FB-600 Fully Automatic FOG Bonder

FB-600 Fully Automatic FOG Bonder

1. Introduction

The FB-600 Fully Automatic FOG (Film on Glass) Bonder is a cutting-edge device designed for the manufacturing of LCD products. This machine is specifically tailored for 1″-6.5″ vertical screen LCD products, handling single-edge, single-segment ACF (Anisotropic Conductive Film) attachment, pre-bonding, and main bonding processes. It can be integrated with other production line equipment for seamless manufacturing operations.

2. Equipment Information

• Equipment Name: Fully Automatic FOG Bonder
• Model: FB-600
• Application: Suitable for LCD products with sizes from 1″ to 6.5″, designed for automatic ACF application, pre-bonding, and main bonding of single-sided, single FPC (Flexible Printed Circuit).
• Compatibility: Can be integrated with other machines in a production line for seamless operation.

3. Working Principle

The FB-600 operates through a series of coordinated mechanical and automated processes:

• Feeding: Components are fed via conveyor belts or platforms, either manually or automatically from connected machines.
• Positioning: A robotic arm (Mechanical Hand 1) picks up the LCD, which is then corrected in position using CCD (Charge-Coupled Device) technology before being placed on the ACF platform.
• ACF Application: The ACF platform advances, the pressing head descends to apply the ACF, and then retreats for position verification and ACF attachment quality inspection.
• Pre-bonding: Another robotic arm (Mechanical Hand 2) places the LCD on the pre-bonding platform while the FPC is simultaneously positioned. The pressing head then performs the pre-bonding.
• Main Bonding: Mechanical Hand 3 transfers the product to four main bonding platforms for final bonding, after which Mechanical Hand 4 moves the finished product to the downstream platform or conveyor belt.

4. Product Specifications

LCD Specifications

• Size Range: Minimum 20mm x 20mm, Maximum 150mm x 90mm, Thickness 0.15mm to 1.1mm.
• Alignment Marks: Pitch ≥ 5mm between any two points on the glass, Mark size 200µm to 1000µm.

FPC Specifications

• Size Range: Minimum 20mm x 10mm, Maximum 150mm x 80mm, Thickness 0.1mm to 0.5mm.
• Terminal Pitch: ≥ 50µm.
• Alignment Marks: Pitch 5mm to 70mm.

ACF Specifications

• Types: Roll-based, 2-layer or 3-layer.
• Application Length: 5mm to 80mm (adjustable based on bonding head length and customer requirements).
• Application Width: 0.8mm to 2.5mm.
• Reel Specifications: Inner diameter options of 18mm and 25mm, Maximum reel diameter 200mm.

Buffer Material Specifications

• ACF Section: Single-piece buffer material, manually clamped.
• Main Bonding Section: Roll-based, automatic front-to-back rotation.
• Reel Dimensions: Outer diameter ≤ 100mm, Inner hole diameter 32mm.
• Width: Adjustable from 5mm to 20mm.
• Feed Frequency: Adjustable from 1 to 999 cycles for automatic tape rotation.
• Feed Length: Single-step length adjustable from 1mm to 99mm.

5. Machine Performance

Production Accuracy

• ACF Application Accuracy: ±0.2mm in X-axis, ±0.15mm in Y-axis.
• FPC Pre-bonding Accuracy: ±8µm in X-axis, ±8µm in Y-axis.
• FPC Main Bonding Accuracy: ±15µm in X-axis, ±15µm in Y-axis.

Production Cycle

• Cycle Time: 3.5 seconds per piece for screens up to 4 inches, and 4.2 seconds per piece for screens between 4 and 6.5 inches.
• ACF Application Time: ≤ 0.5 seconds.
• Pre-bonding Time: ≤ 0.2 seconds.
• Main Bonding Time: ≤ 12 seconds.

Product Type

• Supported Type: Single-sided, single FPC.

Model Changeover

• New Model Setup: ≤ 120 minutes.
• Existing Model Recall: ≤ 60 minutes, depending on the operator’s proficiency.

Equipment Yield

• Yield: ≥99.5% (excluding material issues).

6. Process Parameter Specifications

Temperature Control

• Setting Range:
  • ACF-bonding: Room Temperature (RT) to 120°C.
  • Pre-bonding: RT to 80°C.
  • Main-bonding: RT to 400°C.
• Heating Method: Constant heat.
• Control Method: Touchscreen setting with 1°C increments, PID control.
• Temperature Uniformity: ±5°C.
• Thermocouple Type: K type.

Time Setting

• Setting Range:
  • ACF-bonding: 0.1 to 9.9 seconds.
  • Pre-bonding: 0.1 to 9.9 seconds.
  • Main-bonding: 0.1 to 99.9 seconds.
• Setting Method: Configured via touchscreen interface with 0.1-second increments.

