Automation of horizontal technological PCB plating lines

System description

The system is a family of automated horizontal technological PCB plating lines.

Depending on a technological process there are several main types of lines:

  • Pretreatment of plates after drilling (Pretreatment);
  • Non-electrolyte copper deposit (LB process);
  • Electrolyte copper deposit with the help of current sources with microprocessor control (Cu plating);
  • Chemical stannic deposit (Stannatech);
  • Plate surface treatment before multulayer board fabrication (BondFilm);
  • Secondary processes (Resist assist, Adhere promoter, etc).

Each line is formed from several units and a common transportation system. The units can be of the following types:

  • Secondary units and units for mechanical positioning of plates on the conveyor (Loader, Unloader, Positioner, CGA);
  • Units for panels cleaning between various stages of processing;
  • Units for chemical processing of panels.

Each of the units, depending on the type, can contain the following equipment:

  • pumps;
  • devices for chemistry level management;
  • devices for pre-set temperature maintenance;
  • devices for automated dosing of process solutions during operation mode;
  • a system for refreshment and maintenance of a process solution pre-set concentration;
  • current sources with microprocessor control;
  • controlled ultrasonic generators;
  • frequency converters, etc.

During the work process a panel is placed on the conveyor by automated loading device and moved with a pre-set speed by this conveyor through various processing units. Depending on the panels placement the control system enables pumps and other necessary equipment, automatically maintains the intended liquid levels and pre-set temperature values.

System functions and purpose

The main purpose of this automatic control system is to control PCB production process, automated line service operations, generation and delivery of reports and statistical data and also provide batch control. This allows us to formulate the following aims:

  • Reduction of "human factor" influence and improvement of service personnel safety during production process;
  • Waste reduction;
  • Consumables control (with the help of automated dosing);
  • Technological process logging;
  • Productivity gain;

Main system functions

  • Measurement and handling of signals from sensors and control objects;
  • Control over equipment operability (including components of automatic control system);
  • Alarm logging (hierarchical system of critical messages and events);
  • Automatic and manual management of the line;
  • Automatic maintenance of technological parameters at the intended level;
  • Automatic regeneration of expendables (solutions);
  • Technical registration of expendables;
  • Reflection of technological process parameters and support of operator interface;
  • Accumulation and storage of technological information in the database and its reflection by operator’s request;
  • Hierarchical access rights management system;
  • Data archiving system;
  • Service maintenance forecasting.

Specification

  • Hardware:
    • PC PLC, Beckhoff CPU CX1000;
    • HMI - SCADA for PC.
  • Upper-level control software:
    • fastCenter.
  • Programming language:
    • Structured text (ST);
    • Sequential Function Chart language (SFC);
    • JScript.
  • Communication:
    • Profibus;
    • CanBus;
    • Ethernet;
    • K-Bus.
  • OS:
    • Windows XP;
    • Windows CE.

Equipment

  • digital sensors;
  • temperature and level sensors;
  • frequency inverters;
  • electromotors;
  • electrovalves;
  • encoders (positioning devices);
  • pneumatic cylinders and valves;
  • heaters;
  • linear cameras;
  • loading/unloading and positioning devices;
  • current sources with microprocessor control;
  • consumption indicators;
  • ultrasonic generators.

System advantages

  • Back-up and stability of production process.
  • Accessible report system.
  • Operability and low demands to personnel qualifications;
  • Flexibility and adaptability to the customer’s demands;
  • Scalability – possibility to increase functionality or make changes in the already existing;
  • Increase in productivity, quality of production, speed, precision and flexibility of PCB assembling;
  • Easy maintenance which contributes to reduction of the total cost of ownership.