PCB manufacture is a progressive process adding value at each step. At the end of the line the maximum value has been assembled leaving only the depaneling or singulation process to take place. This mechanical separation is often under estimated and dealt with in the simplest possible manner giving inadequate attention to stress. Often this results in damage to PCBs and a significant loss of value. This Presentation outlines the basics on how to best protect the investment in the assembled PCBs by using the right level of cutting and handling technology.

1. Automated Depanelling Technology
• Why Depanel Automatically
• Process Parameters and Control
• Machine types, Technologies and
System overview.

2. Why is Automated Depanelling
Important
• When a circuit Board is singulated – removed from its frame or matrix panel - it
will be subject to mechanical forces induced by the tool used to break the tab.
• The systems employed vary but include:
• Hand breaking
• Pizza Cutter [opposing rotating discs – don’t cut they tear]
• Shear
• Punch
• Router or Saw
• Today lead free alloys compound the issue and challenges of limiting the
mechanical stress due to being less ductile and malleable. This makes them
more prone to micro cracks.
• The cost to repair a soldered PCB is considered to be 10X that of a non soldered
PCB. Choosing the right tool to accurately remove the Circuit while protecting
the value added investment of parts and process cost down stream is critical.

3. Why is Automated Depanelling
Important
Life Failures
• The most insidious types of failures, and the hardest to predict. Most
expensive to rectify
• Often a result of a partial mechanical failure resulting in total failure after
environmental exposure
Causes
• Poor process
• PCB layout
• Singulation methodology
Cure
• Minimize the mechanical stress exerted on the board throughout the
assembly process particularly after the soldering process has been
completed.

4. Cutting & Breaking.
Generallyacceptedlimitsfor
straininsingulation
Cutting and breaking PCBs, Shears and Pizza style devices will exert
considerable more strain than Routing or Sawing. Often 10X the
recommended levels.

5. Board stress analysis
Stress from Punching
Punching of 3 tabs Peak Stress points – 5x recommended

6. Board stress analysis
Stress from Routing
Router diameter: Ø1,5mm Speed: 42000 rpm Feed: 50mm/ sec

7. Board stress analysis
Stress from Sawing
Disk thickness: 0,7mm Diameter: 75mm Speed: 12000rpm Feed: 3 m/min

8. Stress “Free” separation
• Stress incurred from Punching or
manual breaking >2500µm/m
• Stress incurred from
routing <150µm/m

9. What if – The V score is too shallow
The Natural tendency to “Work” the board until it breaks results in multiple
levels of strain being exerted for extended periods. In this instance 5.5
seconds before the circuit separates from its surrounding material.

10. SMD Placement
Break
out
Bare PCB Fully assembled
PCB
Print Reflow
Test
Value Aggregation
& the potential for loss
Relative REWORK
costs through the
Process
Choice of an appropriate depanelling system insures the value invested in building the PCB

11. Machine Design
Stand-Alone Machine Outline
 Single and dual-pallet systems available
 High speed, air cooled spindle
 Optional dual cutting heads for maximum throughput
reduces cycle time by more than 50%
 Multiple fixture options:
 Universal Fixtures for Proto and low volume runs.
 Rigid, dedicated pin fixtures for production use
 Vacuum Fixtures for Flex circuits
 Single and multi-up board designs on the same pallet
 Independent fixtures per table
 Concurrent processing maximizing throughput
 Panel sizes:
 Min: 51 mm x 51 mm (2” x 2”)
 Max: 500 mm x 650 mm (20.50” x 25.6”)

12. Machine Design
In-Line Machine Outline
 Single and Dual Table Systems
 Patented dual-pallet shuttle
 Full Robotic [X,Y,Z offload per part] or
simpler gang pick and place.
 Routing and Saw configurations
 Panel sizes:
 2” x 2” (51mm x 51mm) to
 13.7” x 12.2” (350mm x 310mm)
 Pre-routed or solid panels
 Integration with Test systems prior to
determine good and bad boards for
sorting at offload.

