Overview:

The FPLD Tinning & Forming system is a free standing robotic processing cell developed for processing low-volume military electronic components.  The cell tins and forms fine-pitch leaded devices prior to installation.  The cell consists of an Adept One robot, three component forming presses, fluxing and cleaning stations, an inspection station, and an intert tinnning station.

Process Description:

As a standalone cell, the FPLD Tinning & Forming system processes components from tray to tray. Components are acquired by a servo-controller rotating gripper, which can re-orient the component about an axis parallel to the horizontal plane. Once acquired, the component leads are formed using a precision pneumatic forming press. A strain-gage sensor monitors the insertion process to ensure that the component leads are not damaged during insertion. After forming, the component leads are inspected at a visioin station for deviation and coplanarity. Finally, the component leads are dipped into a fountain-type flux bath, and then into a solder pool.  The tinned leads are then cleaned using a foutain-type solvent bath.  The tinning process is repeated for all four banks of leads, and then the device is replaced in the presentation tray.

Technical Challenge:

During development, it was found that insertion of the FPLDs into the die cavities required placement accuracy beyond the capability of the system. To alleviate this issue, the insertion routine was adjusted so that the gripper made small circular oscillations in the plane perpendicular to the insertion axis. This motion helped align the FPLD body to the die cavity eliminating the problem.