There are three (3) enhancements that distinguish the Radial 5 from the Radial IIIXQ:

Auto Recovery
Increased Cycle Rate to 9,200 Cycles/Per Hour
New Machine Cover Package

Auto Recovery:

Auto recovery was introduced to aid our customers in their continuous pursuit of high quality electronics manufacturing. By having the machine repair misinsertions automatically, you greatly reduce the opportunity for operator error, and consequently increase the quality of your product.

First, we will briefly describe auto recovery and then follow with a discussion of some of the common questions customers might have about auto recovery. To initiate auto recovery, there is a set command in the software “auto R” that must be set to 1. If this set command is set to 0, the machine will perform repairs the ame as previous level machines did, with the operator placing a component in the board and pressing the repair button to activate the cut and clinch.

If auto R is set to 1 and the machine experiences a misinsertion, the misinserted component should be cleared from the board by the operator. Once the component has been cleared, the operator presses the repair button, then the start button. At this point, the operator can leave the machine and continue doing what they were before the misinsertion occurred. The chain will sequence the carrier clip back to the dispensing head that the misinserted component came from, and the dispensing head will then place a component in that carrier clip. That carrier clip then travels back to the insertion area and the component is inserted into the printed circuit board. The machine then continues automatically with the remaining insertions of the pattern program.

Some questions that customers may ask are listed below:

1. Question: Is auto recovery an option that I need to buy?
   Answer: No. It comes standard with the machine software. Also, the price
   of the Radial 5 is the same as the Radial IIIXQ.
2. Question: How long does it take the machine to perform auto recovery?
   Answer: The time required to perform auto recovery is based on the length
   and configuration of the sequencer module. We have not tested all
   sequencer configurations, but we believe the time for auto recovery
   will be between 29 seconds (20 station straight back) and 90
   seconds (80 station in-line). The other configurations that have
   been tested are 40 station straight back (50 seconds) and 60 station
   straight back (62 seconds).

3. Question: Do I have to repair misinsertions through auto recovery?
   Answer: No. You can repair misinsertions manually also.

As noted earlier, the customer can choose the operate the machine in auto recovery mode or they can perform repairs in the traditional manner, they simply enter a 1 or 0 in the auto R set command.

1. Question: If I have a older Radial machine, can I retrofit auto recovery
   onto it?
   Answer: Auto recovery will be available as a purchased retrofit for
   Radial IIIXQ machines only, and is available in the near future.

Question: Since auto recovery takes longer to repair a misinsertion than an
operator does, why would I want to use it?
Answer: Operators make mistakes and put polarized components
(electrolytic capacitors, diodes, transistors, etc.) in the board
backwards which causes test failures after wave solder. This
causes the PCB line throughput to decrease along with possible
component damage. Auto recovery will not put a component in
backwards, and in combination with the Expanded Range Verifier
(ERV) will verify the component before inserting it again.

The auto recovery function should be presented as a repair alternative. Not all customers will use auto recovery because of the time required, especially on larger machines, but the option is there for customers who believe from a manufacturing quality standpoint that misinsertions need to be repaired automatically. From a competitive standpoint, Panasonic through the use of its shuttle can perform auto recovery faster than the Radial 5 users can use auto recovery and still maintain greater throughput vs. Panasonic. When in competition with TDK, it is important to note that we give the customer a choice in terms of auto recovery (see competitive matrix). TDK does not offer auto recovery at all.

 

Machine Speed Increase:

Once again, as we introduce a new machine, we also have been able to increase the machine speed. The Radial II had a machine speed of up to 7,300 cycles per hour, the Radial III, 8,700 cycles per hour, the Radial IIIXQ, 9,000 cycles per hour, and now the Radial 5, with 9,200 cycles per hour. This slight speed increase was attained by some subtle changes to the machine and the manufacturing processes. The speed of 9,200 cycles per hour allows us to retain our position as the fastest Radial Inserter on the machine, (TDK’s VC7 with a speed of .39 sec/component–9,230 will not be introduced until the third quarter of 1994). By increasing our speed and maintaining our current pricing, we continue to position ourselves as the best price/performance Radial machine on the market. (Price/performance analysis using your customers data is available through the product teams.)

New Machine Cover Package:

When we looked at redesigning the machine cover package, we wanted to accomplish three things. We wanted a cover package with lines that appealed aesthetically, a consistent “look” with the VCD/Sequencer 3, and to aid the manufacturability of the machine.

The new cover package features rounded edges and corners, along with an integrated pushbutton panel for a smoother, more modern look. The new VCD/Sequencer 3 and the Radial 5, now have the same cover package. This allows us to have a consistent look for our machines, especially when they are sitting side by side in a manufacturing line.

 

 
Radial IIIXQ Enhancements

 

I. – 70% fewer setup adjustments.
– 56% fewer piece parts.
– Larger component body diameters.
– Increased reliability of component transfer from chain to chain
to insertion head.
– Clip locating at all component transfer points.

Component Transfer Assembly:

The component transfer assembly (CTA) on the Radial IIIXQ replaces the loader used on the Radial II and III machines. The CTA provides the same function as the loader did, namely moving components from the chain clip into the insertion head, but does so without the use of loader blades. The elimination of the loader blades and their associated setup and adjustment reduces the wearable tooling and the required adjustments in the loader area. (See Component Transfer Assembly (Drawing 1))
Drawing here.

