mobile | classic
Dataweek Electronics & Communications Technology Magazine





Follow us on:
Follow us on Facebook Share via Twitter Share via LinkedIn


Search...

Electronics Buyers' Guide

Electronics Manufacturing & Production Handbook 2019


 

Tips for placing 01005 components
8 August 2012, Manufacturing / Production Technology, Hardware & Services

One of the hottest topics in SMT assembly today is placement of the latest ultra-small component package: the 01005. The 01005 (or metric 0402) measures just 0,01” x 0,005”, half the width and half the length of the previous smallest component, the 0201. As of this writing, 01005s are still rare, but that has not stopped most SMT equipment vendors from touting their ability to place them.

The placement of 01005s presents challenges in nearly every aspect of the assembly process. Special solder pastes must be used, stencil aperture and thickness must be carefully controlled, placement machines must be able to pick and place the components reliably, and even the reflow profile may need to be adjusted to accommodate these tiny parts.

Other equipment such as AOI/AXI and especially rework are also affected. But the never-ending push of miniaturisation dictates that the 01005 is here to stay and likely will become commonplace in the near future. This article focuses on the placement-related issues of 01005s.

High-volume production demands high-reliability picking and placing. At 25% of the total surface area of an 0201, the 01005 is especially challenging to pick up, centre and place accurately and reliably.

Component pick

Frame design: To pick 01005s, the most basic requirement is a machine that has an accurate and repeatable positioning system. The use of rotary encoders is typically very accurate when a machine is new, but mechanical wear can reduce their accuracy over time. Linear encoders, on the other hand, measure true head position and offer higher and more consistent accuracy.

Another key component of positioning repeatability and accuracy is the system’s basic construction. For the highest reliability, best accuracy and longest life, the machine’s frame should be as stiff as possible. A one-piece cast frame is recommended because this design incorporates the base frame and both Y axes into a single casting, resulting in an extremely rigid platform.

With the high speed of today’s machines, this rigidity is key to being able to place components accurately over time. Compared to welded and bolted steel frames, a cast frame will provide much better stiffness over a longer period of time.

Feeder design: The feeder is also a critical component, as it has been since the widespread adoption of the 0402 many years ago. At that time, it was discovered that typical 8 mm feeders did not have sufficient accuracy for reliable picking. This process started again with the 0201 a few years ago, and again for the 01005.

It would be easy to claim one’s machine can pick and place 01005s using existing 0201 feeders, but when there is only 25% of the surface area to work with, this is not a practical claim. A system designed specifically to pick and place 01005s is necessary.

01005s are currently quite expensive, making it critical to have minimal part loss. The price for a 0402 resistor is typically about $0,003 to 0,004 each. It jumps tenfold for 0201 resistors to $0,03 to 0,04 each. For 01005 resistors, the price is ten times the price of 0201s, or about $0,45 each.

If history is any guide, these prices will come down dramatically as production volumes increase, but for now, 01005s will probably only be considered in space-premium applications.

So would you be willing to accept a pick ratio of 99,8% for a component that costs $0,45 a piece (and basically impossible to find after they are lost)? Probably not. At that rate, if just ten 01005s were placed per board on a run of 1000 boards, you would be throwing away $90 per run.

For this reason, a special 01005 feeder that can meet the high pick reliability customers require for such expensive parts is mandatory.

Centring. The last part of the high-reliability picking equation is the nozzle. Here we can see one of the benefits of laser centring. Camera-based centring systems take an upward-looking view of the component. With a component as small as the 01005, it is likely that the component is even smaller than the nozzle, which can create centring difficulties if the camera confuses the nozzle for the component.

Laser centring measures the component from the side. So if the nozzle tip is bigger than the component, it creates no problems for centring. A special nozzle that has a rectangular tip instead of the typical round tip provides key advantages. This design holds the 01005 better, reduces the chances of a tombstone pick and increases the pick reliability.

Once the component is picked, the challenge is to centre it accurately. Again, laser centring is ideal for this situation. Using a laser with approximately 5000 pixels is key to accuracy.

Typical camera systems are just 1000 x 1000 pixels. This means that when measuring an 01005, the effective size of the component is 30 x 15 pixels using laser centring vs. about 9 x 5 for a camera system (more is better).

Conclusion

Excitement over the 01005 continues to grow and forecasts show increased use in the future. It is safe to assume that 01005s will find their way into many more products as the price comes down and they become more widely available.

It is important to recognise the challenges this will present to the entire SMT assembly process. Juki addresses this challenge with four key elements:

* A one-piece cast frame for rigidity and long-term accuracy and repeatability.

* Specially designed nozzles for high reliability.

* Specially designed feeders for accurate ­component presentation.

