Newsletter 12/2015

Self-organizing materials
logistics with PULSE UNITR
ASYS Group Newsletter 12/2015
Fair impressions
08
OPAK research project
10
New EKRA Printer
12
Content
04
ASYS Software Solutions
PULSE UNITR
06
INSIGNUM Marking
Sophisticated calibration
08
Impressions
Productronica 2015
10
ASYS Group
OPAK research project, Success Story
12
EKRA
New Printer SERIO 5000
14
DIVISIO Depaneling
New Depaneling System DIVISIO 6000
16
ASYS Solar
Research project Rock-Star
18
ASYS Group
Short News, Success Story
04
06
08
11
14
19
ASYS GROUP Newsletter | 3
PULSE UNITR
ASYS optimizes material logistics within SMD production. An
autonomous transport robot – PULSE UNITR – supplies the
SMD line continuously with material. Intelligent loading and
unloading systems communicate with the mobile robot, allowing self-organizing materials logistics.
The VEGO Dynamic line loader sends a signal to the mobile robot via the ASYS PULSE software, instructing the
robot to replace the empty magazine. The PULSE UNITR
robot navigates autonomously through the production
area, finally docks to the loading system and swaps the
empty magazine for a full magazine. This automated
process eliminates the physical exertion required of
operators and users. In addition, it significantly increases
the transport safety, and the operator can perform other
activities. Valuable time and costs are saved.
› Seamless integration into the existing infrastructure
› Flexible configuration for different needs
› Independent and fully automated module changes
› Increases the safety of manufacturing processes
Advantages PULSE UNITR
Besides traditional robots in industrial environments,
mobile transport robots are rather new in SMD production. However, there is high potential for autonomous
material transport. Not only magazines can be transported, transportation of feeder carts, component reels,
stencils, or trays would be possible as well. The fields of
application are plentiful.
ASYS GROUP Newsletter | 5
Calibration process in SIMPLEX
Precision
The ASYS SIGNUM 4000 laser marking system has a superior
positioning accuracy of 150µm@5Sigma. Sophisticated calibration, powerful linear drives and a high resolution camera make this
possible.
Factors influencing the accuracy
To ensure proper identification and full traceability,
printed circuit boards are marked with a complex Bar
or Datamatrix code. ASYS specializes in using laser for
direct labeling. In addition to printed circuit boards, any
other material can be marked as well, such as metal,
plastic or ceramic.
The available space for markings on printed circuit
boards gets increasingly smaller, which is why precise
positioning is becoming more and more important in
laser marking. Various factors influence the positioning
accuracy of a system. A high-resolution camera for clear
detection of reference points, a robust machine construction to compensate forces from the axis system
and possible vibrations and precise calibration of the
system are crucial.
Sophisticated calibration for accurate marking
The ASYS developer team succeeded in designing a
unique method for calibrating laser marking systems
that ensures top precision. The machine is fully calibrated within just a few minutes without using an external
measuring device. There are no unnecessary downtimes, and the machine is quickly ready for use again.
What is special about this: the operator can perform the
calibration at any time quickly and independently. The
intuitive SIMPLEX user interface guides him through
the process with simple steps. The camera is calibrated,
while the axis system is aligned at the same time. This
so-called mapping process is performed by using a glass
plate on which a special dot pattern is applied. Then the
marking field of the lens is calibrated and the offset from
the PCB zero point is determined.
This entire calibration process is completed in less than
ten minutes. The operator then receives in SIMPLEX an
evaluation of the X/Y deviation including a machine capability indication.
Glass plate with dot pattern
ASYS GROUP Newsletter | 7
Impressions
The focus of this year’s Productronica trade show was on
future-oriented solutions for Industry 4.0. The PULSE live line
was a magnet for visitors to the ASYS Group’s booth of more
than 350 square feet.
A highlight of the first days of the
trade show was the presentation of the Innovation Award. The
ASYS PULSE software solution
was honored with the “Productronica Innovation Award” as the
best future-oriented product innovation in the category of “Future
Markets Cluster.”
“The four days of the trade show
were a huge success! The interest
in sustainable solutions such as
our PULSE connection to autonomous robots, which continuously
attracted many visitors, was overwhelming,” says Karin Walter, Vice
President of Product Management
and Marketing.“
ASYS GROUP Newsletter | 9
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OPAK
More throughput thanks to ASYS software
In the topical OPAK (Open Engineering-Platform for autonomous, mechatronic Automation Components) research
project, ASYS – along with seven other cooperation partners
– develops intelligent machine components for the smart factory of the future.
