Automation technology in the age of automotive electronics
Automakers recognize that increasing the use of in-vehicle electronic systems is the best way to deal with today's regulations and market pressures. It is predicted that the value of automotive electronic systems will reach 30% of the total value of automobiles by 2005. This has huge business opportunities for electronics manufacturers who can fully meet the needs of the automotive industry; the market needs high-quality and reliable products, low cost and prompt delivery. These manufacturers themselves have strict requirements on manufacturing automation technology, so they need to work with partners to help them solve the technical and logistics challenges they face.
All-round technology
In general, automotive electronics subsystem developers are identified as TierOne component and subsystem assembly suppliers. They now often receive assistance and support from expert partners who use advanced technologies to develop innovative processes. Developers of these subsystems are under tremendous pressure and must produce more intelligent systems at lower cost. These systems must also be lightweight, compact and reliable. In addition, they often need to use cutting-edge semiconductor and assembly technology. In real-world applications, these systems must operate flawlessly throughout the extended warranty period, regardless of the unimaginable and harsh environment: under the hood, in the drive tractor or fixed in the range from Arctic to tropical Anywhere on the car body. Even in the cab, the system needs to be able to withstand shocks or vibrations, splashes of hot or carbonated beverages, changes in temperature, and careless maintenance by careless users. These factors also bring about the quality and integrity of the installed system. Very high requirements.
Although automated assembly technology can help manufacturers in all electronics markets improve quality and repeatability while reducing costs, especially in terms of labor, automotive suppliers are different. They need special solutions to The unique challenges they face should be met. This article will discuss some considerations specific to the automotive industry.
Special substrate
Usually, it is used under the engine cover or other occasions where the expected operating temperature changes greatly, such as the system of the engine control module, etc., will use a ceramic substrate because it has good thermal stability. If manufacturers consider assembling such modules in a linear and automated manner, they must find a solution that can meet the special performance requirements of ceramic substrates; during substrate alignment before component placement, it is difficult for machine vision systems to identify fiducial marks . Therefore, it is expected that the reproducibility and output of the former will be reduced when using the "torch" type lighting device assembly machine and the ordinary FR4 type circuit board assembly machine. Polarized lighting devices can achieve better results, but the optimized multi-directional lighting matrix assembled on the Universal Instruments platform such as HSP (High Speed ​​Placement) or GSM series will significantly improve its placement performance when working with these ceramic substrates. Compared with the FR4 circuit board, the ceramic substrate is more abrasive to the circuit board transmission device. Universal Instruments has developed a stainless steel kit to prevent excessive wear on the machine.
Assembly of various mixed components and shaped components
Any production line configured to assemble automotive products must be able to handle a variety of mixed components, send them into the production line, and maintain high-efficiency machine uptime. For example, the fuse box circuit board or busbar manufacturing line for the upcoming 42V power distribution system will be able to perform the following operations: press-fit terminal blades on both sides of the circuit board; mount a small amount of SOIC, general semiconductor devices and surfaces Mount 20A relay. The new production line configuration may combine the terminal plug-in machine with other machines, such as Global Instruments' GSM platform, but planners must also consider the possible product composition, and the output and complexity of each product.
Other subsystems may need to mount large or special-shaped components, such as motor actuators, relays, or automotive connectors. Its mounting requirements are influenced by a variety of automotive electronic connectors; although standardization can reduce the number of parts in the future, today ’s first-level assemblers may need to handle thousands of part numbers to cover their customers All connector and terminal types required.
The best solution for the mounting of shaped components depends on the number of components, and depends on whether it can be applied to a standard mounting platform such as Universal Instruments' GSM flexible mounting platform and whether it can be completed within the target cycle time. Factors such as component size and feeder type, or requirements for high-speed production lines, can determine whether it is necessary to add placement machines or use special shaped component assembly functions. The solution provider's ability to configure the best solution would be the most ideal way.
Another option is Universal Instruments' new GSMGenesis machine, which can implement a full-platform solution in certain situations, especially when more shaped components and large parts are required, or where small or medium-volume production is required. Currently, GSMGenesis machines are suitable for manufacturing cycle rates of 20,000 to 40,000 cph. Future improvements will make GSMGenesis faster, but HSP series high-speed placement machines from Universal Instruments are the best solution for applications requiring higher cycle rates.
In addition, driver and passenger information systems such as radio / CD players, GPS navigation or integrated communication / multimedia systems may pose the same challenges. If compared with other systems such as 42V power distribution modules or engine controllers, more A large number of components. The challenge here is to combine high-speed placement and flexible precision placement capabilities to optimize production capacity and reduce equipment asset costs.
