SICK ELECTRONICS EFFICIENT APPLICATION SOLUTIONS User guide

EFFICIENT APPLICATION SOLUTIONS

ELECTRONICS

INDUSTRY GUIDE

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TABLE OF CONTENTS

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INHALTSVERZEICHNIS

Challenges in the electronics industry

Sensor solutions for the electronics industry 4

Logistics gets smart 6

The Hermes standard 8

Navigation technologies 10

SAFE EFI-pro system 12

Safe Robotics 14

Robotics 16

Flexible automation 20

Smart sensors 22

Safety 27

Quality control 32

Applications in focus

Front-end production 39

Back-end production 45

PCB production 53

Electronic Device Production 59

Products

Product overview 70

General information

Company 112

Industries 114

SICK LifeTime Services 116

Versatile product range for industrial automation 118

Industry 4.0 – digitization and networking 122

Industrial communication and sensor integration 124

Services 131

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CHALLENGES

IN THE ELECTRONICS INDUSTRY

Sensor solutions for the electronics industry

The electronics industry is a driving force of industrial progress and is greatly impacted by the

pressure of the market. It must innovate – quickly, reliably and economically – while maintaining

the lowest possible error rates. High-tech machines and production sites need to be equipped

with state-of-the-art sensors to satisfy market requirements for quality and cost-effectiveness.

SICK sensor technology has proven itself in all areas of the electronics industry - from chip pro-

duction to complex assembly and inspection processes for computers, smart phones, tablets and

other touchscreen devices.

Monitoring and controlling

Electronic components are being used in a growing number of

different applications. Extreme reliability is also required here.

This is an incredibly demanding task for quality control. SICK’s

distance sensors, vision sensors and systems support nearly

every type of monitoring.

Detecting and measuring

The short product life cycle of electronic devices requires

exible production lines with minimum downtime and a high

diagnosability. modern, intelligent sensors from SICK are able

to store settings in memory and feature automatic teach-in

and diagnostic capabilities, making a signicant contribution

towards meeting these challenges.

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CHALLENGES

IN THE ELECTRONICS INDUSTRY

Identiying

Reliable object identication is a requirement for smooth

production ow and forms the basis for traceability and con-

tinuous quality improvement. SICK offers a wide range of both

permanently installed and mobile readers for bar codes, 2D

codes and RFID technology.

Protection

Linking automated production equipment with semi-automated

assembly cells requires intelligent and exible safety concepts.

SICK safety solutions ensure the protection of operating per-

sonnel, optimize production, and reduce the machine footprint

and downtime.

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Companies are faced with a huge challenge: Reacting as efciently as possible. Material ows and

intralogistical processes must be perfectly coordinated with each other at all times. Intelligent sensor

technology and networked systems ensure efcient logistics processes in the context of Industry 4.0.

Data is collected, processed in real-time and creates the basis for making decisions on autonomous and

controlled processes. Practical: The continuous traceability of goods and processes paired with intelligent

systems makes it possible to independently optimize processes.

LOGISTICS GETS SMART –

MORE EFFICIENCY FOR THE ENTIRE SUPPLY CHAIN

Challenges in the Electronics Industry

LOGISTICS GETS SMART

Automated supply of production facilities

Be it automated guided vehicles (AGVs) or tugger trains: Supplying production with new devices and

returning empty containers becomes highly efcient and exible with the help of these mobile platforms.

Thanks to the most cutting-edge RFID and code-reading technologies, identication processes during

loading and unloading can be carried out quickly and exibly for almost all types of goods. LiDAR sensors,

cameras and radar sensors make autonomous and semi-autonomous as well as manned vehicles in

production safer. Obstacles on the routes are immediately detected and avoided.

More information starting on page 68

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Challenges in the Electronics Industry

LOGISTICS GETS SMART

Localization: Complete transparency in the

material ow, at all times and in all places

Material handling in production is getting easier: Sensors for localization provide complete

transparency for all important objects in manufacturing.

With the LOCU, SICK is presenting various hardware components for indoor localization, which makes

consistent traceability of intralogistics processes possible. Consisting of localization tags and antennas

based on ultra-wideband (UWB) technology for receiving and evaluating the telemetry data, the LOCU

localizes tagged objects in covered logistics and production areas.

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The Hermes standard, listed under IPC-HERMES-9852, is a modern machine-to-machine communication

protocol for SMT production equipment customized for printed circuit board placement lines. Used

consistently, this standard enables higher automation of the line control as well as consistent traceability.

