BP-4100 Automated Programming System
- The most successful line of vision-based, automated systems available
- Variety of input/output options with tubes, trays, or tape
- Programs and marks in a single operation
- Throughput of up to 1,200 devices per hour
- Programs Flash memories, FPGAs, CPLDs, and microcontrollers
- Handles PLCC, SOIC, TSOP, BGAs, µBGAs and fine pitch QFP to 208 pins
- Leads touched only once during programming and marking
- Vision centering compensates for component variation
- Accurate placement virtually eliminates component lead damage
- Glass encoder scales guarantee accuracy even after millions
- of cycles
- Software setup reduces changeover time
- Very few moving parts for high reliability
The BP-4100 meets the rigorous demands of real-world programming centers with state-of-the-art performance and field-proven technology. The BP-4100 is the first automated programming system capable of programming fine pitch (20 mil or 0.5 mm) QFP and TSOP surface-mount programmable integrated circuits including Flash memories, antifuse FPGAs, CPLDs, and microcontrollers. The BP-4100's throughput, accuracy, and flexibility make the system more economical to operate than either conventional autohandlers or manual gang programmers. Service, training, and upgrades are available from more than 20 field service locations worldwide. BP Microsystems stands behind every BP-4100 with unparalleled support.
The BP-4100 has proven to be the system of choice among advanced programming centers around the world. Having installed more fine pitch programming systems than any other company, BP Microsystems has the know-how and experience to meet your needs.
World Class Performance
Every aspect of the BP-4100 has been engineered to deliver the highest possible level of performance. The system has eleven high speed universal programmers that operate independently and concurrently, allowing the system to simultaneously program eleven devices, whether they are Flash memories or FPGAs. Component leads are touched only once by the system with the programmer pin contactor. This reduces any possibility of damage during the centering and marking operations, and increases the outgoing quality level of programmed devices. The BP-4100's remarkable pick-and-place system moves the integrated circuits and places them accurately into the programming sockets in less than one second. Components are centered using a patented camera system mounted to the pick-and-place head to guarantee each part is placed exactly in the socket without bending its leads. The system incorporates a laser marking system to help reduce component handling to a minimum. To guarantee the highest levels of incoming and outgoing quality, the vision system can be programmed to inspect every lead of the device for damage before or after programming and marking.
High Accuracy Is Not Optional
The BP-4100 is the world's first programming system to incorporate vision centering. The vision centering and closed-loop positioning systems of the BP-4100 deliver the accuracy essential to achieve good programming and handling yield. Fine pitch SMT devices are easily damaged by incorrect handling. When blank devices are removed from their protective tubes or trays, they must be aligned exactly before they can be placed into the programming sockets. Failing to accurately align the device will result in damage to the part's leads. The corner leads are especially vulnerable to being bent by the socket's bumpers. Bent leads will not only cause programming failures, but also soldering defects when the programmed device is used in a circuit.
The benefits of vision centering have been proven by the SMT board assembly industry, which has millions of hours of experience operating pick-and-place systems with both vision and numerous mechanical centering methods. Hundreds of companies in the industry have learned over time that vision systems provide much greater accuracy and reliability than mechanical systems, which justifies their increased cost many times over in savings. Typical placement error rates for standard-pitch (0.050") devices are around 0.5% for mechanical systems and 0.005% (50ppm) for vision systems. The error rates for mechanical centering of fine-pitch devices are even higher than the rates for standard pitch. The improvement in error rates can easily save $50,000 to $100,000 per year when comparing the BP-4100 to competing mechanical centering machines.
Vision Centering for Components
The BP-4100's vision centering system allows the machine to accurately place components in programming sockets without touching the leads. The system's leading-edge optical technology precisely measures and aligns TSOP, SOIC, and PLCC components on-the-fly. Since this camera is mounted to the head, the entire centering operation can be performed during the travel time from the input tray or tube to the programming socket. The system performs the entire pick-align-place operation in about 1 second.
Centering for large QFP devices and PLCC devices is provided by the optional VU-6 camera. The VU-6's telecentric optics measure parts with a video camera and image processing computer that not only calculates the component's center and rotation, but also inspects every single lead on the device for any damage. Vision centering allows the machine to compensate for differences between devices, since the leads are measured for each device. On the other hand, the mechanical centering used on competing equipment requires the services of a machine shop to adjust for daily variations in component size.
Precision X-Y Linear Glass Scales
The BP-4100's placement head is guided by precision glass scales. Acting like high-tech rulers, the scales allow the system to know the head's exact location to achieve extreme accuracy even after years of use. Since the scales are mounted directly over the nozzle, any sources of error in the motors, bearings, and belts are eliminated.
