PCB Assembly

Low cost PCB assembly

Publish Date:2020-11-06

In general, the electronic products we use are designed by PCB plus various capacitors, resistors, and other electronic components according to the designed circuit diagram, so all kinds of electrical appliances need different SMT chip processing technology to process.
SMT is the abbreviation of surface-mounted technology, which is the most popular technology in the electronic assembly industry. Surface mount technology (SMT) of the electronic circuit is called surface-mount or surface mount technology. It is a kind of circuit assembly technology that SMC / SMD (short for SMC / SMD) without a pin or short lead is installed on the surface of the printed circuit board (PCB) or the surface of other substrates, and is welded and assembled by reflow soldering or immersion soldering.
The advantages of IDEASPCB’s PCB assembly are high assembly density, small volume, and lightweight electronic products. The volume and weight of chip components are only about 1 / 10 of that of traditional plug-in components. Generally, after SMT is adopted, the volume of electronic products will be reduced by 40% – 60%, and the weight will be reduced by 60% – 80%. It has high reliability and strong anti-vibration ability. The defect rate of the solder joint is low. Good high-frequency characteristic. Reduced electromagnetic and radio frequency interference. It is easy to realize automation and improve production efficiency. Reduce costs by 30% – 50%. Save materials, energy, equipment, manpower, time, and so on, truly realize the low-cost PCB assembly.
SMT chip refers to the printed circuit board (PCB) which is a series of process flow based on PCB. The Chinese name is printed circuit board, also known as printed circuit board and printed circuit board. It is an important electronic component, the support of electronic components, and the provider of electrical connection of electronic components. Because it is made by electronic printing, it is called a “printed” circuit board.
SMT basic process elements: solder paste printing, part mounting, reflow soldering, AOI optical inspection, maintenance, and plate splitting.
Some people may ask why electronic components should be so complicated. In fact, this is closely related to the development of our electronics industry. Nowadays, electronic products pursue miniaturization, and the perforated plug-in components used in the past can not be reduced. The functions of electronic products are more complete, and the integrated circuit (IC) used has no perforated components, especially the large-scale and high integrated IC, so surface mount components have to be used. With mass production and automatic production, manufacturers should produce high-quality products with low cost and high output to meet the needs of customers and enhance market competitiveness. The development of electronic components, the development of integrated circuits (IC), and the diversified application of semiconductor materials. The revolution of Electronic Science and technology is imperative to pursue the international trend.
In PCBA production and processing, how can we effectively save processing costs and realize low-cost PCB assembly without affecting product quality— ideaspcb.com To introduce the factors that affect the cost of PCBA processing.

Low cost PCB assembly

Factors affecting PCBA processing cost

  1. The size of the PCB is the key. The smaller the PCB size, the lower the cost. Reducing the size of non-standard PCBs can effectively reduce the cost of PCB.
  2. Compared with plug-ins, SMT processing can save money, because SMT can connect more components to PCB.
  3. In addition, if the components on the PCB are dense, the PCB wiring must be thinner and the equipment used should be more advanced. At the same time, PCBs should be made of better materials, and special care should be taken in wiring design to avoid problems such as power consumption, which may affect the formation of the circuit. The cost of such problems is greater than that of reducing PCB size.
  4. The more layers of PCB, the higher the cost. However, the smaller the total number of layers, the larger the size.
  5. Drilling takes time, so the fewer holes in PCB, the lower the cost.
  6. A blind hole is more expensive than a through-hole. Because the blind hole must be drilled before PCB bonding.
  7. The diameter of the guide hole on the PCB depends on the diameter of the port pin. If the pin types on the PCB are different, the machine can not drill all the holes with the same drill bit, which is relatively time-consuming and the corresponding cost will increase.
  8. Electronic testing using flying needle testing is usually more expensive than optical testing. Optical testing is usually enough to ensure that there are no errors on the PCB. Optical testing is easier to detect the gap between the electrical conductors.
Low cost PCB assembly

Why Ideaspcb.com Provide PCBA production service?

