Southern Machinery

To Convert Radial 8 Dual Span to Triple Span 2.5/5/7.5mm Configuration

Occasionally, customers will request quotations for machine conversions.  Typical requests will be 

for conversion from Dual Span 2.5/5mm to Triple Span 2.5/5/7.5mm.  This retrofit is available on a 

RFQ basis from the Special Products Group.  There are restrictions and considerations:

  1. Only 6380A and 6388A machines are eligible for this retrofit.

  2. Installation will be performed by a factory technician along with a service engineer.

  3. Any machine issues unrelated to the actual conversion will be addressed on a time and material 

basis at then current service rates and WPSD parts pricing.

  4. Retrofit warranty will be for 90 days from installation and will apply only to affected assemblies.

No warranty is extended or implied to extend to unrelated items.

  5. Lead times will be based upon resource availability, with manufacturing production requirements 

receiving first priority.  This will be confirmed at the time of order placement.

  6. Orders placed against SPG quotations will be processed as machine orders through the COC.

This retrofit will not be handled through WPSD.

  7. Spares kits for affected tooling are included in the retrofit. This is not subject to negotiation.

  8. An application review is recommended to determine if the application is appropriate.

  9. Radial components are taped at either 12.7 or 15mm pitch. 7.5mm parts are often taped on 15mm 

pitch tape. 15mm heads must be purchased new. They cannot be converted from 12.7mm pitch heads.

10. Double pitched taping will cause dispensing head refires.  This will affect machine throughput.

Please consult the appropriate General Specifications to determine the actual derate.

11. Please provide the machine serial number and a description of the machine condition with all inquiries.

12. Please contact the product team for performance details and terms.

To Convert Radial 8 Dual Span to Triple Span 5/7.5/10mm Configuration

Occasionally, customers with a Dual Span machine will request a conversion to 5/7.5/10mm capability.  

There are also requests to convert a 2.5/5/7.5mm machine to this configuration.  There are restrictions 

and considerations in place for this upgrade:

  1. Only 6380A, 6388A and 6389A machines are eligible for this retrofit.

  2. Retrofit will be performed in Binghamton by factory technicians. The customer is responsible 

for all transportation and crating charges. It is strongly recommended that a service engineer 

is involved in the preparation of the machine for shipment to Binghamton.

  3. Any machine issues unrelated to the actual conversion will be addressed on a time and material 

basis at then current service rates and WPSD parts pricing.

  4. Retrofit warranty will be for 90 days from installation and will apply only to affected assemblies.

No warranty is extended or implied to extend to unrelated items.

  5. Lead times will be based upon resource availability, with manufacturing production requirements 

receiving first priority. This will be confirmed at the time of order placement.

  6. Orders placed against SPG quotations will be processed as machine orders through the COC.

This retrofit will not be handled through WPSD.

  7. Spares kits for affected tooling are included in the retrofit. This is not subject to negotiation.

  8. An application review is recommended to determine if the application is appropriate.

  9. Radial components are taped at either 12.7 or 15mm pitch. 7.5mm and 10mm parts are often 

taped on 15mm pitch tape. 15mm heads must be purchased new.

10. Dispensing heads for this machine use a special head casting. They cannot be converted from 

existing heads. Dispensing heads for this type of machine must be purchased new. 

11. Double pitched taping will cause dispensing head refires. This will affect machine throughput. 

Please consult the appropriate General Specifications to determine the actual derate.

12. Please provide the machine serial number and a description of the machine condition with all 

inquiries.

13. Please contact the product team for performance details and terms.

Radial 8 Affected Assemblies:

Chain Assembly and Carrier clips (new)

2.5/5/7.5mm Dispensing Head Pusher (Rebuilt)

5/7.5/10mm Dispensing Heads (new)

Cutter Station (rebuilt)

Chain Guide Assembly (new)

Component Transfer Assembly (rebuilt)

Insertion head Assembly (rebuilt)

Cutter Head Assembly (new)

