Control system of SMT high-speed chip mounter based on EtherCAT

Abstract

The invention discloses a control system of an SMT high-speed chip mounter based on EtherCAT, which takes a PC industrial personal computer as an EtherCAT master station, takes a cabinet comprehensive control card, an XY axis and head flight camera servo drive controller and a head Z axis and R axis servo drive controller as EtherCAT slave stations, and is characterized in that the master station is connected with each slave station in a series topology form of an EtherCAT bus; the multi-axis motion control system has the technical advantages of multi-axis motion control real-time performance, high data transmission rate and high whole machine intelligence at the same time, and more efficient and more accurate electronic component assembly is achieved.

Description

Technical Field

[0001] The invention relates to the technical field of control systems for SMT high-speed placement machines, and in particular to a control system for an SMT high-speed placement machine based on EtherCAT. Background Art

[0002] In the modern electronic manufacturing industry, with the growing market demand for miniaturization, multifunctionality and shortened production cycles of electronic products, high-speed placement machines are becoming increasingly important as the core equipment for efficient and accurate electronic component assembly. Placement machines not only need to have fast and accurate placement capabilities, but also need to work in conjunction with other equipment on the production line to ensure the smooth progress of the entire manufacturing process. Therefore, an efficient and reliable control system has become one of the key factors in the performance of placement machines.

[0003] At present, the high-speed placement machines in the domestic market use control systems based on CAN bus or RS-422 serial bus. Although these two bus technologies can meet the basic control requirements of placement machines to a certain extent and have a wide application base in the field of industrial automation, they have exposed some inherent limitations in the actual application process. For example, although the CAN bus has strong anti-interference ability and good reliability, it is limited by a low data transmission rate. Its maximum data transmission rate is about 8Mbps, which will affect the response speed of the control system; and although the RS-422 bus theoretically supports a higher data transmission rate, due to its half-duplex working mode, its efficiency will be greatly reduced in situations where frequent bidirectional large-scale data exchange is required.

[0004] Especially in terms of multi-axis synchronous motion control and real-time data interaction, the performance of the above two bus technologies is not ideal. Since the electronic manufacturing process often involves the precise coordination of multiple actuators, if the control system does not respond quickly enough or there is a delay in data transmission, it is likely to cause a decrease in placement accuracy, thus affecting the quality of the final product.

[0005] In addition, existing placement machine feeding systems usually lack an effective communication mechanism with the control system, which means they cannot achieve intelligent management of material information or provide real-time status feedback. This lack of intelligent management not only increases the frequency of manual intervention, but may also lead to material shortages or waste due to untimely information transmission, thereby reducing overall production efficiency and increasing production costs.

[0006] In summary, the defects of existing technologies in real-time performance, data transmission rate and whole machine intelligence limit the space for further performance improvement of high-speed placement machines. Therefore, it is particularly urgent to develop a new control system architecture to overcome the above problems and adapt to the development trend of the future electronic manufacturing industry. Summary of the invention

[0007] In view of the shortcomings of the prior art, the purpose of the present invention is to provide a control system for an SMT high-speed placement machine based on EtherCAT, which has the technical advantages of real-time multi-axis motion control, high data transmission rate and high intelligence of the whole machine, so as to achieve more efficient and accurate electronic component assembly.

[0008] In order to achieve the above object, the technical solution adopted by the present invention is: a control system of an SMT high-speed placement machine based on EtherCAT, comprising an EtherCAT master station, multiple slave stations and multiple control cards;

[0009] EtherCAT master station, using PC industrial computer as EtherCAT master station, running the whole machine control system on the EtherCAT master station;

[0010] The slave station includes the cabinet integrated control card, XY axis and head flight camera servo drive controller, head Z axis and R axis servo drive controller;

[0011] Control cards, including conveyor control cards and feeder communication cards;

[0012] The EtherCAT master station, cabinet integrated control card, XY axis and head flight camera servo drive controller, head Z axis and R axis servo drive controller are connected in series topology using the EtherCAT bus. The cabinet integrated control card, XY axis and head flight camera servo drive controller, head Z axis and R axis servo drive controller are used as EtherCAT slave stations. The cabinet integrated control card manages various functions in the entire cabinet.

[0013] The cabinet integrated control card is connected to the conveyor control card and the feeder communication card through the RS-422 bus. The conveyor control card controls the feeding and discharging of PCB boards, and the feeder communication card manages the control and status information of all feeders of the whole machine.

