Odd Form
Mirae MAI Series

Apex Factory Automation proudly introduces the Mirae MAI Series of Odd Form Component Insertion machines.

The Mirae MAI is a hybrid machine which uses SMT Mounter technology to perform through hole odd part insertion and placement. Its unique features include lead straightness inspection of thru hole parts before placement into the PCB via laser (preventing scrap parts and boards.) It also features a post placement component insertion verification using it’s unique ZHMD system.

The MAI Series is an exceptionally flexible platform that is offered in four configurations:

  • MAI-H4: Inserts parts up to 25mm tall using 4 Precision heads
  • MAI-H4T: Inserts parts up to 55mm tall using 4 Precision heads
  • MAI-H6: Inserts parts up to 25mm tall using 6 Precision heads
  • MAI-H6T: Inserts parts up to 55mm tall using 6 Precision heads
KEY FEATURES

ODD FORM INSERTION AUTOMATION

MAI-H4 and H4T – Odd Part Inserter for large parts such as relays, connectors, heatsinks, as well as Axial and Radial leaded components up to 55mm tall.

mr_40lp_dual4nozzle02The MAI H4 Placement Head has 4 Precision placement nozzles

  • 4 heads give faster speed than most other odd form machines: 19,500 CPH Optimal Speed – 15,000 CPH IPC 9850 Speed for chips
  • Large Part Size placement range up to 50mm square or 30 x 90mm long
  • H4 – Max Part Height 25mm
  • H4T – Max Part Height 55mm
  • Large PCB Capability – up to 27.9” long x 20.1” wide (700mm x 510mm)

 

Both Camera and Laser Vision systems are available:

  • Camera vision, from below, used for standard parts recognition
  • Laser vision, from the side, used for lead straightness checking

4precision-head-3_cropped

Mirae’s unique ZHMD (Z Height Measurement Device) can be used to verify correct part insertion:

  • After insertion, ZHMD system automatically checks part height to verify correct and complete insertion into the PCB
  • The ZHMD module is located between the heads and behind the downward looking camera

4Precision Head crop

Axial tape and reel feeders are available:

  • Parts are cut from axial tape and formed before insertion into PCB

Axial Feeder crop

 

Radial tape and reel feeders are also available:

  • Parts are cut from radial tape and formed before insertion into PCB

Radial feeder-2

 

Automated stick feeders are available:

  • Single stick feeders for lower volume parts
  • Multi Stick changers available for higher volume parts
  • Ideal for Relays and parts that have leads that could be damaged by bowl feeding

Milti Stick Feeder-2

Large component Bulk Feeders are available:

  • Bulk feed large parts such as connectors and headers
  • Available in single, dual and 4 up bowl configurations

4Lane Bowl Feeder

Stacked Bowl Feeders:

  • Maximum bulk part capacity is available with stacked bowl configurations

stacked bowl feeders

Gripper Nozzles are available for difficult to pick components:

  • Many standard sizes available, as well as special and custom grippers

 

grippers

State of the Art Linear Motors

  • Our new 4th generation Linear Motors are considered the premium motion control system on SMT equipment today.
  • Provides faster movement and less friction than older generation Linear motors.
  • Mirae’s LMT (Linear Motor Technology) group, a leader in this field, currently holds 68 patents in this technology.

Smart Feeders and Smart Machine functionality are standard:

  • Intelligent Electronic eX Feeder indexes 6x faster than previous design.
  • Feeder stores part number, quantity remaining, index pitch, index speed, feeder width, error codes in addition to other performance data.
  • Includes Pre-Empty Warning, Alternate Pick and Parts Empty Skip software features.

120 – 8mm Feeder Capacity

  • Increased feeder capacity to 120 – extending the machines ability to handle bigger setups.
  • No loss of feeder slots if you specify the Feederbase Exchange System for fast changeover.

 

Built in machine software and NPI features are unsurpassed:

  • Easy to use and learn operator interface.
  • PIC tool (Virtual Sticky Tape) is standard.
  • Auto Component Teach and Pattern Matching tools are standard.

Software

Mirae features powerful, yet easy to use, Windows Software:

  • Easy-to-learn software includes a “Wizard” which helps new programmers and operators program new products

The Offline Editor Suite (OES) includes many features that are unavailable, or  extra cost in competitors’ software:

  • Cad centroid text converter
  • Gerber data converter
  • Scanned PCB data program creation
  • Program optimizer AND line balancer
  • Common setup optimizer

Production Management Software (MES):

  • E+Net – Production Manager and Scheduling
  • Line and machine production are thoroughly quantified and maximized, resulting in increased production efficiency and profit

Options, Parts and Accessories

Feeders and Parts Supply

New, 3rd Generation Electrical and Intelligent Feeder

  • 6x faster indexing speed than previous feeder design
  • Soft start and stop, with 9 programmable speeds
  • Self-diagnosis upon insertion into the feederbase:
    • Automatic feeder recognition upon insertion
    • Interface displays feeder location & index pitch
    • Automatic pickup position calibration by the machine head camera; simultaneous pickup rate is increased – giving higher productivity
    • Integral cover tape waste chamber with cutter in door
    • Empty feeder slides out, not up, so can be removed safely while machine is running, providing uninterrupted production