………………………

………………………

Interconnect Inserter Comparison Matrix

Feature	Universal 3785	Universal 3789	Panasonic NM2209	Panasonic 2204B	TDK VC7	Eun Seong (Korean)
Insertion Head Options	Eyelet, Pin, Socket, Terminal	Eyelet, Pin, Socket, Terminal	Only Eyelet	Only Pin	Eyelet or Pin	Only Eyelet
Multiple Head Options	Yes	Yes	Yes	No	No	No
Inputs	Up to 3	Up to 4	1 or 2	1	1	1
Feed Options	Bulk or Strip	Bulk or Strip	Bulk	Bulk	Bulk	Bulk
Speed	Eyelets – 6,500/hr Pins – 6,000/hr Sockets – 5,800/hr Terminals – 11,000/hr	Eyelets – 3,000/hr Pins – 12,000/hr Sockets – 10,600/hr Terminals – 22,000/hr	5,140/hr	5,140/hr	4,500/hr	4,000/hr
Board Size	457.2mm x 559mm Stand-Alone 483mm x 406mm Pass-Thru	457.2mm x 559mm Stand-Alone 483mm x 406mm Pass-Thru	381mm x 457mm	250mm x 330mm	250mm x 330mm	250mm x 330mm
Component Range	1.3mm to 4.75mm	1.3mm to 4.75mm	1.6mm to 4.0mm	Factory Quote	Factory Quote	xxxxx
Board Handling	Available	Available	Available	Available	Available	From OEM
Pin Insertion	Available	Available	No	Yes	Available	No
Socket Insertion	Available	Available	No	No	No	No
Terminal Insertion	Available	Available	No	No	No	No
Board Error Correction	Available	Available	Available	Available	Available	No
Safety Enclosure	Standard	Standard	No	No	Yes	No
CE Mark	Yes	Yes	No	No	No	Yes
Design To Order	Yes	Yes	No	No	No	Yes
World Wide Service	Yes	Yes	Yes	Yes	No	No
World Wide Spares	Yes	Yes	No	No	No	No
Notes:	Worldwide installed base.  Machines have been produced for over 15 years.  Custom machine configurations are available, including special clinch sets.  Simple head and feed concept never releases the component during insertion.	Worldwide installed base.  Machines have been produced for over 15 years.  Custom machine configurations are available, including special clinch sets.  Simple head and feed concept never releases the component during insertion.	Uses a weak component transfer concept which releases and transfers the component four times prior to insertion.  Feed bowls are not attached to the machine and are easily disturbed, causing down time.	Extremely slow and expensive.  Spare parts are extremely high priced ad have long lead times.	Unreliable, and only available with the Radial Lead Inserter, resulting in poor throughput for both the eyelet and the Radial Inserter.	Extremely slow machine with a very weak positioning system.  Supplier is inexperienced with auto insertion machine export and support.

Axial Products Competitive Analysis

Competitor	Location	Key Weaknesses	Key Strengths	Comments
TDK  (Rank 2)	Japan/U.S.	No Axial experience No previous Axial machines in product mix, offering only a SH VCD (no Sequencer, DH, etc.) Axial product offering is VERY similar to Dynapert V12000.  Possible patent infringements on Dynapert design. Support infrastructure is inferior to UIC’s.	Low price machines Field proven reliability of Radial Inserter Large multi-national installed base for Radial Inserter Japanese firm, thus strong JMA loyalty Asian company, thus understands Asian business needs Operates in Microsoft Windows interface, which provides immediate productivity feedback Financially sound and stable	Offer a  SH VCD – Avisert AC-7

TDK Competitive Summary

AC-7 Avisert Features: · Board offset correction · Insertion hole correction · Ammo or reel input packaging · Push button control panel · Microsoft Windows interface · Intelligent operator message feedback · Servo driven cam operated insertion head · Servo motor driven rotary table · Available Options:  – Pass through capability – Throughput optimizer – Flexible work board holder – Touch screen   – Pattern repeat – Multi tier security software – Optical safety device – Integrated machine enclosure

Key Sell Against Points:

Universal offers a complete Axial product line; Single Head, Dual Head, VCD Sequencer and Sequencers while TDK offers a single Axial machine.

Universal completes the IM product offering with Radials and Special Products which include Eyelet and Pin Inserting Machines, and 3-Span Radials.

We offer optional Universal board handling on most models.

Universal offers a superior training, service and support infrastructure.

We offer industry leading cost per insertion and the highest throughput per square foot of floor space.

