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An automatic pick and place machine, also known as Pick & Place Machine (PNP), is a vital component of automated assembly lines. These machines are used to position components on a printed circuit board (PCB) for assembly. In the context of PCB assembly, pick and place refers to a robotic technique where an SMD is picked up and placed accurately on a circuit board. This technique is completed with the help of sensors, cameras, and software. There are primarily two main categories of automatic pick-and-place machines: gantry systems and cobot systems.
Gantry pick and Place systems:
The gantry pick and place machines use the gantry robot system architecture for movement. In comparison to traditional articulated arm robots, gantry robots have a fixed axis with moving carts. Generally, these kind of automatic pick and place machines are automated systems with high RPA implementation and are often seen in business process automation. The advantages of gantry pick and place systems is usually high speed, high accuracy, and heavy load capacity. They are well-suited for high-speed assembly tasks where thousands of PCBs need to be populated in a single hour. Moreover, gantry pick and place systems often cost-effective solutions for high-volume production.
Cobot pick and place systems:
Compared to their gantry counterparts, cobot pick and place machines are more flexible but also a little slower. Cobots are collaborative robots, and they are designed to work alongside humans, so they are also known as collaborative robots. Cobot pick and place systems offer flexibility to easily accommodate product changes and reconfigurations. In addition to this, they can work safely beside human operators without the need for safety cages or barriers. This makes cobot pick and place systems well-suited for small to medium-scale production runs, assembly tasks requiring human-robot collaboration, and environments with frequent product changeovers.
Speed and Efficiency:
Automatic pick and place devices have varying speeds, typically measured in parts per minute (PPM). PPM depends on factors like machine type, complexity of parts, precision required, and efficiency. The efficiency of automatic pick and place machines varies by model and design. It is often influenced by line efficiency, which considers downtimes, routine maintenance, and system inefficiencies. With a focus on efficiency, a pick and place machine can achieve up to 90% line efficiency.
Payload and Dimensions:
Payload capacity tells how heavy an object a pick and place machine can handle. This capacity depends on the machine type, whether it's a robot, gantry, or other design. A pick and place robot, for instance, may have a maximum payload capacity of 10 kilograms. The dimensions of a pick and place device, its length, breadth, and height, will depend on the model and design. A small pick and place machine can be as small as a few centimeters, while larger ones are many meters long.
Control Systems
Gantry pick and place devices use control systems like servo motors or stepper motors. These motor systems have a driver and controller that move the gantry’s beam, aligning it with the target object. Gantry systems may have open or closed loop control. In open loop, the controller sends signals without getting feedback. Closed loop does otherwise and uses feedback to adjust movements. As for the programmed tasks, operators can use preset programs in the controllers or custom ones for specific needs.
An automatic pick and place device is better with regular maintenance. Doing this will help ensure the machine works well and stays dependable and accurate. Operators can follow a few simple maintenance steps for longevity.
Regular Inspection:
Operators can routinely check the pick and place machine for signs of wear, damage, or loosened parts. Be on the lookout and promptly address any issues noticed.
Lubrication:
The moving parts need to be appropriately oiled and serviced from time to time. Pick and place devices can work smoothly, avoid excessive wear and tear, and lower their risk of breakdown.
Calibration:
A pick and place machine can be routinely checked against known standards to ensure it remains precise and accurate. Any deviation from standards found can be corrected to restore its precision. Routine calibration enhances reliability and boosts overall performance.
The automatic pick and place devices have a very wide range of applications in diverse sectors. These machines are capable of carrying out high-speed product assembly, making them critical components in many manufacturing lines.
Electronics industry:
Automated pick-and-place machines are extensively used in the electronics industry. For example, they place surface-mounted devices (SMDs) on printed circuit boards (PCBs) during PCB assembly. Components like resistors, capacitors, microcontrollers, integrated circuits, etc., all make use of these machines to increase production efficiency and speed. Also, because they are able to position tiny components precisely on complex boards, they help improve manufacturing quality.
Food and beverage industry:
In the food and beverage industry, automatic pick-and-place machines can be used for picking and placing bakery products, fruits, vegetables, and other food items. They can also be used to place bottles, cans, and cartons in packing boxes on assembly lines. Using such machines ensures that food products are handled hygienically and reduces the risk of contamination.