The OPAK project team develops hardware components
and software tools to simplify complex engineering processes. A key element of the development process is a
simulation software that creates a virtual, fully functional
model of the planned system. This 3D-supported, innovative engineering tool will enable a simple and purely
function-oriented view of highly complex automation
processes. It will allow the developer to concentrate
on the actual process flows. Focusing on an abundance
of details of abstract IT variables and terms will no
longer be necessary. Processes can be simulated and
sequences can be precisely planned already in advance.
The OPAK research findings will demonstrably make
the design of automation systems simpler, faster
and more cost-efficient.
In addition to software tools, it is a main objective of
the consortium to implement plug-and-produce-capable
machine components. Flexible and alterable production
systems will play a critical role in production systems
of the future. Machines are expected to adapt faster
and more efficiently to individual products, without the
need for costly modifications and reprogramming. For
example, smart grippers have been developed that
can be exchanged in a matter of seconds like USB
devices.
The grippers inherently carry the required software modules, miniaturized control electronics, and valve blocks
that allow them to configure themselves automatically
after connecting. This means production can be automated in a highly flexible manner with minimized retooling
costs, paving the way for Industry 4.0.
The Bruchsal manufacturer of geared motors, servo
drive systems and industrial gear units has equipped
parts of its production with the ASYS line software OIC
(Overall Inline Communication). This software allows
operators to monitor and control the line status, as
well as the product and manufacturing events in real
time.
With OIC, creating and setting up new products is extremely fast, because cross-line product control is possible during production on a central computer. Thanks
to a central setup process, manual change on individual
equipment is eliminated. This reduces line downtime, increases productivity and reduces possible setup errors.
small lot sizes,“ enthuses Bernhard Kirchgaessner,
head of the Automatic Assembly Department at SEW
Eurodrive. Using special ASYS buffer systems, equipped printed circuit boards can be stored temporarily to
effectively bridge production times of the furnace and
avoid line downtime.
In the future, ASYS will further expand the Software Solutions division. In 2016, the OIC modules will
become an integral part of the PULSEONE product
portfolio.
Even different products with different widths can be
easily processed within a line. With OIC, each facility converts itself automatically and gets ready for the
product to be processed. And what’s truly special: not
only ASYS modules are controlled, but also machines of
other manufacturers such as placement systems, furnaces and automatic, optical inspection systems.
„With the help of OIC line software, it is possible to manufacture even small lot sizes, down to size one, economically on a line. Thanks to the clever ASYS software
and a special type of machine setup, the throughput
can be increased by around 8%, especially with
Sebastian Eise (ASYS Group Sales) and Bernhard Kirchgaessner (SEW Eurodrive)
ASYS GROUP Newsletter| 11
› Print repeatability of ± 20µm@6Sigma
› iROCS light oscillating stencil cleaning
system for perfect and fast stencil
cleaning
› iQUESS squeegee quick-exchange
system and the closed loop print head
› Easy and comfortable operation thanks
to SIMPLEX user interface
Features SERIO 5000
For demanding
applications
The new EKRA printing system, SERIO 5000, is designed for
demanding tasks that require high printing accuracy and excellent quality of the final product. Electronic manufactures
from the areas of Automotive, Life Science and Medicine can
should be delighted.
It is based on a platform concept and can be fitted at any
time with a wide range of options and features to flexibly adapt it to individual needs. Future extensions can be
added either directly during the initial configuration or
later in everyday production.
With a cycle time of seven seconds (plus processing
time), SERIO 5000 is one of the most accurate and fastest printers in its class. In addition to automatic paste
height monitoring, adjustable clamping pressure for
lateral clamping of PCBs, a temperature and humidity
sensor is included in the standard version.
There are currently two models within the platform. The
printing system SERIO 5000 Volume contains all the features of SERIO 5000 and is additionally equipped with
the following features. The package offers everything
that is necessary for realizing demanding applications.
ASYS GROUP Newsletter| 13
All-rounder
ROTARY TABLE
The DIVISIO 6000 Speed depaneling system is a multi-function cell for maximum throughput. The high productivity is
achieved by a central rotary indexing table. This allows direct
integration of modular final assembly processes, simplifies
product handling and significantly increases throughput.