[0014] The whole machine control system of the EtherCAT master station generates the mounting trajectory and motion control plan, and sends the instructions to each cabinet integrated control card, feeder communication card and conveyor control card through the EtherCAT bus. At the same time, the EtherCAT master station is responsible for collecting the status information from each cabinet integrated control card, feeder communication card and conveyor control card, and the EtherCAT master station processes the data and adjusts the control strategy according to the actual situation.

[0015] The cabinet integrated control card is connected to the EtherCAT master station through the EtherCAT bus and maintains real-time communication to ensure that the equipment in the cabinet operates in the best state.

[0016] The cabinet integrated control card forwards conveyor belt control commands and feeder control commands, collects and forwards feeder data, manages power supply signals and instructions, environmental monitoring signals and instructions, and safety protection measures signals and instructions.

[0017] The environmental monitoring signals and instructions include but are not limited to signals and instructions for monitoring temperature and air pressure.

[0018] The conveyor belt control card is connected to the EtherCAT bus through the cabinet integrated control card, so as to realize real-time communication and close cooperation between the conveyor belt control card and the EtherCAT master station, and the speed and position of the conveyor belt are precisely controlled through the cabinet integrated control card, so as to ensure that the PCB board enters the next process smoothly and accurately.

[0019] The Feida communication card is connected to the EtherCAT bus via the cabinet integrated control card to achieve real-time communication and close collaboration between the Feida communication card and the EtherCAT master station, including but not limited to enabling the Feida's feeding system to exchange data in real time with the whole machine control system of the EtherCAT master station, enabling the whole machine control system of the EtherCAT master station to automatically identify and track material information, thereby achieving intelligent material management and real-time status monitoring.

[0020] The XY axis and head flight camera servo drive controller are connected to the EtherCAT master station via the EtherCAT bus.

[0021] The servo drive controller of the XY axis and the head flight camera is integrated with a servo drive controller of a multi-axis servo motor.

[0022] The position of the SMT high-speed placement machine's placement head is precisely controlled by the XY axis and head flying camera servo drive controller, including controlling the movement of the placement head along the X-axis and Y-axis directions, ensuring that the components can be accurately placed at the specified position during the placement process.

[0023] The positioning of the head flying camera is precisely controlled by the XY axis and head flying camera servo drive controller.

[0024] The head Z-axis and R-axis servo drive controllers are connected to the EtherCAT master station via the EtherCAT bus, and the head Z-axis and R-axis servo drive controllers are used to control the up and down movement of the placement head of the SMT high-speed placement machine along the Z-axis and the rotation along the R-axis.

[0025] Import the PCB file information in the EtherCAT master user interface.

[0026] The EtherCAT master automatically parses the PCB file information and automatically calculates the motion parameters and corresponding control parameters and / or control instructions.

[0027] The control parameters and control instructions are sent to the corresponding control cards and the corresponding slave stations through the EtherCAT bus.

[0028] Each slave station and each control card respectively executes corresponding actions after receiving corresponding control parameters and / or control instructions, and feeds back the execution results to the EtherCAT master station.

[0029] The advantages of the present invention compared with the prior art are:

[0030] 1. Significantly improve production efficiency: The present invention improves the real-time performance of multi-axis motion control and the data transmission rate, reduces the waiting time of the SMT high-speed placement machine during operation, speeds up the production rhythm, and thus improves the overall production efficiency.

[0031] 2. Enhance the reliability and stability of the whole machine control system: The master station and each slave station of the present invention are connected in a series topology form of the EtherCAT bus, and the optimized wiring scheme reduces the wiring difficulty, reduces signal interference, and improves the stability and reliability of the system.

[0032] 3. Reduce costs: The present invention achieves the purpose of further reducing production costs, reducing material waste and improving resource utilization through intelligent management and optimized design.

[0033] 4. Enhance competitiveness: The present invention provides a more advanced whole machine control system for the SMT high-speed placement machine, which helps the SMT high-speed placement machine to stand out in the fierce market competition and improve the market share. BRIEF DESCRIPTION OF THE DRAWINGS

[0034] Figure 1 It is the overall framework schematic diagram of the present invention

[0035] Figure 2 Schematic diagram of the framework of the cabinet integrated control card of the present invention

[0036] Figure 3 Schematic diagram of the framework of the Feida communication card of the present invention

[0037] Figure 4 Schematic diagram of the framework of the XY axis and flying camera servo driver of the present invention

[0038] Figure 5 Schematic diagram of the framework of the Z-axis and R-axis servo drivers of the present invention

