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Heller Industries 1911MK5-VR Nitrogen Vacuum reflow oven comprises 11 zones, a vacuum chamber, closed-loop nitrogen atmosphere control and Heller’s award-winning COOL-PIPE flux management system.
Of the oven’s 11 zones, ten deliver convection heating with one infra-red (IR) zone located strategically inside the oven’s vacuum chamber. This delivers proven advantages in void-less solder paste reflow processing, leading to long-term solder joint reliability.
The 1911MK5-VR delivers on ambitious performance metrics to help manufacturers streamline SMT assembly. It targets voiding ratios of less than 2% and cycle times of 40 seconds for single-lane implementation and 20 seconds for dual-lane systems. It maintains Heller’s solder paste reflow specification, including liquidous times of under 60 seconds. In addition, the oven is suitable for high temperature applications up to 450°C.
Flux Free within the vacuum chamber. In-zone IR Heating prevents flux residues precipitating within the vacuum chamber routine lubrication PM every 4 months.
Advantages and unique features
10 convection heating zones (top & bottom)
Replicate standard thermal profiles
1 IR heating zone (Top)
Single lane EHC
Active heating through the vacuum phase
3 cooling zones
Cycle times of 40 seconds
< 1% Void Rate – Heller vacuum reflow ovens provide best-in-class performance for removing voids in solder joints and interfaces.
No Solder or Flux Splatter – Heller vacuum pumps offer closed-loop control for a controlled multi-step pump down and re-fill. This prevents yield-killing solder and flux splatter that can occur with single stage, open-loop vacuum systems.
Heated Vacuum Chamber – Heaters allow for peak temperature to be reached inside the vacuum chamber for more process flexibility. High chamber temperatures ensure for no flux buildup inside the chamber.
Low Maintenance for Low Operating Costs – Advanced flux management systems allow for less periodic maintenance and fewer required consumables.
No Shifting Parts – Heller’s smooth-travel conveyor system ensures that components are not shifted or moved during travel throughout the oven. Boards on conveyor experience minimal vibration during travel – including entering and exiting the vacuum chamber.
Highest UPH – Heller vacuum reflow offers an optional dual rail conveyor, for the fastest throughput.
Leadership and Experience – With over 5 years’ experience in vacuum reflow, Heller Industries is recognized as a leading supplier of vacuum reflow technology.
Other Heller vacuum reflow models available;
Heller 1808MK5-VR (8 Heating Zones with a 2.6m Heated Length)
Heller 1808MK5-VHT (High Temperature 450°C)
Heller 2043MK5-VR (11 Heating Zones with a 4.3m Heated Length)
Heller 2156MK5-VR (15 Heating Zones with a 5.6m Heated Length)
This Vacuum Reflow Oven will be displayed during; Heller / Europlacer Stand SMT-Nuremberg Exhibition Hall 4, Stand 4-259
LPKF´s brand-new Tensor technology overcomes limitations in laser beam delivery
With this technology the cutting speed can be up to four times faster compared to standard systems. The cutting quality and productivity, even of thicker PCB materials, are significantly higher with Tensor technology.
Why depaneling with a laser is the most efficient solution
For years now, there have been rumors going around in the electronics industry that laser depaneling is very costly. This may have been true for investments in laser machines ten or more years ago – but when considering the operating expenses, especially with newer systems, the situation looks quite different today. In the end, depaneling with laser systems has become by far the most efficient method for a wide range of applications and the cutting results are excellent, which means that the highest quality standards are also met.
The trend in the price-to-performance ratio for current laser systems, especially with respect to production of rigid PCBs, is quite obvious: The cost of depaneling based on the effective cutting speed has fallen to approximately one tenth of what it was a decade ago. (Fig. 1)
There are two main drivers for this phenomenon: on one hand material costs are much lower today than they were a few years ago, and on the other hand, the performance of laser systems has improved dramatically due to integration of more powerful lasers and the more advanced process know-how developed by leading laser machine manufacturers such as LPKF.
Material Savings and Fewer Upstream Processes
With the use of modern laser systems such as LPKF’s CuttingMaster 3000, savings in terms of PCB material of more than 30% on average can be achieved. This is made possible by utilizing a full-perimeter cut through the panels with the laser, rather than cutting tabs of pre-routed boards. With a full-perimeter cut, PCBs can be spaced very closely together for minimal material loss; taking full advantage of the narrow kerf width of a laser tool which is typically around 0.15 mm vs. a 1-2 mm router bit. This eliminated the space that is otherwise occupied by pre-routing lanes around each PCB on the panel. Another advantage is the variable and exact laser guidance and the narrowest possible cut to accommodate even the most intricate geometries, ensuring optimum material utilization. Through these factors, laser systems can realize even greater savings potential, especially for smaller-sized PCBs. In addition, the costs of upstream process steps are reduced, and users also profit from indirect savings because of the higher number of PCBs per panel: The handling time for the individual PCB is reduced and human errors caused by manual handling are minimized.
