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SMT Patch Production Management: Key Steps and Considerations from a Technical and Management Perspective
- Oct 25,2024
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In the intricate ecosystem of electronics manufacturing, the Surface Mount Technology (SMT) patch process constitutes the core link for guaranteeing the quality and performance of electronic products.
From the perspective of production management, an in-depth analysis of the key steps and precautions of SMT patches not only encompasses the precise application of technology but also covers effective management strategies.
Firstly, Solder Paste Printing: Collaboration between Technology and Management
Critical Step Device Preparation and Parameter Setting
Before commencing solder paste printing, technicians are required to select the appropriate solder paste printing machine based on the design requirements of the PCB (Printed Circuit Board). This involves considering the type, function, and accuracy of the printing press.
Precisely set printing parameters, such as scraper speed, pressure, angle, and release speed. These parameters directly influence the printing quality of the solder paste on the PCB pad
Solder Paste Selection and Management
From among numerous solder paste products, select the appropriate solder paste based on the PCB material, component type, and subsequent reflow soldering process requirements. This necessitates an in-depth comprehension of the composition, melting point, viscosity, and other properties of the solder paste.
The storage management of solder paste is of great significance. Storage should be conducted in accordance with the specified temperature and humidity conditions, and the necessary stirring should be carried out before usage to ensure the uniformity of the solder paste.
Template Installation and Alignment
Install a steel mesh template that precisely aligns with the PCB design, ensuring that the openings on the template correspond precisely to the positions of the PCB pads. This demands a high degree of accuracy, often achieved with the assistance of high-precision positioning devices.
Precautions - Integration of Technology and Management
Technical Specifications
The selection of the material and shape of the scraper should be based on the characteristics of the solder paste and printing requirements. For instance, a higher hardness scraper might be necessary for a high-viscosity solder paste.
Regular technical maintenance of the printing machine should be conducted, checking the flatness of the scraper, the flatness of the printing platform, etc., to ensure that the printing accuracy remains within the allowable error range.
Management Strategy
Establish a rigorous solder paste usage registration system to record the batch, usage time, remaining amount, and other information of the solder paste for traceability and quality control.
Formulate a detailed plan for the maintenance and replacement of the template, regularly check the wear of the template, and repair or replace it in a timely manner according to the degree of wear.
Secondly, Component Mounting: Technical Control and Management Supervision
Critical Step Feeding System Configuration
According to the production plan and the type and quantity of PCB components, the feeder is rationally configured on the SMT machine. This requires a clear understanding of the type, capacity, and speed of the feeder.
The precise parameters of the feeder are set, including the spacing of components, the feeding sequence, etc., to ensure that components can be accurately and continuously supplied to the mounting position.
Component Identification and Mounting Positioning
The SMT machine employs an advanced visual recognition system to identify components and determine their shape, size, polarity, and other crucial information.
Based on the identification results, the components are precisely mounted to the corresponding solder paste position on the PCB, a process that demands a high degree of positioning accuracy.
Precautions - Equal Emphasis on Technology and Management
Technical Focus
Regularly calibrate the visual identification system and update the component database to adapt to the identification requirements of different types of components.
Optimize the mounting path algorithm of the mounter, enhance the mounting efficiency, and ensure the mounting accuracy. For example, the shortest path algorithm is utilized to reduce the travel distance of the mounting head.
Management Action Follow-up
Establish the daily inspection system of the feeder, promptly discover and resolve the issues that might arise in the feeder, such as material jamming and material shortage.
The quality of incoming components shall be strictly managed, and the standards for sampling and full inspection shall be formulated to prevent defective components from entering the mounting process.
Thirdly, Reflow Soldering: Technical Support and Management Optimization
Critical Step
Welding Furnace Parameter Setting
Based on the characteristics of the solder paste and the PCB structure, set the temperature curve of the reflow soldering furnace. This encompasses multiple parameters such as temperature and time in the preheating zone, constant temperature zone, reflow zone, and cooling zone.
Adjust the transfer speed of the welding furnace to ensure that the PCB can complete the soldering process in each area within the furnace as per the set time.
Furnace Environment Control
Monitor and control environmental factors such as oxygen content and airflow speed within the welding furnace to reduce oxidation and enhance soldering quality.
Note - Parallel Technical Management
Technical Requirement Implementation
With the aid of temperature sensors and thermal imaging technology, monitor the temperature distribution within the welding furnace in real-time and adjust the temperature curve promptly to ensure temperature uniformity.
Regular technical inspection and maintenance of key equipment such as the heating element and ventilation system of the welding furnace should be carried out to ensure its normal operation.
Management Work Development
Formulate the operation procedure of the welding furnace, clarify the responsibility and operation process of operators, and prevent soldering quality issues caused by improper operation.
Establish maintenance files of the welding furnace, record the content, time, maintenance personnel, and other information of each maintenance to facilitate equipment management and quality traceability.
Fourthly, Testing and Repair: Technical Support and Management Coordination
Critical Step
Detection Method Selection and Execution
According to the quality requirements of the product and the characteristics of the production process, select the appropriate inspection methods, such as automatic optical inspection (AOI), X-Ray inspection, etc.
Conduct a comprehensive inspection of the welded PCB in accordance with the testing standards and mark the parts with soldering defects or component mounting issues.
Repair Operation Implementation
For the detected nonconforming products, professionally trained technicians will carry out repair operations, including re-welding, component replacement, etc.
Note - Technical and Management Coordination
Technical Operating Instructions
Regularly calibrate AOI and X-Ray inspection equipment, adjust the detection algorithms and thresholds to improve the accuracy of inspection.
Repair personnel should master the repair techniques for different types of soldering defects, such as the use of appropriate soldering iron power, soldering time, and soldering materials.
Management Coordination Mechanism
Establish the statistical analysis system of test results, through the analysis of test data, identify the weak links in the production process, so as to adopt targeted improvement measures.
Strictly manage the repair process, record the reasons for repair, repair times, repair personnel, and other information to prevent excessive repair leading to a decline in product quality.
In the SMT patch production process, technology serves as the cornerstone for achieving high-quality products, and management ensures the effective application of technology, an efficient and stable production process.
Only the organic combination of technology and management can achieve multiple goals such as product quality, production efficiency, and cost control in the fierce competition within the electronic manufacturing market.
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