Intelligent Feeder – Parts Management

  • Pre-Empty Warning feature: Allows setting of a minimum part-quantity alarm, allowing time to prepare a replacement reel of parts, to minimize machine down time
  • Alternate Pick feature: If feeder runs out of parts, machine will pick the same part if it is duplicated elsewhere the machine
  • Parts Empty Skip feature: If the feeder runs out of parts and no duplicated parts are available, it will skip the empty parts and continue running until the rest of the board is finished and wait until the feeder is replenished, thereby minimizing down time

Vibratory Stick Feeder

  • Plug and Play installation
  • Amplitude, frequency and fine frequency enable fine-tuning for feeder performance
  • Adjustable tooling for up to 5 different components

Tray Feeding Units

  • Multiple tray feeding unit for up to 20 unique trays; sits on the back of the machine
  • Direct pick from tray for reliable pickup

Other Tray Feeders: Internal “2.5” Tray Feeder:

  • Feeds 2 Jedec Trays (3, if tray is rotated)
  • No loss of feeder space

Strip Component Feeders – Jedec-sized tray

  • Fixed-width strip component feeder holds 6 lanes of 8mm tape and 2 lanes of 12mm tape
  • Capable of holding multiple parts per lane
  • Can go on any of the fixed tray plates

Options and Accessories

Feederbase Exchange System (FES)

  • Offline preparation and fast feeder changeovers
  • Factory built-in option, also field retrofittable
  • Changeovers of complete feeder sections within minutes
  • Compatible with tape cutter option
  • Automatic power, air and communications coupling (no manual coupling needed)
  • 60 position trolleys, same as fixed feederbases

Offline Setup Verification (OSV) Feeder System

  • Feeder trolleys are connected to the offline loading station
  • Setup verification offline – barcode scan parts and load feeders

KEY FEATURES

ODD FORM INSERTION AUTOMATION

MAI-H6 and H6T – Odd Part Inserter for large parts such as relays, connectors, heatsinks, as well as Axial and Radial leaded components up to 55mm tall.

The MAI H6 Placement Head has 6 Precision placement nozzles

  • 6 heads give faster speed than most other odd form machines: 16,000 CPH Optimal Speed – 11,000 CPH IPC 9850 Speed for chips
  • Large Part Size placement range up to 50mm square or 30 x 90mm long
  • H6 – Max Part Height 25mm
  • H6T – Max Part Height 55mm
  • Large PCB Capability – up to 27.9” long x 20.1” wide (700mm x 510mm)

 

Both Camera and Laser Vision systems are available:

  • Camera vision, from below, used for standard parts recognition
  • Laser vision, from the side, used for lead straightness checking

4precision-head-3_cropped

Mirae’s unique ZHMD (Z Height Measurement Device) can be used to verify correct part insertion:

  • After insertion, ZHMD system automatically checks part height to verify correct and complete insertion into the PCB
  • The ZHMD module is located between the heads and behind the downward looking camera

4Precision Head crop

Axial tape and reel feeders are available:

  • Parts are cut from axial tape and formed before insertion into PCB

Axial Feeder crop

 

Radial tape and reel feeders are also available:

  • Parts are cut from radial tape and formed before insertion into PCB

Radial feeder-2

 

Automated stick feeders are available:

  • Single stick feeders for lower volume parts
  • Multi Stick changers available for higher volume parts
  • Ideal for Relays and parts that have leads that could be damaged by bowl feeding

Milti Stick Feeder-2

Large component Bulk Feeders are available:

  • Bulk feed large parts such as connectors and headers
  • Available in single, dual and 4 up bowl configurations

4Lane Bowl Feeder

Stacked Bowl Feeders:

  • Maximum bulk part capacity is available with stacked bowl configurations

stacked bowl feeders

Gripper Nozzles are available for difficult to pick components:

  • Many standard sizes available, as well as special and custom grippers

 

grippers

State of the Art Linear Motors

  • Our new 4th generation Linear Motors are considered the premium motion control system on SMT equipment today.
  • Provides faster movement and less friction than older generation Linear motors.
  • Mirae’s LMT (Linear Motor Technology) group, a leader in this field, currently holds 68 patents in this technology.

Smart Feeders and Smart Machine functionality are standard:

  • Intelligent Electronic eX Feeder indexes 6x faster than previous design.
  • Feeder stores part number, quantity remaining, index pitch, index speed, feeder width, error codes in addition to other performance data.
  • Includes Pre-Empty Warning, Alternate Pick and Parts Empty Skip software features.

120 – 8mm Feeder Capacity

  • Increased feeder capacity to 120 – extending the machines ability to handle bigger setups.
  • No loss of feeder slots if you specify the Feederbase Exchange System for fast changeover.

