September, 2016
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What Makes a Reflow Oven “Smart?” Continued from previous page
window, and the cause/effect dynam- ics between the oven recipe and the resulting profile.
Interconnectivity The reflow oven is only one cog
in a larger wheel and cannot be iso- lated. Dynamic, real-time process data flows through the factory LAN for use in MES and ERP systems, and is accessible by other machines in the production line. The timeliness of the information enables better pro- duction execution as well as efficient management of the entire shop floor. For example, improved communica- tion with material vendors is helpful for better inventory control as well as the occasional root cause analysis. Many EMS clients can already log into their own folder on the network, or in the cloud, to access all relevant information specific to the manufac- turing of their products. “Smart” is a relative term.
There is an expectation in the indus- try today that machines will continu- ously learn and get smarter over time. Much work is yet to be done to
It is not enough to do good work some of the time, or even most
of the time. Production has to be right all of the time, and data is required to enable it.
make the machines more intelligent, but one can foresee a future where, for example, the AOI machine learns from the oven process monitor, as well as other processes on the line, in order to automatically correct upstream machines for improved performance. Today, the oven database keeps
learning the relationship between oven thermal properties, the PCB process window, and the PCB ther- mal dynamics to build insight. Such insight reduces or eliminates oven set-up and changeover time. The automatic process monitoring system will learn about the absolute level of changes in the process, where in the oven they occur, and the rate by which the changes occur. This infor- mation can help determine the tim- ing of preventive maintenance, when the oven is no longer capable of exe- cuting the application, if it needs to be replaced, or when the production should be shifted to another line.
Energy Efficiency Most factories in our industry
have programs for sustainability, reducing the carbon footprint and other environmental considerations. The reflow oven is likely the most energy hungry of all the machines in the factory. A truly “smart” oven automatically optimizes its electrici- ty use for any given application. Case studies have consistently indicated an approximate 15 percent reduction potential in energy use due to intelli- gent software’s ability to adjust and eliminate wasteful conditions. Today’s SMT factories have a
tremendous amount of cost sunk in their current and previous genera- tion equipment. Clearly, very few companies would want to sell off all existing equipment to acquire new smart technology in the new genera- tion of capital equipment. Therefore, the smart technology needs to be retrofittable onto existing machines, preferably with a similar interface to make the user interface and inter-
connectivity easier to manage. Consumers drive the industry
towards mass customization, faster time to market and lower cost. Smart
machines are producing smart prod- ucts and everything connected is gaining traction throughout numer- ous industries. A key aspect of the
Page 57
new intelligent factories is not only to monitor what the machines do, but to focus on the outcome of their activ- ities.
Smart factories are more trans-
parent to everybody involved, includ- ing their suppliers and customers, are highly-automated and flexible, and are much more efficient in their use of energy. These factories are growing more suitable for shorter production runs of vastly more diverse products and will keep learn- ing and getting smarter over time. Contact: KIC Thermal, 16120 W
As factories become smarter, interconnectivity between automated machines will become more prevalent.
Bernardo Drive, San Diego, CA 92127 % 858-673-6050 fax: 858-673- 0085 E-mail:
bdahle@kicmail.com Web:
www.kicthermal.com r
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