Besides reduced setup and adjustment, the new CTA along with a redesigned guide jaw allows the Radial IIIXQ to insert components with 13mm body diameters and a height of 38.5mm as measured from center of tape feedhole to the top of the component. The new CTA also allows for rotation of 10 pin resistor networks by the insert head in 90 degree right, 0, or 90 degree left orientations, with the old loader there were rotational limitations.

The Component Transfer Assembly also features clip locating similar to the clip locating found on the dispensing head. The clip locating combined with the smooth cam action (see drawing 2) of the CTA helps to ensure reliable component transfer from the carrier clip into the insert head.

II. – 13mm Body Diameter Capability
– Ability to run wider range of components.

As mentioned earlier, there have been some changes to the insert head. The footprint of the insertion jaw was slightly elongated in the back to allow for 13mm body diameter capability. The 10.5mm insert head is still offered for those customers who have 10.5mm body diameter as their largest component, and required the smaller footprint for board density issues. For customers who only insert 5mm span components and require yet a smaller footprint, we still offer high density tooling, but the maximum body diameter is 9.0mm.

Along with the modifications that were done to be able to run 13mm body diameter components, further modifications were done to the insertion jaw for all insertion heads to allow for more reliable insertion of a wider range of components. The area of the insertion jaw where the component leads are grasped has been polished at a 8 micro inch finish; any sharp corners/edges have been rounded. This, combined with the CTA transferring components into the head at a higher point allows us to run a wider range of components in terms of different standoffs on the bottom of the component and on the leads (such as box capacitors).

III. – Superior clinch scrap lead removal.
– Easier access to machine assemblies.

Another area of the machine that has been enhanced is the clinch scrap lead removal system. This system clears lead scrap out of the cutter head. This new system features improved air flow through the cutter head due to an in-line vacuum transducer that is able to allow scrap material to pass through it. This allows for the transducer to be located closer to the clinch for superior air flow and scrap clearing characteristics.

To further air in scrap removal, a hole has been added to the cutter head (see drawing 3). This hole allows for greater air flow through the clinch which aides in clearing scrap from the clinch.
Drawing here.

Along with the enhancements done to improve air flow through the cut and clinch, the scrap bowl was relocated to the back side of the cover door for easier access and the bowl was enlarged to allow for longer run times between bowl emptyings. With the scrap bowl mounted on the access panel door, a window was added (see drawing 4) so that the scrap level could be checked without removing any cover panels. Along with the scrap bowl being relocated, the cut and clinch valve pack was relocated; this was done to allow easier access to the clinch base.

Drawing here.

IV. – European Code Enhancements
– Enhanced Tape Scrap Removal System
– Enhanced Documentation

The Radial IIIXQ also addresses the unique code issues of our European customers with a new “E” stop redundant interlock circuit on the inserter and sequencer covers. This new redundant interlock circuit features European code approved componentry including failsafe mechanical relays. A new light curtain cover package was also developed for European customers ordering non pass-thru machines. A new power disconnect lockout and main power circuit breaker was added to the machine (see drawing 4). Other enhancements were also done to the electronics of the machine that were not related to European code issues. Examples include new servo amplifier, new power supply, and the addition of a power conditioner.

The tape scrap removal system and machine documentation were enhanced. The tape scrap removal system was designed with anti-static consideration in mind, such as different tubing material and a grounded scrap bin (see drawing 5). The machine documentation has added icons for clarification and has replaced some text with tables that are easier to use and understand (see attachment 1 and 2).

Feature	6346A/6348A Radial II	6360A Radial III	6360B Radial IIIXQ	Benefit
Machine Speed	.5 Sec/Ins** (7,200/Hour)	.41 Sec/Ins (8,700/Hour)	.40 Sec/Ins (9,000/Hour)	Higher throughput.
Chain Clip Locating	No*	Yes	Yes	Reliability
Soft Touch Pusher (STP)	No*	No	No	Higher throughput reliability.
100 Station Sequencer	No	No	No	More components/input.
Component Transfer Loader Blades	Loader Blades	Loader Blades	Component Transfer	Increased uptime/reduced wear tooling, fewer adjustments.
Auto Recovery	No	No	No*	Higher PCB quality.
Clinch Scrap Lead Enhancement	No*	No*	Yes	Increased uptime.
Odd Form Capability	Limited	Yes	Yes	Increased component insertion capabilities.
In-Line Sequencer Available	No	Yes	Yes	Manufacturing floor space.
Single Pivot Clinch	No*	Yes	Yes	Increased uptime/longer tooling life, fewer adjustments.
13mm Body Diameter Component Capability	No	No	Yes	Increased component insertion capabilities.
Audible Low Part Warning	Yes	No	Yes	Audible as well as visual notification to operator.
Tech Advisor (Available Std or Purchase)	No	No	Yes*	Provides on-line maintenance documentation and step-by-step troubleshooting procedures.
CE Mark European Code	No	No	No	Compliant with European community safety standards.

