Yamaha Motor Upgrades Flagship Surface Mounter

Yamaha Motor Co., Ltd. will soon launch the new premium high-efficiency YRM20DL surface mounter*1. YRM20DL is built on the basic performance of the company’s flagship high-speed, high-accuracy, high-versatility, universal mounter YRM20.

The YRM20DL, to be launched on April 3, is a premium high-efficiency modular. It achieves improved actual and per-unit-area productivity achieved through the newly developed high-rigidity dual-lane conveyor with reduced transport losses. Mainly, YRM20DL supports a maximum PCB width of up to 330mm. Also, the same width PCB is being conveyed at the front and rear while in dual-lane production mode. In the case of parallel mounting, the front and rear heads operate without any interference up to a maximum PCB length of 380mm, enabling high-efficiency mounting without loss.

The YRM20DL is a premium high-efficiency modular that achieves improved actual and per-unit-area productivity.

Furthermore, the basic performance of the unit was further enhanced to achieve an overwhelming productivity of 120,000 CPH*3 (under optimal conditions)*2. This rate is the highest speed level in its class. Moreover, it features a higher-accuracy placement of ±15µm (Cpk≥1.0) through the revision of the layout. Among them include bringing the mounted components pick-up area and the mounting area closer together, optimizing the main spindle motion control, improving the rigidity of the conveyor and the corrective functionality. These adjustments enabled the unit to achieve an overwhelming productivity.

Embodies 1 Stop Smart Solution

Yamaha Motor realized the ideal concept of a 1 STOP SMART SOLUTION by taking advantage of the company’s strengths as a full-lineup manufacturer of mounting equipment. Among them include surface mounters, printers, dispensers, and inspection systems. Mainly, the company promotes the Intelligent Factory system, which comprehensively realizes higher efficiency in the mounting process through smooth and advanced inter-equipment cooperation without black boxes.

*1: Surface mounters: Production equipment designed to mount various electronic components onto printed circuit boards, which are then incorporated into electronic products.

*2: Comparative mounting capacity (CPH) under optimal conditions for surface mounters in the 2-Beam, 2-Head Class. Yamaha Motor survey, February 01, 2023

*3: CPH (Chips Per Hour): Total number of chips that can be mounted per hour (unit time). Indicates processing capacity under various conditions.

Market Background and Product Outline

There is a rapid electrification of powertrains for in-vehicle electronics. More so, the miniaturization, high-densification, high functionality, and diversification, as well as shortened product cycles increasingly accelerated for a variety of products such as appliances, personal computers, and mobile telephones. In response to this, the miniaturization of components also progressed. Moreover, higher-performance, higher-efficiency equipment with greater flexibility and efficiency were introduced. This promoted a dramatic increase in production capacity at manufacturing sites. However, along with improvements of these throughputs, the ratio of fixed-value losses that do not generate value, such as transportation time to production time, also came into focus.

Mounting example using dual lanes (Arrows indicate movement of the head)

Therefore, Yamaha Motor developed the YRM20DL, a dual lane version of its latest flagship mounter YRM20, to adopt the new generation platform. The new system supports various dual-lane production methods. Specifically, these include transporting two PCBs of the same type by parallel mounting, transporting two PCBs of different types, and alternate mounting. This function makes it possible to select and operate the optimal production system for each product PCB type. As a result, fixed-value losses such as transport losses can be greatly reduced in a wide variety of SMT production lines, from high-speed mass production to high-mix low-volume production, along with improved actual productivity and per-unit-area productivity.

YRM20DL Main Features

1) Achieves higher speed and higher accuracy through improved basic performance

By revising the dynamic layout, the unit achieved the world’s highest level of 120,000CPH in its class, realizing overwhelming productivity. Mainly, this was achieved by minimizing the movement distance. Particularly, the pickup and mounting areas were brought closer to each of the two heads and the overall spindle motion control was further optimized.

Also, high-accuracy mounting of ±15μm (Cpk≧1.0) is achieved by increasing the rigidity using the newly developed conveyor and improving the correction function. In particular, the RM head/HM head supports 0201-sized (0.25×0.125mm) ultra-small chip component mounting and narrow adjacent mounting.

2) Adoption of a newly developed dual-lane conveyor that reduces transport loss and improves per-unit-area productivity

Additionally, the newly developed high-rigidity dual-lane conveyor supports a maximum PCB width of up to 330mm. Particularly, the same width PCB is being conveyed at the front and rear while in dual-lane production mode. Also. an ultra-high-speed rotary RM head, which employs overdrive motion (mutual head insertion), allows the front and rear heads to operate without any interference up to a maximum PCB length of 380mm. This enables highly efficient mounting without head standby loss.

Moreover, in single-lane production, it is possible to transport PCBs up to a maximum length of 810mm, a maximum width of 610mm, a transportable weight of 3kg, and a maximum PCB thickness of up to 6.5mm. Also, this new model is compatible with a wide range of extra-large-sized PCB’s, jig conveyance, including for automotive products, industrial, medical, power devices, and LED lighting.

3) Other key features

The head can be selected from three types:

– Ultra-high-speed rotary RM head with overdrive motion;

– In-line HM head that combines high speed and high versatility with “1-head solution”. It handles ultra-small chip components to larger components with one type of head;

– In-line type FM head capable of handling tall and odd-shaped components.

Supports various labor-saving functions:

– Auto-loading feeder that can easily replenish tape components at any time without the need to stop production;

– eATS30, a non-stop tray supply device that can supply tray components in units of pallets/magazines without the need to stop production;

– Non-stop loading/unloading feeder carriages that enables setup work for feeder carriages replacement without the need to stop production on one lane;

– Automatic exchange of push-up pins, greatly reducing workloads when changing products.

Integrity and ease of maintenance:

– Nozzle ID management that enables maintenance optimization according to the number of accumulated shots;

– Self-diagnostic and self-recovery functions maintain a clean state. This allows continued high-quality production nozzle health care/feeder maintenance warnings.