The installation and adjustment of a CCD alignment pick-and-place machine directly affect the equipment's precision and production efficiency, requiring strict control from multiple dimensions such as the environment, mechanical structure, vision system, and pneumatic control. Below are the key requirements and operational guidelines:

I. Installation Environment Requirements

1. Site and Foundation

Floor Flatness: Calibrate with a level, ensuring the floor flatness error is ≤0.2mm/m. Fix with anchor bolts or shock-absorbing pads if necessary to avoid vibration affecting alignment accuracy.

Space Layout: Reserve ≥1.2m of operational space around the equipment, and ensure the top allows for the maximum range of the robotic arm for easy maintenance and loading/unloading.

2. Environmental Control

Temperature and Humidity: Maintain an operating environment of 20±2℃ and 45%–65%RH to prevent thermal expansion/contraction of mechanical components or fogging of optical elements.

Cleanliness: Preferably used in a class 10,000 cleanroom or equipped with local purification devices to reduce dust contamination on lenses, nozzles, and products.

Power Supply and Grounding: Provide a stable AC 220V±10%/50Hz power supply with a grounding resistance ≤4Ω to avoid electromagnetic interference with the control system.

II. Mechanical Structure Installation and Adjustment

1. Machine Body and Rail Calibration

Leveling Adjustment: Use a high-precision level to check the machine body, controlling the levelness error within ≤0.1mm/m to ensure the straightness and perpendicularity of the X/Y-axis rails (perpendicularity error ≤0.02mm).

Lubrication Maintenance: Apply lithium-based grease to linear guides, lead screws, and other transmission components to ensure smooth movement without jamming.

2. Pick-and-Place Head (Robotic Arm) Debugging

Verticality Calibration: Use a square or laser interferometer to check the verticality of the pick-and-place head relative to the worktable, with an error ≤0.05mm to avoid tilting during picking/placing.

Pressure Control: Set the pick-and-place pressure (typically 5–10N) using a pressure sensor or pressure regulating valve to ensure components are securely 吸附 (adsorbed) without damaging the product.

3. Fixture and Stage Installation

Positioning Accuracy: Fixtures must be strictly aligned with the equipment’s coordinate system via reference pins or optical positioning holes, with a positional error ≤0.03mm to avoid cumulative deviations in batch production.

Surface Flatness: Check the stage with a dial indicator, ensuring a flatness error ≤0.02mm to prevent uneven stress on components during placement.

III. Vision System (CCD) Debugging

1. Camera and Light Source Installation

Installation Precision: Mount the camera perpendicular to the work surface, with the lens center deviating from the pick-and-place head center by ≤0.1mm to avoid perspective distortion; adjust the light source angle (e.g., ring light, coaxial light) based on product characteristics to ensure shadow-free imaging.

Focus and Aperture: Adjust the focus using a calibration plate to achieve the highest image resolution (pixel accuracy ≤0.01mm/px), and balance the aperture for depth of field and brightness to avoid overexposure or blurring.

2. Vision Algorithm Optimization

Coordinate System Calibration: Establish a pixel-to-physical coordinate mapping using a chessboard calibration plate, with an error ≤0.02mm; perform drift compensation before each shift to ensure coordinate accuracy.

Alignment Algorithm Setup: Select edge detection or template matching algorithms based on component types (e.g., chips, films), and adjust thresholds and contrast to reduce background interference, with an ideal alignment error ≤±0.05mm.

3. Dynamic Linkage Calibration

Fly Shooting Technology: Compensate for mechanical vibration deviations by taking dynamic photos during pick-and-place head movement to ensure alignment accuracy at high speeds.

Delay Compensation: Calculate the time difference between vision processing and mechanical movement, and eliminate delays by triggering photos in advance or pre-displacing the head.

IV. Pneumatic and Vacuum System Adjustment

1. Air Pressure Control

Maintain a stable air supply pressure of 0.5–0.7MPa, using filters to remove moisture and impurities; adjust the nozzle vacuum according to component weight (typically -50 to -80kPa) to avoid misalignment or component damage.

Ensure smooth air tube routing without bending or tangling, with a suction/placement response delay ≤50ms.

2. Nozzle Maintenance

The coaxiality deviation between the nozzle and pick-and-place head center should be ≤0.03mm. Regularly check airtightness with a negative pressure gauge and replace worn or blocked nozzles.

V. Electrical and Control System Debugging

1. Sensor Calibration

Photoelectric sensors (home position, limit switches) should have a trigger position error ≤0.5mm; proximity sensors must detect distances within the design range (typically 2–5mm).

Calibrate the zero point and range of tension sensors to ensure tension fluctuations in the material tape ≤±5%.

2. Motion Parameter Setup

Speed Matching: High-speed movement ≤500mm/s, low-speed alignment ≤50mm/s, with acceleration/deceleration times controlled at 0.1–0.3s to reduce inertia deviations.

Safety Protection: Emergency stop buttons and safety gratings should respond within ≤100ms, and the alarm system must display real-time fault information (e.g., insufficient vacuum, missing components).

VI. Comprehensive Testing and Trial Operation

Single-Machine Calibration: Use a standard fixture for empty running tests, with the pick-and-place head’s repeat positioning error ≤±0.03mm.

Pilot Production Verification: Test yield (target ≥99.5%) and production capacity (e.g., placement speed ≥3000pcs/h) with actual products, fine-tuning vision tolerances and pick-and-place pressure.

Long-Term Stability: Run continuously for 8 hours, monitoring temperature rise of key components (≤45℃), vibration (acceleration ≤0.5g), and precision drift (≤0.01mm per hour).

Daily Maintenance Key Points

Cleaning and Maintenance: Wipe lenses, guides, and nozzles daily; check screw tightness and lubrication status weekly.

Wear Part Replacement: Regularly replace nozzles, seals, light sources, and other components to avoid performance degradation.

Personnel Training: Operators must understand the equipment’s principles and are strictly prohibited from 擅自 modifying (arbitrarily modifying) vision parameters or mechanical structures.

By following these steps, the CCD alignment pick-and-place machine can achieve high-precision and high-efficiency operation, minimizing production losses and downtime.