Downward Vision for Easy Teaching
A downward looking video camera mounted to the pick-and-place head allows accurate teaching of pick-and-place locations. Unlike other systems without vision, aligning components and sockets is quick and easy. A glance at the video monitor's crosshairs will let you see exactly where the head is located.
Software Programmable for Quick Changeovers
All component centering and positioning is done in software, not hardware, so changing the machine from one job to another is easy. You will not have to set any precision setscrews, look for precision alignments, or use special tools. Just snap on the socket modules and pressure plates, slide on the appropriate vacuum nozzle, swap out the component feeder tops, and load the software.
Concurrent Programming System
The BP-4100 employs the Concurrent Programming System with eleven universal programmers linked together. Invented by BP Microsystems, the Concurrent Programming System is the programmer of choice for leading programming centers by delivering more flexibility, speed, and reliability than any other programmer. Unlike old-fashioned gang programmers, the concurrent programmer can program any device whether it is a simple memory or a complex FPGA. Ideally suited to automation, the programmer starts programming each device as soon as it is inserted in the socket by the pick and place head. By the time the last socket is loaded, the first one will have completed programming so the head can remove the programmed devices without waiting. The eleven sites can outpace as many as 44 conventional universal programmers.
The system has many features to meet the requirements of real-world production facilities. The programmer's fault tolerant architecture allows the system to continue production even if one of the sockets or boards should fail. Programming jobs can be stored on the unit's hard disk to eliminate the manual setup of programming jobs. Programming files download in seconds, not minutes, so setup is a snap. The system can be networked into a LAN or WAN for enterprise-wide sharing of data files and JIT pattern updates.
High Performance Automated Socket Modules
Each BP-4100 socket module provides support for a particular package size. By using the same precision test and burn-in sockets that semiconductor manufacturers use, BP Microsystems has guaranteed compatibility with the devices you will be using. Sockets are opened and closed by individual precision actuators on each programming site to provide true independence between sites.
The BP software functioning in concurrent mode presents real time process data.
Laser Marking
The optional CO2 laser marker provides an economical way to mark devices. The laser marking system requires very little maintenance and no consumable supplies for marking. The size of the mark and label contents are easily programmable in the software. Laser marking is the preferred method for fine pitch devices because it cannot introduce coplanarity defects.
Component Feeders
The system can operate a variety of input and output options with tubes, trays, or tape. Four JEDEC trays are held on tray platforms, allowing TSOP and QFP devices to be programmed, marked and returned to trays in a single operation.
Tubes of components are fed by reliable vibratory feeders. The machine can be equipped to hold up to 24 input tubes and 24 output tubes. Each vibratory feeder has fully adjustable vibration and can accommodate any tube design with interchangeable tops.
Standard tape input feeders are also available. The versatility of the system allows the user to load components from one storage medium and place them into another.
Tape and Reel Output
The optional tape and reel output system allows you to program, mark, and tape devices in a single operation, providing flexibility and efficiency while minimizing the handling of devices. Interchangeable taping heads allow for quick trouble-free set ups. The system may be used for taping devices with or without programming.
Unsurpassed Support and Training
BP Microsystems supports the BP-4100 automated programming system with a direct factory hotline and a worldwide network of field service sites. There are seventeen field service sites in the United States as well as numerous locations throughout Europe and Asia that can service the BP-4100. Training is available to teach customers how to operate, configure, or service the unit.
Vibratory Feeders (Optional)
Type: unidirectional vibratory feeders
Functions: feeders can either load or unload parts
Adjustment: amplitude and frequency for fine-tuning feeder operation
VIBRATORY FEEDERS TOPS (Optional)
Size: platforms are 3.5 in. (89mm) wide
Functions: a platform either loads or unloads parts
Capacity: a platform can support 8 lanes of SOIC parts, 5 lanes of PLCC parts up to PLCC-32, 5 lanes of SOLIC parts, 5 lanes of SOJ-20 parts, 3 lanes of PLCC parts up to PLCC-52, 2 lanes of PLCC parts up to PLCC-100
TAPE INPUT FEEDERS (Optional)>
Type: programmable electronic feeder
Capacity: 13 in. reels of up to 44mm wide tape
TAPE AND REEL OUTPUT (Optional)
Type: programmable electronic tape loader
Functions: heat sealing or pressure sensitive sealing units available
Input Capacity: 22 in. reels
Output Capacity: 13 in. reels of up to 56mm wide tape
BP Microsystems, 1000 N. Post Oak Rd, #225, Houston, TX 77055. Tel: 713-688-4600; Fax: 713-688-0920.