 

 

 

 

 

Feature	6360C Radial 5	6360D Radial 5	6360E Radial 5	6380A Radial 8	Benefit
Machine Speed	.39 Sec/Ins (9,200/Hour)	.39 Sec/Ins (9,200/Hour)	.327 Sec/Ins (11,000/Hour)	0..22 Sec/Ins (16,0000/Hour)	Higher throughput.
Triple Span Radial	No	No	Yes	Yes	Can insert either 2.5/5.0/7.5 mm span components, or 5.0/74.5/10.0 mm span components.
Main Drive System	Pneumatic	Pneumatic	Pneumatic	DC Brushless Servo	Significant reliability increase.  Lower noise level and higher machine uptime.
Machine Controller	DEC J11	DEC J11	DEC J11	VME 68000	Higher speed, higher resolution capable of running more machine features than the DEC J11.  Modern architecture supporting future developments.
Man/Machine Interface	UICS	UICS	UICS	IM-UPS (Like GSM) USOS	Windows, powerful color interface with CRT, keyboard, trackball, consistent with GSM products.
Management Data	Non-user friendly binary format	Non-user friendly binary format	Non-user friendly binary format	Easily accessible management data	Displays management data in graph form at the click of a button.
Diagnostics	Non-user friendly binary format	Non-user friendly binary format	Non-user friendly binary format	Menu Driven	Powerful IM diagnostics allow for easy troubleshooting and machine feedback.
On Line Documentation	No	No	No	Yes	Supports quick on-line retrieval of machine operating and maintenance information.
Chain Clip Locating	Yes	Yes	Yes	Yes	Reliability
Soft Touch Pusher (STP)	Yes	Yes	Yes	Yes	Higher throughput reliability.
Feature	6360C Radial 5	6360D Radial 5	6360E Radial 5	6380A Radial 8	Benefit
100 Station Sequencer	Yes	Yes	Yes	Yes	More components/input.
Component Transfer Loader Blades	Component Transfer	Component Transfer	Component Transfer	Component Transfer	Increased uptime/reduced wear tooling, fewer adjustments.
Auto Recovery	Yes	Yes	Yes	Yes	Higher PCB quality.
Clinch Scrap Lead Enhancement	Yes	Yes	Yes	Yes	Increased uptime.
Odd Form Capability	Yes	Yes	Yes	Yes	Increased component insertion capabilities.
In-Line or Straight back  Sequencer Available	Yes	Yes	Yes	Yes	Manufacturing floor space.
Single Pivot Clinch	Yes	Yes	Yes	Yes	Increased uptime/longer tooling life, fewer adjustments.
13mm Body Diameter Component Capability	Yes	Yes	Yes	Yes	Increased component insertion capabilities.
Audible Low Part Warning	Yes	Yes	Yes	Yes	Audible as well as visual notification to operator.
Uninterruptable Power Supply	Optional	Optional	Optional	Standard	Allow for proper machine shut down and uninterrupted operation in power unstable environments.
Tech Advisor (Available Std or Purchase)	Yes*	Yes, standard.	Yes, standard.	No	Provides on-line maintenance documentation and step-by-step troubleshooting procedures.
Product Trainer	No	No	No	Operation Module Standard	CD Rom Software that provides on-line training for basic machine operation.
CE Mark European Code	No	Yes***	Yes***	Yes, In BHS Only (6388A)	Compliant with European community safety standards.
Sound level for a BHS package	NA	NA	78 dba	75 dba	Quieter operation!
4 Tier Light	No	Yes*	Yes	Yes	Improved machine status information for more efficient machine operation.
CD-ROM for software loading	No	No	No	Standard	Allows for fast loading of software updates and on-line documentation.

 