  1. Strength guarantee

    SMT workshop: with imported SMT machine, optical inspection equipment, 4 million points per day. Each process is equipped with QC personnel, able to focus on product quality.
    Dip production line: it has two wave soldering machines, among which there are more than ten employees who have worked for more than three years. The workers are highly skilled and can weld all kinds of plug-in materials.

  2. Quality assurance and high cost performance

    High end equipment can be pasted with precision special-shaped parts, BGA, QFN, 0201 materials. It can also be placed by hand.
    Samples and large and small batch production, proofing from 800 yuan, batch 0.008 yuan / point, no start-up costs.

  3. Experienced in chip mounting and welding of electronic products, stable delivery

    Accumulated service thousands of electronic enterprises, involving a variety of automotive equipment and industrial control motherboard SMT chip processing services, products are often exported to Europe and the United States, quality can be affirmed by new and old customers.
    Delivery on time, after the materials are complete, normal 3-5 days shipping, small batch can also be expedited on the same day shipping.

  4. Strong maintenance ability and perfect after-sales service

    The maintenance engineer has rich experience, can repair all kinds of bad products caused by chip welding, and can ensure the connectivity of each circuit board.
    24 hours customer service staff at any time to respond, the fastest way to solve your order problems.

  5. Mature and stable purchasing channels of components

    Ideaspcb.com There are professional components procurement team, are engaged in more than ten years of procurement personnel, have rich experience and professional knowledge. Long term stable demand for components procurement, close cooperation with suppliers, mature and stable procurement channels, 100% quality of components and genuine products of original brands. This is one of the reasons to realize low cost PCB assembly

With the continuous development of science and technology, SMT processing gradually comes into our lives and is gradually known by more people. It belongs to a new type of electronic components, which is more common in the current society. So how can we reduce the production cost of PCBA and do a good job in quality control? The following is a brief introduction made by DEASPCB, a professional PCB assembly factory

Basic knowledge of low-cost PCB assembly

1、 Traditional patch
Brief introduction of SMT process
The traditional perforated electronic assembly process is to insert the components’ pins into the guide holes of the PCB and fix them, then use the wave soldering process to complete the whole welding process through the steps of flux coating, preheating, solder coating, detection, and cleaning.
2、 Introduction of SMT technology
With the development of the electronic industry, the products are designed to be short and light, making the volume and weight of various components smaller and smaller. The function density is also relatively improved to meet the trend of the times and customer needs. Under the influence of this change, surface adhesive components have become the main components of PCB, and its main feature is that it can greatly save space and reduce cost. Replace the traditional dip (dual inline package)
The surface adhesion assembly process mainly includes the following steps: solder paste printing, component placement, reflow soldering
The main steps of low-cost PCB assembly are summarized as follows:
Stencil printing: the solder paste is the bonding material between the surface adhesive assembly and PCB. First, the steel plate is etched or laser cut, and then the solder paste is printed on the PCB pad through the holes on the steel plate by the squeegee of the printer, so as to enter the next step.
Component placement: component placement is the key technology and focus of the whole SMT manufacturing process. In the process, high precision automatic placement equipment is used, and the surface adhesive components are accurately placed on the solder pad of printed solder paste PCB through computer programming. As the design of surface adhesive components becomes more and more precise, the distance between the pins becomes smaller, so the technical level of placement becomes more and more difficult.
Reflow soldering: reflow soldering is to preheat the PCB that has been placed with surface adhesive components in a reflow oven to activate the flux, then raise its temperature to 183 ℃ to melt the solder paste, connect the module foot with the PCB pad, and then cool down to solidify the solder, that is, to complete the bonding of surface adhesive components and PCB.
3、 Introduction of SMT equipment

