From depanelizing to highly efficient automation lines with IPTE

Sales Director Rainer Krohmann and Dr. Jörg Handke, Business Unit Manager Systems, from the company’s German office in Heroldsberg, discuss the success and benefits of the systems. “Our market position has become clear by the matter of fact that customers often come to us with demand for an efficient depaneling machine. And then as further discussions and questions on application, handling, functionality and automation reveal, they are going to order a comprehensive automation solution, including the router, for their electronics production, because our highly flexible and efficient range of equipment has convinced them.”

Solutions with flexibility

It is important, as the managers make clear, that as a supplier of such system solutions, the company has always actively and cooperatively taken up the requirements of the market and then, on a case-by-case basis, implemented promptly the relevant options requested. In this case, they are also a competent partner for users resolving such projects. After all, these system solutions have to exhibit their performance in daily operation. “The feedback from our customers in the field, with whom we generally maintain long-term and trustful relationships, including the exchange of special know-how, is very important for such further developments,“ emphasizes Rainer Krohmann. This also applies to upcoming manufacturing concepts, such as Industry 4.0/Smart Factory and their implementation.

In addition, there are user requests for easy program generation and CAD import of product data, high flexibility and functions, such as the optimization of the edge-cut procedure, detailed system monitoring and ergonomics, as well as application-specific customization and user aids. As Dr. Handke states, “operation, programming and maintenance must be practically intuitive and self-explaining. Straightforward and machine-aided troubleshooting, as well as preventive maintenance and statistical process control (SPC), are inherited elements of our machine concept. Of course, also a reduction of downtime is very important, because shutdowns in lines are always very costly. The system also includes so-called software wizards for providing user assistance. It is not exaggerated to say that our software has now become a unique selling point in the equipment design.“

Transparent cost and quality situation

“To set up a cutting process, the operator has to only follow the carving process on the panel with the aid of the machine. The result, including possible optimization, is thus immediately available. The transfer of CAD data to a cutting program is likewise convenient. Because the trend towards smaller boards is increasing, panels with 256 single assemblies are already a reality in production, high precision and cutting speed are essential. Also, we have further optimized the management of dust generation and extraction as well as the reduction of operating noise. And, of course, the exact monitoring of tool wear or tool breakage as well as statistical evaluation and traceability are included in the performance machine package. And for production monitoring, users can extract the data from the running process and prepare it immediately,“ Dr. Handke further explains. Therefore, not only the costs for the separation of a single board assembly are transparent for the user, but also the quality of process and product.

No wonder that besides the outstanding hardware design, the company also gives high priority to software development. Rainer Krohmann underlines the current development in this topic of interest in the industry and its impact on the company: “For some time now, we have been hiring an above-average number of employees in the software area, in order to meet the increasing demands in the application, optional enhancement, functionality and user-friendliness. The software‘s proportion of added value in our machines is thus constantly increasing.“

Frameless routing increases efficiency and profitability

As well as on the hardware side, highly innovative solutions continue to be developed. As Dr. Handke, responsible for the design of the SpeedRouter and FlexRouter II product families, points out: “With the new frameless routing (option), we are now increasing the efficiency of the FlexRouter II. Because with frameless routing, i.e. without the use of frames, there are only very few circuit board leftovers.“ This is also interesting from both, an ecological and a cost-related point-of-view, because it reduces the amount of non-recyclable material and therefore reduces the amount of waste that has to be disposed of. This solution also features a transport mechanism without any edges, which enables fast, stress-free and precise separation by milling. Further enhancements in the cutting process are the outstanding board cut quality, in which no torque (force) is applied to the part singularized, whereby the grippers work without any distortion and with absolute positioning accuracy.

A system was developed according to customer specifications in which the panels are processed via 12 motorized axes, and additional processes are also integrated into the depaneler machine. In addition to the relevant cutting options, such as sawing, milling or laser operations as well as various application-specific gripper mechanisms, the integration of in-line cells for handling, transport, stacking and barcode reading or writing, is also part of feasible system configurations. Furthermore, optionally available are optical process monitoring as well as the measurement and control of the singularized boards by automatic vision system (AOI). The outstanding performance of the equipment used is, of course, decisive for meeting the requirements of the customers with high precision, speed, availability and economy. “It goes almost without saying, the implementation of all relevant industry standards and interfaces for automation in electronics manufacturing is an essential task for us,“ adds Sales Director Krohmann.

High-speed and precision

For IPTE as a supplier, this means that the range of solutions extends from various in-line systems for the large volume to small series production, each of which can be specifically configured according to application requirements. The high efficiency can also be seen, for example, with maximum cutting speeds of up to 60 mm/s, resulting in short processing times of approx. 1 to 1½ seconds per board. Line cycle times in the region of 7 seconds can, therefore, be realized without complications, depending on the user‘s requirements. In addition, there are very small positioning tolerances of the axes (repeatability) in the order of ± 1–2 µm and, as Dr. Handke explains, „with this specification we have clearly a leading position in the depaneler industry. A further decisive factor of economic efficiency is also the fast retooling and high user-friendliness of the machines, as well as the very small footprint required on production floors. In general, space is very limited here and therefore also a cost factor that should not be underestimated.“

The technology of the company’s equipment can also be seen in other relevant characteristics. The automation specialist also implements additional work cells into the integrated line, such as odd-form assembly, electrical and/or electromechanical testing back-end tasks, etc., right through to the packaging of the finished product. Users can thus put together turnkey production configurations that are individually tailored to their specific requirements. Irrespective of whether the product mix consists of small and medium-sized production batches or very large volumes of practically identical boards, the configurations can be matched precisely to the production volumes and individual automation concepts. Dr. Handke comments: “Of course, a system solution must be exactly tailored to the task and the customer‘s requirements. Parameters, such as cutting speed and cycle time, are just as important as the quality of the cut-out edges of the material, the efficiency of the dust extraction or the required space on the production floor.“

And as Rainer Krohmann adds: “As a general contractor for a complete production line, our customers can take it for granted that IPTE is fully in charge of adhering to the performance parameters of such system solutions and of the smooth integration and operation of the individual modules and processing stations. The advantage for the customer is quite obvious: there is always only one contact for whatever issue may turn up, namely, just us“. As both, Business Unit Manager Systems Dr. Handke, and Sales Director Krohmann, conclude commonly: “It is essential, in addition to flawless, efficient and safer processes and procedures, that we offer our customers optimal and trouble-free operation of their plants and systems with an explicitly increased added value.“ The current position on the market, which the managers describe in unison positively, shows that the company‘s machine concept turned out a grand success: “The demand for our depaneling systems continues to be high. Since 2016, we have been able to increase sales significantly by more than 100 %, and even this year and next year, we can also expect excellent figures of plus 50 %.“ (Gerhard B. Wolski)

productronica, Booth A1-534

www.ipte.com

• IPTE Germany GmbH