Low Operating Expenses, Minimal Downtime
In addition, unlike with milling machines, there are no significant operating expenses. Background: The laser as a tool has no mechanical wear and the quality of the laser is constant. There is no need for regular replacement of saw blades or router bits also eliminating the unproductive downtime and cost to replace such tools. Preventive maintenance work can be done at longer and planned intervals because the replacement of machine wear parts is done during regular preventive maintenance deployments. Through this, the downtime can be reduced to a minimum.
Error Minimization and Quality Improvement
For high volumes, laser machines integrated into production lines are often advantageous. (Fig. 2) Extensive automation often reduces manual errors. By using a laser for PCB depaneling operations, both dust and stress to the PCB are eliminated, drastically improving production yield. Unlike traditional mechanical depaneling methods, laser depaneling machines, do not generate milling dust which can become airborne and cause quality issues anywhere in the plant, as well as cause health problems for employees exposed to these airborne particulates. Lasers also don’t create the mechanical stresses that are imparted when using a dicing saw or router, which could jeopardize the functionality of sensitive components on the circuit board or even compromise the integrity of the board itself. PCB manufacturers achieve a higher quality and a better yield if laser depaneling system are being used. These two factors together provide a significant advantage, which traditional depaneling technologies cannot equally provide.
Even if it seems at first that the energy use for depaneling was negligible for many production facilities, this factor is nowadays often considered more carefully. Over the years, the performance of the laser has risen considerably while their overall power consumption in relation has dropped significantly. This translates into a sixfold increase in overall energy efficiency – a remarkable factor that can currently only be achieved by laser technology. (Fig. 3)
When considering the above-mentioned aspects in terms of the cost-effectiveness of laser systems for depaneling of rigid and flexible PCBs, modern laser machines are the tools of choice, especially for high throughput applications. These systems save on material costs, handling efforts, and improved production quality which equates to higher yield. The return on this investment is easy math.
Atlanta, GA – Koh Young, the industry leader in True3D™ measurement-based inspection solutions, proudly announced it joined the IPC-DPMX (IPC-2581) Consortium to advance the adoption of a data and transfer methodology, which will improve efficiency and reduce costs for electronicsmanufacturers. Combining IPC-DPMX (IPC-2581) with IPC-CFX will help deliver engineering data directly to machines to streamline the process andenable smart factory automation.
IPC-DPMX is a generic standard for printed circuit board and assembly manufacturing description data and transfer methodology. Developed in 2004 by IPC, IPC-DPMX is used for transmitting information between a printed circuit board designer and a manufacturing or assembly facility. For nearly every step in the industrial process flow, IPC-DPMX offers a standard to help companies ensure superior manufacturability, quality, reliability, and consistency in electronics assemblies built for their products.
“Koh Young are leaders in the integration of data exchange with IIoT-driven MES solutions and other machine technologies within the SMT line, satisfying their customers’needs through interoperable and holistic smart factory solutions”, states Michael Ford, Senior Director of Emerging Industry Strategy at Aegis Software. “Using the 100% machine-automation readable DPMX design file, together with the context ualization of work-assignment and schedule, deliverable using CFX from the Digital Manufacturing Engineering (DME) component of MES, allows Koh Young the opportunity to feed-back manufacturing intelligence to design in the same format that strongly augments design for manufacturing activity, decreasing lead-times and costs, as well as improving end-product quality and reliability,” he concluded.
Traditionally, it could take days for manufacturers to compile the necessary file bundle needed for production. Worse, the antiquated data formats may exclude critical elements like transfer stack-up data, materials, design intent, and more. Today, IPC-DPMX has streamlined the process. What took days, now takes minutes thanks to intelligent data exchange between OEM designers, printed circuit board manufacturers, and electronics manufacturers, including the vital equipment suppliers. The IPC-DPMX and IPC-CFX combination provides production flexibility and advances the movement towards Industry 4.0.
“Koh Young leverages its True3D™ measurement-based inspection solutions to simplify the lives of our customers by delivering innovative inspection technologies that increase productivity,” said Brent Fischthal, Senior Marketing Manager for Koh Young America. “To that end, the adoption of IPC-DPMX and IPC-CFX perfectly aligns with our charter to make life easier for our partner customers.”
