INTERNSHIP REPORT 2022-2023

Continuous Internal Evaluation- CIE - III

Assessment of On Job Training (OJT)-2 + use case

INTRODUCTION OF 9TH TO 12TH WEEK

I will make it clear that the subjects I have learned may be technical
subjects which I understand fairly well. I have learned that name of the PCB Board
Pick and Place Machine Automation / Robotic Process.

1. SURFACE MOUNTING TECHNOLOGY (SMT).

2. SMT ASSEMBLY PROCESS.
3. PICK & PLACE MACHINE WORKING & OPERATION.
4. PICK AND PLACE MACHINE PROCEDURE.

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3.1 SURFACE MOUNTING TECHNOLOGY (SMT)

SMT is an electronics technology which mounts components on the surface of

PCBs instead of inserting them through the holes. All the mass-produced electronics
these days use SMT to increase performance and reliability, and to reduce production
costs. The following figure shows the SMT:

Fig: 3.1 SMT

Fig: 3.2 SMT Machine

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3.2 SMT ASSEMBLY PROCES

2.1 SMT Assembly Process

The following figure shows the steps of SMT assembly process:

Fig: 3.3 SMT assembly process

2.1 Solder Paste Stencilling

The first step of PCB assembly is applying a solder paste to the board. In this
process a thin, stainless-steel stencil is placed over the PCB. The assemblers then apply
solder paste only to those parts of the would-be PCB where components will sit in the
finished PCB. The following figure shows the composition of a solder:

Fig: 3.4 Composition of solder

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3.3 PICK & PLACE MACHINE WORKING & OPERATION.

3.1 Introduction to Pick and Place Machine

Pick and place machines are basically robotic machines that place surface-
mount devices (SMDs) onto a PCB. Also, known as SMT component placement systems,
these machines are used for precision positioning of electronic components like
integrated circuits, resistors, capacitors or ICs on PCBs. Traditionally, this was a manual
process where the assemblers picked and placed the components by hand with the help
of a pair of tweezers. Nowadays, it is an automated process. Further, in case of humans,
working with such small components leads to fatigue and eyestrain after a few hours.
Machines work around the clock without such fatigue. Pick and place machines are
essentially used in consumer electronics, computers and also in industrial,
telecommunication, automotive and military equipment. The following image shows a
pick and place machine for a PCB assembly:

Fig: 3.5 A pick and place machine for PCB assembly

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3.2 Parts of a Pick and Place Machine

Fig: 3.6 Pick and Place Machine

After applying the solder paste to the PCB board, the PCBA process moves on
to the pick and place machine. It is a robotic device that sets the surface mount
devices (SMDs) on a prepared PCB. The following image shows a pick and place
machine:

WORKING:

A pick and place machine are a robotic style machine that places different types of
components onto the PCB. It includes features such as: component pickup feeder
locations, vacuum pickup, vision system, automatic component realignment, repeatable
placement accuracy, and transportation system for PCBs. The pick and place machine
are very important part of the PCBA process as it places the components reliably and
accurately to meet throughput requirements.

OPERATION:
Since a pick and place machine is accurate to the millimetre in placing electronic
components onto a PCB, therefore, it is used in mass manufacturing of PCBs. It
eliminates the need to manually place the components and solder them onto the board;
hence, reducing time and labour requirement. Pick and place machine is a robotic
assembly device that requires specialized skill for operating; so, there are certain things
that need to be kept in mind. The following image shows a pick and place machine
operating on a PCB:

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3.3PICK AND PLACE MACHINE PROCEDURE

1.0 PURPOSE

This work instruction describes basic flow in pick and place machine.

2.0 SCOPE

PCB after Screen Printing.

3.0 EQUIPMENTS/ACCESSORIES RREQUIRE

Pick and Place Machine.

4.0 SAFETY INSTRUCTIONS

4.1 Observe the safety precautions displayed on the machine.

4.2 Ensure that respective program is loaded in the machine
4.3 Only trained operator should operate the machine.
4.4 Ensure the PCB is loaded in the correct direction.

5.0 CONTROL PARAMTERS

5.1 Ensure part no./ part code on spool before loading.

5.2 Ensure fallen components are cleaned in the machine before starting process
5.3 Ensure recycle bin is clean before start of process
5.4 Ensure correct selection of nozzle to avoid component missing
5.5 Ensure correct nozzle pressure to avoid component missing.
5.6 Ensure verification loading with respect to loading / reloading chart and program by
QA (Quality Assurance) before tart to avoid wrong value.

