ECI has utilized a pick-and-place machine for a number of years, mostly for placing metal domes within a membrane switch assembly. The process of placing the domes begins with adhesive and spacer layers being inserted in the PPM with a pin registration system. A hollow nozzle uses a vacuum to pick up the domes and place them within the opening of the spacer layer and circuit assembly.
We spoke with ECI Designer, Dan Army who is in the process of unlocking the potential of the PPM to attach LEDs onto a flexible membrane switch.
“ ECI’s lean approach aims to maximize value from parts, services and equipment. Using the PPM to its maximum potential benefits both the company and our customers.” Dan Army, ECI Designer.
Traditionally, skilled technicians would place the LEDs by hand and in some cases, this is still the preferred process, depending on the job requirements. The downfall to hand placing large quantities of complex orders is that it is tedious and monotonous, resulting in technician fatigue and higher cost. The ECI team knew the equipment was being underutilized and held the potential to solve this production dilemma.
After rigorous testing and research ECI has been able to optimize the PPM for LED placement. This adds value to both the company in time and labor, but also to customers in providing precision, quality and quick turn-around.
The process now includes the same hollow nozzle vacuum that picks up the metal domes for picking up the LEDs and placing them in the programmed location. It is then secured to the polyester with Loctite glue from a syringe dispenser apart of the automated process. With a maximum placement rate of 3600 CPH (components per hour) this opens up the opportunity to process large-quantity orders with attached components quickly. After months of testing the ECI team is excited to utilize this process in future orders.
ECI Technologies has been using the pick-and-place machine for meatal dome components for many years advancing our capabilities with the PPM for placing components, like LEDs, focuses on our overall corporate lean initiatives and utilizes our equipment to its maximum potential.