When acquiring completely new SMT lines, consistent application of the Hermes standard is easy to

implement. It gets more complex when existing machines with SMEMA interfaces and new machines with

Hermes interfaces are supposed to operate together in an SMT line. SICK offers scalable solutions for the

retrotting of machines to solve exactly these challenges.

INNOVATIVE TRACK AND TRACE SOLUTIONS:

THE HERMES STANDARD

Challenges in the Electronics Industry

THE HERMES STANDARD

Loading unit – board and magazine ID

in focus

The SICK gateway makes it possible to integrate

a loading unit with a SMEMA interface into the

Hermes network. When extended by an image-

based code reader or RFID read/write device,

the gateway can also read board and magazi-

ne IDs and forward this data via the Hermes

interface. A modular and readily expandable

solution that can also be vertically integrated

into higher level production systems via the IPC

CFX standard.

More information: www.sick.com/the-hermes-standard

ELEKTRONIK

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The basic function:

SMEMA-Hermes standard gateway

A SICK gateway can easily integrate a machine

with a SMEMA interface into a SMT line with a

Hermes interface. System operators can either

perform the integration themselves after a

short training or have it done by SICK.

Flexible extension with track-and-trace

The SICK gateway can be extended with 1D and

2D code readers and RFID read/write devices.

The data collected by these devices is made

available in the Hermes network as board and

magazine IDs.

Nonstop Consistent

traceability

Smart investment

2708

RFID

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Challenges in the Electronics Industry

THE HERMES STANDARD

Transport units – continuous

implementation of the Hermes systems

Process machines are usually connected by

transport units. When investing in new process

machines, existing transport units are often

supposed to be reused. A SICK gateway closes

the gap in communication between the process

machines and translates the Hermes informati-

on into SMEMA communication for the transport

units.

Unloading unit – magazine ID enables

WIP tracking

The SICK gateway can be congured for use on

the unloading unit at the end of an SMT line. A

SMEMA-compatible unloading unit is therefore

integrated into the Hermes network. Assignment

of the board ID to the magazine ID is possible

by extending the gateway with code reading

devices from SICK. An important cornerstone for

paperless work-in-process tracking.

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Grid localization

In warehouse logistics, automated guided vehicles must move freely without being

bound to lanes. Marker-based localization solutions are particularly suitable for

material handling due to the dynamic nature of these applications. They are usually

based on optical or magnetic markers that are applied to the ground/oor and are

detected by a sensor on the vehicle as it travels over them.

NAVIGATION TECHNOLOGIES FOR MOBILE

APPLICATIONS

Line guidance

Thanks to their principle of operation, line guidance systems are particularly easy

to integrate and can be commissioned quickly, which makes them the number one

choice for AGV applications of low complexity.

In the case of optical or magnetic line guidance, reference marks are placed on the

ground/oor which are detected and evaluated by sensors as the vehicle passes

over them. Besides the actual reference direction, further information can be read

and transmitted via the oor markings.

Challenges in the Electronics Industry

NAVIGATION TECHNOLOGIES

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LINE GUIDANCE AND LOCALIZATION SOLUTIONS FOR AUTOMATED

GUIDED VEHICLES ANDMOBILE PLATFORMS

Automated guided vehicles (AGVs) are used for intralogistics in all industries these days. Automated, e-

xible and safe transport of goods is therefore an indispensable part of logistics now and the “state of the

art”. SICK offers a broad spectrum of sensor solutions to satisfy the needs of different industries and indi-

vidual companies. Its solutions portfolio also encompasses localization systems and sensors to support all

common navigation methods for automated guided vehicles.

Transport logistics is a dynamic and fast-moving eld, digitalization is in full swing, and the call for more

exibility in intralogistics is justied. Navigation systems for automated guided vehicles must be able to

be quickly and easily adapted to changing ambient conditions. This is the only way that logistics specia-

lists will be able to respond to the ever shorter product life cycles and the demand for larger numbers of

product variants. This places special requirements on the technologies employed for AGVs, in particular on

the sensors and systems

used for navigation: These technologies must be exible and serve both the individual and commercial

needs of the user.

Map-based navigation

In the case of map-based navigation, the vehicle uses a digital representation of

the environment. The map contains the geometric data for the environment inclu-

ding all contours that the sensor used can “see”. These can comprise not only the

natural features in the environment, but also articial landmarks such as reec-

tors. The vehicle can localize itself by comparing the current sensor data with the

stored map and thereby determine its position.