Feature	Universal 6380A/6388A/6389A	Panasonic RHS2	Panasonic RH 5
Insertion Rate	16,000 CPH	18,000 CPH	12,400 CPH
Tact Time	0.225 sec Constant Speed	0.2 sec Maximum (0.25 sec for the component with 12mm diameter and 18mm height or bigger)	0.29 sec Maximum   (Speed slows depending on component type.)
4 Axis Insertion	Yes, by rotating insertion head and/or table.  Head rotates in three directions; -90, 0, and +90 degrees.	Yes, the insertion head can rotate in four directions: 0,     -90, +90, and 180 degrees.	Yes, but optional. (Standard Only) 0, 90 Degrees by Head
Rotary Table	Yes, 90 and 180 Degree Increments	No – Head Rotates 3600	No
Insertion Span	2.5/5.0mm Dual Span 2.5/5.0/7.5 or 5.0/7.5/10.0 Triple Span	2.5/5.0mm	2.5/5.0mm
Maximum Body Diameter/Height (Height measured from center of feedhole to top of component.)	13.0mm/38.5mm	13mm/39mm	13mm/39mm
Board Handling Transfer Time (from the last insertion of the first PCB to the first insertion of the second PCB, including table movement)	3.5 seconds	4 to 5 seconds	5 to 6.5 seconds (NM 8245 A,B,C) 4 to 5.5 seconds (NM 8244 A,B,C)
Maximum Board Size	559 x 470mm (NPT) 483 x 406mm (PT)	508mm x 381mm	508mm x 381mm (NM 8245 A,B,C) 330mm x 250mm (NM 8244 A,B,C)
Insertion Area	470 x 470mm (NPT) 470 x 406mm (PT)	508mm x 371mm	508mm x 371mm (NM 8245 A,B,C) 330mm x 240mm (NM 8244 A,B,C)
Allowable PCB Thickness	0.79mm to 2.36mm	1.6 +/- 0.15mm standard The RHS can accommodate a range of 0.8 to 2.0mm, however the PCB transfer rails must be changed for PCBs with nonstandard thickness. This is an option.   Even when using the standard 1.6mm thick PCB, there are chances of lead length/angle variation which causes PCB transfer error depending on the shapes of boards and/or insertion holes.	1.6 +/- 0.15mm standard The RH5 can accommodate a range of 0.8 to 2.0mm, however the PCB transfer rails must be changed for PCBs with nonstandard thickness. This is an option.   Even when using the standard 1.6mm thick PCB, there are chances of lead length/angle variation which causes PCB transfer error depending on the shapes of boards and/or insertion holes.
PCB Warpage	Maximum of 3.17mm downward and 1.6mm upward	Maximum of 1.2mm downward and 0.5mm upward	Maximum of 1.2mm downward and 0.5mm upward
Part Transfer Method	Sequencer	Sequencer	Shuttle
Number of Input Stations	20, 40, 60, 80, 100	80	40, 62 (Single Shuttle) 80 (Dual Shuttle)
Component Supply	Reels or ammo packs on any input.	Reels or ammo packs.  Reels can only be used on the lower input bank (40 station).	Reels or ammo packs.  Reels can only be used on the lower input bank
Component Taping Pitch	12.7/15/25.4**/30mm**	12.7/15.0mm	12.7/15.0mm
Odd Form Component Insertion	Yes, at a constant rate of speed	Yes, but at a derated insertion speed, dependent on component shape/size.	Yes, but at a derated insertion speed,  dependent on component shape/size.
Verification	Yes, value polarity.	No	No
Board Error Correction	Yes, Standard	Yes	Yes
Low Part Warning	Yes, Standard	No	No
Insertion Density	Tooling effects footprint.	Tooling effects footprint.	0.5mm on all sides–use of guide pins allows for same insertion density capabilities regardless of component
Auto Recovery	Yes – Semi-Automatic	Yes – Interrupt Recovery Enabled (Automatic supply recovery function)	Yes – Fully Automatic
Component Replenishment	Any disp.head location can be spliced w/o stopping the machine.	Although this is a sequencer based machine, when a feeder is low on components, that feeder and the two adjacent feeders must be turned off before reloading or splicing additional components.  If during the reloading process the machine requires components from those three feeders, the machine stops until the reloading process is completed by the operator.	Machine needs to be stopped for component replenishment.
Uninterrupted Power Supply	Standard.  When the UPS detects a power interruption, its fully-charged battery can run the machine for up to 10 minutes.	No	No
Language	English is the main language, however Chinese is available for event messages.	Japanese/English	Japanese/English
Machine Dimensions	80 Stations (In-line): W = 5428mm D = 3226mm H = 1746mm   80 Stations (Straight Back): W = 1800mm D = 6397mm H = 1746mm	80 Stations: W = 3125mm D = 2210mm H = 1560mm	NM-8244C (80 Sta): W = 5160mm D = 1860mm H = 1650mm   NM-8245C (80 Sta): W = 5160mm D = 2110mm H= 1600mm
Marketing Evaluation	2 years with more than 200 installed machines worldwide, good public praise	Brand new machine without marketing evaluation	New machine with few marketing evaluation

 

 

