PNP Manual
- Ryan Quan
(numbering messed up on confluence, for printable version see https://docs.google.com/document/d/1kRDmrYKu8PqYBCgJOFuMVkTvsQp52_QeWTWWAi77KVw/edit?usp=sharing )
Neoden 4 Manual
All images and instructions from Neoden 4 Manual 1.0
(https://neodenusa.com/media/wysiwyg/pdfs/Neoden_4_Manual_1_0.pdf)
Introduction
“The Neoden 4 is a 4-axis Windowscontrolled CNC with four separate vacuum nozzles, each connected to its own vacuum pump. The machine employs a single X-Y coordinate system covering the entire movement range of the head, which is 310x500 mm. With resolution of .01 mm (10 µm) and repeatability of .02 mm (20 µm), any X-Y coordinate can be identified as the location of a feeder, the start of an array of components in a tray or short tape, a fiducial mark or the location at which a component is to be placed on a circuit board.”
2. Installing Components:
Installing tape and reel components:
Lift the angled tab on the feeder, and insert the tape so the sprocket holes rest on the tooth of the gear.
Pull the end of the cover tape through the large feeding slot in the feeder, over the brass block.
Allow the spring to pull the feeder cover over the tape.
Lift the silver tab on the peeler to separate the gears.
Thread the cover tape through the slot on the angled tab, and through the gears on the peeler until the tape extends through the back slot of the peeler. If the tape does not extend through the whole peeler before the gears are closed, it will likely jam.
Allow the spring in the peeler to close the plastic feeding gears.
2. Installing tube-fed components:
i. Install the tube feeder guide. This polished steel guide is included with the machine and bolts to the table with two Allen screws (included).
ii. Screw the round horizontal tube guides into the plate as shown. These round guides will hold pressure on the tube to maintain a good feeding angle and prevent movement.
iii. Adjust the width of the black vibration feeder guides as necessary for each tube. If the tubes hold very small components, it may be beneficial to use tape to cover the front slots between the black guides.
Installing trays and short tapes
Trays and short tapes can be placed anywhere on the table that is not in the space or path required by the board. If the width of the rail setting necessitates removal of the left steel table extension, first install a piece of metal or plastic sufficient to raise the height of the table to roughly the height of the extension. If the table extension is installed, simply affix the tray or tape to the extension using double-sided tape or any other suitable method. It is important that the components be placed in a reasonably straight horizontal or vertical orientation, and that the tray or tape is placed flat to avoid variations in pick height.
Interface Page
The second tab at the top of the interface opens the manual test screen. This screen contains a convenient selection of tools to verify the operational status of most components of the Neoden 4. Most functions of the manual test screen can also be accessed from other areas of the interface.
Feeder/Peeler. Arranged on the left and right sides of the screen are feeder and peeler IDs that correspond graphically to a typical arrangement of feeders on the Neoden 4. Clicking on any feeder or peeler will activate the assigned feeder/peeler combination (assuming, that a unit is configured and connected for the ID clicked). Use these tests conservatively when parts are loaded, because the feeder will advance, and a component will be ejected from the tape.
Placement Head. This section contains tools to verify the proper operation of the head, head movement system and nozzles. To use these tools, first select the nozzle of interest.
The “Blow” button will release a brief jet of air from the selected nozzle. Place a finger under the nozzle to verify operation. A small increase in positive value should appear on the screen.
The “Suck” button will engage vacuum for the selected nozzle. Place a finger over the nozzle to block airflow, and press the button. If the unit is operating correctly, you will feel the vacuum, and the “pressure” indicator will change from a positive to a significant negative value while vacuum is present.
The “Turn left” and “Turn right” buttons activate the rotational axis of the selected nozzle. Because rotation of the smooth black nozzles is difficult to observe, it is easiest to verify function by watching the motion of the vacuum tubes at the top of the head.
The “Nozzle Down” button will lower the selected nozzle by the full 12 mm travel. Releasing the button causes the nozzle to return to its upper position.
The “Flash” button activates the lighting for the downward looking camera. Press once for the inner lights, again for the outer lights, again for both, and a fourth press will turn the lights off.
The “Photograph” button verifies operation of the downward-looking camera by moving the head back and displaying a photograph of the table.
The “Move Head” button allows repositioning of the head in three ways:
By using the “Visual field” method, the head can be moved precisely by clicking on the portion of the screen relative to the center crosshairs, which indicate the current position of the camera. Because of the extreme closeup vision of the camera, only small moves are possible with each click.