* Laser centring that can more accurately ­measure and handle ultra-small components.


Credit(s)
Supplied By: Allan McKinnon & Associates
Tel: +27 11 704 3020
Fax: 086 555 0111
Email: info@testerion.co.za
www: www.ama-sa.co.za
  Share on Facebook Share via Twitter Share via LinkedIn    

Further reading:

  • Designing PCBs for Mil Spec
    29 May 2019, Cirtech Electronics, Manufacturing / Production Technology, Hardware & Services
    In the field of electronics, Mil Spec – or Military Specification – has a very clear and understood meaning. It denotes equipment designed and made to exacting standards, in accordance with precise rules ...
  • Continued success for Zetech’s stencils division
    30 April 2019, Zetech, This Week's Editor's Pick, News, Manufacturing / Production Technology, Hardware & Services
    Best known for supplying SMT (surface mount technology) equipment and consumables for printed circuit board assembly for 33 years, Zetech is enjoying success with its more recently established stencils ...
  • How to analyse blind via hole failures
    27 March 2019, This Week's Editor's Pick, Manufacturing / Production Technology, Hardware & Services
    It has become common practice to use blind, filled and stacked vias in many portable electronics products. Experience has shown that this method of interconnection is reliable, provided the fabrication process is well defined and controlled.
  • PCB microsectioning – paying attention to detail
    27 March 2019, Cirtech Electronics, This Week's Editor's Pick, Manufacturing / Production Technology, Hardware & Services
    In our high-tech world, it’s easy to overlook the importance of the humble printed circuit board (PCB). Buried in each electronic gadget or appliance there’s always at least one PCB and each one has ...
  • X-ray dose considerations
    27 March 2019, MyKay Tronics, Manufacturing / Production Technology, Hardware & Services
    The benefits of using X-ray technology in the electronics industry to inspect printed circuit board assemblies are well proven. This article summarises X-ray radiation dose, and the techniques that ...
  • Product development issues explored in new video
    27 March 2019, Manufacturing / Production Technology, Hardware & Services
    Printed circuit broker, Elmatica, recently released a new film about product development, explaining why cooperating with an experienced partner could be a smart move. “We have several times seen the ...
  • Flux management system earns APEX award
    27 March 2019, MyKay Tronics, Manufacturing / Production Technology, Hardware & Services
    BTU International was awarded a 2019 NPI award in the reflow soldering category for its new Aqua Scrub flux management technology. The award was presented to the company during a ceremony that took place ...
  • Solder dross recovery system
    27 March 2019, Electronic Industry Supplies, Manufacturing / Production Technology, Hardware & Services
    Stannol’s Solder Saver is a mechanical device to reduce dross, which occurs as an unavoidable side effect in wave soldering systems. According to its manufacturer, solder consumption can be reduced by ...
  • Water-soluble solder paste
    27 February 2019, Techmet , Manufacturing / Production Technology, Hardware & Services
    Indium has released Indium6.6HF solder paste – a new water-soluble, halogen-free solder paste that is compatible with both tin-lead and lead-free alloys. It is designed to provide enhanced stencil printing ...
  • Affordable soldering station
    27 February 2019, Electronic Industry Supplies, Manufacturing / Production Technology, Hardware & Services
    The Industa 550 soldering station, available from Stannol, is an affordable unit characterised by easy operation and universal fields of application. The temperature is easy to set using a potentiometer, ...
  • Stencil underside cleaning and manual post-cleaning
    27 February 2019, Testerion, Manufacturing / Production Technology, Hardware & Services
    According to experts, between 60 and 70% of all defects and failures during or after the soldering process are attributable to defects in the printing process (Figure 1). In general, these are faulty ...
  • What you need to know about the Hermes standard
    EMP 2019 Electronics Manufacturing & Production Handbook, Manufacturing / Production Technology, Hardware & Services
    Taking advantage of modern TCP/IP communication and XML data format technologies, Hermes is effectively a replacement of the more than 20-year-old SMEMA standard.

 
 
         
Contact:
Technews Publishing (Pty) Ltd
1st Floor, Stabilitas House
265 Kent Ave, Randburg, 2194
South Africa
Publications by Technews
Dataweek Electronics & Communications Technology
Electronics Buyers’ Guide (EBG)

Hi-Tech Security Solutions
Hi-Tech Security Business Directory

Motion Control in Southern Africa
Motion Control Buyers’ Guide (MCBG)

South African Instrumentation & Control
South African Instrumentation & Control Buyers’ Guide (IBG)
Other
Terms & conditions of use, including privacy policy
PAIA Manual





 

         
    Classic | Mobile

Copyright © Technews Publishing (Pty) Ltd. All rights reserved.