Updated 10/28/2024
These days, we can’t build electronics quickly enough. From the way cars can sense their surroundings and refrigerators can reorder groceries to our ability to look up anything in the palm of our hand, electronics are at the center. Consumers and businesses alike want all of it — fast.
The pace at which we’re becoming comfortable and accustomed to powerful electronics in the everyday world has put extreme pressure on electronics manufacturers, resulting from the volume of demand and the expectations around continuously condensed and connected capabilities.
To accommodate these needs, the use of automation in electronics manufacturing processes has become essential.
In this article, we’ll explore:
- Benefits of automation in electronics manufacturing
- Types of automation solutions benefitting electronics manufacturing
- Internet of Things (IoT)
- Decentralized Enterprise Resource Planning (ERP) Systems
- Artificial Intelligence (AI)
- Additive Manufacturing
- Collaborative Robot Systems
- Surface Mount Technology (SMT) Automation
- Automated Inspections and Testing
- Automated Coating and Dispensing Systems
- Where to see the latest in electronics manufacturing automation
BENEFITS OF AUTOMATION IN ELECTRONICS MANUFACTURING
Electronics manufacturing is prime for automation. Not only can automated systems accelerate throughput and time to market — both essential for highly competitive electronics manufacturers — but they can also improve output quality overall. The implementation of automation removes the potential for human error, guaranteeing consistency and precision for the most complex or delicate tasks.
Automation also opens the door to more possibilities around customization. As demand for personalization surges, automation provides the flexibility needed to seamlessly adapt processes to different designs, specifications, and small-scale production needs.
Plus, automated systems can gather data from various stages of the manufacturing process in real-time, at all times. Sensors, machines, and IoT devices can track performance metrics, quality control data, and equipment conditions and produce immediate insights, helping manufacturers make faster decisions and adjustments without waiting for manual reporting.
TYPES OF AUTOMATION SOLUTIONS BENEFITING ELECTRONICS MANUFACTURERS
Here are eight examples of how electronics manufacturers are taking advantage of automation in their facilities.
1. Internet of Things (IOT)
IoT is everywhere. It’s the idea that more than just a computer or smartphone can be connected to the internet. Examples include voice assistants, wearable fitness trackers, cars, and many more. IoT can be used throughout the electronics manufacturing process, from equipment monitoring to real-time workflow optimization.
For example, digital twins — virtual replicas of physical assets — leverage real-time IoT data to simulate and predict performance, optimize operations, and support maintenance activities for electronics manufacturers. By using data from IoT sensors and devices to power digital twins, manufacturers are able to not only monitor their systems, but make data-driven decisions on the spot.
A subset of the broader IoT, the Industrial Internet of Things (IIoT) refers to the use of interconnected sensors, devices, machinery, and systems within industrial settings specifically. IIoT is used to enable the predictive maintenance of industrial equipment, optimize the supply chain and transform production processes via smart manufacturing.
2. Decentralized Enterprise Resource Planning (ERP) Systems
Take the idea of predictable maintenance and multiply it again and again. That’s an ERP in essence. They’re nothing new, but with the sensors and communications that the IoT affords, ERPs can reach further into an operation to extract granular, real-time, and actionable data.
Where in the past, a single ERP may have handled several locations, today there are more organized tiers, and data can be analyzed in the cloud or your cell phone instead of in the back office. This can all but automate decisions that once required light coordination or discussion—everything from stocking inventory to workflows.
3. Artificial Intelligence (AI)
Both the data generated by all the inventory moving across a floor and the robotics performing thousands of repetitive tasks make for a manufacturing environment that’s rich in AI potential. Most electronics manufacturers fit that bill.
Any abnormalities, improvements or trends in performance can not only be identified, but specifically diagnosed. This level of intelligent AI can impact everything from improving product design processes and workflow to reducing defects.
4. Additive Manufacturing
Also known as 3D printing, additive manufacturing has made the once time-consuming and expensive prototyping phase much more efficient. Instead of machining tiny molds or delicate parts, these detailed pieces can be built into near-finished components.
Electrical engineers and designers can troubleshoot and test their products faster and with more certainty than ever. Additive has enabled innovative chip designs and chips that can’t be recreated with subtractive machining, including fabricating multiple components more efficiently as a single part.
In addition to the actual printing of parts, robotics are used for post-processing tasks. This could include removing supports, surface finishing, polishing, and painting. With integrated sensors and machine vision, these robots can detect the slightest of variations in part geometry. This is particularly important in aerospace, automotive, and medical device industries where regulations are tight.
5. Collaborative Robot Sytems
No, the robots haven’t taken over. In fact, electronics manufacturers are finding great value in collaborative robot systems. These robots work alongside humans, typically handling repetitive tasks or moving a heavy component from one place to another. They may have a drill at one end or a gripper to pick and place.
Collaborative robots have gotten much easier to use and safer in recent years making them an attractive option in electronics fabrication. User interfaces have become more standardized, and the hardware is easier to integrate than ever. In the right manufacturing volume/mix environment, collaborative robot systems have proven a great way to fill in gaps and open up bottlenecks.
6. Surface Mount Technology (SMT) Automation
SMT automation in electronics manufacturing increases production speed while minimizing human error and lowering labor costs. It can be used for high-speed component placement, where SMT machines place thousands of components per hour with extreme precision.
Automated technologies are also often employed during the soldering process. Automated stencil printers can apply solder paste precisely to reduce defects caused by uneven coatings; automated reflow ovens use controlled heating profiles to ensure consistent soldering through temperature management; and selective soldering can be automated to solder specific components without affecting nearby parts.
7. Automated Inspections and Testing
The automation of these critical steps during the electronics manufacturing process drives accuracy when it matters most. Automated Optical Inspection (AOI) systems use high-resolution cameras and software algorithms to visually inspect printed circuit boards (PCBs) for defects.
With Automated X-Ray Inspection (AXI), X-rays are used to inspect hidden or internal features of components and solder joints that are not visible using optical methods.This is ideal for more complex assemblies with densely packed PCBs.
Flying probe testing uses automation to electrically test a PCB without a custom test fixture, making it ideal for small batches or prototypes. The method uses moving probes to contact the board’s test points, allowing for extremely thorough electrical testing.
8. Automated Coating and Dispensing Systems
Coating and dispensing systems play an integral role in protecting PCBs. Automating these processes ensures efficiency and accuracy, which is particularly important when dealing with high volumes or intricate designs.
Automated coating machines use precise nozzles, robotic arms, and programmed movement patterns to apply protective layers, such as conformal coatings, over PCBs. This ensures uniform protection while reducing waste thanks to a decrease in excess application.
Automated dispensing systems are used to apply controlled amounts of materials (adhesives, sealants, solder paste, thermal compounds, etc.), onto hyper-specific areas of a PCB. The selective dispensing process relies on robotic nozzles or valves to dispense materials with exacting precision, avoiding all other areas. This prevents issues like adhesive bleed, which can damage nearby components.
See the latest in electronics manufacturing automation at Automate
The possibilities are endless for the use of automation in the electronics manufacturing process, with new, exciting applications on the horizon. Experience the latest in electronics and other manufacturing automation for yourself at Automate. Register FREE today!
« View All Blogs