With the “Mouse Vectors” setting, the screen turns grey, and represents the entire area of movement possible over the table. Clicking in any region of the screen allows rapid, coarse movement of the head. This can be convenient for speeding alignment, as well as for moving the head to a more convenient general location for the task being performed.
The ”Keyboard Jog” method allows movement in of the head along the X-Y axes in .1 mm increments. Additional keyboard controls are noted on the screen. To exit this mode, press the Escape key.
Z Axis. When in an alignment screen, the default “camera” setting allows the visual check of X-Y coordinates. But the selection of one of the nozzles as an alignment method allows the manual extension of the nozzle along its 12 mm Z-axis travel. This feature is useful not only to verify operation of the Z-axis motor, but to determine the best values for “pick height” and “place height” in the feeder settings of a P&P program.
In addition, when using feeders too far back for the camera to align, (e.g., usually 17-19 on the right-hand side) this method allows the user to position a nozzle and test to ensure that it descends onto the component in the feeder. While this method is less convenient that camera alignment, it allows the user to make the greatest use possible of the available table real estate by installing additional feeders.
The “Rail Control” button allows a simple means of moving the rail system forward and backward to verify operation.
In the “Host Control” section, seven controls complete the manual test interface.
The “Flash” button activates the lighting system for the upward-looking camera. A second press turns off the lights.
The “Image” button verifies operation of the upward-looking camera by displaying an image on the screen. Because the camera focus is set to take very sharp pictures of the nozzles and any components they are carrying, pressing this button may produce only a blurry image unless an object (like the head) is present over the camera at the correct height. Pressing “Cancel” returns the user to the main screen. (The Lens Rotation and Save buttons are used for nozzle alignment purposes, and perform no valuable function in the Manual Test context).
The “Feed Command” activates the rail system for those units so equipped.
The “Buzzer” button sounds the internal warning tone for as long as it is pressed.
The “Clear X-Y” button should only be used to correct an error condition displayed in the “XX Status” annunciator position. When the status reads “Idle,” the system is functioning normally and there is no need to use this button.
The “Home” button causes the X-Y drives to return the head to the machine’s home position, and reset the X-Y geometry based on the physical limit switches in the unit. Use this button to verify operation of the limit switches, and also to restore the home position in the event of an accidental head crash into an object inadvertently left on the table.
The “Vibration feeder” check-box will activate the vibration feeder motor when checked. Leave the box unchecked except for this brief test.
PCB INFORMATION PAGE
PCB Feed Settings. This section determines the manner in which the PCBs will be sent to the machine for pick-and-place operations. On machines with the rail system installed, the “Mag fixture,” “Rail Single,” and “Rail Multi” are available. On machines without the rail system, always select “Mag Fixture.”
Mag Fixture. This option assumes that the user will place the board in a location determined by the placement of the magnetic fixture blocks (supplied) on the table. This is a simple and reliable system, but the accuracy of a program depends upon the magnetic fixtures being installed to ensure that the placement of the board is essentially the exact placement that existed at the time the program was created.
Users relying on the magnetic fixtures for several different boards should place fixtures on the table to ensure that the lower left corner remains in the same place for all boards. This will ensure that the origin of each board remains constant with respect to the machine coordinates. The remaining fixtures can then be varied to ensure stable placement of different-size boards.
Rail Single. This option is the most frequently used on machines equipped with the rail system. Checking this box will cause the machine to feed a single board (or panelized board) to the appropriate location and then commence fiducial recognition and component placement.
Rail Multi. This option is used when boards (or panels) longer than the machine table are to be populated. In this mode, the machine will place components between the first set of fiducials, then advance the board automatically to place components between the next set of fiducials, and so on.
Front Eject. When this box is ticked, the rail system will eject the PCB from the machine toward the front when the program has completed running.
“Forward” and “Backward.” These buttons manually move the PCB within the rail system. When setting up a new program, use these buttons to move the PCB to a suitable position for placement operations. Follow the instructions to complete the program without moving the board until the program is completed, verified and saved.
“Align.” This button activates the camera. Once a board has been placed in the desired location using the “Forward” and “Backward” buttons, press “Align.” Move the head so that the crosshairs are centered on the leading edge of the board. The X-Y coordinates of the aligned location will be displayed in the “Detect X” and “Detect Y” fields. Though the user can enter values manually to change the feed location, this should rarely be necessary. TIP: When running a program, the board will advance slightly farther than the edge identified with the “Align” command. This is normal, and the machine will proceed to recognize fiducials to properly place components.
“Feed.” Unlike the “Forward” button, “Feed” will automatically advance the board to the position identified with the “Align” command. It is not necessary to use this feature in normal operations. However, if a PCB is moved before programming is completed, verified and saved, this feature can be useful in restoring the board to its proper position.
