More automation – even in traditionally manual processes such as THT

Kelsterbach, January 10th, 2024 Automation is increasingly finding its way into the PCB manufacturing process – even in areas that are considered to be the last remaining labor-intensive manual processes, such as THT production. With its sFAB-D, FUJI EUROPE CORPORATION (www.fuji-euro.de) offers a machine for the automation of THT placement processes, which are often still carried out manually. The AIMEX IIIc also enables automated processes for flexible high-mix production and higher productivity. FUJI will be showcasing both solutions at “Southern Manufacturing & Electronics” from February 6-8, 2024 in Farnborough (UK) at stand L80.

Placement processes today are subject to constantly growing requirements with regards to high-mix or variable-mix and variable-volume production. This calls for solutions which enable processes to be adapted quickly and easily and increase speed.

“Speed and flexibility are among the main reasons why many of our customers are increasingly turning to automation – even in areas that have been managed manually for decades,” explains Martin Rennie, Branch Manager UK at FUJI EUROPE CORPORATION GmbH.

The AIMEX IIIc all-in-one placement machine supports all types of production and changes in used package shapes. It allows easy ramp-up of new productions or reaction to changes in package shapes and any errors that occur. Several test functions prevent defects and ensure high quality. Reduced time and labor costs are drastically minimized by advantages such as the reduction in the number of changeovers. Operation is extremely simple thanks to the use of pictograms.

Continuity and flexibility required

Alongside AIMEX IIIc, FUJI is also presenting sFAB-D, a placement machine for automated PCB production, at the “Southern Manufacturing & Electronics” in Farnborough (England). The platform automates THT (Through-Hole Technology) placement processes and thus increases efficiency significantly – while maintaining high precision. It flexibly supports various part sizes, shapes and delivery types, from leaded components to large special components such as transformers, etc.

Through-hole technology is a labor-intensive method for manufacturing PCBs, as components are inserted through holes on the board and then soldered on the other side.

Vasilii Afanasev, sFAB Manager at FUJI EUROPE CORPORATION GmbH, explains: “Inserting and soldering the components is usually done manually and is therefore very time-consuming. The automation of THT board placement provides an alternative. It relieves employees of laborious, monotonous work and makes the placement workstations more effective. It also helps to ensure quality. Modern production relies on automated processes to ensure the high level of efficiency and competitiveness that is essential today.”

FUJI will be exhibiting both placement machines at “Southern Manufacturing & Electronics” from February 6 – 8, 2024 in Farnborough (UK) on stand L80.

Specialist for pick-and-place machines pushes productivity increase and a more sustainable future with “R” machine series

Kelsterbach, 21 September 2023 – The electronics industry is in the midst of digital transformation. The sector and production requirements are changing. With its “R YOU READY?” campaign, FUJI EUROPE CORPORATION GmbH ( www.fuji-euro.de) is helping companies to solve the challenges posed by this change. In the course of this, the specialist for electronics placement machines is presenting its “R-Series” at “productronica 2023”. These are machines that reduce manual activities to a minimum and are aimed at energy efficiency, flexibility, high-speed and high-precision placement. At the show, FUJI will showcase these and other solutions for automated and flexible placement in Hall A3, Booth 317.

The electronics industry is facing growing challenges. On the one hand, digitization and networking must be driven forward – equipment and systems must be able to communicate seamlessly with each other for end-to-end processes and be integrated into software landscapes. At the same time, market players are facing staff shortages, a lack of raw materials, the energy crisis and fluctuations in demand with rising production costs. Competitive pressure is high.

“Productivity in manufacturing has never been as important as it is today. With our “R” placement machines, we aim for highly efficient and agile production that is also designed for sustainability. Our placement machines of the R-Series support a wide range of production types and prove to be very economical and energy-saving,” says Stefan Janssen, Managing Director of FUJI EUROPE CORPORATION GmbH.

At “productronica”, FUJI will demonstrate various automation solutions as well as an electronics production line without human intervention, consisting of the NXTR PM printer and the NXTR A placement machine, with a connection to an AMR (Autonomous Mobile Robot). This allows FUJI to show visitors the interaction of the machines, the heart of the FUJI Smart Factory 2.0, and in the course of this the newly developed RH placement heads, which are used in the R series. The NXTR A automates previously manual processes such as feeder exchange and material replenishment. This frees machine operators from feeder exchange and parts supply tasks, which usually account for the largest share of the operator’s work in front of the placement machines.

Automation and sustainability in placement

The NXTR A and NXTR S placement machines belong to the “R” machine series. They offer a modular design that allows quick adaptations to changing production requirements. Heads, units and even entire modules can be changed without tools. Predictive maintenance is enabled by self-diagnostics that prevent sudden machine stops from affecting the production schedule.

The NXTR models support high-speed panel production, with high throughput without compromising quality. With the intelligent sensor system, stable and high quality placement is guaranteed. The status of the machine is monitored in real time and the load on components and panels is controlled at the same time.