[0039] Figure 6 Schematic diagram of the mounting process of the present invention DETAILED DESCRIPTION

[0040] A control system for SMT high-speed placement machines based on EtherCAT. Figures 1 to 6 As shown, it includes an EtherCAT master station, multiple slave stations and multiple control cards;

[0041] EtherCAT master station, using PC industrial computer as EtherCAT master station, running the whole machine control system on the EtherCAT master station;

[0042] The slave station includes the cabinet integrated control card, XY axis and head flight camera servo drive controller, head Z axis and R axis servo drive controller;

[0043] Control cards, including conveyor control cards and feeder communication cards;

[0044] The EtherCAT master station, cabinet integrated control card, XY axis and head flight camera servo drive controller, head Z axis and R axis servo drive controller are connected in series topology using the EtherCAT bus. The cabinet integrated control card, XY axis and head flight camera servo drive controller, head Z axis and R axis servo drive controller are used as EtherCAT slave stations. The cabinet integrated control card manages various functions in the entire cabinet.

[0045] The cabinet integrated control card is connected to the conveyor control card and the feeder communication card through the RS-422 bus. The conveyor control card controls the feeding and discharging of PCB boards (printed circuit boards), and the feeder communication card manages the control and status information of all feeders of the whole machine.

[0046] The PC industrial computer as the EtherCAT master runs the supporting developed whole machine control system. The whole machine control system of the EtherCAT master generates the mounting trajectory and motion control plan, and sends the instructions to each cabinet integrated control card, feeder communication card and conveyor control card through the EtherCAT bus. At the same time, the EtherCAT master is responsible for collecting the status information from each cabinet integrated control card, feeder communication card and conveyor control card, and the EtherCAT master performs data processing and adjusts the control strategy according to the actual situation.

[0047] In practical applications, the above control units are closely connected through the EtherCAT bus to form a highly integrated control system. The user imports PCB file information in the user interface of the EtherCAT master station, and the EtherCAT master station automatically parses the PCB file information and automatically calculates the motion parameters and corresponding control parameters and / or control instructions. The control parameters and control instructions are sent to the corresponding control cards and the corresponding slave stations through the EtherCAT bus. Each slave station and each control card executes the corresponding action after receiving the corresponding control parameters and / or control instructions, and feeds back the execution results to the EtherCAT master station. In this way, the whole machine control system can not only realize real-time multi-axis synchronous control, greatly improving the working efficiency and accuracy of the placement machine, but also the whole machine control system can automatically identify information such as material category and quantity through the integrated Feida communication card, and transmit these data to the whole machine control system in real time, so as to facilitate the intelligent management and scheduling of materials, which can not only improve the accuracy of material management, but also reduce production delays caused by human errors.

[0048] in,

[0049] The cabinet integrated control card is connected to the EtherCAT master station through the EtherCAT bus and maintains real-time communication to ensure that the equipment in the cabinet operates in the best condition. The cabinet integrated control card forwards conveyor belt control commands and feeder control commands, collects and forwards feeder data, manages power supply signals and instructions, environmental monitoring signals and instructions, and safety protection measures signals and instructions. Environmental monitoring signals and instructions include but are not limited to signals and instructions for monitoring temperature and air pressure.

[0050] The conveyor belt control card is connected to the EtherCAT bus through the cabinet integrated control card, realizing real-time communication and close collaboration between the conveyor belt control card and the EtherCAT master station. The speed and position of the conveyor belt can be accurately controlled through the cabinet integrated control card to ensure that the PCB board enters the next process smoothly and accurately.

[0051] The Feida communication card is connected to the EtherCAT bus through the cabinet integrated control card to achieve real-time communication and close collaboration between the Feida communication card and the EtherCAT master station, including but not limited to enabling the Feida feeding system to exchange data with the whole machine control system of the EtherCAT master station in real time, enabling the whole machine control system of the EtherCAT master station to automatically identify and track material information, and realize intelligent material management and real-time status monitoring.

[0052] The Feida communication card is used to manage the control and status information of all feeders of the SMT high-speed placement machine. The Feida communication card is connected to the EtherCAT bus through the cabinet integrated control card to realize real-time data exchange between the feeder feeding system and the whole machine control system running on the EtherCAT master station. The whole machine control system of the EtherCAT master station can automatically identify and track all material information through the Feida communication card, realize intelligent material management and real-time status monitoring, and reduce the need for human intervention.