Panelized PCB Origin. A fundamental principle of the Neoden 4 software is that the origin of a file is the X-Y coordinates of the first component to be placed (expressed as absolute machine coordinates). Even when single (not panelized) boards are being produced, the machine treats the board as a part of a panel (with one row and one column equaling one board). Therefore, the X-Y coordinates of the first component must be entered in the Left Bottom X-Y fields. Components entered in the component list must identify the locations of components on the left bottom PCB in a panel. A single PCB will be treated as if it is the left bottom board in a panel.
For a single board, leave the number of rows and columns set at “1.” For a panel of multiple boards, enter the number of rows and column in the drop-down menus. If the number of columns and rows is greater than 1, the machine will then require entry of coordinates for the first part as it appears under the camera for the right top and left top panels. With these values, the machine can extrapolate the size of the panels and compute the location of every component on each panel.
Component List. The component list is the heart of the pickand-place program. It contains the location and rotation of every component, along with other identifying information about the components. There are two ways to create this list:
File Import. This is the simplest method to create a map of placement locations and angles for your board. This method will quickly create a valid component list from a .CSV file, as long as the coordinates in the file are computed with reference to the location of the first component in the list. In other words, before generating and exporting the .CSV file, the PCB design software must be supplied with the location of the first component in the list as determined by the Neoden 4 camera with the board in place. The appropriate export routine will compute the coordinates of the remaining components relative to this user-supplied origin point. Coordinates must be specified in millimeters, to two-decimal precision. Export routines for the Neoden 4 are available for popular PCB design software, including Eagle and Altium. To use this feature, insert a USB drive containing the exported .CSV file into any port on the Neoden 4, and press Import (with the “manual” box unchecked). The system will locate available .csv files in on the USB drive, and clicking “Save” after selecting a file will import the list. To edit the list after import, check the “Manual” box. This allows the user to check and correct individual components with the camera by pressing “Align.”
Change to current position. This is a powerful feature that will change the coordinates of the entire component list if the board is placed in a different position on the table than the position that was used to compute the original origin. To use this feature, locate the first fiducial with the camera. Press “Cancel,” and press “Change to current position.” The machine will locate both fiducials and compute the offset from the original program. It will then change the values in the component list to conform to the new board location. After this process is complete, it is necessary to ensure that the new coordinates for the first component are entered in the “Left Bottom” location, and that the “Create Panelized List” button is pressed so that the X-Y coordinates of the first component appear in all three locations on the screen.
FEEDER SETTINGS SCREEN
The Feeder settings screen is critical to the successful operation of any program. Setting the many parameters on this screen for each feeder is the most time-consuming part of preparing the Neoden 4 for production, but careful attention to detail in this section will assure trouble-free operation and the best results in the finished boards.
Though the Neoden 4 will work without precise data in the Value and Footprint fields, several powerful automatic functions that can greatly speed programming require that each instance of the same component in the component list contain identical entries in the Value and Footprint fields.
Feeder Layout. One of the important functions of the Feeder Settings screen is the assignment of discrete components to individually-numbered feeders. This can be accomplished manually or automatically. The Neoden 4 supports programs with components placed randomly in feeders all over the machine. While random placement works, it is always not the most efficient means of programming the machine.
If components are assigned in the order in which the first appear in the component list, automatic assignment is possible. In other words, if the first component in the list physically resides on Feeder 1, the next different component in Feeder 2, etc., then the user need only press “Assign All Sequentially.” Each feeder will then be assigned the appropriate value and footprint.
In many cases, however, components will be installed without regard to their relative position in the component list. In that event, the user should first click on the dropdown menus next to each feeder and select the component that corresponds to that feeder. (The contents of the dropdown menus are derived from the data in the component list).
Feeder Basic Information. To edit information for each feeder, first check “Apply.” Next, press “Align” in the Feeder Basic Information section. This will move the camera to the location of the components in the feeder. As in Section 2.3.2, center the crosshairs in the hole in the tape where components sit – not the center of any given component. Using this method, the Neoden 4 will be able to use any of its four nozzles to pick parts from the feeder.
For feeders installed in the far back of the machine (often feeders 18 and 19 on the left side) the camera, which is mounted on the front of the head, will not be able to be moved far enough to view the necessary location. For these feeders, after clicking “Align,” select the desired nozzle as the “Alignment method” on the right side of the screen. Then use the mouse to move the nozzle to the desired pick location, and slowly pull the vertical slider down to lower the nozzle. Continue to fine-tune the location of the nozzle until it is centered in the hole in the tape. Click “Save.”
