The PULSE Community Grows Welcome Fuji!

ASYS Group Newsletter 07/2016

PULSE Community

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Industrie 4.0 CommitmentNew EKRA Printer

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ASYS Technology Days09th – 10th November 2016, Dornstadt

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EKRASERIO 4000 Back to Back

15 ASYS GroupSuccess Story Novotechnik & ASYS

CONTENT

ASYS GroupAutonomous Transport Robot

16 DIVISIO DepanelingNew Calibration Method

ASYS Software SolutionsPULSE Community

ASYS TECTONNew Tray Buffer

14 ASYS GroupIndustrie 4.0 Commitment

12 HYCONCompact Wafer Processing Cell

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PULSE CommunityASYS has already created a dense network of partners in the electronics industry with the PULSE software solution. An entire production line can be linked to PULSE. This is only possible because renowned manufacturers collaborate in the PULSE network. Since April 2016, Fuji is now also an official member of the PULSE community.

ASYS’ vision is “really smart” production, self-organized manufacturing with human support in core tasks. With the PULSEONE software solution, ASYS introduces mobile devices and transport robots into the production environment, which makes them a pioneer in the indu-stry. This much dedication in terms of Industry 4.0 was honored with an “Innovation Award” at Productronica 2015.

The range of PULSEONE functions is extensive and there is no end in sight. PULSEONE can be upgraded with new features at any time using apps. A user working with PULSE responds faster and minimizes downtimes. For example, the PULSE smartwatch dis-plays the most important line information in real time to the user. To-do items such as “Refill solder paste” or “Change magazine in 10 minutes” are organized by prio-rity. Plainly speaking, this means: The most important task is always shown first, and you can see how much time is still left until a task must be completed. Thus,

PULSE offers a clear to-do list directly on the wrist. In-coming messages are announced via vibration alarm. The user does not need to look at the smartwatch all the time. He can complete his tasks and has both hands fully available.

PULSE is a leading solution for networking machines and supporting production systems. ASYS is working on partnership concepts that make the technology even more interesting for the customer. It should be possible to operate equipment made by different manufacturers with one software only. Since April 2016, Fuji is now an official member of the PULSE community. The PULSE network continues to grow. Become a member of PULSEONE now and optimize your production to a smart factory.

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PULSEONE Membership

Back to BackThe SERIO 4000 Back to Back printing system is pointing the way, when there is a demand for floor-space. Due to its small footprint and smart design, the printer can be used in production in a very space- saving manner, having achieved the utmost of space-utilisation.

The high-volume production demands of the consumer electronics manufacturing market, require smart, powerful and cost effective solutions. EKRA can support these demands with the SERIO 4000 Back to Back. The printer is especially designed for small to mid-sized, high-running PCBs. Designed for SMT-environments that require, optimized room-utilization and high-end through-put, this printer can be configured as a single, dual or multi-lane solution.

As additional advantage, two printing systems can be installed „back-to-back“ and work individually. This not only ensures a flexible and space-saving layout design, but also a significantly higher throughput rate.

Expandable at any timeThe stencil printer is based on the SERIO 4000 system platform that stands for impressive scalability. Using several selected options, the SERIO 4000 Back to Back can be tailored to individual needs. Additional features can be added either directly during initial configuration or later on in the field. For example, the stencil printer can be extended significantly with respect to precision. With a printing repeatability of ± 20µm@6Sigma (optional), it is unique in its class.

Two printing systems can be installed „back-to-back“ and work individually.

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Small Batch SizesASYS TECTON, tray handling specialist and subsidiary of the ASYS Group, presents a new tray logistics system at SMT 2016. The PARIO 1000 flex features different trays for diffe-rent products that can be buffered and outputted individually as needed. Thus, small batch sizes, including a batch size of one, can be implemented fully automatically with minimum setup effort.

The palletizing system PARIO 1000 flex can be connec-ted to any process system at any time, such as a milling cutter or laser. Different trays for different products can then be outputted separately as needed. Storage within the PARIO follows the chaotic storage principle. In other words, the palletizer can enter carriers into storage, wherever space is available. As a result, the space can be used optimally and fast storage withdrawal and tray exchange times can be implemented ideally. If a down-stream process system requests a certain carrier, it can be outputted via a lift system within the palletizer. Alter-natively, the entire buffer can be loaded and unloaded via a separate access.