[0053] The XY axis and head flying camera servo drive controller are connected to the EtherCAT master station through the EtherCAT bus. The servo drive controller of the multi-axis servo motor is integrated in the XY axis and head flying camera servo drive controller. The position of the SMT high-speed placement machine's patch head is accurately controlled by the XY axis and head flying camera servo drive controller, including controlling the movement of the patch head along the X-axis and Y-axis directions respectively, to ensure that the components can be accurately placed at the specified position during the patch process, and the positioning of the head flying camera is accurately controlled by the XY axis and head flying camera servo drive controller. The XY axis and head flying camera servo drive controller also maintains real-time communication with the EtherCAT master station through the EtherCAT bus to ensure that the components can be accurately placed at the specified position during the patch process, and to ensure high-precision component positioning and rotation adjustment during the mounting process, thereby improving the mounting quality and speed. The servo drive controller uses the high-speed data transmission capability of the EtherCAT bus to achieve rapid response and ensure mounting accuracy.

[0054] The head Z-axis and R-axis servo drive controllers are connected to the EtherCAT master station via the EtherCAT bus, and the head Z-axis and R-axis servo drive controllers are used to control the up and down movement of the SMT high-speed placement machine's placement head along the Z-axis and the rotation along the R-axis.

[0055] Glossary: ​​EtherCAT (Ethernet Control Automation Technology) is an open architecture, Ethernet-based fieldbus system. The CAT in its name is the abbreviation of the first letter of Control Automation Technology (Control Automation Technology).

[0056] Feeder, also known as component feeder, feeder feeder or feeder feeding system, is a feeding component used to transport electronic components in SMT high-speed placement machines.

[0057] The present invention improves the real-time performance of multi-axis motion control: The control system of the existing SMT high-speed placement machine performs poorly in multi-axis coordinated control and real-time data interaction, especially in application scenarios requiring high-frequency and high-precision control, where the system's response speed and synchronization performance become bottlenecks. The present invention improves the time certainty and response speed of the whole machine control system by introducing EtherCAT summary technology, a high-speed real-time communication technology, and the technology of integrating multi-axis servo controllers, thereby improving the real-time performance of multi-axis motion control.

[0058] The present invention enhances the data transmission rate: Traditional CAN bus technology and RS-422 bus technology have limitations in data transmission rate and cannot meet the needs of modern SMT high-speed placement machines for rapid exchange of large amounts of data. The present invention utilizes the high bandwidth and low latency characteristics of EtherCAT summary technology to significantly increase the data transmission rate, ensure that the whole machine control system can transmit more information in a short time, and optimize the overall performance of the whole machine control system.

[0059] The present invention realizes intelligent management: the current feeder feeding system of the SMT machine lacks effective communication with the control system, which makes it impossible to realize intelligent material management and real-time status monitoring. The present invention embeds a communication module in the feeder feeding system, and combines the communication module with the EtherCAT summary technology to realize seamless connection between the feeder feeding system and the whole machine control system, thereby supporting automatic identification and management of feeder material information and improving production efficiency.

[0060] The present invention reduces the number of wiring harnesses: Traditional control systems have complex wiring, which is prone to signal interference, and often require additional space in mechanical design to accommodate complex cable layouts. The present invention uses EtherCAT bus technology, which can not only simplify wiring and reduce the possibility of signal interference, but also save space and facilitate maintenance through compact wiring solutions and optimized mechanical structure design, thereby improving the overall reliability and durability of the equipment.

[0061] In summary, the present invention has the following advantages:

[0062] 1. Significantly improve production efficiency: The present invention improves the real-time performance of multi-axis motion control and the data transmission rate, reduces the waiting time of the SMT high-speed placement machine during operation, speeds up the production rhythm, and thus improves the overall production efficiency.

[0063] 2. Enhance the reliability and stability of the whole machine control system: The master station and each slave station of the present invention are connected in a series topology form of the EtherCAT bus, and the optimized wiring scheme reduces the wiring difficulty, reduces signal interference, and improves the stability and reliability of the system.

[0064] 3. Reduce costs: The present invention achieves the purpose of further reducing production costs, reducing material waste and improving resource utilization through intelligent management and optimized design.

[0065] 4. Enhance competitiveness: The present invention provides a more advanced whole machine control system for the SMT high-speed placement machine, which helps the SMT high-speed placement machine to stand out in the fierce market competition and improve the market share.