Medical industry:
Pick-and-place machines are also employed in the medical industry. They can be used to pick and place medical instruments, syringes, vials, and other medical devices. These machines eliminate human contact and reduce the risk of contamination when handling sensitive medical devices or samples. They also increase productivity and efficiency in medical device manufacturing by streamlining the assembly process.
Packaging industry:
In the packaging industry, automatic pick-and-place machines can be used for picking and placing products in packaging. For instance, they can pick and place bottles, jars, and containers in boxes or on pallets. These machines integrate seamlessly with robotic arms and conveyor systems to increase packing efficiency.
Automotive industry:
In the automotive industry, automated pick-and-place machines are often used for assembling parts of various vehicles. For instance, they are used to pick and place headlights, taillights, dashboards, and other automotive components. Their use reduces assembly time and increases production efficiency in automotive manufacturing.
Textile industry:
In the textile industry, pick-and-place machines can be used for picking and placing fabrics, garments, and other textile products. Once again, the automation improves productivity and efficiency by streamlining the production process and reducing manual handling.
Construction industry:
In the construction industry, the pick-and-place robots can be used to handle construction materials such as bricks, tiles, and lumber. They can also be used to assemble prefabricated structures and modular components.
When choosing a suitable automatic pick and place machine for a business, it is crucial to consider the following factors:
Production needs analysis
It is very important to choose an automatic pick and place machine that matches the production scale and requirements by analyzing factors such as the production volume, types of products, and alignment needs. These factors will help determine the placement speed, accuracy, load capacity, and flexibility of the machine.
Pick Place Machine Types
Consider the most suitable type of pick-and-place machine for the business from among the various options. Based on the production line setup, some may choose gantry-based machines for their affordability and reliability, while others may go for delta robots for their faster speeds and greater flexibility.
Technical specifications
When choosing an automatic pick and place machine, it is vital to pay attention to its technical specifications to ensure they are optimized for business operations. Consider the speed of the machine, which is usually measured in cycles per minute (CPM) or picks per minute (PPM). This is important because choosing a machine with an appropriate speed can help meet production deadlines. In addition, accuracy is also an important factor to consider. Selecting an automatic pick and Place device with a high-level placement accuracy can reduce product defects and increase customer satisfaction. The load capacity of the machine should also be considered to ensure that it can handle the weight and size of business-related products.
Flexible product and fixture change
Consider whether the automatic pick and place machine is suitable for handling multiple products and moudule changes. Some may choose machines that support vision systems for better adaptability, while others may prefer those with dedicated fixtures for higher cost-effectiveness.
Integration and scalability
This includes determining whether the selected machine can be integrated into existing production lines and automated systems. In addition, it is also essential to ensure that the equipment will allow future scalability and flexibility to meet the changing business needs.
Cost analysis and budget considerations
Analysis of equipment costs in conjunction with performance and features will help ensure a wise investment. This may include determining the total cost of ownership (TCO), which encompasses not only the initial purchase price but also ongoing operating and maintenance expenses. At the same time, it is essential to ensure that the pick and place machine aligns with the budget and explores potential financing options or collaborations.
Supplier assessment
Business owners must choose a reputable supplier with strong after-sales support, warranty services, and a proven track record of successful case studies. Additionally, it is suggested to read user reviews and compare different suppliers to help understand their credibility and customer satisfaction.
Q: What components does a pick and place machine have?
A: The pick and place machine comprises these main components: placement head, vision system, feeder system, conveyor system, and control software. Upgradable components may include the speed, accuracy, and product compatibility.
Q: Which products utilize pick and place automation?
A: Many industries use pick and place automation. The food processing industry uses it to package snacks, bakery products, and dairy products. The electronics industry utilizes pick and place machines to assemble circuit boards, place components like resistors, capacitors, chips, and connectors, and for other electronic manufacturing applications.
Q: How does item orientation work in a pick and place machine?
A: When an item needs to be placed in a specific orientation, the control system will program the robot's path and the precise motion needed to rotate the item. The machine will then pick the item, rotate it to the desired orientation, and place it in the right location.
Q: How do users upgrade the automation level of a pick and place machine?
A: To increase the automation level of a pick and place machine, connect it to a conveyor belt or sorting system. Another method is to install an advanced vision system that can identify and locate items with high accuracy. Increasing the automation level also requires upgrading the control software to handle more complex tasks and integrating it with other automated systems to create a fully automated workflow.