 

Built in machine software and NPI features are unsurpassed:

  • Easy to use and learn operator interface.
  • PIC tool (Virtual Sticky Tape) is standard.
  • Auto Component Teach and Pattern Matching tools are standard.

Software

Mirae features powerful, yet easy to use, Windows Software:

  • Easy-to-learn software includes a “Wizard” which helps new programmers and operators program new products

The Offline Editor Suite (OES) includes many features that are unavailable, or  extra cost in competitors’ software:

  • Cad centroid text converter
  • Gerber data converter
  • Scanned PCB data program creation
  • Program optimizer AND line balancer
  • Common setup optimizer

Production Management Software (MES):

  • E+Net – Production Manager and Scheduling
  • Line and machine production are thoroughly quantified and maximized, resulting in increased production efficiency and profit

Options, Parts and Accessories

Feeders and Parts Supply

New, 3rd Generation Electrical and Intelligent Feeder

  • 6x faster indexing speed than previous feeder design
  • Soft start and stop, with 9 programmable speeds
  • Self-diagnosis upon insertion into the feederbase:
    • Automatic feeder recognition upon insertion
    • Interface displays feeder location & index pitch
    • Automatic pickup position calibration by the machine head camera; simultaneous pickup rate is increased – giving higher productivity
    • Integral cover tape waste chamber with cutter in door
    • Empty feeder slides out, not up, so can be removed safely while machine is running, providing uninterrupted production

Intelligent Feeder – Parts Management

  • Pre-Empty Warning feature: Allows setting of a minimum part-quantity alarm, allowing time to prepare a replacement reel of parts, to minimize machine down time
  • Alternate Pick feature: If feeder runs out of parts, machine will pick the same part if it is duplicated elsewhere the machine
  • Parts Empty Skip feature: If the feeder runs out of parts and no duplicated parts are available, it will skip the empty parts and continue running until the rest of the board is finished and wait until the feeder is replenished, thereby minimizing down time

Vibratory Stick Feeder

  • Plug and Play installation
  • Amplitude, frequency and fine frequency enable fine-tuning for feeder performance
  • Adjustable tooling for up to 5 different components

Tray Feeding Units

  • Multiple tray feeding unit for up to 20 unique trays; sits on the back of the machine
  • Direct pick from tray for reliable pickup

Other Tray Feeders: Internal “2.5” Tray Feeder:

  • Feeds 2 Jedec Trays (3, if tray is rotated)
  • No loss of feeder space

Strip Component Feeders – Jedec-sized tray

  • Fixed-width strip component feeder holds 6 lanes of 8mm tape and 2 lanes of 12mm tape
  • Capable of holding multiple parts per lane
  • Can go on any of the fixed tray plates

Options and Accessories

Feederbase Exchange System (FES)

  • Offline preparation and fast feeder changeovers
  • Factory built-in option, also field retrofittable
  • Changeovers of complete feeder sections within minutes
  • Compatible with tape cutter option
  • Automatic power, air and communications coupling (no manual coupling needed)
  • 60 position trolleys, same as fixed feederbases

Offline Setup Verification (OSV) Feeder System

  • Feeder trolleys are connected to the offline loading station
  • Setup verification offline – barcode scan parts and load feeders

Optimal Speed
19,500 cph (0.18sec/chip)
IPC9850 Speed
15,000 cph (0.241 sec/chip)
Min Component Size
0603
Max Component Size
<50x50mm or 90 x 30mm
Max Component Height
25mm - H4, 55mm - H4T
Accuracy
25 micron QFPs, 50 micron chips (3 sigma)
Head Configuration
Single Gantry 4P
Min PCB Size
50mm x 50mm x .4mm (2" x 2")
Max PCB Size
700mm x 510mm x 5mm (27.6" x 20.1")
Feeder Slots
120
Floor Space (W x D x H )
1,488mm x 2,090mm x 1,500mm
Power
200 - 430v, 50/60 Hz, 3-phase, 5kVA
Air
.5 Mpa (72 psi); 130 NI/m (5 CFM)
Weight
1,800 kg (3,960 lbs.) approx.
Optimal Speed
16,000 cph (0.22sec/chip)
IPC9850 Speed
11,000 cph (0.32 sec/chip)
Min Component Size
0603
Max Component Size
<50x50mm or 90 x 30mm
Max Component Height
25mm - H6, 55mm - H6T
Accuracy
25 micron QFPs, 50 micron chips (3 sigma)
Head Configuration
Single Gantry 6P
Min PCB Size
50mm x 50mm x .4mm (2" x 2")
Max PCB Size
700mm x 510mm x 5mm (27.6" x 20.1")
Feeder Slots
120
Floor Space (W x D x H )
1,488mm x 2,090mm x 1,500mm
Power
200 - 430v, 50/60 Hz, 3-phase, 5kVA
Air
.5 Mpa (72 psi); 130 NI/m (5 CFM)
Weight
1,800 kg (3,960 lbs.) approx.