Claims

1. A control system for an SMT high-speed placement machine based on EtherCAT, characterized in that: Includes EtherCAT master, multiple slaves and multiple control cards; EtherCAT master station, using PC industrial computer as EtherCAT master station, running the whole machine control system on the EtherCAT master station; The slave station includes the cabinet integrated control card, XY axis and head flight camera servo drive controller, head Z axis and R axis servo drive controller; Control cards, including conveyor control cards and feeder communication cards; The EtherCAT master station, cabinet integrated control card, XY axis and head flight camera servo drive controller, head Z axis and R axis servo drive controller are connected in series topology using the EtherCAT bus. The cabinet integrated control card, XY axis and head flight camera servo drive controller, head Z axis and R axis servo drive controller are used as EtherCAT slave stations. The cabinet integrated control card manages various functions in the entire cabinet. The cabinet integrated control card is connected to the conveyor control card and the feeder communication card through the RS-422 bus. The conveyor control card controls the feeding and discharging of PCB boards, and the feeder communication card manages the control and status information of all feeders of the whole machine. The whole machine control system of the EtherCAT master station generates the mounting trajectory and motion control plan, and sends the instructions to each cabinet integrated control card, feeder communication card and conveyor control card through the EtherCAT bus. At the same time, the EtherCAT master station is responsible for collecting the status information from each cabinet integrated control card, feeder communication card and conveyor control card, and the EtherCAT master station processes the data and adjusts the control strategy according to the actual situation.

2. According to the control system of a SMT high-speed placement machine based on EtherCAT according to claim 1, it is characterized in that: The cabinet integrated control card is connected to the EtherCAT master station through the EtherCAT bus and maintains real-time communication to ensure that the equipment in the cabinet operates in the best state. The cabinet integrated control card forwards conveyor belt control commands and feeder control commands, collects and forwards feeder data, manages power supply signals and instructions, environmental monitoring signals and instructions, and safety protection measures signals and instructions.

3. The control system of a SMT high-speed placement machine based on EtherCAT according to claim 2, characterized in that: The environmental monitoring signals and instructions include but are not limited to signals and instructions for monitoring temperature and air pressure.

4. The control system of the SMT high-speed placement machine based on EtherCAT according to claim 1, characterized in that: The conveyor belt control card is connected to the EtherCAT bus through the cabinet integrated control card, so as to realize real-time communication and close cooperation between the conveyor belt control card and the EtherCAT master station, and the speed and position of the conveyor belt are precisely controlled through the cabinet integrated control card, so as to ensure that the PCB board enters the next process smoothly and accurately.

5. The control system of the SMT high-speed placement machine based on EtherCAT according to claim 1, characterized in that: The Feida communication card is connected to the EtherCAT bus through the cabinet integrated control card to achieve real-time communication and close cooperation between the Feida communication card and the EtherCAT master station, including but not limited to, Enables real-time data exchange between Feida's feeding system and the whole machine control system of the EtherCAT master station. The whole machine control system of the EtherCAT master station automatically identifies and tracks material information, realizing intelligent material management and real-time status monitoring.

6. The control system of the SMT high-speed placement machine based on EtherCAT according to claim 1, characterized in that: The XY axis and head flight camera servo drive controller are connected to the EtherCAT master station via the EtherCAT bus. The servo drive controller of the XY axis and the head flight camera is integrated with a servo drive controller of a multi-axis servo motor. The position of the SMT high-speed placement machine's placement head is precisely controlled by the XY axis and head flying camera servo drive controller, including controlling the movement of the placement head along the X-axis and Y-axis directions, ensuring that the components can be accurately placed at the specified position during the placement process. The positioning of the head flying camera is precisely controlled by the XY axis and head flying camera servo drive controller.

7. The control system of the SMT high-speed placement machine based on EtherCAT according to claim 1, characterized in that: The head Z-axis and R-axis servo drive controllers are connected to the EtherCAT master station via the EtherCAT bus, and the head Z-axis and R-axis servo drive controllers are used to control the up and down movement of the placement head of the SMT high-speed placement machine along the Z-axis and the rotation along the R-axis.

8. A control system for an SMT high-speed placement machine based on EtherCAT according to any one of claims 1 to 5, characterized in that: Import the PCB file information in the EtherCAT master user interface. The EtherCAT master automatically parses the PCB file information and automatically calculates the motion parameters and corresponding control parameters and / or control instructions. The control parameters and control instructions are sent to the corresponding control cards and the corresponding slave stations through the EtherCAT bus. Each slave station and each control card respectively executes corresponding actions after receiving corresponding control parameters and / or control instructions, and feeds back the execution results to the EtherCAT master station.

Images