** Capable of processing 25.4 mm and 30 mm pitch taped components.

Feature	Universal 6380A6389A	Panasonic RHS	Panasonic RH III
Insertion Rate	16,000/Hour Constant Speed	14,400 Maximum	10,000 Maximum   (Speed slows depending on component type.)
4 Axis Insertion	Yes, by rotating insertion head and/or table.  Head rotates in three directions; -90, 0, and +90 degrees.	Yes, the insertion head can rotate in four directions; 0, -90, +90, and 180 degrees.	Yes, but optional.(Standard Only) 0, 90 Degrees by Head
Rotary Table	Yes, 90 and 180 Degree Increments	No – Head Rotates 3600	No
Insertion Span	2.5/5.0mm Dual Span2.5/5.0/7.5 or 5.0/7.5/10.0 Triple Span	2.5/5.0mm	2.5/5.0mm
Maximum Body Diameter/Height (Height from center of feedhole to top of component.)	13.0mm/38.5mm	13mm/38mm	13mm/38mm
Board Handling Transfer Time	3.5 seconds with BHS.	“About 3 seconds”	Approximately 4.5 to 6 seconds.
Maximum Board Size	457 x 508mm (NPT)406 x 457mm (PT)	381mm x 508mm	508mm x 381mm (NM 8225 A,B,C) 330mm x 250mm (NM 8224 A,B,C)
Part Transfer Method	Sequencer	Sequencer	Shuttle
Number of Input Stations	20, 40, 60, 80, 100	80	40, 62 (Single Shuttle)80 (Dual Shuttle)
Component Taping Pitch	12.7/15/25.4**/30mm**	12.7/15.0mm	12.7/15.0mm
Odd Form Component Insertion	Yes, at a constant rate of speed	Yes, but at a derated insertion speed, dependent on component shape/size.	Yes, but at a derated insertion speed,  dependent on component shape/size.
Verification	Yes, value polarity.	No	No
Board Error Correction	Yes, Standard	Yes	Yes
Low Part Warning	Yes, Standard	No	No
Insertion Density	Tooling effects footprint		.5mm on all sides–use of guide pins allows for same insertion density capabilities regardless of component
Auto Recovery	Yes – Semi-Automatic	Yes – Interrupt Recovery Enabled (Automatic supply recovery function)	Yes – Fully Automatic
Component Replenishment	Any disp. Head location can be spliced w/o stopping the machine.
Uninterrupted Power Supply	Standard.  When the UPS detects a power interruption, it’s fully –charged battery can run the machine for up to 10 minutes.	No	No
Language	English is the main language, however Chinese is available for event messages	Japanese/Chinese	Japanese/Chinese
Optical Safety Device	Yes, Optional	Yes	Yes
Machine Dimensions	20 Input Stations:W = 80 Inches (2032mm) D = 115 Inches (2921mm) H = 66 Inches (1676mm)   100 Input Stations: W = 253 Inches (6426mm) D = 115 Inches (2921mm) H = 66 Inches (1676mm)	80 Input Stations:W =Inches (3125mm) D = Inches (2210mm) H = Inches (1560mm)	40 Input Stations:W = 151.97 Inches (3860mm) D = 62.6 Inches (1590mm) H = 63 Inches (1600mm)   62 Input Stations: W = 168.5 Inches (4280mm) D = 65.74 Inches (1670mm)   80 Input Stations: W = 203.1 (5160mm) D = 83.0 (2110mm)

 

 

Fact	Both the UIC Radial 8 and Panasonic RH III and RHS feature auto recovery capability; the TDK VC7C does not.  The TDK VC-21S does have auto recovery, but its full capability is still unknown.
Fact	The Panasonic RH III auto recovery is faster than the Radial 8 auto recovery because the RH III is a shuttle based machine with random access capability, while the Radial 8 has pre-sequenced components that must be left on the sequencer chain.   The Panasonic RHS is a sequencer.  However, the sequencer moves in either direction and more quickly when auto recovery is invoked.  The RHS auto recovery is possible in 8 –10 seconds for an 80 station machine.
Fact	The UIC Radial 8 with a machine speed of 16,000 CPH is 9% faster than an RHS with a machine speed of 14,400 CPH.
Fact	The Radial 8 and RHS both offer reliable insertions and low PPM levels.
Fact	The Radial 8 offers 3 modes of Auto Recovery: ¨      Auto Recovery Disabled ¨      Active Auto Recovery: Upon a misinsertion, the chain will cycle for a new component, stop at the head, and wait for the operator to clear the board and push Repair. ¨      Passive Auto Recovery: Upon a misinsertion, the machine will stop, wait for the operator to clear the board and push Repair before cycling the chain to retrieve a new component.
Conclusion	Universal Radial 8's Auto recovery is not advantageous on a Manual Load machine.  However, in an Automatic Board Handling environment, Universal’s 3 modes of Auto Recovery provide the flexibility that manufacturers need to maintain their production flow and level of quality.

 

 

 

 

TDK is a Japanese manufacturer and supplier of both radial components and Radial insertion equipment.  Unlike other Japanese companies, TDK is not vertically integrated in that they do not produce end products.  In the past, they did not have dedicated Axial or DIP insertion equipment; this served as a deterrent to customers desiring to buy all their insertion mount equipment from a single source.  In 1995, TDK addressed this issue by teaming up with ex-Dynapert personnel to design an Axial component inserter.  This agreement produced the AC7 in 1996, followed by the ACS-2 Axial Sequencer.

 

Similarly, TDK's Radial Inserter's are not manufactured by TDK.  Instead, they are manufactured by Okuma, Japan, which also produces other TDK products.

 

Machine Design:

 

The VC7B, VC7C, and now VC-21S machine designs incorporate a sequencer chain that delivers sequenced components to the insertion http://www.buydiazepamcheaponline.org area, much the same as UIC's Radial.  The main advantage associated with a sequencer design over a shuttle design (such as Panasonic) is greater throughput speed.  The component location does not effect throughput speed, and allows for replenishment of depleted components without interrupting production.

 

VC-21S

In late 1999 TKD introduced the VC-21S, a Radial inserter with a maximum speed of 15,000 cph.  Available either as a 2.5/5.0 mm or 5.0/7.5 mm lead span machine, The VC-21S is equipped with an Auto Recovery feature.  Additionally, the VC-21S operated with Windows NT.  It is available in 40, 80, or 120 stations.

 

Although the VC-21S has been advertised, no further information is available at this time.

 

 

VC7B & VC7C

 

Horizontal Transfer

There is one fundamental difference between the Radial 8 sequencer design and TDK's design.  The VC7A/B/C series transfers the components by grasping the cardboard carrier tape of the component and carrying it horizontally. During the component transfer from the chain clip to the insertion head, the component is rotated 90 degrees to a vertical position and the cardboard tape is cut from the component.  The component is then ready for insertion into the PCB, but must be transferred one more time to the insertion head.