Traceable traysPARIO 1000 flex saves tray type and position during sto-rage. Data saving and reading combined with tray detec-tion enable traceability.

Compact and space-saving Based on the separation of production and operation area, independent and flexible loading and unloading is possible throughout the production process. At the same time, the system features a compact and space-saving design and can be easily integrated in existing lines or new line plannings.

New tray logistics system PARIO 1000 flex

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Autonomous transport robot supplies the line continuously with material.

Autonomous HelperFor flexible and adaptable production in the future, ASYS uses autonomous transport robots in production already today. Connected to the ASYS PULSE software solution, a robot (PULSE UNITR) continuously supplies material to the produc-tion line.

The intelligent automation of the material flow in SMT production represents a major step towards Industry 4.0. Autonomous helpers ensure an even faster and more reliable material supply and minimize machine downtimes significantly. First customer evaluations show that machine stops could be reduced by up to 70 % thanks to PULSE. With the autonomous PULSE UNITR transport robot, ASYS realizes an independently navigating solution in production that substantially con-tributes to productivity.

Universally applicableThe transport robot supplies the line continuously with material. For example, it picks up full magazines, fee-ders, or trays and supplies them to the line. Different transport modules can be exchanged fully automatically.

This saves time and effort. Thus, the UNITR can comple-te different tasks in production.

Safety concept – Drive SafeThe autonomous PULSE UNITR transport robot is ideally suited for deployment in complex environments. It fea-tures a clever “Drive Safe” safety concept. This concept ensures driverless and anticipatory driving. Using inte-grated safety sensors, the UNITR detects obstacles ear-ly on, stops depending on the situation, moves around objects, or automatically adjusts its speed. Prior teaching of the robot to the work environment ensures safe colla-boration between man and machine.

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Without any StressUsing the new, compact wafer processing cell XW made by EKRA, front- and backside prints (bumping and wafer backside coating) can be realized on round wafers without stress. Even very thin or curved wafers can be printed optimally.

Due to the small material thickness, thin wafers tend to break and bend quickly, when they are transported, mechanically secured, or printed. To avoid this, the wafer should be transported using an area gripper.

EKRA uses here a special, fully automated robot system with vacuum gripper (end effectors). This system trans-ports the wafers from the magazine into the printer without exposing them to any mechanical stress.

Cell componentsThe machining cell consists of a loading unit and a printing system. The loading unit comprises a magazine feed, a robot unit, a pre-align station, and a removal station. A particular benefit here is that the magazine feed can be equipped with up to two magazine locations. This enables a magazine change without having to stop the system.

Stress-free process flowUsing a flexible mounting on the robot unit, different grippers (end effectors) can be used even for very thin or curved wafers. After taking a substrate from the magazine, it is pre-positioned in the integrated pre-align station via flat or notch recognition for subsequent printing. The robot then places the wafer on vacuum pins at the print nest. No stress occurs during this process either.

It should be highlighted that the print nest is a universal print nest that can be individually adjusted to different wafer sizes. Next, they are lowered and the wafer is secured on the print table using vacuum.

Expandable at any timePrinted wafers can be removed individually from the machining cell using a drawer system. Subsequent process steps, such as heat treatment, can optionally be integrated in or on the loading cell. Connection of the wafer machining cell to customer-specific MES systems is also possible as an option.

Wafer in print position

XW wafer machining cell

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Secretary of State Peter Hofelich (right) presents Werner Kreibl (left) with the award.

CommitmentASYS was honored as one of the „100 Places for Industry 4.0 in Baden-Wuerttemberg.“ As such, ASYS belongs to the most innovative companies that generate groundbreaking impulses for production of the future.

The competition initiated by the “Allianz Industrie 4.0 Baden-Württemberg“ was looking for exemplary and practical solutions from the economic sector. Compa-nies successful in intelligent networking of production and value-creation processes were eligible to partici-pate. That‘s because the expert jury also evaluated the specific practical relevancy in addition to the degree

of innovation. Werner Kreibl, Managing Director of the ASYS Group, is thrilled about the award: “This confirms our product and development strategy of the past years in an impressive manner. Industry 4.0 within electronics production is a commitment for us to set standards for our customers in the international arena and to remain competitive.”