UIC Strengths and Proof Points:

UIC Strengths	Benefit	For the Customer:
Machine designs allow flexibility in the production environment.	Universal offers a complete IM product line of Axial inserters, Sequencers and combination machines, as well as Radial product offerings. Universal board handling is optional for machine integration.	Discuss customer need for  factory integration. Possible future need for increased automation.
High value for the price, and  fastest inserters in the industry.	Dual Head machines provide  the highest throughput in the industry, 32,000 cph, a cost effective approach for high volume applications.	Ask the customer to compare cost per insertion.
Superior service, support and training.	Excellent investment protection. UIC is a respected and secure provider of insertion equipment. Pre and post sale assistance with specific applications and systems integration.	Ask the customer to compare UIC’s support infrastructure (tech. specialists, spare parts, FE response time) to Panasonic.  Also discuss unique value benefits – Uptime 100 and Tech Advisor.

TDK Strengths and Counter Points:

Competitor Strength	The Facts	For the Customer:
Perceived high throughput (16,000 CPH).	The throughput Nepcon Tokyo 觀appeared closer to 10,000 CPH. Noisy.	Demonstrate UIC’s commitment to reducing customer costs by:  1.  Comparing cost per insertion.
Single insertion head provides better stability and less maintenance and setup.	Dual head machine is the  highest throughput inserter in the industry with exceptional reliability and insertion performance. Single head machine offers competitive cost per insertion with all the other values of UIC.	Demonstrate UIC commitment to customer support with: 1. Service and support, including PM schedules and maintenance manuals. 2. Uptime 100 program. 3. Tech Advisor. 4. Superior training program.
Priced competitively in the 80K – 106K range.	Targeting existing Dynapert accounts where support requirements are minimal.	Demonstrate UIC’s commitment to reducing customer costs by:  1.  Comparing cost per insertion.
Financial backing from a major IM provider.	Very similar to Dynapert V12000 machine  Possible patent infringements on Dynapert design. Not a complete product line, no complementary Sequencer available to date or board handling.   May not have devoted TDK backing for service and support.	Determine if customer is will to obtain investment protection: 1. From a supplier that may not remain in business due to legal problems. 2. Has revived very old designs. 3. Discuss Broome Engineering products for low cost entry and their ability to allow trade-up.

Appendix – Reference Accounts and Testimonials:

Account Name	Salesman to contact	Comments
AT&T Monterey, Mexico	Michael Lewis	TDK offered AT&T accepted an all expenses paid trip to Boston to evaluate the AC-7 but still prefers the UIC Dual Head machines.

This paper compares Amistar’s Model AI-6448 Inserter/Sequencer and Universal’s Model 6241D VCD/Sequencer machines.  

Amistar Corporation, head quartered in San Marcos, California, is a small company – 154 employees and ~ $20 mil in annual sales.  Both resources and exposure are limited and Amistar predominantly sells via representatives.  To my knowledge, manufacture of the Amistar Model AI-6448 was discontinued approximately 7 years ago.  Because of this, current information about Amistar is limited.

Amistar advertises the AI-6448 on their web page as follows:

The Amistar AI-6448 is a fully automated Axial component inserter. 

Stand alone automation: sequences & inserts in one operation 

Cycle rate of 9,600 insertions per hour 

Capacity: 64 cartridges, 88 reels 

Automatic optical position correcting via PCS (Position Correcting Servo) 

Axial component verifier 

Lead protrusion inspection 

Microprocessor control 

Easy to program 

Easy to use

Amistar’s approach to axial insertion with their model AI-6448 is very different from Universal’s.  Axial lead components are cut at the dispensing head and dispensed down a tube via free fall (gravity) compressed air. The component is then recaptured at the transfer station for eventual insertion into the PCB.  The Amistar machine has capacity for 88 reels and 64 cartridges, but no ammo pack capability.  Each cartridge is kitted off line and capable of handling a maximum of 75 components.  Some customers believe this feature works well for small production runs, although it does add another preparation step to the process, as well as additional component handling, which increases the potential for component damage and or errors.

Other differences from the method in which Universal handles axial components include the way in which components are centered.  Amistar centers on lead end instead of the component body.  This can lead to components being cut off-center and consequently effect insertion reliability.  