 

Advantages

When equipped with certain optional features, various processes can be exercised on the component while it is being transferred on the sequencer chain. Components may be electrically verified for capacitance, resistance, and inductance.  Minor bends in the leads may be corrected (straightened) by a reforming unit (standard on the VC7B).  Components may be rotated using the four position component rotator for insertion of polarized components but not for insertion tooling density clearance issues. However TDK's process requires an increased number of component transfers. TDK does not offer a rotary table, which is one reason why they offer the component rotator.

 

Disadvantages:

1)      Horizontal component transfer increases the frequency a component is handled, increasing the possibility of mishandling and mis-insertions. In contrast, the Radial 8 carries the component to the insertion area vertically by the component leads, reducing the “handling” to a single step once the component is placed in the carrier clip.

2)      The VC7A/B/C series machine must slow down and therefore reduce productivity for certain component types depending on type and size.

3)      The VC7A/B does not offer an auto recovery capability, while the Radial 8 features auto recovery as a standard feature.

4)      Like the Radial 8, TDK can employ a soft touch pusher motion when inserting delicate components (stamped leaded parts, for example).  However, unlike the Radial 8, this programmable feature slows down the machine.  UIC's soft touch pusher design is utilized for all insertions and does not effect cycle speed, but rather enhances insertion reliability for all components being inserted.

 

 

Until the release of the VC-21S in late 1999, The VC7C was TDK's current Radial offering, a 2.5/5.0 mm lead span machine designed to insert traditional Radial components and radially taped “odd form” type components such as tact switches, potentiometers, and fuse clips.  The VC7C can insert components with a maximum body diameter of up to 11mm and is available in three sequencer sizes; 40, 80, and 120 feeder stations.

 

Options available on TDK's Radial machines include the four direction reverse unit, reforming (lead straightening) unit (standard on the VC7B), parts checker (verifier), component supply warning (low parts sense) unit, optical correction device (BEC), and board handling (which may include automate PCB width adjuster).

 

Axial Equipment

TDK offers also offers limited Axial insertion equipment.  The AC7 single head inserter with a 16,360/hour cycle rate.  They also offer a ACS-2 Axial component sequencer with up to 180 stations.  TDK's product line also includes a full line of SMC products.

 

Distribution & Pricing Strategies

TDK's presence is global and they maintain a large installed base.  Their pricing strategy is both geographic and situation specific.  TDK's prices tend to be lower and their allowable discounts tend to be higher in Asia and with multi-national accounts, than in other parts of the world.

 

We have seen aggressive discounting by TDK to acquire or in an attempt to retain key accounts in North America.  When board handling is required, the Radial 8 with board handling allows UIC to be very price competitive with similarly configured VC7B/C.  The price should be weighed against other factors such as features, capabilities and on a price/performance basis.  While TDK's machine is generally perceived as a reliable machine, when a hard failure does occur is has been difficult and time consuming to return the machine to production status.  Also, there have been reports (especially in North America) of poor field service and replacement parts availability.

 

About Panasonic

Panasonic is a division of Matsushita (Japan), one of the largest companies in the world.  They are highly vertically integrated in that they manufacture Radial componentry, Radial insertion equipment and end products with PCB's populated with Radial components (consumer electronics, for example).  This structure affords them some advantages and disadvantages.  The advantages include:

 

1)                              first hand experience using equipment,

2)                              in-house production testing prior to release of new equipment designs,

3)                              ability to sell components and equipment,

4)                              keen understanding of market trends, new componentry and design considerations from both componentry and end product perspectives.

 

One glaring disadvantage is that many times their customers are also their competitors–this sometimes causes conflict of interest.

 

Machine Design:

 

RHS

The RHS was introduced in late 1998.  It operates at a maximum speed of 14,400, and is different from previous Panasonic Radials in 2 main areas:

¨      it uses a sequencer design

¨      it no longer uses guide pins

 

Advantages

The sequencer and insertion head designs that Panasonic adopted carry many of the same advantages as the Radial 8.  The additional advantages are:

1)      Auto Recovery is still fast (8 – 10 seconds), even though the RHS uses a sequencer.  The sequencer chain is bi-directional, and increases speed when only travelling with a component.

2)      30% smaller footprint.  Even with a sequencer, the RHS footprint is smaller than the Radial 8.

3)      180⁰ head rotation, although this feature slows down the machine.

 

Disadvantages

The main disadvantage for Panasonic is that they have no prior experience with this design.  The RHS, consequentially, has gotten off to a bumpy start.  However, we anticipate the experience gap to close quickly.

RH II & RH III

Shuttle Design

The RH II and RH III utilize a component shuttle system to bring the components to the insertion area.

Advantages

The advantage of a shuttle system is that “automatic recovery” (repair) can take place quickly.  Once a misinsertion is detected, a replacement component is automatically dispensed and inserted into the original location.  Manufacturers desire this feature as it leads to less operator interface and it ensures that the correct component is reinserted in the correct position and polarity.  This recovery mode is selectable and may be programmed to attempt up to ten (10) “auto recoveries” before the machine stops.  This feature reduces operator interaction and ensures the correct component is inserted.

