After the automation transformation of the reflow soldering process production line, the efficiency improvement is usually 30%~60%, which is affected by the transformation plan, the existing production line foundation, and the matching degree of the front and rear processes.
1, The core efficiency increment source of automation transformation (1) Invalid time-consuming compression
Automatic temperature control curve closed-loop control replaces manual temperature control, eliminating rework caused by temperature deviation (virtual soldering, continuous soldering, solder balls) and reducing rework time by 15% to 25%;
Automatic loading and unloading, online turnover line replaces manual handling, compressing PCB circulation time from 100-120s/block to 20-30 s/block, reducing changeover and waiting time by about 20% -30%; (2) Abnormal shutdown reduction
Automatic scanning to prevent errors and real-time alarms for process abnormalities replace manual inspections, avoiding unplanned downtime caused by missed operations and inspections, and reducing downtime by 10% to 20%;
2, Efficiency improvement range of different transformation schemes (1) Local automation transformation (only upgrading loading and unloading)
The increase range is 20%~30%; (2) Moderate automation transformation (upgrading temperature control+loading and unloading)
The improvement range is 40%~50%; (3) Full process linkage automation transformation (including online AOI and MES linkage)
The increase range is 55% to 60%;
3, Boundary limitations for efficiency improvement (1) upper limit of production line rhythm
If the original reflow soldering equipment has reached the rated maximum cycle time (such as 12 pieces/minute), the efficiency improvement space after the transformation can be compressed to within 10%, which can only reduce the ineffective time consumption; (2) Matching of front-end and back-end processes
If the production capacity or rhythm of the front-end SMT placement machine does not match the automated production capacity of reflow soldering, the efficiency improvement of reflow soldering will be offset by more than 30%; (3) Personnel operation adaptation
It is necessary to match the operating specifications of automation equipment. If the frequency of personnel misoperation is too high, the actual improvement will be reduced by 15% to 20%.