Pressure Control

• Adjustment Range:
  • ACF-bonding: 10 to 150N.
  • Pre-bonding: 10 to 150N.
  • Main-bonding: 20 to 400N.
• Control Method: Precision pressure regulator.
• Setting Unit: 0.001MPa.

7. General Machine Specifications

Dimensions and Weight

• Machine Length: Approximately 2100mm.
• Machine Width: Approximately 1060mm.
• Machine Height: Approximately 1800mm (excluding FFU and tri-color light).
• Working Height: 1000mm.
• Machine Weight: Approximately 1500kg.
• Color: White, with customization options available.

Environmental and Power Requirements

• Operating Environment: Class 1000 or lower cleanroom.
• Power Supply: Single-phase AC 220V±10%, 50 Hz, with a 2-meter power cord for connection to factory power.
• Power Consumption: Maximum 5KW.

Air and Vacuum Supply

• Air Supply: Clean compressed air with a minimum pressure of 0.5-0.7MPa, consumption approximately 150L/min.
• Vacuum Supply: Built-in vacuum pump (200L/min) and storage tank. Optional customer-provided vacuum source with a 12mm diameter hose connection. Vacuum level: ≥ -70Kpa (≥ 525mm Hg), flow approximately 150L/min.

Safety Features

• Emergency Stop: Equipped with anti-misoperation covers.
• Interlocked Design: Ensures machine safety during operation.
• Audible and Visual Alarms: Alerts for errors or operator attention via the touchscreen.
• Safety Labels: Warnings for electrical shock, mechanical injury, etc., in hazard areas.

8. Equipment Unit Specifications

Feeding and Discharging

• Feeding: Conveyor belt loading or upstream machine integration.
• Discharging: Conveyor belt unloading, direct handover to downstream machines.

Robotic Arms

• Mechanical Arm 1# (from Conveyor to ACF Platform):
  • Vacuum nozzles with adjustable numbers and configurations based on product size.
  • Digital vacuum gauge for real-time monitoring.
  • X-axis: Servo motor + rail.
  • θ-axis: Stepper motor.
  • Z-axis: Sliding table cylinder with manually adjustable position.
• Mechanical Arm 2# (from ACF Stage to Pre-bonding Stage):
  • Vacuum nozzles with adjustable numbers and configurations based on product size.
  • Digital vacuum gauge for real-time monitoring.
  • X-axis: Linear motor + rail.
  • Z-axis: Sliding table cylinder with manually adjustable position.
• Mechanical Arm 3# (from Pre-bonding Stage to Main Bonding Platform):
  • Vacuum nozzles with adjustable numbers and configurations based on product size.
  • Digital vacuum gauge for real-time monitoring.
  • X-axis: Linear motor + rail.
  • θ-axis: Stepper motor for angle adjustment.
  • Z-axis: Sliding table cylinder with manually adjustable position.
• Mechanical Arm 4# (from Main Bonding Stage to Discharge Conveyor):
  • Vacuum nozzles with adjustable numbers and configurations based on product size.
  • Digital vacuum gauge for real-time monitoring.
  • X-axis: Linear motor + rail.
  • Z-axis: Sliding table cylinder with manually adjustable position.

ACF Unit

• ACF Cutter:
  • Cutting Method: Automatic semi-cutting.
  • Depth Adjustment: Micrometer fine adjustment.
  • Blade Movement: Cylinder-driven up and down, with adjustable X-axis position.
• ACF Head:
  • Number of Bonding Heads: 1.
  • Drive Method: Cylinder + rail.
  • Pressure Control: Cylinder control with precision pressure regulator.
  • Material: SUS440C.
  • Dimensions: W 6mm × L 60mm.
  • Surface Flatness: ≤ 5µm.
• ACF Stage:
  • Y-axis Movement: Servo motor + ball screw + rail.
  • Z-axis Movement: Manual sliding table.
  • Vacuum: 1mm hole diameter, 2mm vacuum slot width.
  • Material: Aluminum with anodized hard oxidation treatment.
  • Flatness: ±0.02mm.
• ACF Backup:
  • Material: Quartz.
  • Dimensions: L100mm × W10mm × H18mm.
  • Surface Flatness: ≤ 5µm.
• ACF Inspection: CCD inspection system.
• ACF Supply:
  • Operation Method: Torque motor.
  • Reel Tensioning: Belt tensioning structure.
  • Protective Film Recovery: Vacuum move to waste bin.
  • Separation Rod Movement: Cylinder-driven rod.