Disadvantages

The shuttle design has two negative impacts on the inserters throughput capability:

1)                              Depleted components cannot be replenished “on the fly”, because the entire shuttle system (all reels/packs) moves to deliver a component to the insertion area.  The inserter must be stopped to replenish reels/ammo packs.  To improve this situation the RH III utilizes a split shuttle (2x 40 inputs = 80 total). While this improves this flaw, it does not eliminate it. Components must be double-loaded to take advantage of this feature and maintain production.

2)                              The specific component location on the shuttle effects throughput.  Shuttle travel time must be added for each insertion cycle.  Reels located at the end of the shuttle system (furthest from the head) will have a longer insertion cycle.  This also requires increased machine programming in order to optimize the component location, and maintain throughput at an acceptable level.

 

Guide Pin System

The RHII and RHIII use guide pins instead of an insertion head.  The pins come up from the clinch through the holes in the PCB guide the component leads into the PCB while the component is pushed from the top.

Advantages

The guide pin system provides excellent topside insertion density capability.  However, the cut and clinch, which determines their bottom side density, has a footprint similar in size to that of the Radial 8.

 

By comparison, the Radial 8 utilizes insertion tooling to guide the component leads into the hole.  The footprint associated with the Radial 8's insertion head tooling limits the overall topside insertion density capabilities in comparison to Panasonic's guide pin design.  Panasonic's guide pins allow for a component to be inserted with only .5mm clearance on all four sides.

 

Disadvantages

The guide pins are delicate and have a tendency to wear and break.  They are only (.040″) 1mm in diameter and approximately 6″ long (152mm).  Operators typically carry “spare” pins in their pocket.

 

Panasonic Machine types

Panasonic, like Universal, has a number of machine styles.  The RH, RH6, RHB, RH6B, RH II and RH III insert 5mm components with two or three leads and are capable of 2.5mm insertion (2 leads) as an option.  These older models differ in the number of input locations and the size of the components they can insert.  The RH II features 80 input locations on a split shuttle (40 + 40), with a cycle speed of 7,800 CPH (maximum on certain components) vs. 6,000 CPH on other older Panasonic Radial Inserters. The RH III is similar to the RH II, but it is available as a 40, 62, and 80 station machine configurations. The RHUP and the RHU are Panasonic's large component insertion machines that feature body diameter capability of up to 18mm and 7.5mm lead pitch.  The RHU “special”, features a body diameter capability of 20mm and up to 10mm lead pitch.  These machines are very slow and expensive.

 

The main advantages of the RH III over the RH II is its price, speed, and automatic recovery features.  It also appears to be priced well below their previous machine models, with pricing estimated at 226K-270K (US$) and a maximum speed of 10,000 cycles per hour.  The RH III's only “real” performance advantage when compared to the Radial 8 is in terms of its insertion density as discussed earlier in its use of guide pins.  However, this can be offset by the Radial 8's throughput and reliability.

 

Panasonic offers a complete product line in both IMC and SMC technologies.  All Panasonic inserters (RH II, RH III and AVK) use a shuttle design to deliver components to the point of insertion.

 

Two (2) Axial Inserters; Models AVK and AVK

A Jumper Wire Inserter; Model JVK

Odd Form Inserter; Model U2 (which also inserts DIP components), Square Pin Inserter, Model P, Round Pin Inserter, Model G, Eyelet Inserter, Model E

 

All are designed with board handling capability.

 

Although Panasonic's presence is global, their main thrust in IMC has been in Japanese and Korean multi-national companies.  They have a large installed base and as a manufacturer of electronics end products, they utilize much of their equipment in their own plants and influence their many sub contractors to utilize Panasonic equipment as well.

 

Panasonic's pricing strategy varies depending upon the geographic location account and the specific situation.  In the United States, for example, in comparison to the Radial 8, Panasonic's RH product line is much higher in price (although they typically discount between 10 and 15%).  In Southeast Asia, however, their prices are much lower and in some cases their prices have been considerably less than UIC's (up to 30-40% below UIC list price).

 

 

