LED displays are increasingly being used in a wide range of scenes and fields, and there is growing demand for higher definition images. To meet these changing market requirements, the number of placed parts is increasing due to the miniaturization of placed parts and fine pitch circuits.
We are going to summarize the requirements for LED display production and introduce Fuji solutions.

In addition to the trends mentioned at the beginning of this document such as miniaturization of parts, fine pitch circuits, and an increase in the number of placed parts, rising labor costs and chronic labor shortages have become problems in production sites. There is also an urgent need to create a system that can respond flexibly to rapid changes in market conditions.
Based on these industry trends and issues in production sites, solutions that meet the three requirements of "high productivity, high quality, and labor saving" are necessary to realize the ideal production for users.

We will now introduce Fuji solutions based on the three requirements, "High productivity, high quality, and labor-saving" required for LED display production.

We cater meet the demands of LED display production, for which the number of placed parts is expected to increase, with industry leading placement speeds.
We also provide systems that minimize losses in speed and a space-saving environment that allows work to be performed without waste.

An industry leading throughput of 120,000 cph (a 39% improvement when compared with conventional machines) has been achieved. This is highly effective for LED placement, where the number of LEDs placed is on the rise.

When parts are set in feeders at empty slots in the module to be used as replenishment parts for those used in production, and when the original parts run out, production automatically switches to the feeder with these replenishment parts and continues.
Production can be continued at the fastest speed even after exchanging to the replenishment parts because the original parts and replenishment parts can be set side by side in the center in units of two ^Note.

Note: LED display production limited function

Downtime loss can be reduced and a high productivity rate can be maintained because solder cups and cleaning paper can be exchanged from small windows without stopping production.
In addition, the temperature inside the machine can be kept within a certain range and defects such as smearing due to hardened solder can be prevented because only a small section of the cover is opened.

The industry-leading area productivity, 70,999 cph/m2 has been achieved (120,000 cph in a 795 x 2,126 mm space).
Single-side operation for the NXT series shortens and simplifies operator work paths, making it compatible with production with a small number of operators and suitable for automating material transfer.

As labor saving increases, the work range becomes wider, which can lead to delayed actions due to missed alerts or the machine may stop in the worst case.
To avoid these situations, notification functions using a mobile device are effective.
By preventing error and warning signs from the equipment from being overlooked and encouraging prompt action, drops in the operating rate can be minimized.

High-accuracy placement required for LED placement for which the number of small parts and fine pitch circuits is increasing is supported by control technology and correction technology that provide high positioning accuracy with low vibration and low impact. In addition, machine-to-machine communication functions prevent defects from occurring and proceeding to later stages.

Parts are placed on fine pitch circuits without interference at high accuracy even during high-speed operation with the industry's lightest heads ^Note and our unique servo control technology.

Note: Investigated at Fuji

Target parts are always picked up accurately by using a pickup position correction function that takes into account discrepancies between individual feeders.
High accuracy and high quality production can be maintained by automatic correction before pickup and after placement.

Image recognition of the nozzle tip from the side makes it possible to eliminate defect causes that cannot be detected by the parts camera.

　Check points
　- Checks for tombstoned parts and up-side down parts
　- Part thickness checks
　- Checks for dropped parts and parts remaining on nozzles

Parts are placed at the accurate placement height calculated from the panel warpage and part height.
In conjunction with Fuji's low-impact nozzles, this works to prevent damage to fragile parts and solder bridging.

Upon receiving inspection results from SPI and AOI, the necessary actions are performed automatically in line with any trends that indicate status changes. Because any quality lowering issues are responded to before they lead to problems, high-quality production is maintained with no need for operators to perform work.
In the unlikely event that a sudden defect is detected, the line is stopped to prevent defective products from continuing to the next stage.

To ensure that the necessary output can be produced continuously even at sites with insufficient operators, high productivity can be maintained by assist functions that simplify work and by units that perform work automatically instead of operators.

Data such as the pickup rates and usage time is collected by the system. Once a unit ^Note (feeders, nozzles, and heads) has reached a threshold, guidance is issued to perform maintenance.
Follow the guidance provided for maintenance work to keep your equipment in top condition for production with minimum effort.

Note: The applicable units are different depending on the machine.

Collects waste tape that previously needed to be collected at each module into one place to reduce operator work.
The operating rate can be improved because waste tape can be removed without stopping production.

The machine checks the solder roll diameter and automatically supplies solder when it falls below a certain level. Since the solder is always at the optimal volume, it is possible to prevent smearing caused by the insufficient filling amount.

LEDs used in displays are expected to become even smaller in the future. These changes can be supported by our fine pitch placement technology for very small parts cultivated from small panels for mobile devices and optimization for the LED placement.

The industry-leading placement accuracy of ±15 um and a speed of 50,000 cph provide ultra high accuracy placement and high productivity.
Placement of 0201 mm (008004") parts is supported as standard.

Control the nozzle push amount and load when placing parts.
Low impact placements required for fine pitch placement for small parts are supported by a wide range of functions such as dedicated low impact nozzles, pressure calibration units, and soft pickup and soft placement.

Fiducial marks as small as φ0.1 mm can be detected stably with a high resolution camera.
LED placement with reference marks that are miniaturized as parts become smaller is also supported.

To avoid variance in brightness due to differences in production lots, different lots of LEDs are distributed over the entire placement surface.

The functions and units introduced here include option items.
Please contact us if you have any further questions about these or any other solutions.