Essential support
07 September 2006
Novatec, a research laboratory based in France developing new technologies for the electronics assembly industry, have recently developed VacuNest
VacuNest is an advanced shape memory tool for board support that has industrialized the electronics industry on a worldwide basis. Board support is critical within any printer, dispenser and pick-and-place machine in order to run a repeatable process. A custom dedicated machined tooling plate is a solution but it must be planned well in advance because the plate must be designed and then manufactured, but even then this can be costly. Magnetic tooling pin posts and auto pin tooling do offer a flexible solution, but are limited to their pitch and the area they can support.
VacuNest, with its shape memory tool, combines a custom tooling plate with the versatility of pins. An antistatic membrane covers a foam former surrounded by polymer granules. By placing a golden board onto the modules, pressing down, pulling a vacuum, the memory of the board shape profile is held. The chambers are profiled to the shape of the underside of the board _ on activation of the vacuum this shape is now held. The shape will be held until the vacuum is released, whereupon the modules return to their original form, awaiting a new set up for the next version of board. Technical specifications include modules height adaptable to the different equipment, no machine interface, compressed air as the power supply, a 50mm module width, a support length of 480mm and different design possibility.
Board characteristics are board width of 60 - 500mm, bottom side component height of 0 - 12mm, a board thickness of 0.5 - 5mm and maximum board length of 450mm.
There is no risk damage to a component due to the pin/pressure, the support forces are evenly spread over the entire board, the tooling provides precise support, and the shape tool can be reset when a board version changes.
With flexible pin arrangement tools, the support force is applied locally (components can be damaged under the joint action of the pins and the squeegee/transfer head). VacuNest solves this problem by applying firm force consistently to the entire board. VacuNest can be implemented in three steps:
Position required number of modules to suit board width.
Set up tooling plate - with board at print position, place tooling plate on conveyor rails, press down and switch on vacuum _ modules hold board profile.
Run. Production provided vacuum is held (auto regulated) and the shape will hold indefinitely.
Three examples of customers throughout Europe who have implemented VacuNest in their facilities are CRDE, Sigmatek GmbH and Dolby Laboratories Inc.
CRDE, a French subcontracting company involved in Electronics, work for the air industry, bus transmissions, radio and powerline communications. The company has been using two VacuNest systems on its printer for more than a year. CRDE's technical manager is pleased with the time savings achieved during each production change (at least one change per shift).
Sigmatek GmbH called upon Novatec and the VacuNest for help. The comapny needed a flexible resource that would result in both time savings and support. The VacuNest was implemented on both systems. Sigmatek's manufacturing manager reported that both targets have been met by the VacuNest.
Dolby Laboratories develops and delivers products and technologies for the entertainment industry. The facility in Wootton Bassett has its own SMT production manufacturing line producing Dolby's products. After installing VacuNest, Gordon Lawless, the Senior Manufacturing Process Engineer at Dolby, commented: "VacuNest has dramatically reduced setup at each production change, alleviating bottlenecks and increasing accuracy."
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