Generally, odd-form parts are inserted by hand because there are issues concerning what packaging to use and limitations on the part size that can be handled using SMT machines. However, there are problems in which manual insertion processes cause variations in quality and work time. Because of this, the demand for automation is increasing.
sFAB-D, the multi-purpose automated fabrication machine, flexibly supports various part sizes, shapes, and supply packages, from leaded parts to large odd-form parts, and automates insertion processes that are performed manually, providing stable quality and production.
Unparalleled part support range
Using various types of handling tools, heads, and part supply units, the sFAB-D supports large and heavy parts that cannot be handled on other insertion machines. It is possible to automate a wide range of assembly processes that use manual insertion and to stabilize work time and quality.
Tools for handling various part types
Using nozzles and chucks, the sFAB-D can handle diverse ranges of part types and shapes, from odd-form parts with complex shapes to large parts as well as standard and general-use parts.
Nozzles for picking up and handling parts
Parts are handled by picking up using the top surface of supplied parts. Round and rectangular type nozzles are available. Because the pickup surface is made of a rubber material, the impact on parts when picked up is reduced and dropping of heavy parts is prevented. This enables stable transport of parts.
Pivoting nozzle that can handle parts supplied sideways
This nozzle picks up supplied parts with the leads facing sideways, and inserts parts into panels by rotating parts so that the leads face downward.
General-purpose chuck that supports a wide range of part sizes
The same chuck body can be used by changing the combination of the claws, locator, and attachment positions. Therefore, it is possible to start production with new parts immediately.
Tool kits, which are sets of claws and locators that are frequently used, are also available. These kits enable handling of approximately 80% (*) of general-purpose parts. (*Fuji internal investigation)
Compact and lightweight heads that can be exchanged easily
Fuji have a lineup of heads that cover from high-speed transport of small parts to transport of large parts. These heads efficiently and reliably transport nozzles and chucks for handling parts.
High-speed transport of small parts - sH08 head
This rotary head can handle 8 parts on one head at the same time, and transports small parts at a high speed.
Support for parts from small parts to large parts - sH02 head
This head can handle 2 parts on one head at the same time, and supports parts from small parts to large parts.
This head is appropriate when assembling various different part types.
Highly effective head for high-mix low-volume production - sOF head
The clamp width can freely be selected by shifting claws using a motor. Therefore, this head reduces the frequency of tool exchange and is effective for increasing productivity during high-mix low-volume production.
It is possible to change the holding force using torque control, and to use pickup nozzles and part lead chucks. Therefore, a wide range of part types can be supported.
Twin carrier is when using two heads set side by side in a machine. Simultaneous transport and short tool exchange time reduces the production time, and this increases productivity significantly.
For example, when using the combination of an sH02 head and H08 head, the production time can be reduced by 40% (*) compared with production using an sH02 head only. (*Fuji internal investigation)
Supply units that automate manual work
The automation of manual work is achieved by using supply units that support packages for tape parts, tray parts, and loose parts, and supply units that automatically bend and cut leads.
Various feeder types
We have a wide range of feeders that support taped parts and parts supplied in sticks.
Processes before inserting leaded parts
It is possible to obtain stable quality and reduce work time by automating bending and cutting processes that are performed manually on leaded parts.
Tray unit that supplies large parts
Supplying parts without stopping production - sMTU-LT2
The tray unit has the upper and lower magazines and can supply parts during production, so there will be no downtime due to part supply work.
Reducing the frequency of part supply with large tray support - sMTU-XL
The part quantity that can be supplied for one tray drawer has significantly been increased. This makes it possible to reduce the frequency of part supply up to one-sixth (*) that of conventional units. (*Compared to our previous model)
Automatic supply of loose parts
It is possible to automate insertion of loose parts that are not arranged in tape or trays by supplying these parts as is without performing extra work.
Reliable part indexing and easy changeover - BPU2
This can supply 5 types of loose parts. Changeover is easy because only carrier sections are exchanged.
High quality insertion
Processing before and after insertion brings reliable, high quality insertion.
Inserts in the correct direction
Direction checks before and after pickup
The supply direction is checked by imaging the part top before picking up the part. After picking up, the tool is rotated to correct the direction of the part. This prevents parts from being placed in the wrong direction.
For parts for which the direction can be determined from the part bottom, the direction is determined after vision processing the leads and the part is inserted in the correct direction.
Reliable handling, accurate insertion
Reliable part handling
Part lead chucks that support radial parts hold part leads. This ensures that lead pitches are stable and provides accurate insertion.
Part lead chucks that support axial parts handle parts by clamping a part while the part leads are fitted in the grooves on the claws, and by utilizing the tension of the part leads.
Vision recognition with high accuracy
Various lighting patterns and highly accurate vision processing
By imaging and vision processing the tips of part leads using sidelighting, it is possible to offset lead positions and check for bent leads. This enables stable insertion.
Insertion checks and clinching to maintain high quality
Part insertion check
This function is for checking whether a part has been inserted based on a difference between the actual Z-axis stroke and the necessary stroke for successful insertion.
In addition, a conductivity check is performed during cut and clinch operation to check whether the part has been inserted correctly.
Processing for preventing parts from falling over after insertion
A leaded part is inserted and the leads are cut and clinched from the panel bottom. This prevents the inserted part from falling over or coming out. The bending directions of leads are bend in, bend out, and N bend.
As well as leaded parts, connectors can be lightly fastened by bending metal plates that protrude from the panel bottom (*).
*There are restrictions on the metal plate thickness.
Adjustment functions for accurate insertion
Adjusting placement coordinates
There are some cases in which the size of the actual panel on which parts are to be inserted is different from the dimensions in the drawing. Because of this, the machine has functions for finely adjusting the insertion position. This is done by checking the actual insertion positions at the control panel.
Achieving full-scale automation step by step
Even if starting small from the easiest processes to automate, it is possible to step up to full automation through incremental investment. Production model changes are supported by changing units. Therefore, over-investing in equipment can be avoided.