FOR UP TO 12 STATIONS
Dispensing/Potting
The DIVISIO 6000 high-end depaneling system can
be extended by additional process steps. The existing
„Depaneling“ and „Feeding into the follow-up process“
functions are supplemented with final assembly features. This provides an essential benefit: the single circuit picked up at a specific location can be placed directly after cutting on a deposit position of a rotary indexing
table or a shuttle system by the first carbon axis, to be
supplied to the downstream processes. The second carbon axis removes the single circuits again after the final
assembly process. Thus, several process steps can be
integrated in a minimum of space. Any modules or paths
between the modules are not necessary.
End-tested single circuits possible
Another advantage lies in the test and documentation
of single circuits. The new DIVISIO 6000 depaneling system makes it possible for the first time to pass on endtested single circuits to the downstream process. Previously, all test steps were carried out in the panel, and
then the results were sent to the depaneling system,
which then individually cut each single circuit. DIVISIO
6000 checks each single circuit and then provides it with
appropriate test content. At the same time, parts are
diverted for reworking while good parts are placed into
blister trays. Using a kind of drawer system, the reworked single circuits can then be re-inserted, where the
circuits are identified through the previous marking.
Assembly
Carbon axes inside
Laser Marking
Testing
ASYS GROUP Newsletter| 15
Rock-Star
As part of the Evaluation and development of rotary printing methods for the manufacture of Si solar cells (Rock-Star) research
project, a group of renowned industrial companies has now set
itself the goal to explore and evaluate the possibility of using this
technology for the manufacture of Si solar cells.
The German PV industry is facing new challenges due
to the current change in the solar sector. It is important
to address the existing overcapacities and the immense
cost pressure in the production of solar cells and solar
modules with new, innovative concepts and a new generation of production techniques. Special emphasis is
placed on costly process steps such as front and back
metallization, where innovative and material-saving
manufacturing processes could significantly contribute
to reducing manufacturing costs. In particular, the front
metallization process requires high precision. Extremely
fine contact fingers with the width of a human hair must
be accurately printed on the surface of ultra-thin silicon
wafers without interruption at a high throughput. The
aim is to reduce the consumption of expensive silver without a loss in conductivity. This technological challenge
places high demands on the automation technology and
the materials used.
As a new technical solution for the metallization of solar
cells, rotary printing methods such as flexography, rotary
screen printing and indirect gravure printing are taken
into consideration. Rotary printing processes are mainly
used when fine structures have to be transferred at high
throughput rates.
Germany as the production location stands for decades
of experience and global technology leadership in the
construction of high-precision rotary printing machines.
From today’s perspective, it cannot be assessed yet to
what degree the advantages of rotary printing can be
transferred to solar cell printing. To clarify this question,
intensive collaboration of leading industry partners and
research institutes in photovoltaics, mechanical engineering and printing technology is indispensable.
As part of the Evaluation and development of rotary printing methods for the manufacture of Si solar cells (RockStar) research project, a group of renowned industrial
companies has now set itself the goal to explore and
evaluate the possibility of using this technology for the
manufacture of Si solar cells. The joint project belongs to
the R&D Funding Measure for Photovoltaics as part of
the German Photonics Research Funding Program of the
Federal Ministry of Education and Research (BMBF).
Composite partners
› ASYS Automatisierungssysteme GmbH
(Coordination)
› Fraunhofer Institute for Solar Energy
Systems (ISE)
(Co-coordination)
› ContiTech Elastomer Coatings GmbH
› Gallus Druckmaschinen GmbH
› Rehm Thermal Systems GmbH
› Somont GmbH
› Technische Universität Darmstadt Institute of Printing Science and Technology
Associated partner
› Hanwha Q Cells GmbH
› Marabu GmbH & Co. KG
› Kurt Zecher GmbH
Partner
Metallization line for Si solar cells
Flexographic printing front side metallization with laser-engraved elastomer printing form
(Source: FhG ISE, ContiTech)
ASYS GROUP Newsletter| 17
Short News
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In Thomas Hirschfeld and Wolfgang Steinbach, the ASYS Group was able to attract two seasoned sales professionals to strengthen its sales team in Germany.
Wolfgang Steinbach has over 20 years of experience in the electronics industry.
Most recently, he worked in the distribution of placement systems and SMT
equipment. Starting November 1, 2015, Wolfgang will oversee the ASYS „Germany North Center“ sales region. Thomas Hirschfeld worked in various industries
in sales, focusing most recently on handling and laser marking systems. With
immediate effect, he will represent the ASYS Group in the „Germany North-East“
sales region.
