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Point/Counterpoint
December 31, 1969 |Estimated reading time: 4 minutes
Depaneling Analysis
When thinking of the overall value-add equation of assembly, and the cumulative impact of each additive process, little attention is paid to depaneling. The loads a panel is subject to after assembly when circuits are 100 percent of their value are given little consideration. Often, boards are snapped apart in an uncontrolled way, subjecting circuits to high amounts of stress.
In product design phases, it is imperative to consider how the panel design affects the depaneling selection process. For instance, saws can only cut in straight lines and do not need V-groove slots. Routers can cut radii and straight lines but are slower and demand pre-routed slots. Punches need "tabbed" circuits with minimal material to lessen strain and maximize tool life. The one question that has remained open for debate is how individual depaneling processes impact the circuits in terms of strains applied, and potential defects created at the very end of the manufacturing process.
Routing is by far the least stressful of all the processes. However, when considering routing as an alternative to a V-scored panel hand-break process, it does not compare from the standpoint of productivity. But circuits with pre-routs incorporated in the design leave minimal material to be removed, making the routing process reliable and safe, with cut speeds keeping pace with most production tact times. The influence of the feed rate of the bit through the material is interesting when considered alongside the results for faster bit RPM. Higher RPM introduces less strain and should be used in parallel with higher feed rates to offset the higher levels of strain applied, balancing the process.
Sawing at speeds similar to those of a routing process results in stress being applied to the circuit at acceptable levels, albeit slightly higher than a routing process. As the feed rate for the saw increases, so, too, does the degree of strain exerted. However, the levels are well within acceptable norms, and the relative rates of productivity are three times that of routing. In reality, the degree of productivity is significantly higher because the sawing process does not demand pre-route paths and is cutting though solid or V-scored material.
Increased density in industrial electronics products brings with it a need for greater focus on depaneling. This particularly relates to V-scored layouts. Saw systems designed with robust and flexible fixturing systems provide a low-stress and fast alternative to punch and hand-break methods, while bringing all the qualified benefits of an automated process to bear.
"Depaneling remains an essential part of electronics assembly."
Patty Sears, international sales & marketing manager, may be contacted at CENCORP/PMJ automec, 410 South Sunset, Suite A, Longmont, CO 80501; (303) 702-0081, ext. 141; E-mail: patty_sears@cencorp.com.
Post-assembly PCB Singulation
The most widely accepted solutions to singulation are router-type and punch-type PCB depaneling. When selecting a PCB depaneling method, it is important to match the method to the production requirements.
Depaneling machines built with intelligent functionality can help improve production rates and volumes. All routing solutions should, at a minimum, be designed to be flexible, accurate and easy to use. The Smartroute singulation process is an intelligent routing solution for factories that require machine flexibility to process an unlimited number of products. Primary in any routing solution should be a feature that promotes maximum dust extraction. The best way to ensure dust particulate is removed from the cutting area is to include a vacuum system with a selectable configuration for either top- and/or bottom-side dust removal. Other ways to improve machine functionality include adding intelligence to basic components. An example is adding a memory chip to a fixture to create a smart fixture. This feature will enable a machine to read a chip that is mounted on the fixture and automatically download the optimal route path. This download occurs when the fixture is placed onto the machine. If frequent product changeover occurs, a universal fixture can be an integral part of the system.
Features of router-type singulation include:
- Minimal requirements for on-site technician support.
- Universal fixtures are available.
- Configuration for maximum dust extraction.
- Panel sizes of 20 ¥ 18" can be accommodated.
- Video-aided programming is available.
A punch-type singulation process is preferred by electronics assembly factories with medium to high production requirements. This process provides advantages in cycle time, repeatability and ease of use. The system uses a custom tooling fixture to singulate the array. Punch-type machines should have the flexibility to run a number of tools out of a single machine. The punch-type singulation process is an excellent solution for medium- to high-volume applications.
Key features of the punch-type singulation process include:
- Cycle times of 10 to 12 seconds
- Quick-change tooling
- Dust resistant
- No panel flex during depaneling
- Panel sizes of 20 ¥ 18" can be accommodated.
"Punch-type depaneling is an excellent solution for medium- to high-volume applications."
Bill Anderson, business director, may be contacted at Tyco Electronics, 20 N. Wacker, Suite 3305, Chicago, IL 60606; (312) 782-4345; Fax: (312) 782-4241; E-mail: banderson@tycoelectronics.com.