive processes, process temperatures UL rated to 206°C and full traceability. All PCBs are packaged according to process requirements and a certificate of compliance is included. Calumet Electronics Corp., Calumet, Mich.
PICK-AND-PLACEPlacement Machine
FLX2010 SMD pick-and-place machine features 190 feeders and allows for feeder changeover during operation. Precision drive technology enables the placement of advanced components, such as 0201 or ultra-fine-pitch 0.3-mm components. An integrated feeder management system recognizes the feeders and pickup height automatically while LEDs show the feeder status. Based on barcode identification, the feeder control system excludes setup failure for correct placement. The FLX2010 can be expanded to a two- or three-module production line. ESSEMTEC U.S.A., Glassboro, N.J.
High-speed Placement Machine
The FX-1R high-speed placement machine uses advanced linear motor technology and a Hi-drive mechanism to place up to 33,000 cph, or 25,000 cph according to IPC 9850 standards. The machine features a dual-head placement system with four nozzles each on a single X-beam design in which two heads alternate picking and placing. The FX-1R is fully compatible with HLC line-control software and can be integrated into existing production lines. Juki Automation Systems, Morrisville, N.C.
SCREEN PRINTINGStencil Printer
AP Excel stencil printer has a minimum base cycle time of six seconds and uses the SpeedMax high-speed package for triple-track staging capability on a single-track transport. Features include a dual-cartridge paste dispenser, Y-axis board snuggers, a Gel-Flex board support system for product changeovers and a Windows NT operating system for remote file storage and data transfer between printer and network. Speedline Technologies, Franklin, Mass.
Printing Machine
The Vectorguard printing system delivers frameless foil advantages and requires no dedicated loading base. Its aluminum extrusions, which are fixed to the four edges of the laser-cut foil and joined by plastic corner pieces, boost rigidity and cover foil edges completely - easing assembly and changeovers. This also allows for safe handling without the need for gloves. Due to increased rigidity, the foils can be cleaned without a washing jig and fully disassemble for recycling. Large 29" × 29" stencils, PumpPrint and electroformed stencils also are available for this printing format. DEK International, Flemington, N.J.
SOFTWAREMachine Control Software
The TPSys 2.4.3 Linux-based machine control software features vision technology and networking capabilities for high-mix production. Version 2.4.3 includes enhanced assembly speed and a patent-pending calibration method, which uses a smaller calibration device moved automatically to several predefined positions within the placement area. An advanced mathematical algorithm combines the measurements from each position and calculates correction data for the area. Other enhancements include faster tool and conveyor board changes, as well as improved board-level measurement and optimization. MYDATA automation AB, Stockholm, Sweden.
SOLDERING EQUIPMENTSpray Fluxer
The TAF40-12F maintenance-free spray fluxer features product memory with optimized spray efficiency. The fluxer is said to eliminate regular maintenance, automatic start and shutdown features and fluxing defects on lead-free wave soldering. Other features include touch panels to promote ease of operation, a range of flux types and a preheater for no-clean flux. A proprietary Edge-Off feature reduces flux residue. Tamura H.A. Systems Inc., Beaverton, Ore.
TEST EQUIPMENTFlying Test Probe System
The multi-faceted MTS500 CONDOR test system features rapid program development, high throughput and the ability to handle large PCBs (up to 24" × 28"). With four identical flying test probes and more than 1,000 fixed pins, the test system also features a SMEMA-compatible conveyor. By riding on a frictionless air-cushion system, the test heads enable nearly maintenance-free X/Y positioning. Digitaltest GmbH, St.-Blankenloch, Germany.