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Thomas Hirschfeld
Wolfgang Steinbach
ASYS honors APP Electronics as “Distributor of the Year 2015”
ASYS recognises the performance of its best resellers every year with
an award. APP Electronics has been a distributor for ASYS Group products for over 14 years. “That’s why it’s great to see that our continuing
efforts and expertise is appreciated and rewarded. It’s an honour to be
this year’s winner. Cooperation between our two businesses is excellent, and I look forward to more of that, but this adds a lovely shine to
the relationship,” says APP Managing Director Jack Daly. Senior Vice
President Project Engineering & Services at ASYS, Wolfgang Muller,
presented the award to APP Managing Director Jack Daly and Technical
Sales Manager Gerald Rutter at this year’s Productronica exhibition.
Wolfgang Muller, Senior Vice President Project Engineering & Services at ASYS (left); Jack Daly, APP Electronics
Managing Director (centre); and Gerald Rutter, APP
Electronics Technical Sales Manager (right)
Donations instead of gifts
For the tenth time ASYS Automatisierungssysteme and ASYS Metall
GmbH are supporting local associations and non-profit organizations
in the pre-Christmas season.
A donation of € 18,000 ,- benefits the “Hospiz Ulm eV”, the society
for the promotion of “tumor and leukemia sick children” and the campaign “ Aktion Deutschland hilft” for refugees.
Grundig Business Systems relies on ASYS technology
Grundig Business Systems, headquartered in Bayreuth,
Germany, invests in a complete depaneling and test line
of the ASYS Group. “ASYS responded optimally to
our individual needs and was able to realize a tailormade solution with standard equipment requiring
only with minimal customizations. This allows us to
implement different processes in a small space and
with high flexibility,” says Martin Hadero, Production
Head at Grundig Business Systems.
PCB panels are separated and placed into trays in one
direction, a test process with good / bad sorting takes
place at the end of the line in the opposite direction.
The good long-term partnership of the two companies
was one of the reasons why Grundig Business Systems
again chose an ASYS solution. For several years, this
contract manufacturer and one of the world‘s leading
manufacturers of professional dictation systems has
relied on ASYS technology solutions.
The current solution consists of a high-speed depaneling
system, two tray handling systems, one test cell and
several handling modules. What is special about this:
the line is very flexible and can be used, for example, in
both directions and for different processes. That is, while
(f. l. to r.) Henrik Brügging, ASYS Sales Manager, Martin Hadero, Production Head at Grundig Business Systems, and Werner Jonke, Head
of Sales at ASYS
Werner Kreibl, Elvira Wäckerle, Günther Schröder,
Katharina Gräfin Reuttner, Claudia Schumann, Klaus
Mang und Julia Kölle
ASYS GROUP Newsletter| 19
Dornstadt
Suwanee
Shanghai
Singapore
Worldwide Locations
Americas
Europe
Asia
ASYS Group Americas Inc.
Suwanee, GA, USA
Marlborough, MA, USA
São Paulo, Brazil
ASYS GmbH
Dornstadt, Germany
ASYS Mexico S. De R.L. de C.V.
Monterrey, Mexico
Zapopan, Mexico
Botest Systems GmbH
Wertheim, Germany
ASYS Group Asia Pte. Ltd.
Singapore, Singapore
Seoul/Inchon, Korea
N. Delhi, India
Bangalore, India
Pune, India
Penang, Malaysia
Hsinchu, Taiwan
EKRA GmbH
Bönnigheim, Germany
Botest Printed Sensors GmbH
Linz, Austria
ASYS TECTON GmbH
Mönchweiler, Germany
ASYS - EKRA Group Iberica S.L.
Madrid, Spain
ASYS/EKRA Automation Kft.
Sibiu, Romania
Budapest, Hungary
ASYS Group China (Shanghai) Co., Ltd.
Shanghai, China
Shenzhen, China
Baoding, China
Suzhou, China
Wuxi, China
Beijing, China
Dongguan, China
Chengdu, China
Asys Automation Nordic Oy
Tuusula, Finland
Nalden, Sweden
Please note as of January 11th, 2016, the new phone numbers and
e-mail addresses at the location Dornstadt.
Publisher: ASYS GmbH, Benzstraße 10, 89160 Dornstadt, Germany
Editor: Belma Gül, Pamela Kurz, Julia Kölle, Responsible for content: Karin Walter
www.asys-group.com www.s10series.com EKRA S10 SERIES Onlineshop for Consumables & Accessories
Sitz der Gesellschaft: Dornstadt, Deutschland; Geschäftsführer: Werner Kreibl, Klaus Mang
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