13. • Getech Gantry Design has the Y1 Y2 & X axis working independently.
• This will eliminate the possibility of deflection during cutting, especially for
big PCB panel
• This kind of Cartesian robot design is commonly used in the CNC lathe
machines. It can support heavy cutting force and high speed positioning.
• Very stable CPK with high cutting tolerance. [Cpk 1.66]
• However the costs for this design are high.
Getech Gantry Design

14. Router Technology - Summary
Advantages
 Stress “Free”
 High flexibility
 Smooth edge quality, dimensional stability
 Controlled process
 High through-put
 Accommodates a wide range of panel
layout configurations
 Servo driven system maintains a high
degree of accuracy
 Multiple solutions for in-line and stand
alone processing
 On-board vacuum systems to clean
resulting debris

15. Saw Technology - Summary
Advantages
 High Speed
 Long cuts without the need for Pre-Routes
 Smooth edge quality, dimensional stability
 Controlled process
 Very High through-put
 Alternative to V Score and break out
methods
 Only able to accommodate straight cuts
 Servo driven system maintains a high
degree of accuracy
 In-line and stand alone processing
 On-board vacuum systems to clean
resulting debris

16. Machine Platforms
ESR
GSR
GSR 22
IRM
GAR
RBM
GSS
IDM
Standalone Routing In-Line Routing Singulation by Saw

17. Depanelling Process
Control

18. The depanelling process is dependant upon the following factors:
 Machine Gantry and Control:
 Specification and mechanical stiffness.
 Motion control and capability to program non linear cuts.
 Software system that can integrate tool wear with process needs.
 Alignment options.
 Fixtures/Tooling:
 Consistent PCB location is 50% of the Process and needs to adhere to parameters of positional
repeatability without drift – panel to panel.
 Ease of use in operation and at changeover.
 Cleanliness:
 Depanelling creates abrasive p[articles which can be harmful to machinery and people.
 Vacuum systems must be able to capture and filter debris insuring a clean product, work
environment and machine moving members.
 Tool selection and Feed rates:
 The right tool and the correct RPM and linear feed rate will play a significant role in cut quality and
dimensional stability.
Process Control

19. Mechanical Design – Vibration and Positioning
Guide A
Guide B
Air Cylinder
Poor Overall
Control. Poor
positional accuracy
and weak positional
strength.
TABLE
Ball Screw
AC Servo
Poor Torsional
Control. Induces
a Yawing moment
when accelerating
the table.
TABLEAC Servo
Great Overall
Control. Zero Yaw
in drive system and
zero rotation on
table, maximum
positional accuracy.
• Vibration will occur as a
result of both poor fixturing
and machine instability.
• Machine instability can only
be alleviated by the
appropriate mechanical
design and use of closed
loop servo control.
Guide A
Guide B
Guide A
Guide B
TABLE

20. Table
BOSCH Module
TABLEMotor
Hardened Linear Bearing
slides
nut system
nut system
Mechanical Design – GETECH Table Design
Compact Modules
The ready-to-install Compact Modules from B0SCH
1. Fully enclosed – free from dust
2. Bosch factory aligned ball screw and linear bushings and shafts
3. High load capacities and rigidities.

21. • Getech Gantry Design has the Y1 Y2 & X axis working independently.
• This will eliminate the possibility of deflection during cutting, especially for
big PCB panel
• This kind of Cartesian robot design is commonly used in the CNC lathe
machine. It can support heavy cutting force over time
• Very stable CPK with high cutting tolerance.
• However the costs for this design are high.
Getech Gantry Design

22. Air Cylinder
Table Positioned by Air Cylinder
Cutting of PCB creates a Lateral
Load on the PCB AND the Table
Lateral Load creates
deflection in Table position
Pneumatic Gantry
Design issues

23. Air Cylinder
Table Positioned by Air Cylinder
When Cutting tool moves in Z axis to transition
to next tab, Lateral load is released.
When Lateral Load is released.
Table Springs back to initial
position. System has very poor
positional accuracy.
Pneumatic Gantry
Design issues

24. Fixture Design
Poor Fixture design can result in beveled edges, undercut or
oversized tab stubs.
• Beveled Edges result from PCB lift
LiftHeight
Resulting Bevel Edge
PCB edge Undercut due to
poor lateral stability of the
fixture/PCB locations
Poor location results in
undercut or oversized tab
Dimensional difference due to
panel deflection
• PCB Undercut and Oversized Tab Remnants

25. Fixture Design
Machine Table
Tallcompnentsto75MM
Tapered Pins Provide secure
location and ease of
load/unload
Top plate with SSD compliant
foam holds PCB firmly on the
pins
Clearance slots in the top plate
allow the router tool to pass.