Challenges in the Electronics Industry

NAVIGATION TECHNOLOGIES

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More options for challenging applications and higher

productivity

Up to 6 microScan3 EFI-pro units can be linked into a safe and adaptive

environmental perception system - and every single one of them offers a

total of up to 128 individually congurable elds and monitoring cases and

up to 8 simultaneously monitored protective elds. The result: Gap-less

monitoring thanks to the patented safeHDDM® scan technology whose

extreme resistance to environmental inuences ensures fewer downtimes.

Expanded to include the safe motion monitoring functions, monitoring

cases can be adapted dynamically to the respective hazardous situation –

for optimally productive and collaborating machines.

SAFETY SYSTEM OF THE NEXT GENERATION

FOR THE PROTECTION OF PEOPLE

Perfect interaction in the safety system

Safe EFI-pro system combines the modular Flexi Soft safety controller with an

EFI-pro gateway and safe sensors such as the microScan3 EFI-pro safety laser

scanner. The safe integration of actuators from other manufacturers, such as

robot controls, can be done via the EtherNet/IP™ CIP Safety™ interface of the

EFI-pro gateway.

From the design to commissioning and maintenance of your application: In

addition to the most advanced safety components, SICK also offers services and

professional project management tailored just to you.

- SICK LifeTime Services

Challenges in the Electronics Industry

SAFE EFI-PRO SYSTEM

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THE COMPLETE SYSTEM FOR SOLVING

CHALLENGING AGV AND ROBOTICS APPLICATIONS

With the Safe EFI-pro system, high productivity with comprehensive safety monitoring is paramount. The

system solution consists of perfectly harmonized safety sensors, a safety controller and safely connected

actuators. It is ideally suited for use in challenging applications for protecting robots and automated

guided vehicles (AGVs). With more than 65 years of experience in the eld of safety solutions and a world-

wide service network, SICK is offering a fully-edged safety solution from a single source with the Safe

EFI-pro system.

Optimized processes thanks to comprehensive diagnostic

options – data up into the cloud

The Safe EFI-pro system enables the quick exchange and transmission of

time-synchronized (SNTP – Simple Network Time Protocol) processes and

diagnostic data of all network components. Non-safety-related protocols

(e.g. PROFINET, EtherCAT®, Modbus® TCP, CANopen) can also be integra-

ted via other gateways. Quick analysis, for example of machine downti-

mes: The extensive diagnostic options of the Safety Designer engineering

tool and the transport of data up into a cloud application can optimize

your processes. Access to the data can be done centrally via Ethernet,

even cable-free via WLAN.

Quick and cost-effective conguration and commissioning

Easy and extremely intuitive operation: The license-free Safety Designer

engineering tool supports the conguration and commissioning of all

SICK system components - convenient thanks to the central access point.

Linking is very simple as the SICK system components can be integrated

easily by drag-and-drop. The standardized Ethernet technology used con-

siderably reduces wiring effort and costs.

EFI-pro: Safe SICK device communication of the next generation

Based on Ethernet/IP™ CIP Safety™, the EFI-pro offers all benets of the

established and future-proof industrial Ethernet technology. In addition to

the quick exchange of safe and unsafe data via all levels of machine com-

munication, optimal linking of innovating sensor solutions and the Flexi

Soft safety controller is ensured. This enables new, even more productive

safety concepts. The EFI-pro is characterized by its openness, making it

an essential component on the path to Industry 4.0 and the Industrial

Internet of Things (IIoT).

Challenges in the Electronics Industry

SAFE EFI-PRO SYSTEM

ON THE SAFE SIDE WITH SICK AS YOUR PARTNER

Modern industrial robots are an integral part of factory operations these days as they ensure increasing

production output while maintaining a consistently high product quality. With more than 60 years of expe-

rience in safety technology, and as a full-service provider of products, systems and services, SICK is the

company to turn to when it comes to protecting robotic applications. With expert knowledge in a whole

host of industries, SICK focuses its safety solutions on close and, at the same time, safe collaboration

between humans and robots. The aim is to achieve high productivity, increased efciency, and better ergo-

nomics.

Inspection of electronic components

With SICK safety systems, automated nal

inspection stations without doors can be imple-

mented. This reduces the need for plant space

and ensures optimal ease of operation as well

as a high level of personal safety.