In order to utilize the AI-6448’s method of transferring components to the insertion area, the positioning system is very low to the floor making it difficult to maintain and/or access.  Universal FE’s have had the opportunity to evaluate AI-6448’s installed at customer locations and have reported concerns with the durability, accuracy and repeatability of the rotary table.  

While the Amistar Model AI-6448 can be equipped with board handling, the method utilized is limited to stand-alone applications, not allowing for pass-through or in-line capability and takes up a lot of floor space.  

In the past, Amistar has sold the AI-6448 when the prospective customer is interested in combined sequencing and insertion and price is a major factor.  Typically, the price of the AI-6448 is much less than the 6241 in a similar configuration (similar in a sense that there are similar number of inputs).  When speed, capability and machine performance are added to the equation, the AI-6448 is not as attractively priced.  Because Amistar has not manufactured the AI-6448 in 7 years, no current pricing information is available to us.

Feature	Amistar Model AI-6448 Axial Insertion Machine	Universal Model 6241D VCD Sequencer/Inserter
Speed	9,600 cph	16,000 cph
Max PCB Size w/Board Handling	20″ x 20″ (508mm x 508mm)	19″ x 16″  (483mm x 406mm)
Max PCB Size w/out Board Handling	20″ x 20″ (508mm x 508mm)	18″ x 22″  (457mm x 559mm)
Max # of Inputs	52mm only:  64 cartridges, 88 reels 26mm not available ammo pack not available	52mm: 220 stations in 20 station increments 26mm: 220 stations in 20 station increments Reel and/or Ammo Pack
Insertion Span	Std:.300″ – .800″ 7.62mm – 20.3mm) 5mm:  Not available	Std: .300″ – .950″ (7.6mm – 24.1mm) 5mm: .197″ – .850″ (5mm – 21.6mm)
Component Centering	Component Leads	Component Body
Board Error Correction	Yes	Yes
Verification	Yes  – limited capability	Yes
Lead Sensing	Yes	Yes – dual lead
Rotary Table	Yes	Yes
On-Line Programming	Yes	Yes
Automatic Board Handling	Yes	Yes – designed and manufactured by Universal
Part Transfer	Chute	Sequencer
Refire	Yes	Yes
Part Repair	Automatic	Semi-automatic
Max Body Length	.400″(10.2mm)	.620″(15.7mm)
Max Body Diameter	.175″(4.5mm)	.420″(10.69mm) – 2 x PCB thickness
Lead Diameter
Standard Tooling:  copper lead	.015″- .036″(.38mm – .9mm)	.015″- .032″(.38mm – .81mm)
Standard Tooling:  copper lead	.015″- .026″(.38mm – .66mm)	.015″- .032″(.38mm – .81mm)
5mm Tooling: copper lead	Not available	.015″- .032″(.38mm – .81mm)
5mm Tooling: copper lead	Not available	.015″- .032″(.38mm – .81mm)
Jumper Wire Capability	Yes	Yes
Low Part Sensing	No	Yes

Universal’s 6241D is still manufactured and design development activities continue to enhance and improve the machine as part of Universal’s ongoing commitment to the through-

hole market.  In addition to the items listed above, recent enhancements in the Model 6241D product line include:

Axial Tech Advisor is available which provides Operators and Maintenance Technicians on-line, menu-driven diagnostic information and assistance on machine operation, troubleshooting, maintenance and repair at the time of need.  It is available in English, Chinese and Spanish.

Newly designed jumper wire dispensing system provides fast, reliable and accurate wire feed and accommodates .45mm to .6mm wire diameters

Newly designed dispensing heads are easy to operate, greatly extend life of wearable parts and allow for quick changeover with minimal scrap.

The 6241D now offers a low-level Sequencer Add-On Module for easy reach loading.  It features low part sensing to alert the operator before parts are depleted, allowing replenishment without interrupting machine operation, removable end scrap bins for easy clean out, and refire is offered on each dispensing head.

Precision WBH’s, both adjustable and fixed are available.  Universal can also accommodate Amistar WBH’s.   

The 6241D contains a 4 color light tower which signals machine operating status.

New and improved board handling increases system reliability, ease of PCB changeover and ease of assembly. (See SH BHS Improvements Presentation).

Newly designed 5mm tooling is now available for increased reliability, longer life and better handling of bent lead component input.  (See 5mm Tooling Improvements Presentation).  Customers have told us this tooling lasts three times longer than the old style tooling

Universal offers a AAA version of the VCD Sequencer machine that is capable of inserting 26mm input.