26. Fixture Design
PCB Board
Open catch
Top clamp
Top Plate latches in position to secure the
PCB on the fixture.
Resulting in:
• Dimensional Accuracy and repeatability.
• Very low vibration and stress on PCB
• Faster Cycle times.
• Cleaner edge quality
Dedicated Fixtures allows for a consistently
higher Cpk value
• Facilitates a more efficient and reliable
means of loading and unloading
• Substantially reducing the risk of damage to
the PCBs.
• Higher yields

27. • Down cut generally gives better finish but secure tooling and
fixtures are required
Down cutUp cut
Clockwise rotation
Up cut vs. down cut programming.

28. Vacuum
 Adequate vacuum strength is critical to routing performance
 Vacuum blower is designed into the machine to reduce Noise and
footprint
 Getech vacuum consists:
 2 x 5hp blowers.
 3-stage filtration system capable of meeting class 100 clean room demands
 Includes filter and micro-filter to evacuate dust particulates up to 3 microns
 Ionizers for improved fine dust control
 Debris formation and tool breakage are significantly improved by
adequate vacuum
 Pre-routed vacuum slots should be used to assist in air flow and
debris removal
Fixture Design should allow Adequate air flow
through the Fixture
Ionizers can be
deployed to improve
fine dust control

29. Vacuum Layout
External vacuum tanks
for easy maintenance
3 stage dust filtration
• 1st Disposable bag
(20 micron)
• 2nd. Dacron filter
• 3rd. Poly Filter Vacuum Drawn at
cutter - source of dust
2x Vacuum pump inside
machine to shield noise

30. Pressure Foot Brush condition can also significantly affect
vacuum
• Pressure foot brushes should be inspected daily
Good WORN BRUSH
Vacuum - Pressure foot
Bad

31. Managing ESD
Metal Bearing
Static Dissipative Brush
Earth
Earth
Ohm
R
Current (I) = Voltage (V)/ Resistance (R)
The Spindle is running at a very high speed. At time the shaft
is floating. Having no contact with the metal bearings, to
ground.
ESD
ESD generated
during routing
Gradual discharge of ESD
1000 volt
VacuumdustInlet

32. EOS is caused by an unusual spike in voltage applied to the system that causes damage at the
component or board level, rendering system or component failure. The event usually lasts from
microseconds to seconds (short pulses range in the nanoseconds).
EOS damage is typically not visible because the damage is at the transistor level.
Signs of EOS include:
1.Blown metal line – Thermal Damage
2.Molten damage – High Power Consumption
3.Electrostatic Discharge (ESD) is a subset of EOS.
4.The event occurs within pico to nanoseconds and is usually caused by human contact. The impact
is similar with blown metal lines.
What is electrical overstress (EOS)?

33. Types of Anti-Static Brushes:
1.Conductive brushes are used for applications
where it is necessary to reduce the static charge to
0v because even a small charge obstructs the
operation and the medium being discharged is not
sensitive to high current flow.
2.Static Dissipative brushes are used for
applications where high current flow would be
damaging to the product being discharged. Static
dissipative brushes introduce a high resistance [R]
between the charged surface and ground thereby
reducing the current flow proportionally.
PCBA
EARTH
Resistor
What is electrical overstress (EOS)?

34. Machine Standard
Features
Vision System and software interface
Programming
Software options
Vacuum and dust management

35. Vision System
Standard vision system.
 All machines supplied with an analogue CCD video camera,
calibrated to the manipulator and mounted on the x-axis of the
system.
Optional vision system.
 Advance vision system for capturing PCB Fiducial locations.
(Provides means of automatically compensating for
misalignment that may result from inconsistencies in board).
 Step and repeat programming from 3 points.