Testing of printed circuit boards

Printed circuit boards are tested at two test sites

equipped by an industrial robot. Thanks to the intel-

ligent combination of safety controller, safety light

curtain and safety laser scanner, the plant can be

designed to save space and offers the worker free

access with maximum safety. If the worker enters the

hazardous area of the robot, it stops. When the worker

exits the hazardous area, the robot restarts automati-

cally. This increases plant productivity immensely.

The electronics industry is incredibly dynamic. As a driving

force of industrial progress, it is essential to carry constant

technological innovations over into large-scale series produc-

tion in a short amount of time.

Industrial robots help to satisfy these requirements for exible

and efcient production facilities.

And with extensive expertise in the eld of robot applications,

with risk assessments in accordance with the relevant stan-

dards and guidelines as well as safety solutions, SICK ensures

that humans and industrial robots can work together smoothly

and safely, for example in the following applications in the

electronics industry.

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Challenges in the Electronics Industry

ROBOTICS

Automated equipping or soldering processes

Various safety sensors, such as the ES11 emergency stop

pushbutton, the maintenance-free RE13 safety switch for

door monitoring and the deTec4 safety light curtain for pro-

tecting material locks, can be quickly combined into

a complete safety circuit and integrated into the robot cell

thanks to the easily programmable Flexi Soft safety cont-

roller. Due to the exible and modular concept of the safety

system, extensions and changes to the safety circuit can be

done with very little effort.

Work station for quality control

In a quality control process, the robots takes already-tested

parts and places them in a container. Right nearby, a worker

picks defective parts off the conveyor belt and puts them on

a shelf. The safety system

Safe Robotics Area Protection enables easy protection of the

application. The detailed operating instructions and the safe,

tested functional logic support the integration of the safety

system into the robot control. The robot speed depends on

the position of the worker. If the worker enter the hazardous

area of the robot, it stops. When the worker exits the hazar-

dous area, the robot restarts automatically.

- See www.sick.com/Safe_Robotics_Area_Protection

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Challenges in the Electronics Industry

ROBOTICS

Keeping one step ahead with product

innovations

Every day, the products from SICK are demonstrating

their high performance in a wide variety of industries.

The products are characterized by their high availabi-

lity – even under difcult conditions. On top of this, as

the inventor of the safety light curtain and safety laser

scanner, SICK is continuously working on new ideas

for offering more productivity with the same level of

safety.

EVERYTHING FROM A SINGLE EXPERT SOURCE

As an expert on everything having to do with safety solutions, SICK offers a com-

prehensive portfolio of tried and proven products, perfectly matched systems, and

highly competent services. Thanks to our sound knowledge in more than 40 key

industries, we create complete customized solutions for protecting robotics applica-

tions.

PRODUCTS

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Challenges in the Electronics Industry

ROBOTICS

Achieving goals faster with intelligent systems

SICK provides everything you could possibly need to protect ma-

chines and plants, from components and services right through to

a complete solution. The experts at SICK develop and verify custo-

mized automation solutions to closely suit the specic application

requirements. These automation solutions increase productivity,

ensure safe machine operation, and offer real added value: They can

be exibly adapted, and are quick and efcient to implement.

Competent service provides total peace of mind

Reliable advice, functional design, and turnkey solutions:

SICK’s LifeTime Services offer a comprehensive range of

services for machine safety. The services are delivered

worldwide, and take the applicable standards and regulations

into account. A network of over 150 functional safety experts

in 80 countries help solve a wide variety of safety tasks with

independence and competence, from the rst consultation to

commissioning and maintenance right through to training and

education.

SERVICES

SYSTEMS

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Challenges in the Electronics Industry

ROBOTICS

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Companies are faced with a huge challenge: Reacting as efciently as possible. Material ows and

intralogistical processes must be perfectly coordinated with each other at all times. Intelligent sensor

technology and networked systems ensure efcient logistics processes in the context of Industry 4.0.

Data is collected, processed in real-time and creates the basis for making decisions on autonomous and

controlled processes. Practical: The continuous traceability of goods and processes paired with intelligent

systems makes it possible to independently optimize processes.