“In response to market demand, we have released new 2RV modules as part of our NXTR S. The 2RV modules are even faster than the NXTR modules without compromising the transportability of the NXTR modules. The NXTR modules have the largest supported plate size among the NXT machine series. This makes the 2RV modules suitable for a wide range of production, including automotive panels, mobile devices, LED displays and much more,” explains Stefan Janssen.

The third and last in the alliance of the R-series is the new placement solution AIMEXR, which also addresses several central challenges of SMT production: Energy saving, individualization and flexibility as well as speed and efficiency. The solution is designed for uninterrupted operation while reducing energy consumption by around ten percent compared to previous solutions. The AIMEXR can accommodate up to 130 different part types and produce panels up to 1,068 x 610 mm, a very high level of versatility.

In addition, FUJI’s support tool “mobile Conductor” makes it possible to schedule woman and manpower in order to save walking distances. This results in reducing downtime, as operators are informed and can act immediately. Notifications can also be made for non-FUJI equipment.

Automation solutions for the entire process chain

At “productronica”, FUJI will also be showing other solutions and tools that enable fully automated processes. “Our aim is to continuously increase efficiency throughout the entire process chain of placement, while at the same time reducing the environmental impact. With our placement machines, we support, among other things, the optimization and automation of logistics, maintenance and changeover processes. This saves time, effort and ultimately energy,” says Stefan Janssen.

E²MS-Dienstleister zielt auf höhere Geschwindigkeit und Flexibilität

Kelsterbach, 2. August 2023 – In der Elektronikfertigung sind die Auftragsbücher derzeit vielerorts prall gefüllt. Der E²MS-Spezialist ETB electronic erhöht daher seine Fertigungskapa­zitäten und legt dabei Wert auf Flexibilität. Das bedeutet, das Unternehmen möchte in Zukunft die Fertigung an aktuelle Anforderungen besser anpassen können. Im ersten Investitionsschritt kommen in der 4.000 qm großen Produktionshalle sechs skalierbare Be­stückungsplatt­formen NXTIII zum Einsatz, ein Konzept der FUJI EUROPE CORPO­RATION GmbH (www.fuji-euro.de). Auf ins­gesamt fünf Produktions­linien sollen sukzessive weitere Bestückungsauto­maten von FUJI installiert werden, um eine hocheffiziente und agile Fertigung zu erreichen.

Die 1983 gegründete ETB electronic entwickelt, produziert und montiert technisch anspruchsvolle Elektronik und komplette Geräte. Das Unterneh­men beschäftigt rund 200 Mitarbeitende und hat die Hauptkundschaft in den Be­reichen Industrie, Maschinenbau, Automatisierung, Medizintechnik und Automotive.

Der E²MS-Spezialist strebt eine hochautomatisierte Fertigung an. In der im Jahr 2022 erweiterten Produktionshalle werden Muster, Vorserien und Serien gefertigt. In der SMD-Bestückung kommen bislang auf vier Linien Bestücker eines anderen Anbieters zum Einsatz.

Mit flexibler Technologie schnell an Veränderungen anpassen

Für die Zukunft möchte ETB electronic noch schneller auf neue Kundenbedürfnisse und Nachfrageschwankungen reagieren. Die Linien werden daher vorerst um sechs Bestücker der NXTIII-Serie von FUJI erweitert, woraus sich eine Erhöhung der Ge­samtleistung um rund 60.000 CPH (Components per hour) ergibt. Es sollen suk­zessive weitere Bestückungslösungen von FUJI folgen.

Die Bestückungsautomaten NXT III von FUJI bilden künftig das Herzstück der SMD-Bestückung bei ETB electronic. Damit wird nicht nur die SMT-Bestückungskapazität ausgebaut und die Produktivität erhöht, sondern auch die gebotene Flexibilität erzielt. Die NXT III ist für die flexible High-Mix-Produktion ausgelegt. Die modulare und skalierbare Lösung eignet sich insbesondere für die Bestückung multi­funktionaler und leistungsstarker Elektronik bei beispiels­weise hoher Bestückungs­dichte von winzigen Bauteilen und vielem mehr. Durch die Skalierbarkeit und einen hohen Grad an Auto­mati­sierung kann sich ETB electronic in Zukunft agil auf neue Markt- und Kundenan­forderungen einstellen.

Automotive supplier establishes plant in Novi Sad as new Competence center for inverter production in Europe

Kelsterbach, 4. July 2023 – Kelsterbach, xx. Juni 2023 – The development of new technologies and the creation of a corresponding infrastructure is essential to meet the growing demand for electric vehicles. The NIDEC Group is therefore expanding its capacities in Serbia – among other things with a plant for the production of automotive inverters and control units. There, the automotive supplier is using the scalable FUJI placement machine NXTR, handled by FUJI EUROPE CORPO-RATION GmbH (www.fuji-euro.de). The NXTR aims to optimize product preparation and maintenance processes as well as the automation of manual placement processes for the purpose of comprehensive networking and self-optimized production.

