English (UK) 
简体中文 Hey, is your workshop like this? When the roller line has a tantrum, the whole SMT line is paralysed, and the boss is so anxious that he jumps to his feet!Global electronics factory downtime losses due to drum failures exceed $12 billion per yearToday, we will break down and talk about how to use the "three-dimensional question and answer matrix" to solve the maintenance problems of SMT precision roller lines. Today we will break open the crumbs to say, how to use the "three-dimensional question and answer matrix" to deal with the SMT precision roller line maintenance problems - the basic problem (what / why), the scene of the problem (how to do / where to look for), the solution (if not / what will happen)!
The first dimension: the fundamental question - what is maintenance really defending against?
"No maintenance? Static, offsets, and jammed boards will teach you in minutes!"
Why must SMT roller lines be specially maintained?
Precision roller line and ordinary assembly line are completely different things.SMT workshop requirements:
- Anti-static is the bottom line: Normal drum resistance >10¹²Ω, SMT <10⁶Ω, a difference of 6 orders of magnitude! Electrostatic discharge does not meet the standard? Chip directly "violent death"
- Accuracy error ≤0.5mm: PCB runout exceeds 0.1mm, mounter goes on strike
- Dust = Stealth Bomb: The accumulation of solder paste dust to 6000V static electricity, can burn the whole batch of main control chip.
What are the core objectives of maintenance?
Just three things.Precision preservation, anti-static, dust control! Anything less is a mine.
Dimension 2: Scenario Questions - How do you actually do it on a daily basis?
"All the maintenance secrets of a master craftsman are here!"
What do you do first thing every day at work?
- feel the temperature: Back of hand against bearing shell, hot (>70°C)? Immediately stop the machine to check the lubrication
- mishear::
- "Squeak" sound → bearings out of oil
- "Clunking" sound → loose bolt
- groundingMeasure ground resistance >10Ω with a multimeter and retighten the earth wire.
Weekly Must-Do Deep Maintenance Checklist
| sports event | Operating Points | artifact |
|---|---|---|
| Roller cleaning | Rub the surface with anhydrous alcohol, do not use a wet cloth! Cotton swabs to empty the crevices of the rollers | Dust free cloth + precision swabs |
| Static Detection | Static pen 10mm from the drum to measure the voltage, >100V immediately check the ion fan | Static Tester |
| Chain Lubrication | High-temperature lithium grease coated links, so thin that "you can't see the oil dripping". | Grease gun + high temperature grease |
| Tension adjustment | Belt sag >3mm, adjust to 1.5-2mm with a tensiometer. | Belt Tension Gauge |
Where is the best place to find spare parts?
- Bearings/Rollers: Find the original! Cottage goods accuracy difference of ± 0.3mm, resulting in PCB snake alignment
- Anti-static brushesChoose the one with "Conductive Carbon Fibre" material, the life span is 5 times longer than ordinary brushes.
The third dimension: solutions - how to save when things go wrong?
"How many roller lines have been dry scrapped by these death-defying manoeuvres!"
What happens if I miss maintenance?
▶Case 1: Lazy cleaning at a plant, dust build-up causes drum jamming
- result: Motor overloaded and burnt out, production stopped for 16 hours at a cost of $800,000
- emergency treatment: Clean the jam with a hoover + dust free cloth, forced prying is strictly prohibited!
▶Case 2: Lubricate bearings with ordinary grease
- result: Low-temperature solidification of jammed rollers, common in bonder shops at -30°C!
- emergency treatment: Use ofLow temperature fluorine grease(-60℃ still flowing), dismantle the bearing and soak in paraffin to clean.
How can I save myself from a warped roller?
- mildly curved: Elevation point marked by laser level, fine adjustment by hydraulic machine (<0.1mm/m)
- heavily deformed: Straightforward replacement! Don't believe in "knocking it back", you'll never get the accuracy back!
The ultimate anti-dorking strategy - get on the IoT.
In drum shaft mountingVibration sensors, mobile phone app for real-time monitoring:
- Amplitude > 5 mm/s² → Pre-warning bearing wear
- Sudden change in temperature profile → Indicates lubrication failure
real effect: After a factory in Shenzhen retrofitted, the failure rate dropped straight down 67%!
In the end, SMT drum line maintenance is not "spending money", it islife-preserving investment! A 10-minute daily inspection and a 2-hour weekly maintenance is much more cost-effective than losing a day of production downtime - after all, theWhen the assembly line stops, the money burns to ashes.The truth of the matter is understood by those who understand it!