Comparative Matrix of Universal Radial 8 & TDK
Feature	Universal 6380A/6388A	TDK VC-21S	TDK VC7C	TDK VC7B
Maximum Board Size	457 x 508mm (NPT), 406 x 457mm (PT)	400mm x 300mm (508mm x 381mm – Optional)	400mm x 300mm	400mm x 300mm
Insertion Span	2.5/5.0mm	2.5/5.0 or 5.0/7.5 mm	2.5/5.0mm	2.5/5.0mm
Cycle Rate	16,600 cph (0.22 sec./insert.)Constant Speed	15,000 cph (0.24 sec/insert), for X -Y movements under 30 mm (1.20”)	12,400 cph Maximum (Speed is dependent on component type.)	10,500/7,200/6,000 cph (Speed is dependent on component type.)
Rotary Table	Yes, 90 and 180 degree increments.	No information	No	No
Part Transfer Method	Sequencer	Sequencer	Sequencer	Sequencer
4 Axis Insertion	Yes, by rotating insertion head and/or table. Head rotates in three directions; -90, 0, and +90 degrees.	Orientation: 0, +-90, 180	Head only rotates 0+90 (std).  Part is rotated for polarity at station prior to insertion head.  This is possible only with optional 4 direction reverse unit.	Head only rotates 0+90 (std).  Part is rotated for polarity at station prior to insertion head.  This is possible only with optional 4 direction reverse unit.
Number of Input Stations	20, 40, 60, 80, 100	40,80,120	40, 80, 120	40, 80, 120
Operating system	OS/2, IM-UPS	Windows NT
Languages	English, Event messages available in: Chinese, Spanish, Polish,  French	English, Japanese
Verification	Yes, value, polarity.	No information	Yes, optional.	Yes, optional.
Board Error Correction	Yes, standard.	No information	Yes, optional.	Yes, optional.
Low Part Warning	Yes, standard.	No information	Yes, optional.	Yes, optional.
Optical Safety Device	Yes, optional.	No information	Yes, optional.	Yes, optional.
Maximum Body Diameter/Height (Height measured from center of feedhole to top of component.)	13.0mm/38.5mm	13.0mm / 26.0 mm	10.0mm/32.25mm	10.0mm/32.25mm
Odd Form Comp Insertion – Stamp leaded parts including; potentiometers, tact switches, fuse clips, connectors.	Yes, standard.	No information	Yes, but at a derated insertion speed which is dependent on component shape and size.	Yes, but at a derated insertion speed which is dependent on component shape and size.

 

 

Comparative Matrix of Universal Radial 8 & TDK (Continued)
Feature		Universal 6380A/6388A	TDK VC-21S	TDK VC7C	TDK VC7B
SIPs		Yes, up to 10 pin.	No information		Yes, up to 9 pin.
Lead Diameter Range		.3mm – .7mm	No information		.4mm – .65mm
Insertion Density		Tooling effects footprint.*	No information		Tooling effects footprint.*
Component Taping Pitch		12.7/15/25.4**/30mm**	No information		12.7/15.0mm
Auto Recovery		Yes	Yes		No
Board Handling Transfer Time		3.5 seconds on BHS equipped inserters.	Approx. 2.5 sec.		Approximately 4 seconds.
	Machine Dimensions	20 Input Stations:W = 2,032mm (80”) D = 292 mm (115”) H = 1,676mm (66”)   100 Input Stations: W = 6,426 mm (253”) D = 292 mm (115”) H = 1,676mm (66”)	40 Input Stations:L = 2,120 mm (83.5”) W = 1,980 mm (80”) H = 1,850 mm (73”)   80 Input Stations: L = 3,580 mm(141”) W = 1,980 mm (80”)   120 Input Stations: L = 5,100 mm (201”) W = 1,980 mm (80”)		40 Input Stations:W = 5,870mm (231”) (Front) W = 2,890mm (114”) (Seq) D = 2,210 mm (87”) H = 1,390 mm (54.7”)   80 Input Stations: W = 4,160 mm (164”) D = 2,210 mm (87”)   120 Input Stations: W = 5,870mm (231”) (Front) W = 5,430mm (214”) (Seq) D = 2,210 mm (87”)

 

	RH II			Radial 5
	62 Input, Single Shuttle		X	20-100 Input Sequencer
	Top Speed – 8,000 CPH		X	Machine Speed – 11,000 CPH; 37% Faster than Panasonic
	Automatic Recovery			Automatic Recovery
	No electronic support system.		X	Electronic support system (Tech Advisor – Bi-Lingual).
X	Pin Method – High density insertion.  (Sell Around:  Pin method is complex and expensive, pins break.  See sell around section.)			Guide Jaw – Provides positive control of the component leads; non-fragile.
	Small Machine Footprint			Footprint is relative to cost/insertion.  UIC offers superior cost per insertion and two machine shapes.
	Machine speed can vary based on component type; 4,000, 6,000, 8,000 CPH.		X	Constant machine speed for all insertable components; 11,000 CPH.
	No parts checker.		X	Parts Checker (ERV)
	Optical Correction Unit			Optical Correction Unit

	VC7			Radial 5
	25% faster than VC5.		X	Radial 5 is 19% faster than the VC7A or B.
X	Smaller machine footprint than the Radial 5.  (Sell Around:  Production capability per square foot.)			The VC7A or B is only 4 square meters smaller; comparisons should be speed based.
	Four direction reversing unit.		X	The VC7A or B’s four direction unit slows the machine down.
	No electronic support system.		X	Electronic support system (Tech Advisor – Bi-Lingual).
X	Lead Reforming Unit (Sell Around:  Questionable performance.)			No lead reforming unit.
X	Square Pin Inserter (Sell Around:  Significantly decreases throughput.)			No square pin inserter.
	Optical Correction Unit			Optical Correction Unit (BEC)
	Parts Checker			Parts Checker (ERV)
	Bad Board Sensor			Bad Board Sensor
	Three Lead Sensing Clinch (See sell around section.)		X	Only two lead sensing needed.
	Machine speed can vary based on components.		X	Two component transfer points.
X	120 station sequencer capability (40, 89, 120).			100 station sequencer capability (20, 40, 60, 80. 100).
	10mm maximum body diameter.		X	13mm maximum body diameter.
	No auto recovery capability.		X	Auto recovery capability.