  1. Stencil Printing: MP0 / MPM2000 / PVⅡ
  2. Component Placement: FUJI ( CP643E / CP742ME & QP242E / QP341E )
  3. Reflow Soldering: FURUKAWA( XN-425PHG / XN-445PZ / XNⅡ-651PZ ) ET10, ET11.
    4、 Explanation of SMT common names
    SMT: Surface Mounted Technology (SMT): the assembly technology of directly mounting components on the surface and welding them to the specified position on the surface of the printed circuit board
    SMD: surface mounted devices (SMD): the shape of SMD is a rectangular sheet, cylindrical line, or special-shaped, and its welding end or pin is made in the same plane, which is suitable for surface adhesive electronic components
    Reflow soldering: by remelting the paste solder paste pre-distributed on the PCB pad, the mechanical and electrical connection between the surface adhesive module terminals or pins and the PCB pad can be realized
    Chip: rectangular chip component: there is no lead at both ends, with solder end, and the surface of the chip is rectangular
    SOP: Small Outline Package: small molded plastic package with wing or J-shaped short pins on both sides
    QFP: Quad Flat Pack: thin surface assembled collective circuit with wing short pins on four sides and pin spacing of 1.00, 0.80, 0.65, 0.50, 0.40, 0.30mm
    BGA: Ball grid array: packaging form of the integrated circuit, whose input and output points are tin balls arranged in a grid pattern on the module’s bottom surface.
Low cost PCB assembly

5、 Packaging method of low-cost PCB assembly
Ribbon/stick (shipping tube) – main component container: the ribbon is made of transparent or translucent polyethylene (PVC) material and extruded into a standard shape that meets the current industrial standards. The strip size provides appropriate component orientation and orientation for industry-standard automatic assembly equipment. Strips are packaged and transported in the form of a combination of the number of individual strips.
Tray – main component container: the tray is made of carbon powder or fiber materials selected based on the special tray’s temperature rate. Trays designed for components requiring exposure to high temperatures (moisture sensitive components) have a temperature resistance of usually 150 ° C or higher. The tray is cast into a rectangular standard shape, which contains a uniform alternate cavity matrix. Cavities hold the assembly and protect during transportation and handling.
The bay provides an accurate component location for standard industrial automation assembly equipment used for mounting during PCB assembly. Pallets are packaged and transported in the form of a single pallet, then stacked and bundled together with a certain rigidity degree. An empty cover tray is placed on the loaded components and stacked trays.
Tape and reel – main component container: typical tape and reel structures are designed to meet modern industrial standards. There are two generally accepted standards for the construction of covered coil packaging. EIA-481 is used for embossed structures, while eia-468 is used for radial LED components. So far, the structure of active IC is embossed tape
6、 Why is the cleaning free process applied in low-cost PCB assembly processing technology?

  1. The wastewater discharged from the product cleaning in the production process will bring pollution to the water quality, the earth, and even animals and plants.
  2. In addition to water cleaning, the use of CFC & HCFC for cleaning also pollutes and destroys the air and atmosphere.
  3. The cleaning agent remains on the machine plate and causes corrosion, which seriously affects the product quality.
  4. Reduce the cost of cleaning operation and machine maintenance.
  5. No cleaning can reduce the damage caused by PCBA in the process of moving and cleaning. There are still some components that cannot clean.
  6. The residual flux has been controlled and can be used by the product appearance requirements to avoid visual inspection of the cleaning state.
  7. The residual flux has continuously improved its electrical performance to avoid leakage of the finished product and any injury.
  8. The wash free process has passed several international safety tests, proving that the chemical substances in the flux are stable and non-corrosive.
Switch knowledge of low-cost PCB assembly

SMT processing is a kind of technology and process in the current electronic assembly industry. It compresses the traditional electronic components into only one-tenth of the device’s volume to realize the degree of electronic product assembly, high reliability, miniaturization, low cost, and production automation. Its related assembly equipment is called SMT equipment. As the key equipment in SMT, SMT processing, and placement machine, You need to know a lot about it. Ideaspcb to talk about SMT Mounter switch knowledge.
The switches of low-cost PCB assembly machines are divided into emergency switches and general stop switches. They are different and cannot be used casually.
The emergency switch is used in emergencies, such as life-threatening or the risk of crashing the machine, we need to use the emergency switch. If you also use the emergency switch when the machine is running normally, What will immediately cut off all servo power of the machine, and the machine will stop running immediately. If you choose the general stop switch, the machine will stop after completing its steps.
Let’s take an example. If the machine is sucking material, the machine must stop after it is pasted. At this time, if you press the emergency switch, the machine will stop sucking material immediately, which obviously can’t achieve our goal. Therefore, when we use SMT to process SMT, we can’t ignore its switching problem.