What should be paid attention to when installing and debugging equipment for CCD contraposition suction and pasting machine?

CCD alignment suction and pasting machine is a kind of high-precision automatic equipment, which is mainly used for precision pasting of electronic components and optical components. The accuracy of its installation and debugging directly affects the accuracy and production efficiency of the equipment. The following are the key points to pay attention to when installing and debugging:

First, the installation environment requirements

Site and space

The equipment should be installed on a flat and firm ground, ensuring the levelness (it can be calibrated with a spirit level) and avoiding vibration sources (such as punching machine and large motor, etc.), otherwise the visual positioning accuracy of CCD may be affected.

Sufficient operating space (at least 1m in front, back, left and right) shall be reserved to facilitate maintenance, overhaul and material handling.

Power supply and gas source

Power supply: make sure that the voltage and frequency are consistent with the nameplate of the equipment (usually AC 220V/380V, 50/60Hz). A voltage regulator or UPS is required to prevent voltage fluctuation, and the grounding must be reliable (grounding resistance < 4 Ω).

Air source: clean and dry compressed air (pressure 0.5-0.8MPa) shall be provided, and filtering devices (such as air dryer and oil-water separator) shall be installed to prevent oil pollution from blocking the air path or damaging the cylinder.

Ambient temperature and humidity

Temperature: It is recommended to control it at 20 5℃ and humidity 40%-70% RH (no condensation). High temperature may lead to the aging of electronic components, and abnormal humidity may easily lead to static electricity or mechanical parts corrosion.

Dust-proof: the equipment should be installed in a clean workshop (such as a 10,000-level clean room) to avoid dust adhering to the lens, guide rail or moving parts, which will affect the visual accuracy and mechanical operation.

Second, the mechanical parts installation and debugging

Mechanical structure installation

Guide rail and lead screw: ensure that the installation is straight and the screws are fastened without looseness. Clean the surface of the guide rail with alcohol and apply proper amount of grease (such as lithium grease) to ensure smooth movement without jamming.

Suction nozzle and fixture: select suitable suction nozzle (such as vacuum suction nozzle and electromagnetic suction nozzle) according to product specifications, and align the center when installing to ensure uniform suction and pasting strength; Fixture shall be fixed firmly, and the positioning surface shall be free from abrasion.

Motion calibration

Axis motion test: Manually operate each axis (X/Y/Z/θ axis) to check whether the motion direction is correct, whether the limit switch is sensitive, and whether there is abnormal noise or vibration during operation.

Repeated positioning accuracy: use a dial indicator or laser interferometer to detect the repeated positioning accuracy of each axis (usually ≤±0.01mm). If it is out of tolerance, adjust the gap between the lead screw and nut or the parallelism of the guide rail.

Mechanical safety protection

Install emergency stop button, safety grating and other protective devices to ensure quick stop in case of emergency; Check whether the protective cover is firm, so as to avoid safety accidents caused by exposure of moving parts.

Third, the CCD vision system debugging

Camera and light source installation

Camera fixation: ensure that the camera lens is perpendicular to the surface of the workpiece and the distance is moderate (adjusted according to the field of view) to avoid shaking; The lens should be clean and stain-free, and wiped with a dust-free cloth if necessary.

Selection and angle of light source: according to the material (such as reflective/matte) and features (such as color and texture) of the workpiece, select the type of light source (such as ring light, backlight and strip light), and adjust the angle of light source to the best image contrast (clear edge of features and no reflective interference).

Visual parameter setting

Image acquisition: adjust the exposure time and gain of the camera to ensure that the image brightness is uniform and there is no overexposure or underexposure; Use ROI (region of interest) function to focus on the detection area and improve the processing speed.

Positioning algorithm: Select the appropriate alignment mode (such as template matching, edge detection and feature point identification), and cover the possible tolerance range of the workpiece when training the template to ensure accurate identification under different angles and illumination.

Visual and mechanical coordinate calibration

Coordinate system calibration: the mapping relationship between visual coordinate system and mechanical coordinate system is established through calibration board (such as checkerboard) to ensure the accurate conversion between pixel coordinate and physical coordinate (error ≤±0.005mm).

Alignment accuracy test: use standard parts for multiple suction tests, and measure the mounting offset (X/Y direction ≤±0.02mm, angle θ ≤ 0.1). If it is out of tolerance, re-calibrate the coordinate system or adjust the camera installation position.

Four, electrical and software debugging

Electrical connection inspection

Cable arrangement: power line, signal line and gas pipe should be wired separately to avoid electromagnetic interference; Check whether the connectors (such as aviation plugs and terminal strips) are firm and clearly marked.

Sensor debugging: test the sensing distance and sensitivity of photoelectric sensor and proximity switch to ensure the normal functions of material arrival detection and suction nozzle height detection.

Software parameter configuration

Process parameters: Set the suction and pasting speed, vacuum pressure (usually-60kPa to-80kPa) and mounting pressure (adjusted according to the fragility of components, such as chip ≤0.5N) to avoid damaging the workpiece.

Program logic: write or import the production program to verify whether the process is correct (such as material picking → visual alignment → load shifting → mounting → detection), whether the actions are connected smoothly and whether there is interference risk.

Linkage test

Manual mode: test the single-step actions such as picking, moving, aligning and mounting in turn, and observe whether the mechanical motion is synchronized with the visual feedback (such as whether the camera trigger signal is consistent with the motion stop).

Automatic mode: run the whole process, continuously test for 50-100 cycles, check the stability of the equipment (such as nozzle blocking rate < 0.1%, mounting yield ≥99.5%), record abnormal data and optimize parameters.

V. Safety and Reliability Testing

Electrostatic protection

Equipment should be grounded, operators should wear anti-static bracelets, and anti-static rubber covers should be laid on the workbench to avoid electrostatic damage to precision components (such as CMOS cameras and chips).

Overload protection test

Artificial simulation of mechanical jamming, vacuum leakage and other faults, check whether the equipment can automatically alarm and stop, and whether the protection mechanism (such as anti-collision sensor and overload clutch) is effective.

Long-term operation test

Run continuously for 8-24 hours, monitor the temperature of heating parts such as motor and driver (temperature rise ≤30℃), and check the lubrication state of guide rail to ensure that there are no abnormalities such as oil leakage and abnormal sound.

VI. Documentation and Training

Record debugging data

Save the installation and debugging report, including environmental parameters, mechanical calibration data, visual parameters, test yield, etc., for subsequent maintenance reference.

Operation training

Conduct safety training (such as emergency shutdown process) and skills training (such as parameter adjustment and simple troubleshooting) for operators to ensure the correct use of equipment.

summary

The coordination of mechanical precision, visual algorithm and electrical control should be taken into account in the installation and debugging of CCD contraposition suction machine, and the key lies in accurately calibrating coordinate system, optimizing visual imaging quality and verifying equipment stability. The debugging process should be carried out step by step, from single machine action to whole process linkage verification step by step, to ensure that the equipment meets the design accuracy and production requirements.