ASYS wins new customer in the sensor field

The electronics manufacturer produces sensors for the machinery and automotive industries, which are used, for example, in cars as accelerator pedal or throttle sen-sors. With the new production line, thick film resistors are printed in the screen printing process on FR4 or other substrate materials. A challenge is that the accura-cy, layer thickness and reproducibility must remain con-stant.

Networking of systems and softwareThe focus of the sophisticated line concept was on fully automatic linking of a plasma activation system, a screen printing system and two continuous ovens for burning in the paste. Particularly noteworthy is the lin-king of all process steps by using the line control soft-ware OIC (Overall Inline Communication). “The chan-geover to different products is managed centrally through a central control computer thanks to fully auto-matic interconnection.

All stations in the line consistently adjust to the parame-ters stored in the product recipe. This allows us to re-duce the setup time significantly,” describes Markus

Novotechnik has invested in a sophisticated ASYS production line that primarily applies a uniform layer of resistor paste. Its design is particularly space-saving and arranged in a U-shape.

Rösch, project manager at Novotechnik. Since the end of 2015, the OIC components have been an integral part of the PULSEONE software product portfolio.

Screen printer was the decisive criterionDue to the high quality demands, the production pro-cess requires precise layer thicknesses of +/- 4 µm. Against this background, the decision was made for the high end screen and stencil printer X5 Professional from EKRA. “Our premium printing system was, so to speak, the door opener for joint cooperation. It allows applying uniform layer thicknesses with extre-mely small tolerances perfectly and reproducibly,” says Sebastian Eise, sales manager at ASYS.

Convinced by long-time project experienceASYS could convince Novotechnik and win it as a new customer thanks to its wide product range and long-time process know-how in the area of special solutions. But also many years of project experience as a comple-te provider of interconnected standard solutions, high-performance production systems and software soluti-ons were essential for the joint cooperation.

Michael Limmer and Markus Rösch in front of the screen printing system X5 Professional (left to right)

Fully automatic interconnected screen-printing line in a space-saving layout

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Success Story

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Step-by-stepASYS developed a new calibration method for high-speed panel separation systems of the DIVISIO division. Thanks to this method, a perfect depaneling result can be realized. The calibration can be performed by the user in less than ten mi-nutes.

Process systems must be calibrated from time to time to compensate for mechanical influencing factors and fluctuations and to ensure consistently high quality stan-dards.

Thanks to the award-winning SIMPLEX user interface, the user is guided through the calibration process in simple steps. As a result, the method can be applied easily and quickly by any operator at any time without additional training effort.

Step-by-step calibration The panel separation system passes through the com-plete alignment process in only four steps. The camera,

Calibration plate in the DIVISIO panel separation system

milling and handling axes are newly aligned. A so-called mapping method is used with the help of a calibration plate on which a special drilling pattern is applied.In the first step, the camera is calibrated and aligned to the defined zero point in the work area. Next, the came-ra approaches the measuring points and calculates the required correction values.

The panel separation system corrects the milling cutter axis using the previous values. Finally the handling axis is positioned to ensure that all axes are aligned to the machine zero point. This entire calibration process is completed in less than ten minutes.

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This calibration process is com-pleted in less than ten minutes.

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Publisher: ASYS GmbH, Benzstraße 10, 89160 Dornstadt, GermanyEditor: Belma Gül, Pamela Kurz, Julia Kölle, Johanna Boos, Katinka Eberl, Responsible for content: Karin Walter

Sitz der Gesellschaft: Dornstadt, Deutschland; Geschäftsführer: Werner Kreibl, Klaus MangSubject to change without notice. All information provided is only general in nature and features may in a specific case not always match the described details or could be changed through further developments. Binding are solely the agreed upon contractual specifications. Note: This e-mail and any attachment are confidential and may contain trade secrets and may well also be legally privileged or otherwise protected from disclosure. If you have received it in error, you are on notice of its status. Please notify us immediately by reply e-mail and then delete this e-mail and any attachment from your system. If you are not the intended recipient please understand that you must not copy this e-mail or any attachment or disclose the contents to any other person. Thank you for your cooperation.

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