The 6241D is CE marked to meet all European health and safety standards.

While Universal does not offer conversion software for converting Amistar pattern programs, the Amistar programs could be treated as CAD data and translated via the CAD translator available in PPU.  If your prospective customer would like to supply us with one of their programs and briefly explain the fields, we will review the program and offer suggestions for performing the translation.

And last, but not least, Universal offers a support infrastructure which includes a knowledgeable and experienced Field Service organization, world wide Training Centers and Parts Distribution Centers as well as an extensive installed base.     

1.0 INTRODUCTION

Do you have customers who are willing to simplify the Axial automated insertion process, speed up machines, lower preventative maintenance (pm) downtime and ppm levels and generally reduce manufacturing costs?  If so, then this paper may interest you.

Universal Instruments Corporation is currently working to customize tooling for customers who have evolved their manufacturing processes to two and three step processes for Axial insertions, thereby dedicating machines to run a limited range of components.  In step one for example, a machine inserts only 5mm insert spans and then in step 2, a second machine inserts various wire diameters.  This is a radical change from the current manufacturing philosophy of fully populating a board in one pass through a machine.  However, history has shown that by limiting the range of wire diameters inserted and then designing tooling to specifically handle that range, the manufacturing process becomes more controlled, insertion performance improves, pm downtime and ppm levels decrease and ultimately, manufacturing costs decrease.

Admittedly, this approach is not viable for every customer.  Universal offers a variety of tooling configurations that if used according to specification, will provide excellent insertion performance.  A customer may have no need to run a wide range of wire diameters or they may want to revisit their manufacturing process to make improvements.  For those customers, Universal offers customized tooling for dedicated applications.  Customized tooling will handle a limited range of wire diameters to optimize insertion performance and maximize tooling life.

This paper discusses the relationship between tooling design and  wire diameter range of inserted components with the goal of creating an awareness and understanding of this relationship and it’s significance.

2.0 FACTORS AFFECTING THIS RELATIONSHIP

2.1 Depth of V-Groove of Outside Former

One important factor affecting the relationship of tooling design and range of insertable wire diameters is the depth of the V-groove of the Outside Former.  Our current specifications for Axial tooling are as follows:

	Standard	High Density	Large Lead	5mm	26mm AAA
Bottom View of Outside Former
Wire Diameter Range / Material	Steel: .015”-.032” (.39) – (.82) Copper: .015”-.032” (.39) – (.82)	Steel: .015”-.025” (.39) – (.64) Copper: .015”-.032” (.39) – .82)	Steel: .025”-.032” (.64) – (.82) Copper: .025”-.042” (.64) – (1.01)	Steel: .015”-.025” (.39) – (.64) Copper: .015”-.028” (.39) – (.72)	Steel: .015”-.020” (.39) – (.51) Copper: .015”-.024”(.39) – (.61)
Driver Tip Width	.030” (.77)	.030” (.77)	.050” (1.27)	.017”* (.44)	.012”* (.31)

Metric equivalents are bracketed

* Not entire width but dimension from edge of Driver Tip to side of Outside Former

When the wire diameter is smaller than the depth of the V-groove of the Outside Former, the lead has excess space and moves within the V-groove.  This uncontrolled condition leads to a ‘weak’form. 

 V-groove with Small Lead Diameter

When the wire diameter is larger than the depth of the V-groove of the Outside Former, the yieldable Inside Former flexes to make room for the bigger lead.  Continual flexing causes the O-rings to wear out which leads to a ‘sloppy’Inside Former and ‘weak’forms.  Outside Formers have been known to split at the V-groove from continual stress.  Long term, continual flexing will damage the Tooling Housing by loosening it and making it ‘sloppy’.  

 V-groove with Large Lead Diameter

The optimal condition is wire diameter equal to the depth of the V-groove of the Outside Former.  In this condition, the lead is large enough so that is does not ‘move’within the V-groove, and yet it does not continually flex the Inside Former.

 V-groove with Optimal Lead Diameter

When Standard tooling is compared to 5mm tooling, it becomes clear why 5mm tooling is less reliable when inserting components with large lead diameters than Standard tooling.  