FPC Pre-bonding Unit

• Pre-bonding Head:
  • Number of Bonding Heads: 1.
  • Z-axis Drive: Servo motor + ball screw + rail.
  • Y-axis Transmission: Servo motor + ball screw + rail.
  • Pressure Control: Cylinder control with precision pressure regulator.
  • Material: SUS 440C.
  • Dimensions: W 1.2mm × L 80mm (customizable).
  • Surface Flatness: ≤ ±5µm.
  • Vacuum: Segmentable vacuum selection with vacuum detection.
• Pre-bonding Stage:
  • X-axis Movement: Servo motor + ball screw + rail.
  • Y-axis Movement: Servo motor + ball screw + rail.
  • Z-axis Movement: Manual sliding table.
  • θ-axis: DD motor.
  • Vacuum: 1mm hole diameter, 2mm vacuum slot width.
  • Material: Aluminum with anodized hard oxidation treatment.
  • Flatness: ±0.02mm.
• Pre-bonding Backup:
  • Material: Quartz strip.
  • Surface Flatness: ≤ ±5µm.
• FPC Supply: Manual or automatic feeding (separately purchased).

FPC Main Bonding Unit

• Main Bonding Head:
  • Number of Bonding Heads: 4.
  • Drive Method: Cylinder + rail.
  • Pressure Control: Cylinder control with precision pressure regulator.
  • Material: SUS440C.
  • Dimensions: W 1.0mm × L 60mm (customizable).
  • Surface Flatness: ≤ ±4µm.
• Main Bonding Stage:
  • Y-axis Movement: Servo motor + ball screw + rail.
  • Z-axis Movement: Closed-loop stepper + cam structure.
  • Vacuum: 1mm hole diameter, 2mm vacuum slot width.
  • Material: Aluminum with anodized hard oxidation treatment.
  • Flatness: ±0.02mm.
• Main Bonding Backup:
  • Material: Quartz.
  • Dimensions: L100mm × W6mm × H18mm.
  • Surface Flatness: ≤ ±5µm.
• Buffer Material Supply:
  • Rotation Method: Stepper motor drive.
  • Rotation Direction: Automatic front-to-back rotation.
  • Width Adjustment: Manual width adjustment with limit wheel.
  • Sensor detection for tape end monitoring.

Image Processing Unit

• LCD Correction:
  • System: Boss image processing system.
  • CCD: 1.
  • Coaxial Light Barrel: 1.
  • Magnification: 1x.
  • Field of View: 4.8mm × 3.6mm.
  • Light Source: Coaxial light LED.
  • Z-axis Adjustable Travel: 10mm.
• ACF Inspection:
  • System: Bosch detection system.
  • CCD: 1.
  • Coaxial Light Barrel: 1.
  • Magnification: 0.5x.
  • Field of View: 9.6mm × 7.2mm.
  • Light Source: Coaxial light LED.
• Pre-bonding Alignment:
  • System: Boss image processing system.
  • CCD Cameras: 2.
  • Coaxial Light Barrels: 2.
  • Magnification: 2x.
  • Field of View: 2.4mm × 1.8mm.
  • Light Source: Coaxial light LED.
  • Alignment Method: Mark coincidence.
• FPC Feeding:
  • System: Boss image processing system.
  • CCD Camera: 1.
  • Coaxial Light Barrel: 1.
  • Magnification: 1x.
  • Field of View: 4.8mm × 3.6mm.
  • Light Source: Coaxial light LED.
  • Z-axis Adjustable Travel: 10mm.

Control Unit

• Control Method: PLC control.
• Touchscreen:
  • Interface: Chinese, touch-enabled.
  • Modes: Manual and automatic.
  • Functions: Parameter display, data storage for 100 varieties.
• Manual Control Buttons:
  • Emergency Stop Buttons: 3.
  • Main Power Switch: 1.
  • Lighting Power Switch: 1.
• Access Control: Machine pauses when doors are opened during operation.
• Operation Indicator Lights: Tri-color lights.

9. Documentation and After-sales Service

• Documentation: Machine operation manual included.
• Training: Covers installation, operation, calibration, maintenance, troubleshooting, and safety precautions.
• After-sales Service: One year of free service for non-human-induced faults, with lifelong technical support.

10. Main Component Brands

• Servo Motors: Fuji/Rite/Hechuan/Huichuan (Japan/China).
• Angle Motors: Huichuan/Hengchuan/Yakobes (Japan/China/China).
• Linear Motors: Yakobes/Linea/Dongxin (China/China/China).
• Ball Screws: THK/Hiwin/TBI (Japan/China/China).
• Guideways: THK/Hiwin/TBI (Japan/China/China).
• Pneumatic Components: SMC/Airtac (Japan/China).
• PLC: Keyence (Japan).
• Touchscreen: Proface (Japan).
• Sensors: Panasonic/Huan (Japan/China).
• Power Supply: Mean Well (China).
• Circuit Breakers and Contactors: Schneider/Shihlin/Chint (China).
• Drag Chains: Igus (Germany).

In summary, the FB-600 Fully Automatic FOG Bonder represents a significant advancement in the field of LCD manufacturing equipment. Its precise engineering, user-friendly design, and comprehensive support make it an ideal choice for manufacturers seeking to enhance productivity and product quality in the competitive electronics market.