The process of customizing CCD high-speed mounter is generally as follows:

Demand communication and determination

Clear application scenarios: communicate with customers in depth to understand the specific application scenarios of the mounter, such as electronic component mounting, label attachment, panel attachment, etc., as well as the types, sizes, shapes, materials and other information of products produced.

Determine the production requirements: define the production capacity requirements, such as the number of components or products to be mounted per hour; Determine the mounting accuracy, including position accuracy and angle accuracy; Understand the specific expectations for mounting speed and efficiency, as well as the requirements for equipment stability and reliability.

Understand the working environment: consider the space layout, environmental temperature and humidity, cleanliness and other conditions of the place where the equipment will be installed and used, so as to design a mounter that conforms to the actual use environment.

Scheme design and evaluation

Formulate technical scheme: according to customer's demand, design the overall structure of the mounter, including mechanical structure, transmission system, control system, visual system, etc. Select the appropriate CCD camera model, lens, light source and other visual components to ensure that the accuracy and speed requirements can be met; Determine the type, quantity and layout of mounting heads, as well as the design of feeding system, such as the type, quantity and arrangement of feeder.

Feasibility evaluation: evaluate the technical feasibility of the design scheme, and check the compatibility and cooperative working ability between components; Whether the evaluation scheme meets the performance indicators proposed by customers, such as accuracy, speed, productivity, etc.; Consider the cost-effectiveness of the scheme to ensure that the cost is reduced as much as possible under the premise of meeting the performance requirements.

Offer scheme quotation: according to the design scheme, list the detailed equipment configuration list, including hardware, software, accessories and other expenses; Calculate the costs of customized development, manufacturing, installation and debugging, after-sales service and other links, and provide accurate quotations to customers.

Mechanical and electrical design and manufacturing

Machining of mechanical parts: according to the design drawings, machining and manufacturing the mechanical parts of the mounter, such as machine frame, workbench, transmission mechanism, mounting head, etc. Check the quality of the finished parts to ensure that their dimensional accuracy and surface quality meet the design requirements.

Electrical system integration: purchasing the required electrical components, such as motors, drivers, controllers, sensors, etc., and wiring, connecting and installing the electrical system; Write a control program to realize the functions of motion control, visual inspection and data processing of the mounter.

Assembly and debugging: assemble the mechanical parts and electrical system to form a complete mounter; Make a preliminary debugging of the equipment, and check whether the running conditions of various components, such as the rotation of the motor, the transmission of the transmission mechanism and the image acquisition of the vision system, are normal.

Adjustment and optimization of visual system

Installation and fixation: install CCD camera, lens, light source and other visual components on the mounter according to the design requirements, and ensure their firm installation and accurate position.

Parameter adjustment: adjust the exposure time, gain, white balance and other parameters of the camera to obtain a clear and stable image; According to the characteristics and accuracy requirements of the mounted object, appropriate visual detection algorithms and parameters, such as threshold, edge detection and feature extraction, are set.

Accuracy calibration: use standard calibration tools and samples to calibrate the measurement accuracy of the vision system to ensure that it can accurately identify and locate the mounting object; Through many tests and optimization, the stability and reliability of the vision system are improved, and the probability of misjudgment and missed judgment is reduced.

Performance testing and verification

Function test: comprehensively test the functions of the mounter, such as whether the suction and placement actions of the mounting head are accurate, whether the feeding system can feed normally, whether the vision system can accurately identify and locate, etc. Check whether the operation interface of the equipment is friendly and easy to operate, and whether the parameters are set conveniently and quickly.

Performance index test: actually test the mounting accuracy, speed and productivity of the mounter according to the performance index required by customers, and record the test data; Analyze the test results, check whether they meet the design requirements, if not, find out the reasons and make corresponding adjustments and optimizations.

Stability test: test the stability of the mounter for a long time, run it continuously for a certain period of time, and observe whether the equipment will break down or its performance will decline; Through the stability test, the reliability and stability of the equipment are further verified to ensure its stable operation in actual production.

Packaging, transportation, installation and debugging

Packaging protection: package the customized CCD high-speed mounter, and adopt appropriate packaging materials and methods, such as wooden box packaging and foam buffering, to ensure that the equipment is not damaged during transportation.

Transportation and distribution: choose the appropriate transportation mode, transport the mounter to the place designated by the customer safely and timely, and be responsible for the loading, unloading and handling of the equipment.

On-site installation and debugging: at the customer's site, install and fix the mounter according to the installation requirements, and connect external equipment such as power supply and air supply; Debug the equipment on site, and finally adjust and optimize the parameters of the equipment according to the actual production environment and requirements of customers to ensure that the equipment can be put into production normally.

Training and after-sales service

Operation training: provide professional training for customers' operators, including equipment operation methods, daily maintenance, troubleshooting and other aspects of knowledge and skills training; Through practical demonstration and guidance, the operators can be familiar with the functions and operation processes of the equipment, so as to ensure that they can operate the equipment correctly and skillfully.

After-sales service: establish a perfect after-sales service system to provide customers with timely and effective after-sales service, including equipment warranty, maintenance, upgrade and other services; Visit customers regularly to understand the usage of equipment and customers' needs, and provide customers with technical support and solutions.