Boosting SMT Placement Performance with XARP 10-Axis EtherCAT Servo System
The miniaturization of electronic components (e.g., BGA, QFN, 0201) places extreme demands on SMT (Surface Mount Technology) pick and place machines. To meet high-throughput requirements without sacrificing mounting precision, equipment manufacturers are transitioning from legacy motor systems to high-speed, multi-axis servo architectures.
This case study examines how the XARP 10-Axis Servo System (XDQ1 Series Drives and XMQ1 750W Servo Motors) optimizes dynamic motion, multi-axis synchronization, and vibration damping for high-speed SMT placement lines.
Technical Solution & Architecture
The motion control architecture employs a 10-axis closed-loop system integrated with a vision positioning system.
- System Model: XARP 10-Axis Servo System (XDQ1 Servo Drive + XMQ1 750W Servo Motor)
- Communication Protocol: Real-time EtherCAT bus synchronization (synchronization cycle ≤ 1µs)
- Feedback System: High-resolution 25-bit Absolute Magnetic Encoder (8,388,608 CPR) providing robust, interference-resistant position sampling at speeds up to 2.5 m/s
- Control Loops: 3.5 kHz speed loop bandwidth; 625 kHz current loop bandwidth (62.5µs current loop cycle)
Key Technical Advantages & Field Performance
1. High-Speed Dynamic Response for 95,000 CPH Throughput
With a 3.5 kHz speed loop response and rapid current loop processing (62.5µs cycle time), the XDQ1 drive minimizes settling times during high-frequency reciprocating movements. This rapid dynamic response supports double-arm high-speed flying placement up to 95,000 CPH (Components Per Hour).
2. High-Precision Positioning & Angular Adjustment
The 25-bit absolute magnetic encoder delivers ultra-precise position feedback while resisting optical dust and mechanical vibration, maintaining a mounting accuracy of ±0.035mm. The system smoothly manages:
- XYZ Axis Motion: Precise high-speed planar moving (X/Y) and component pickup/placement (Z).
- Mounting Head Tilting: Fine angular adjustments within ±0.1° for complex ICs like BGA and QFN.
- Dynamic Correction: Instant position adjustments executed within 10 seconds of error detection.
3. Advanced Vibration Suppression (1Hz – 5000Hz)
Equipped with adaptive notch filters and end-vibration suppression algorithms, the drive neutralizes mechanical resonance across the entire 1Hz to 5000Hz frequency spectrum. Minimizing gantry tip vibration eliminates residual delay times, allowing the placement head to seat components immediately upon arrival.
| Technical Parameter | Specification Value | SMT Application Impact |
|---|---|---|
| Speed Loop Bandwidth | 3.5 kHz | Rapid response for high-frequency start-stop cycles |
| Current Loop Cycle | 62.5 µs | Zero-lag acceleration/deceleration |
| Peak Torque Output | 350% Rated Torque | Ample power reserve for heavy XY gantry moves |
| Sync Accuracy | ≤ 1 µs via EtherCAT | Smooth dual-gantry coordination; zero collisions |
| Encoder Type & Resolution | 25-bit Absolute Magnetic (8,388,608 CPR) | High durability and precise position tracking at 2.5 m/s |
4. Feeder Synchronization & Flexible Manufacturing
The system coordinates feeder feed rates directly with placement head trajectories to prevent component jamming or waste. Furthermore, S-curve acceleration profile algorithms reduce mechanical shock during high-speed switching between different PCB models, extending machine service life.
Frequently Asked Questions (FAQ)
Q1: How does the 25-bit absolute magnetic encoder benefit SMT machine accuracy?
A: The 25-bit absolute magnetic encoder provides high resolution (8,388,608 CPR) for ±0.035mm positioning accuracy while offering high immunity to dust, oil, and vibration commonly found in industrial SMT environments.
Q2: How does EtherCAT communication benefit multi-axis SMT machines?
A: Real-time EtherCAT synchronization ensures multi-axis synchronization cycles of ≤1µs. This prevents inter-axis lag between dual gantries and multiple placement heads, ensuring smooth high-CPH operations.
Q3: How does the vibration suppression feature improve SMT yield rates?
A: The built-in adaptive notch filter eliminates gantry vibration across 1Hz to 5000Hz. Suppressing residual oscillation prevents component displacement during placement and eliminates settling delay.
Application Video
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