Rapid PCB Assembly

2022-12-01 12:03:27 Rapid PCB Assembly 164 Viewed

Steps for rapid PCB assembly

Rapid PCB assembly  has four steps, namely, gluing, automatic placement of components, welding and inspection. The basic equipment required includes: solder paste printing machine, solder paste inspection (SPI) machine, dispensing machine, taking and releasing machine, reflow welding machine, wave soldering machine, AOI, ICT, FVT.

Rapid PCB assembly, the first step is bonding. The bonding step involves solder paste printing machine, SPI equipment.The first step in rapid PCB assembly is to apply the solder paste to the board. While the solder paste is being processed, the PCB plate and PCB are locked in the automatic solder paste printer and the scraper applies the lead-free solder paste to the pad in precise quantities. SPI equipment should be considered when rapid PCB assembly is producing large volumes to avoid elevated rework costs. Using a camera capable of capturing 3D images, the SPI machine assesses the quality of the solder paste based on factors such as the amount of solder, alignment and height.

The second step of rapid PCB assembly is the automatic placement of components, which involves the dispensing machine, component taking and placing machine and additional equipment. rapid PCB assembly production involves dispensing machines, component taking and placing machines and additional equipment. Before placing the component, the dispenser applies the glue dot to the PCB where the component is located to hold it in place until the pins and contacts of the component are soldered. Component retrieval and placement machines in rapid PCB assembly are more accurate than manual and can work all day. They can be placed exactly at a predetermined position on the top of the solder paste, and the pick and place machine proceeds at a rate of 30,000 components per hour.

The third step of rapid PCB assembly is welding, which involves the reflow welder, wave welding machine and different equipment. The reflow welder is the most widely used welding technology in rapid PCB assembly to form a strong electrical connection between the components and their respective pads. Wave welders in rapid PCB assembly form electrical connections between component leads, or with their respective holes and pads.

The fourth step of rapid PCB assembly is inspection, which involves AOI, ICT, FVT and additional equipment. Testing PCBA is a key step in rapid PCB assembly to avoid costly manufacturing and material waste. Rapid AOI system used in the production process of PCB assembly that can be found as early as possible, and allow the process to modify or to correct a single board. The ICT stage is carried out using a fixture and is one of the recognized methods used for the rapid PCB assembly function to assess its performance and detect PCB electrical continuity or short circuits. rapid PCB assembly's Functional Verification Test (FVT) is the final step that provides a pass or fail decision for the PCB prior to shipment, testing that the board will function correctly in any application.

Best practices for the rapid PCB assembly process

The complexity of PCBA requires independent design and rapid PCB assembly manufacturing experts to produce circuit boards needed for electronic systems, appliances, industrial equipment, vehicles, ships and aerospace platforms. The rapid PCB assembly process, which takes place after the bare board is manufactured, is the welding process that connects the components selected during the design and listed in the bill of Materials to the PCB board, depending on the type and size of the components used. Best practices for the rapid PCB assembly process are as follows :

1. Rapid PCB assembly optimization device selection process

Avoid using external components, which will increase the difficulty and slow down the circuit board manufacturing process. Unless both are necessary, choose one of the THT or SMT devices.

2. Do not overload the network in rapid PCB assembly

An overloaded network in rapid PCB assembly means heavy copper weight on the PCB board, which may require wider wiring and may present clearance challenge issues.

3. Rapid PCB assembly follows the rules of device, wiring and edge clearance

Clearance in the rapid PCB assembly ensures easy soldering and assembly. Insufficient clearance can also cause electromagnetic interference problems, affecting operation and performance.

4. Rapid PCB assembly uses the minimum number of layers in the stack while ensuring sufficient levels

The extra layers increase the height of the board, which not only affects the case design, but also increases the cost of materials for high-volume production orders.

5. DFA and DFM checks are commonly performed in rapid PCB assembly

Avoid all DFM and DFA violations in rapid PCB assembly as greatly as possible, thus frequent inspections are required during design.

6. Consider heat dissipation and distribution in rapid PCB assembly

The rapid PCB assembly welding process depends on the full distribution and dissipation of heat, and it is best to conduct heat dissipation simulations, including power distribution analysis, to ensure that there are no hot spots on the board.

7. Rapid PCB assembly shall ensure that the design is accurate and complete

Whether using traditional Gerber documents or ECAD models, circuit board manufacturing, including the rapid PCB assembly process, depends on the accuracy and completeness of the design, with any special instructions that need to be included.

8. In rapid PCB assembly, it is necessary to ensure that the bill of materials matches the circuit board footprint

The BOM element information in the rapid PCB assembly must match the layout parameters.

9. Work with PCBA manufacturers to ensure that the design intent of rapid PCB assembly is adequately communicated

Establishing transparent communication in rapid PCB assembly is the best way to ensure that design ideas are integrated into the entire board build.

10. Understand the importance of design decisions to the rapid PCB assembly process

In addition to the PCBA manufacturer's understanding of design intent, the engineering designer should also understand how the choice of product affects the rapid PCB assembly process.

Advantages of rapid PCB assembly software automation

Rapid PCB assembly software automation Increases productivity: The software automation solution enables continuous batch production of PCBA with minimal downtime, speeding up discrete processes and increasing manufacturing power on the production line.

Rapid PCB assembly software automation can reduce costs: one of the biggest benefits of using software automation is that it reduces the PCBA manufacturing cost. The introduction of intelligent machinery, robots, artificial intelligence support and additional technical solutions can significantly improve production yield and improve company profits.

Rapid PCB assembly software automates a safe workplace: Deploying robots in hazardous conditions can turn the assembly shop into a safe shop, reducing human risk in harsh conditions and potentially increasing employee productivity.

Rapid automated PCB assembly software can improve the quality, can reduce the rapid failure and damage of PCB assembly, which improves the consistency and quality of the product.

Flexible upgrade: rapid PCB assembly software automation provides the advantage of reprogramming and updating automated processes with changing requirements and feedback.

Rapid automated PCB assembly software allows traceability and data aggregation: the article introduces the software automation in rapid PCB assembly process, can be aggregated workshop of a large amount of data available and is used to make strategic decisions, it also supports the component, naked plate, plate assembly, such as traceability, and to reduce the waste of may.

Rapid PCB assembly Software automation Sustainable monitoring and quick correction: The latest industrial automation includes advanced machinery equipped with advanced sensors, provides continuous data of all operational processes and enables early detection of any possible failure, which can be immediately taken appropriate corrective action, thus reducing commissioning time.

These advantages allow PCBA processes to achieve higher productivity and profits. PCBA service providers add facilities in line with the latest technology trends, choose fixed or flexible automation methods depending on assembly requirements, and the latest technological innovations highlight the importance of software automation in the rapid PCB assembly process.