TOOLING	DEPTH OF V-GROOVE	WIRE DIAMETER RANGE
Standard	.028”(0.71mm)	.015”-.032”(0.39mm – 0.82mm).
5mm	.018”(0.46mm)	.015”- .028”(0.39mm – 0.72mm)

The depth of the V-grooves vary by .010”(0.26mm) and yet the range of wire diameter is very similar.

2.2 Radius of V-Groove of Outside Former

Another factor is the radius of the V-groove of the Outside Former.  The V-groove is actually a radius of .016”(0.41mm) for all tooling types except large lead tooling which is .019”(0.49mm).  Because this is a radius, not a diameter, the optimum lead size for this size radius is .032”(0.82mm)  This radius creates a situation that allows a small wire diameter to ‘roll around’or be uncontrolled in the groove.  A true V-groove improves this condition by creating a 2 point contact.  

One Point Contact	Two Point Contact

 

2.3 Body Length to Insertion Length

Body length to insertion length is another critical issue in this discussion.  The bigger the gap between the component body and the bend of the lead, the more room there is for the insertion tooling.  As the Driver Tip descends, it can damage a component body that is too long for the specified insertion span.  Clearance is also needed for the Inside Former coming beneath the bend of the lead.  A bend too close to the component body can also cause damage.  Maximum body length is obtained with the following formula: 

Programmed Z-Span = Insertion Span + 1 Lead Diameter

Maximum Body Length (clearance between Driver Tips)

= Insertion Span + 1 Lead Diameter – 2 x Depth of Outside Former V-groove – 2 x Driver Tip Thickness 

Do not use components with body lengths at the maximum length.  Allow .020”(0.51mm) on each side of a component body for clearance and to account for tolerances.

Component Body Leaving Clearance	Component Body Leaving No Clearance

 

2.4 Driver Tip Position

During a component insertion, the Driver Tip rests on the horizontal surface of the lead.  When a lead has a ‘weak’form, the Driver Tip rests on top of the bent portion of the lead.  As the Driver Tip tries to push a component through the holes of the pc board, it has a tendency to ‘slide off’a lead, leading to a standup or failed insertion.  This is true of 5mm tooling because of its small Driver Tip.

Driver Tip Position during insertion	Driver Tip position during insertion  of weak form lead

 

                                  

               

3.0 SUMMARY OF ABOVE CONDITIONS

· Wire diameters significantly smaller than the depth of the V-groove of the Outside Former are uncontrolled within the V-groove.  This is caused by one point contact and excess space, which leads to a ‘weak’form and poorly controlled insertion.  Small lead components without a ‘crisp’form are also at risk of misinserting because the Driver Tip may ‘slip off’the lead, while pushing it through the pc board.  This condition is seen most often with 5mm tooling.

· Wire diameters significantly larger than the depth of the V-groove of the Outside Former continually flex the yieldable, Inside Formers causing premature tooling wear-out of the Inside and Outside Formers as well as other parts of the tooling.

· Acceptable component body length varies with Z-span, but clearance is required for the Inside Formers and Driver Tips during insertion so the component body is not damaged. 

4.0 OPTIMAL CONDITIONS

To optimize insertion performance and maximize tooling life, it is best to limit the range of wire diameters inserted with any tooling selection, keeping in mind the optimal wire diameter is the same size as the V-groove of the Outside Former.  For example, if the wire diameter range of a particular application is .018”- .022”, a .020”V-groove is optimal.  This eliminates the problems mentioned above and allows optimal tooling life, process control and low insertion ppm.  

Making use of the squeeze function when writing pattern programs can also help.  If a component lead diameter is small in relation to the V-groove of the Outside Former, the squeeze function can improve a ‘weak’form.  The squeeze function is also useful when inserting steel leaded components as they tend to have a memory after the forming process.  It also helps insert components with long bodies and a small insertion span.

Allow clearance on each side of a component body so there is room for the insertion tooling.

Consider dedicating a manufacturing line to a particular application for optimal performance and then customize the tooling for a small range of wire diameters.  Universal offers customized tooling for dedicated applications.  Customized tooling can include the following items, as needed:

2 point contact in V-groove of Outside Former based on an optimum lead diameter

Increase size of Outside Former footprint for a more robust design

Improved bent lead input insertion capability