After aligning the feeder (or nozzle) to the camera, ensure that the remaining data in the Feeder basic information section is correct.
The Pick Angle setting normally does not need to be changed because the machine automatically sets this value based on the feeder’s location on the left or right rail. For trays and sort tapes, however, this value may need to be changed to 0 or 180.
The Footprint setting should contain the footprint of the component in the feeder. If the correct size is not in the menu, it is possible to create new footprints by entering the footprint library.
The Vision Alignment setting is normally set at “Individual.” This setting directs the Neoden 4 to transport each “picked” component to the upward-looking camera to ensure that a component is attached to the nozzle and analyze its position to compensate for X-Y and rotational errors before traveling to place the component on the board. For large ICs, choose “large component” in this field.
The Vacuum Discard function should be left unchecked. This feature measures the vacuum level at the nozzle after a part is picked up, and discards the component if the vacuum is insufficient. Though faster than the camera, this feature is less accurate and can result in wasted parts. We therefore do not recommend its use except in special circumstances.
The Pick Height setting is critical to reliable operation. The nozzles offer 12 mm of total downward travel from their resting position in the head. The value entered in this field represents the distance in millimeters from the maximum extension. Therefore, smaller values indicate greater downward travel. The best way to choose this value is to press “Align,” ensure the camera is properly centered over a component, and then select an appropriate nozzle as the alignment method. Drag the vertical slider down until the nozzle gently touches the component, and note the value shown—this is the value to be entered in the “pick height” field. Should you notice repeated failures to pick a part, the pick height may need to be reduced.
The Pick Delay and Place Delay settings allow a short pause after a nozzle comes into contact with a part, and before it leaves contact. This small pause allows for stable vacuum and cessation of any vibration from the rapid movement of the head that might cause imprecise placement. We recommend entering a value from 100-300 in these two fields for every feeder.
The Place Height setting determines the extension of the nozzle when the component is released into the solder paste. Proper setting of this parameter is important to protect components and nozzles, and to ensure accurate placement. We recommend the following procedure:
Mount a PCB in the rails or magnetic fixtures.
In the “Nozzle Information” area, check the nozzle (or nozzles) appropriate for the component in the feeder.
Press “Pick.”
The Head will move to the feeder and the designated nozzle will pick up a part. Verify visually that a part is attached to the nozzle.
Go to the PCB Information page, and click “Align” on any component. Select the nozzle holding the picked component as the Alignment Method. The component should now be held by the nozzle, suspended above the PCB.
Slide the vertical slider down slowly until the component barely makes contact with the PCB—usually, you will hear a small click when the component touches down.
Note the value shown by the slider display and enter it in the Place Height field.
The Move Speed setting has a default value of 100. This is a very fast setting, and users are advised to start with a slower setting, e.g., 70 for each feeder to verify proper operation of a program. Once satisfied with the program and its accuracy, faster settings may be attempted. For very large components, start with a much slower setting, e.g., 30.
Nozzle Information. For each feeder, check the nozzle(s) that are sized appropriately for the component installed in the feeder. We recommend leaving the threshold settings at their default values, because the vacuum detection feature to which these settings relate is rarely needed or used when the vision system is active.
FINAL PROGRAMMING STEPS
After completing the setup of each feeder, it is time to assign components to feeders and nozzles in the component list. The simplest way to do this is to press “Assign Feeder and Nozzle” in the Feeder Settings screen. If all values are correctly and consistently entered in the component list, and appropriate nozzles have been enabled in the Feeder Settings interface, the Neoden 4 will automatically select the appropriate feeder and nozzle for each component in the component list.
If the data in the component list contains inconsistencies, omissions or small errors, the program will still work, but the automatic assignment feature will not. In such cases, the user can manually enter the desired feeder and nozzle for each component.
Save the program and you’re ready to run!
RUNNING THE PROGRAM
On the pick-and-place programming page, select the program you wish to run and press “Mount.”
If the vibration feeders are needed, activate them with the checkbox.
Place a PCB on the magnetic fixtures or load one into the rail system so that the PCB is in snug contact with the guide belts.
There are two ways to run a program: Step Mode and Continuous Mode. Pressing “Step” will cause the Neoden 4 to execute the program one move at a time. This can be helpful in troubleshooting or doublechecking the integrity of a program before letting the machine run free. Pressing “Continuous” will cause the program to run on its own. The Neoden 4 will first check each nozzle called for by the program. It will the locate the fiducials on the board and begin placement operations.