36. Vision System

37. Windows-based Software
 Windows based interface software is user-friendly and intuitive for
diagnostics and programming
 Multiple security level settings – from operator to maintenance to
engineering
 Helpful operator prompts and notifications:
 Tool bit diameter optimization to increase tool life
 Tool break notification
 Pre-set filter change intervals
 Rapid video-aided programming with onboard camera
 Program verification using camera to validate cut tolerance
 Automated teach mode using known positions
 Step and repeat programming feature cuts programming time
significantly no matter how complex the assemblies

38. Tool control features in
Software
• Cutting tool management
• Tool wear compensation
• Tool life monitoring
• Programmable Z travel
( Allowing full use of tool length)
• Tool break detection

39. Programming
 Straight line and interpolation capabilities
 Jog and teach programming
 Live visual programming of tool path programs: no scrap while setting up
 Utilizes same concept as “G code” programming tool to edge of work piece
 Comprehensive editing / copying facilities
 Fiducial capability linked to step and repeat offset programming.
 Matrix Programming
 Useful when routing panels containing a large number of duplicated PCBs in rows/columns
 Used in conjunction with either or both the “Manual Transformation ” and “Table Program”
 Transformation Programming
 Useful tool when universal fixtures are utilized for securing the panel
 The <Product> is programmed with 2 known reference points on the panel using fiducials.

40. Software Options
Matrix Programming
• Useful when routing panels containing a large number of duplicated
PCBs in rows/columns
• Used in conjunction with either or both the “Manual Transformation
” and “Table Program”

41. Software Options
Fiducial Recognition
 The router will automatically align every panel to 2+ fiducial points prior to
cutting

42. Software Options
Bar Code Software
 1D and 2D barcodes can be utilized.
 The barcode reader in the machine is controlled by the GSR
software
 Reading a code creates a link to an external server for
instructions or simple data recording.
 Typical commands may include
whether to rout the segments
or have an error to prompt on
the screen.

43. Tool Life Optimization
• Preferable cutter depth of 0.8 to 1.5 mm during routing
• Full length of the tool can be used by incrementing Z-axis
• 5 steps down, 5 up and repeat. ! Increment per finished Panel.
• Increment programmable >= 0.5mm
• Tool compensation feature will verify tool diameter wear or to make global offset to a
routing program
• Z-offsets can be programmed to rout a board with different routing heights
0.8to1.5mm
PCB 1 PCB 2 PCB 3 PCB 4 PCB 5

44. Parameters are highly dependent on product type and customer quality
requirements. Data analysis should be performed at customer site to
determine ideal parameters.
Tool Diameter (mm) Plunge Rate (mm/sec) Spindle Speed (KRPM) Typical Feed (mm/sec)
0.80 300- 500 61-73 20
1.00 300- 500 48-57 23
1.60 300- 500 30-37 63
1.80 500 27-33 67
2.00 500 24-29 67
2.40 500 20-24 84
2.50 500 19-23 84
Router Bit Parameters

45. Stand Alone
vs.
In-Line

46. Considerations
 PCB Size and thickness
 Post process handling needs
 Work flow in the factory
 Budget
 Test sequence pre depanelling and Sorting post depanelling.

47. In-Line Machine Features
• Manipulators
• Input shuttle
• Post route board handler [X,Y Z]
• Controller
• Auto tool change system
• Tool optimization and compensation
• High Power Spindle
• Vision system
• High Precision Servo Control

48. In-Line Routing Process – Twin Table
Machine
• Routing starts when the input shuttle receives a panel. The shuttle loads
the free work station with the panel, and routing commences.
• While the first panel is being routed, the shuttle loads the second work
station, which then stands by waiting for the first to complete.
• When the first station has completed, the board handler picks up the
separated PCB’s and places them onto the conveyor, or onto the
customers interfaced utility

49. Getech direct contacts
Asia
 Address
 201, Woodlands Ave 9, #05-50, Spectrum 2,
Singapore 738955
 Sales & Marketing: +65 6756 9722/3
Email: sales@getecha.com
General Enquiry: +65 6756 0777
Fax: +65 6756 0770
America’s & Europe
• Address
• 320 East Vine Dr. Fort Collins, Colorado, 80524,
USA
• Sales & Marketing: +1 970 412 6759
Email: allen_d@getechsys.com
Local Agents details may be found at
http://www.getecha.com/contact-main.html