“Inverters in electric vehicles play an essential role in increasing energy efficiency. They enable precise control of the flow of electricity by converting the direct power from the batteries into the alternating power needed for the electric motors. This enables optimal use of the available energy and reduces the loss of power during conversion,” explains Aleksandar Nestorov, Plant Manager at NIDEC ELESYS CORPORATION.

Recovering braking energy also involves the use of inverters. In conventional internal combustion engines, most of the energy generated during each braking process is lost as heat. Inverters make it possible to recirculate this braking energy back into the batteries and reuse it. This increases the vehicle’s range and the efficiency of the entire drive system.

As a logical consequence of the increasing demand for in-vehicle inverters, partly due to the tightening of environmental regulations in Europe and CO2 emission standards for automobiles, NIDEC Group has expanded its production capacity with two plants in Novi Sad. NIDEC ELESYS CORPORATION produces automotive inverters and control units on an area of 25,000 square meters.

“Novi Sad is the second largest city in Serbia and has a well-developed infrastructure that meets the needs of the automotive industry. Furthermore, the Serbian government is very interested in promoting the automotive sector. In addition, Novi Sad has a labor force of professionals with experience in the automotive industry. This is why we decided to build a plant here for the production of automotive inverters and control units, among other things,” explains Aleksandar Nestorov.

New production line for inverter production

For the construction of a new production line in this plant, NIDEC ELESYS CORPORATION has chosen different suppliers. ASYS automation systems solutions are used for the laser, printing and board handling. The Rehm Group reflow oven is also part of the line. FUJI acts as the general contractor and provides the NXTR smart factory platform for placement processes. NIDEC is the first company in Serbia using the NXTR. The state-of-the-art placement solution offers a wide range of options and scalability. It can also handle increasing volumes without any problem – even with limited space in production.

A special sensor system ensures stable and high-quality placement. The NXTR platform fully automates the feeder exchange process. Heads and other units can be replaced without tools. Predictive maintenance is enabled by self-diagnostics that prevent sudden machine stops from affecting the production schedule.

“The plant in Novi Sad is to become a major new center of competence for inverter production in Europe. At present, 50 employees are working here, later it will be 200. Solutions for automated, efficient processes – especially for repetitive tasks – are a key building block for us. FUJI’s NXTR is easily scalable and supports our goals by enabling more efficient production and providing growth prospects,” says Aleksandar Nestorov.

Production quality and speed increased through use of SMD placement machines

Kelsterbach, 23. March 2023 – Time is the only resource that cannot be bought or produced. But it can be managed. Cycle times are a crucial factor in electronics manufacturing. To reduce cycle times and increase production quality and speed, Pyronix Ltd. uses the AIMEX IIIc SMD placement machine from FUJI EUROPE CORPORATION GmbH (www.fuji-euro.de), among others. Recently, the company invested in an additional AIMEX IIIc. In combination with the previously introduced FUJI solutions, Pyronix now has a highly flexible product line with different placement heads that solve different challenges in high-mix production.

Pyronix is a manufacturer and designer of electronic security equipment for use in home, business and industrial applications. The company develops a wide range of wired and wireless intrusion detection systems and relies on market-leading technologies exclusively designed by its in-house research and development team. Pyronix is constantly expanding and updating its production to be ready for the future.

High placement performance with a wide range of variants in production

As electronics production is becoming more complex due to ever smaller batch sizes, a greater number of varieties and an increasing number of components on a printed circuit board, the demands on placement are increasing. Pyronix therefore expanded its production with flexible placement machines. The company has been using various FUJI placement solutions, including those from the AIMEX family, for many years. Recently, an additional AIMEX IIIc SMD placement machine was purchased for the Rotherham South Yorkshire facility. This provides Pyronix with a complete, highly flexible product line at this site, including high-speed H24, versatile H08m heads and flexible DX heads. The expandable AIMEX IIIc supports Pyronix’s high-mix production with high placement performance and flexibility.

The Single-Robot DX head used in the AIMEX IIIC enables the placement of a wide range of parts with a single head, such as parts as small as 0.3 x 0.15 mm. This is possible because the head can automatically switch between different types of mini turrets during placement. The head applies a maximum pressure of up to 98 Newtons and can also optionally set adhesive dots. Various configurations of single- or double-track transport and with single or double robots are available.

“In terms of flexibility, precision and quality, we have taken our manufacturing to a new level with FUJI solutions and the recent deployment of the new AIMEX IIIC. After only a short period of use, we noticed that production quality and speed improved and that cycle times in product manufacturing were also reduced. The modularity offered by FUJI also allows us to react quickly to changing requirements. The placement solutions grow along with our needs,” explains Lee Reynolds, Supply Chain Director at Pyronix.