OL-FB800 Fully Automatic FOG Bonder

OL-FB800 Fully Automatic FOG Bonder

The OL-FB800 is a cutting-edge fully automatic FOG (Film on Glass) bonder designed to meet the precise requirements of modern electronics manufacturing. This advanced machine specializes in automatic ACF (Anisotropic Conductive Film) application, alignment, and thermal bonding for LCD products ranging from 1″ to 10.1″ in size, with single-sided, single FPC (Flexible Printed Circuit) components. Its innovative design and high-precision features make it an essential tool for manufacturers seeking efficiency, accuracy, and reliability in their production lines.

Equipment Information

• Equipment Name: Fully Automatic FOG Bonder
• Model: OL-FB800
• Application: Suitable for LCD products with sizes from 1″ to 10.1″, designed for automatic ACF application, alignment, and thermal bonding of single-sided, single FPC.
• Compatibility: Can be integrated with other machines in a production line for seamless operation.

Working Principle

The OL-FB800 operates through a series of coordinated mechanical and automated processes. The workflow begins with the loading of the product onto the conveyor belt or platform, either manually or via an automated upstream machine. Mechanical arm 0# picks up the LCD + COF, corrects its position using the CCD (Charge-Coupled Device) system, and places it on the ACF platform. The ACF platform advances, and the bonding head descends to apply the ACF. After the ACF application, the platform retracts for position detection to ensure proper ACF adhesion.

Next, mechanical arm 1# transfers the LCD + COF to the pre-bonding stage while the FPC is simultaneously loaded and pre-aligned on the carrier stage. The bonding head then picks up the FPC and performs the pre-bonding process. Mechanical arm 2# moves the product to one of the four main bonding platforms for final bonding. Finally, mechanical arm 3# transfers the bonded product to the downstream conveyor or production line.

Product Specifications

LCD Specifications

• Size Range: Minimum 20mm x 20mm, Maximum 230mm x 165mm, Thickness 0.15mm to 1.1mm.
• Alignment Marks: Pitch ≥ 5mm between any two points on the glass, Mark size 2mm to 100mm.

FPC Specifications

• Size Range: Minimum 20mm x 10mm, Maximum 150mm x 122mm, Thickness 0.1mm to 0.5mm.
• Terminal Pitch: ≥ 50µm.
• Alignment Marks: Pitch 5mm to 70mm.
• Note: FPC width is related to the bonding head length and can be customized according to customer requirements.

ACF Specifications

• Types: Roll-based, 2-layer or 3-layer.
• Application Length: 5mm to 80mm.
• Application Width: Available in 0.8mm, 1.0mm, 1.5mm, 2.0mm, and 2.5mm widths, adjustable according to requirements.
• 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: 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 130mm.

Machine Performance

Production Accuracy

• ACF Application Accuracy: ±0.2mm in X-axis, ±0.15mm in Y-axis.
• FPC Pre-bonding Accuracy: ±7µm in X-axis, ±7µm in Y-axis.
• FPC Main Bonding Accuracy: ±20µm in X-axis, ±20µm in Y-axis.

Production Cycle

• Cycle Time: ≤ 4.5 seconds per piece.
• ACF Application Time: ≤ 0.5 seconds.
• Pre-bonding Time: ≤ 0.5 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.

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 with 0.001Mpa increments.

General Machine Specifications

Dimensions and Weight

• Machine Length: Approximately 2800mm (including 1500mm conveyor extensions on both sides).
• Machine Width: Approximately 1160mm.
• Machine Height: Approximately 1800mm (excluding FFU and tri-color light).
• Working Height: 1000mm.
• Machine Weight: Approximately 2000kg.
• Color: White, with customization options available.

Environmental and Power Requirements

• Operating Environment: Class 1000 or lower cleanroom.
• Power Supply: Single-phase 220VAC, with a 2-meter power cord for connection to factory power.
• Power Consumption: Maximum 8KW.

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.

Equipment Unit Specifications

Feeding and Discharging

• Feeding: Conveyor belt loading.
• 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 drive.
  • 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: Servo motor drive.
  • Z-axis: Sliding table cylinder with manually adjustable position.
• Mechanical Arm 3# (from Pre-bonding Stage to Main Bonding Stage):
  • Vacuum nozzles with adjustable numbers and configurations based on product size.
  • Digital vacuum gauge for real-time monitoring.
  • X-axis: Linear motor drive.
  • θ-axis: Stepper motor.
  • 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 drive.
  • Z-axis: Cylinder with manually adjustable position.
  • 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 (customizable).
  • Dimensions: W 6mm × L 60mm (customizable).
  • Surface Flatness: ≤ 5µm.
• ACF Stage:
  • Y-axis Movement: Servo motor + ball screw + rail.
  • Vacuum: 1mm hole diameter, 2mm vacuum slot width.
  • Material: Aluminum with anodized hard oxidation treatment.
  • Flatness: ±0.02mm.
• ACF Backup:
  • Material: Quartz.
  • Dimensions: L100mm × W6mm × H18mm.
  • Surface Flatness: ≤ 5µm.
• ACF Inspection: CCD inspection system.
• ACF Supply:
  • Operation Method: Torque motor.
  • Reel Tensioning: Belt tensioning structure.
  • Protective Film Recovery: Vacuum吸取 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 HRC58.
  • 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.
  • θ-axis Movement: DD motor.
  • Vacuum: 1mm hole diameter, 2mm vacuum slot width.
  • Material: Aluminum with anodized hard oxidation treatment.
  • Flatness: ±0.02mm.
• Pre-bonding Backup:
  • Material: SUS440C.
  • Dimensions: L100mm × W10mm × H12mm (customizable).
  • Surface Flatness: ≤ ±5µm.
• FPC Supply Unit:
  • Loading Method: Manual FPC loading or automatic FPC loader (purchased separately).

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.
  • Vacuum: 1mm hole diameter, 2mm vacuum slot width.
  • Material: Aluminum with anodized hard oxidation treatment.
  • Flatness: ±0.02mm.
• Main Bonding Backup:
  • Material: Quartz strip.
  • Dimensions: L100mm × W6mm × H18mm.
  • Surface Flatness: ≤ ±5µm.
  • Vacuum position dimensions customized to product FPC size.
• 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: Bosch 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.
• 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: Bosch 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.

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.

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.

Main Component Brands

• Servo Motors: Fuji (Japan).
• Angle Motors: Huichuan (Japan).
• Linear Motors: Yakobes/Linea/Tongxin (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 (China).
• Drag Chains: Igus (Germany).
• Emergency Stop and Switch Buttons: Schneider (China).
• FFU (Stainless Steel): Yunfeng (China).

In summary, the OL-FB800 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.