"SMT is the abbreviation of surface mount technology, which is the most popular technology and process in the current electronic assembly industry. SMT patch refers to the abbreviation of a series of process flows based on PCB. So what equipment is used to produce SMT patches? What is the SMT production process like? Here we will introduce the equipment related to SMT, the cost of SMT production l
Do you want to know how much it costs to set up an SMT patch production line?
"SMT is the abbreviation of surface mount technology, which is the most popular technology and process in the current electronic assembly industry. SMT patch refers to the abbreviation of a series of process flows based on PCB. So what equipment is used to produce SMT patches? What is the SMT production process like? Here we will introduce the equipment related to SMT, the cost of SMT production line, and the understanding and precautions of SMT process and peripheral items."
Equipment required for SMT production line
There are seven commonly used equipment: Loader, Stacker, Solder printer, Highspeed mounter, Coveryor, Multi function mounter, Reflow, Unloader, Automatic Optical Inspector (AOI), X-ray Inspector (X-RAY). In addition, an air compressor must be installed to supply air to the machine for normal production.
The role of each equipment in the SMT production line
1. Board loading machine: The PCB is placed in the Rack and is automatically sent to the board suction machine.
2. Board suction machine: automatically sucks the PCB, places it on the track, and transfers it to the printing machine.
3. Printing machine: Completely print the solder paste or red glue onto the PCB through the steel mesh.
4. High-speed placement machine: Use the program edited by the equipment to place components on the designated part position. It can install rolled parts below SOP 28pin. It is characterized by fast mounting speed.
5. Connecting station: used for connection between SMT production lines. It can also be used for PCB buffering, inspection, testing or manual insertion of electronic components.
6. General-purpose placement machine: Use the program edited by the equipment to mount components on the designated part position. It can mount SOP 28pin or above (including components that can be mounted by high-speed machines) roll, disc or tubular packaging components. . It is characterized by high installation accuracy and diversification, but the installation speed is inferior to that of high-speed machines.
7. Reflow soldering: Use SMT solder paste or red glue to set the appropriate temperature curve to complete the soldering action between the solder paste and the parts.
8. Unloader: The board is collected in the magazine through the transmission track.
9. Optical detector: Automatic optical detection is a device based on optical principles to detect common defects encountered in welding production. AOI is a new testing technology that has only emerged in recent years, but it has developed rapidly. Currently, many manufacturers have launched AOI testing equipment. During automatic inspection, the machine automatically scans the PCB through the camera, collects images, and compares the tested solder joints with the qualified parameters in the database. After image processing, defects on the PCB are detected, and the defects are displayed/marked through the display or automatic signs. Come out for maintenance personnel to repair.
10. X-ray machine: Mainly used to detect various industrial components, electronic components, and circuit interiors. For example, the inspection of socket plug rubber internal circuit connections, diode internal welding, BGA welding, etc. The X-ray machine is an X-ray machine that can be connected to a computer for image processing. This type of industrial inspection portable X-ray machine provides an excellent solution for the field of factory home appliance maintenance.
So, how much does it cost to assemble an automatic SMT production line? Suppose we need to invest in a new SMT patch production line, the corresponding conditions are as follows:
1、Workshop and environment
The dust-free workshop is about 310 square meters and comes with central air conditioning. The workshop has been renovated and no renovation costs are required, but electricity and gas connections are gas.
2、Production Line Distribution
(1) The whole workshop plans to have four fully automatic patch production lines.
(2) In the first phase, a fully automatic production line will be invested, mainly processing the light strips of LCD module backlight and FPC soft board patch production.
(3) In the future, the production line will be added in time according to the customer's output and the needs of other market customers.
(4) The production line uses second-hand machine configuration.
3、Machine Configuration
(1) The first fully automatic production line configuration.
(2) Board loading machine + fully automatic printing machine + docking station + high-speed placement machine + docking station + high-speed placement machine + docking station + reflow soldering (eight temperature zones) + 2-meter workbench.
4、First Phase Funding
(1) The machine configuration of an SMT patch production line is about USD5700.
(2) The processing jigs and auxiliary facilities are about USD2800.
(3) The working capital (mainly referring to employee salaries) for the first three months is to be determined, estimated to be within USD8500
(4) The first phase of direct investment must be controlled within USD70000.
5、Capacity and output value analysis
Assuming the hourly production capacity is USD25
6、Cost Analysis (Monthly)
(1) Take the first SMT patch production line as an example to analyze the production cost and expenses when the full monthly production capacity is saturated.
(2) Rent: When there are only two production lines, no rent is required. When there are three or more lines, the rent is negotiated separately.
(3) The actual monthly cost is controlled within USD7000, as detailed below↓
7、Monthly cost breakdown of an SMT patch production line
Total: USD8530 1. Solder paste (main auxiliary material): 30 kg * 42/kg = USD1260; 2. Electricity fee: average reflow power 10KW/hour * 22 hours/day * 26 days * 0.14/KW = USD800; 3. Maintenance: USD570; 4. Property damage: USD285; 5. Rework fee: USD285; 6. Manager: USD1428/person; 7. Engineering and technical personnel: USD857/person; 8. Direct workers: day shift + night shift (2+2) * 4K = USD2285; 9. Other expenses: USD715.