As demonstrated with its efforts involving IPC-CFX and IPC-Hermes-9852, Koh Young is a strong driver of standardization for the global electronics assembly industry. “Part of our focus requires converting an extremely complicated set of data into usable information for effective decision making”,added Heriberto Cuevas Velazquez, Project Manager at Koh Young America. “We support IPC-DPMX as an open, neutral standard for efficient PCB data transfer to simplify programming and ensure accurate data, including inspection requirements.”
For information about the Consortium or details about joining, visit www.IPC2581.com. You can learn more about Koh Young and its best-in-class inspection and smart factory solutions by visiting kohyoung.com.
MicroCare released new products to provide safe and high purity cleaning in almost any production environment.
As the world sees the COVID-19 virus makes traditional cleaning products difficult to find, many industries are looking for ways to effectively clean their products and workplaces. In response to those customer requests, MicroCare is expanding its line of electronics and surface cleaners. The purpose is to provide customers with effective fluids to keep surfaces clean.
The new aerosol MultiClean™ MultiTask Surface Cleaner Spray and the new presaturated wipes feature a 70% high purity IPA (Isopropyl Alcohol) and 30% D.I. (Deionized) water mixture that evaporates more slowly, allowing the cleaning fluid to remain on surfaces longer, for better cleaning.
The new cleaners remove flux and white residue from circuit boards, solder paste and uncured epoxy residues from stencils, fingerprints, grease and light oils commonly found in medical device and electronics manufacturing. With excellent materials compatibility, it is safe to use on a variety of metals and plastics.
Do you need better defect analysis? Combine reflow data with your SPI and AOI data for true defect data analytics. Without RPI you don’t have the complete picture!
There is SPI for Screen Printing, AOI for Pick and Place, and there is RPI for the Reflow Oven. KIC’s RPI provides production reports such as yield analysis, DPMO, Pareto Charts, Cpk and much much more. The RPI is an automatic system that, once programmed, works in the background without any operator involvement. Its capabilities include:
Provides process deficiency information to help correct defect issues quickly
Shares all pertinent process and production data in real-time
Automatically profiles each and every PCB
Provides instant alarm for out-of-spec situations
Automatic SPC charting, including Cpk
Process traceability down to individual PCBs
Prevents human error such as production of the wrong PCBs or wrong oven recipe settings (bar code required)
The KIC RPI improves quality and throughput, and is universally applicable. Inspection is independent of the oven model, personnel, PCB types and production site.
Seoul, Korea — Industry leader Koh Young announces it has joined forces with Mentor, a Siemens business, to deliver an enhanced programming solution, which will benefit the printed circuit board assembly market. Building on the AI-powered Koh Young Auto Programming software (KAP), Mentor integrated its Valor™ Process Preparation Software to further simplify Automated Optical Inspection (AOI) programming and reduce production costs by saving time through the implementation of Mentor’s Open Product Model.
“The synergy between our companies has resulted in an outstanding solution that is designed to help reduce time to market and improve production quality across the line,” said Mr. JD Shin, Chief Sales Office for Koh Young Technology. “We are especially excited about this particular collaboration with Mentor, because it was in direct response to the voice of the customer. The partnership highlights the benefits customers can realize when two suppliers work together towards a common goal. It was a win-win for everyone.”
The enhanced software eliminates the need for CAD and Gerber files, which saves time be eliminating the efforts by a programmer to locate, upload, and manipulate these product files. The new solution reduces programming time by blending several elements together that automatically creates the necessary AOI programming files.
One of the elements Koh Young integrated from Mentor includes the Valor Open Product Model (OPM). Introduced in 2018 by Mentor, OPM is an open data assembly format structured in XML, which focuses on the printed circuit board assembly model (PCBA) and the associated manufacturing process plan. OPM is a solution for the open exchange of process engineering information between disparate machines and processes. In the same way that ODB++ works for design data, OPM is the answer to the need for flexibility that Smart Industry 4.0 factories demand.
A second element that is now part of Koh Young software, it the extensive Valor Parts Library (VPL) database from Mentor. Comprised of over 35 million component manufacturers part numbers and package geometry definitions, Valor Process Preparation software uses this information to fully automate the creation of new parts and packages for use in inspection systems and mounters using its “Auto-Generation” rule methodology.
Combining a single assembly format file output like OPM and a standardized machine package library from VPL, the manufacturer minimizes program variations between machines like inspection systems and component mounters. This improved programming approach can eliminate human error and variation, while significantly reducing NPI programming time. Additionally, OPM is generalized so it is interoperable among various systems and easily enables moving production between lines and—more importantly—factories across the world.
“This joint programming project was just the first step in an expanded collaboration to improve the PCBA manufacturing experience for our customer,” said Mr. Rick Esposito, Director of Valor’s Processing Engineering Product Line. “When industry leaders collaborate, remarkable solutions result. We are excited about this relationship and the future together.”