Final assembly of the casing
Most automotive electronic subsystems, especially control units for engine control, ABS, power steering, traction control, and other functions, are housed in heat-resistant, waterproof, anti-condensation, or anti-vibration enclosures. In order to facilitate control and ensure quality, even if the labor cost is low, the assembly of these cabinets is also fully automated. Reconfigurable assembly solutions, such as Universal Instruments' Polaris multi-process assembly unit, provide cost-effective and flexible manufacturing methods to meet many final assembly requirements.
This is an improved version of the Polaris servo clamping unit. It is specifically designed for the mounting of shaped components. It has a tool interface that conforms to the standard. It allows a variety of tool accessories to be interchanged to achieve various final assembly functions, including assembly chassis, Apply sealant or placement glue, visual inspection, screwing, and many other functions. For outsourcing business suppliers or any assembler who needs to produce a highly mixed product, the output is relatively low, or the production line needs to be reallocated to fulfill special contracts, which will be a powerful option.
Usability
Any manufacturer who expects to secure orders in the automotive industry must have effective component and board-level usability. This is mainly applicable to safety-critical systems, such as anti-lock braking and traction control, and secondary safety equipment such as airbags. These systems can be very complex and versatile; for example, a comprehensive airbag controller will include airbag deployment, airflow control, pre-crash detection, passenger detection, rollover detection, and acceleration detection. These systems have almost become standard equipment in today's new cars, and new safety measures will continue to appear, including mechanical devices for pedestrian protection in automobile accidents.
But usability is not limited to the safety performance of in-vehicle electronic systems. Car radios, navigation, telematics, and cellular phone systems, etc., although not regarded as critical safety factors, do not guarantee that the product will not be returned and incur huge expenditures; defective parts or potentially defective ones None of the components can pass the acceptance inspection and be assembled into the system. This also applies to the high-speed Internet system that enters high-end business vehicles.
Universal Instruments' Dimensions Manufacturing Automation Software Suite includes features designed to simplify usability. Dimensions Manufacturing Monitoring Module (DDM) can support component and board level barcode tracking. By querying the SQL database based on the date of the defective component, you can find the circuit board with the defective component. With the ability to quickly detect and identify related defective components, you can prevent products with potential defects from leaving the factory. This low-cost option can bring huge returns, because the cost of using the return product mechanism may be much higher than the price of the entire assembly line.
Logistics
For manufacturers at all levels in the automotive industry, cost and efficiency are the keys to survival. In order to coordinate with the operations of customers and suppliers, electronics manufacturers must adopt a streamlined manufacturing strategy.
According to research from the University of Michigan, automakers can reduce the company's inventory by as much as 60% and transaction costs by as much as 75% by automating the replenishment process within the supply chain. To this end, manufacturers in the entire automotive industry, including electronics manufacturers, are applying third-party supply chain software to integrate various standard business modules, including goods receivable, accounts payable, general ledger, and procurement. Universal's Dimensions software can be easily used with these solutions. For example, the Dimensions Logistics Module (DLM) enables enterprise management to read information on the factory floor, such as collecting inventory information of used components and active components on the production line, as well as the location of feeders and inventory in the workshop. This is real-time data that reflects real consumables information and can be used by enterprise management systems to more effectively improve purchasing operations and manage inventory.
Future integration
Since vehicles began to be equipped with on-board radios, power windows and central door lock systems, the market for automotive electrical and electronic subsystems has continued to grow. Today, there is a huge development space for the development and establishment of automotive electronic systems. The goal is to make the car easier to control, suitable for sale, safer and more convenient for the supervision of the road administration department. Some examples of emerging technologies include wired driving and wired brake (x-by-wire) systems, telematics, advanced automatic transmission, lane departure warning, collision detection and avoidance, and intelligent vehicle number plates; of course there are hybrid and Fully electronic passenger vehicle system.
Therefore, auto manufacturers require subsystem suppliers to provide prices and logistics services such as consumer electronics products, combined with advanced technologies similar to aerospace and medical fields-high reliability and component-level availability.
To meet this integration requirement, the production line needs to be highly automated, capable of mounting various types and specifications of components, and have high flexibility to meet the requirements of larger-scale production and product mix. First-tier suppliers and new automotive technology experts have discovered that working with automotive manufacturing experts can configure the best solutions from various platforms to achieve high-speed, flexible, and sophisticated electronic manufacturing capabilities, benefiting manufacturers a lot .
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