Maintenance notes of a surface mount technology (SMT) machine engineer: Don't panic when encountering these malfunctions

One of the most common malfunctions is that the suction nozzle cannot pick up components, especially when dealing with ultra-small components. This situation usually leads to the production line coming to a standstill and affecting work efficiency.

• Vacuum pump failure: The vacuum pump is one of the core devices for suction components. If the vacuum pump malfunctions, the suction nozzle will not be able to generate sufficient suction force.
• Clogged suction nozzle: If the suction nozzle itself is blocked by foreign objects or accumulates dust after long-term use, it can also lead to the failure of the suction function.
• Damage to the suction nozzle itself: Sometimes, the suction nozzle may have insufficient suction due to excessive wear or physical damage.

• Check the vacuum pump: First, check the working condition of the vacuum pump to ensure it is operating normally. If the vacuum pump malfunctions, it needs to be repaired or replaced.
• Clean the suction nozzle: Remove the suction nozzle for thorough cleaning to ensure there is no dust or debris blocking it.
• Replace the suction nozzle: If the suction nozzle is damaged, replace it with a new one in time to ensure normal suction function.

After the suction nozzle picks up the component, it cannot accurately place it at the predetermined position, resulting in large surface mount errors and even component offset, which affects the production quality.

• Improper calibration of the vision system: The vision system of the surface mount technology (SMT) placement machine locates components and circuit boards in real time through cameras. If the vision system is not accurately calibrated, alignment errors are likely to occur.
• Xy-axis positioning deviation: After long-term operation, the XYZ three-axis system of the machine may have minor errors, resulting in inaccurate positioning of the suction nozzle.
• Software setting error: Sometimes, improper Settings of software parameters can cause the machine to fail to accurately identify the positions of components.

• Recalibrate the visual system: Inspect the camera and optical system, and recalibrate the visual system to ensure the accuracy of image recognition.
• Inspect and adjust the axis system: Conduct a comprehensive inspection of the XYZ three-axis system to ensure there is no wear or looseness. Make fine adjustments to ensure the positioning accuracy of each axis.
• Check software Settings: Inspect the control software Settings of the machine to ensure that the position information of components and PCBS is correct.

The Feida system is stuck with components and cannot supply materials normally, which will cause a serious delay in the production progress.

• Improper placement of components: If components are not correctly placed within the Feida system or if there are foreign objects in the Feida slot, it may lead to material jamming.
• Feida drive failure: When the drive motor or transmission components of the Feida system malfunction, it may lead to poor material supply.
• Wear of Feida slide rails: After long-term use, the slide rails of Feida may wear out, leading to unstable supply of components.

• Check the placement of components: Inspect the components within the Feida system to ensure they are correctly placed and not stuck.
• Check the Feida drive motor: Ensure that the Feida drive motor is working properly and inspect the transmission system for any looseness or damage.
• Lubricate and maintain the slide rails: Regularly inspect the Feida slide rails to ensure their smooth operation. If there is any wear, replace the slide rail in time and carry out lubrication treatment.

During the surface mount process, the position of the circuit board shifts, causing the machine to be unable to accurately identify its position and thus affecting the mounting quality.

• Suction cup system issue: Insufficient suction force or malfunction of the suction cup, resulting in the circuit board not being firmly attached to the workbench.
• Position sensor failure: When the position sensor malfunctions, it cannot accurately detect the position of the circuit board, leading to misjudgment.
• Problem with the circuit board support system: The circuit board support system has malfunctioned and cannot provide stable support.

• Check the suction cup system: Inspect the working condition of the suction cups and confirm whether the suction force is normal. If there is a problem with the suction cup, clean or replace it.
• Check the position sensor: Ensure that the position sensor is working properly and carry out necessary calibration and maintenance.
• Check the circuit board support system: Inspect the stability of the support system to ensure that the circuit board can be firmly fixed on the workbench.

The placement speed of the surface mount technology (SMT) machine is significantly lower than the normal production speed, which affects the production efficiency.

• Excessive machine load: If a machine performs multiple complex operations simultaneously, it may lead to excessive load and reduce overall work efficiency.
• Improper system adjustment: The parameters of the machine were not set appropriately, resulting in the mounting speed not reaching the optimal state.
• Faulty components: Problems with certain parts of the machine, such as the motor or transmission system, may also lead to a decrease in speed.

• Check the machine load: Inspect whether the machine is simultaneously performing multiple high-load operations, appropriately reduce the burden, and ensure that the machine can operate efficiently.
• Optimize system Settings: Adjust the machine's mounting parameters according to the actual situation to ensure that the mounting speed matches the production requirements.
• Inspect machine components: Check key components such as motors and transmission systems, and replace or repair faulty parts in a timely manner.