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6.0 INSTRUCTIONS

6.1 Ensure cleanliness of the pick & place machine.

6.2 Verify whether the Layout Program is available in the Machine.
6.3 Verify whether the PCB is programmed or not as per the current BOB (Bill of
Materials). If the PCB is not programmed, then follow the programming instructions in
the machine.
6.4 Manual for the respective PCB as per the BOM (Bill of Materials). Now the program
for that particular PCB is ready.
6.4 Load the components in the correct feeders after getting issue from stores.
Ensure that the components are loaded as per the program.
6.5 Switch on the machine.
6.6 Load the screen-printed PCB on the machine.
6.7 Run one board and ensure placement accuracy by visual inspection, and get
clearance from the QC.
6.8 If it is not OK, then verify the programming accuracy.
6.9 Again get clearance from the QC.
6.10 Confirm the accuracy by assembling five boards.
6.11 Complete the entire batch of the PCB.
6.12 Send the PCB for Reflow soldering.

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1. Feeder

The feeder is used to supply the components to the movable pick-up mechanism. It
also moves the components to a fixed location and aids the pickup head in removing
components. The following image shows a feeder:

Fig: 3.7 A Feeder

The following figure shows different types of feeders:

Tape and Reel Feeder LED SMT Feeder

Fig: 3.8 Different types of Feeders

2. Vacuum Nozzle and Grippers

Vacuum nozzles are commonly used for handling all the components during the
placement operations. Since the force depends on the cross-sectional area of the nozzle
bore, different sizes of nozzles are used for different parts. For handling small
components, positive pressure is supplied in addition to vacuum at the moment of
placement. A camera is used to check the position and orientation of the component on
the nozzle.

The following image shows some typical vacuum nozzles:

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Fig: 3.9 Some typical vacuum nozzles

3. Setting up Tools for Machine Operation

3.1 Routing Reels and Tape Via the Feeders

Proper care should be taken when routing the tape via the component feeder.
Setting up tools for machine operations is important to avoid any time or material
wastage.

Fig: 3.10 Getting the feeder ready for operation by adding tape and reel to it

3.2 Reel Rack

The following image shows a reel rack which is used to hold the reels:

Fig: 3.11 Reel rack of a pick and place machine

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3.3 Loading/Reloading

Loading of components into the feeder is a very important stage of PCB assembly.
Therefore, it needs to be done with utmost caution. The following figure lists the steps
for loading the components into the feeder:

Fig:3.12 Steps for loading the components into the feeder

When loading components, it is important to keep in mind that:

1. There should be just the specified gap between two PCBs for accurate placement of
electronic components.

2. Once everything is ensured, no further movement or alteration should be done.

Similarly, reloading of components for the next batch needs to be taken forward
following the same guidelines. The following image shows components loaded on the
feeder tape:

Fig: 3.13 Components on feeder tape

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3.4 Adjustments/Configurations

The configuration and adjustment of values according to the planned design of

a PCB is important for smooth manufacturing of circuit boards in a facility. For this, a
pick and place machine have to be fed with the right values in the programming
software and correspondingly the correct components in the reel. The following image
shows the placement head of a pick and place machine on the PCB:

Fig: 3.14 Placement head of a pick and place machine on the PCB

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THE CASE STUDY – 02

1.1 PICK & MACHINE THE CASE STUDY

The Pick & Machine Common Programming Error &Troubleshooting.

Common Programming Error List:

1. The PCB positioning error:

2. The component-picking error
3. The component recognition failure:

1. The PCB positioning error:

❖ The error always appears when the detection sensor cannot find the locating
pin in the PCB location hole.
❖ The solution is adjusting the position of locating pin according to the PCB,
checking and adjusting the top and bottom positions of these two-hole
detection sensors,
❖ Furthermore, also inspecting the conveyor function to make sure the PCB can
stop at the correct position.

2. The component-picking error:

❖ Why this problem happens is always because of the wrong picking position,
incorrect component picking height, improper component pick parameter,
and the wrong feeder as well as nozzle setting.

3. The component recognition failure:

❖ This problem is usually caused by the wrong definition of component vision

parameters and outside sizes.
❖ Moreover, if the laser scanning part of the CCD camera lens. With the dust
also can result in the recognition failure.
❖ At this time, the operator should revise the component vision parameter or
contour size, and clear the laser scanning part or CCD camera lens.

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