MACHINE VISION CONTROLS COLLABORATING ROBOTS

ROBOTS WITH MACHINE VISION

The interaction between humans and robots in factory continues to grow. With the 2D-Vision-Sensor Inspector

PIM60 and the SICK Inspector URCap software

Challenges in the Electronics Industry

ROBOTICS

ELEKTRONIK

Irrtümer und Änderungen vorbehalten

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Challenges in the Electronics Industry

ROBOTICS

Conventional industrial robots are heavy and stationary; they require safety devices or must be kept in cages. The use of industrial

robots often involves high investment costs and their operation requires a high degree of professional knowledge. Once they are set

up, industrial robots repeat the same task day in and day out.

Cobots, on the other hand, are flexible and user-friendly robots with a low weight. Assembly is simple, they can be easily transported to

other places and they do not require programming knowledge. Cobots are more like an additional “arm” in a factory hall – an arm that

never gets tired. Among others, the target applications are packaging and palletizing, machine tending, pick-and-place applications,

mounting and quality tests. Danish company Universal Robots (UR) launched the world’s first cobot in 2008.

Cobots lower the threshold for entry for automation applications

Cobots do not require large investments and have short amortization periods, thereby paving the way for companies to automate.

Like Swedish company Hestra Teknik, which mainly performs cutting processes and used the Cobot to load a CNC machine. The con-

tinuous presence of an operator is no longer required. For exact robot guidance, Hestra Teknik uses the Inspector PIM60 2D-vision

camera from SICK. Using the camera, the robot localizes the position of the objects to be gripped on the conveyor belt, picks the up

and supplies them to the machine. Parameters of up to 32 different parts can be saved directly in the Inspector PIM60.

Even more applications thanks to machine vision

When a robot can “see”, its possibilities are multiplied many times over. As a pilot customer, Hestra Teknik integrated the SICK Ins-

pector URCap software, a UR+ plug-in, into the robot control. With this software, the robot application can easily take advantage of

the complete functional scope of the Inspector PIM60 2D vision sensor. The Inspector PIM60 is an embedded 2D vision sensor. This

means that it does all calculations by itself in the sensor and no external computer is needed.

Especially when it comes to the field of robot guidance, it can be beneficial to combine a machine vision system and robot perfor-

mance: After a short calibration routine, the SICK InspectorP62x UPCap can set gripping positions in the coordinate system of the

robot. In addition, the Inspector PIM60 2D vision sensor is able to execute test and measuring tasks to determine pass/fail criteria

or for trend displays.

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The requirements in the electronics industry are diverse and exacting. The ultimate goal is the fully

automated and industrial production of fully electronic assemblies and devices. This includes the

keywords “batch size 1 production.”

This can be achieved with intelligent and networked production and control processes that ensure a

continuous ow of information, from order placement by the customer to electronics manufacturing

and right through to dispatch. This is exactly where the sensors from SICK come into play. Smart

Sensors support dynamic, real-time-optimized, and self-organizing industrial processes. They record real

operational statuses, turn these into digital data, and share it automatically with the process controller. In

order to create the best-possible basis for a future-ready automation system, SICK has equipped its Smart

Sensors with four special properties to fulll the diverse and challenging requirements of the electronics

industry.

SMART SENSORS –

INFORMATION SUPPLIERS FOR INDUSTRY 4.0

Challenges in the Electronics Industry

FLEXIBLE AUTOMATION

Enhanced Sensing

Custom intelligence and performance

The highest possible level of stability during object detection

and recording of measured values is the basis for every Smart

Sensor. They automatically detect faults during operation and

actively troubleshoot problems that may arise. Smart Sensors

actively help the tter to nd the ideal operating point as they

are being installed. Many even offer various operating modes

including manual adjustment of detection or measurement

parameters so these can be dynamically adapted to tasks as

necessary.

Efcient communication

Smart communication between sensor and control

With superordinate control systems, Smart Sensors commu-

nicate via IO-Link: The stable communication channel used

across the globe for sensors and actuators at the lowest eld

level offers many practical advantages in day-to-day indus-

trial operation. Smart Sensors are diligent data collectors

and intelligent analysts. They share this knowledge with their

environment in real time via their integrated IO-Link interface.

Inversely, they are also capable of receiving all types of control

commands within seconds – for exible production right down

to a batch size of 1.

Enhanced Sensing provides reliable detection and measure-

ment results, which has a direct impact on plant availability.

Efcient Communication is enabled by the bidirectional

exchange of data between the control and sensor

– exible processes and simple service.

ELEKTRONIK

Irrtümer und Änderungen vorbehalten

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