Assembly assistance system for THT manufacturing

Multi Line Assist helps with PCB assembly and automatically checks your THT components for visual characteristics inreal time. THT assembly mistakes and defects are detected immediately and displayed in the field of vision of the assembly personnel. The integrated THT AOI, automated optical inspection of THT components, provides quality assurance for your THT assembly and documents the inspection results as proof of quality.

Printed circuit board assembly station with woman

While automation has been the standard in SMT lines for years, the THT process is still a manual process in many companies. The reasons for this include assembly variants, small batch sizes and complex assemblies, which are difficult to automate. At the same time, the increasing shortage of skilled workers and rising demands for traceability and quality are exacerbating the situation. Production managers are therefore faced with the task of increasing the efficiency of manual processes without compromising on quality.

Multi Line Assist provides a solution to this problem. The system combines worker guidance and optical inspection in a compact unit, thus creating the basis for higher productivity and process reliability in THT manufacturing.

With Multi Line Assist, GÖPEL electronic offers a assembly assistance system with automated optical inspection for integration into THT assembly stations. It is suited for use at manual assembly tables or in automated production lines for THT.

The system concept is based on a 47-megapixel image capture unit combined with a flexible LED lighting system, enabling images to be captured with outstanding image quality and detail resolution. Real-time quality monitoring directly at the assembly station is now a reality.

By integrating a powerful laser projector, the system offers visual and contextual placement guidance during assembly by projecting relevant information into the worker's field of vision.

Placement errors with images of components on printed circuit boards — Errors such as ‘component not present’, ‘component position incorrect’, ‘incorrect polarity’ or “colour”, as well as ‘incorrect labelling’ are detected reproducibly.

Detailed projection of the placement position — Worker guidance during manual assembly

Projection of the placement position — Further instructions are projected next to the assembly. At the same time, the system displays a live image of the assembly on the PC monitor and also marks the position of the component to be assembled.

THT AOI for live inspection or end-of-line control

Presence of components
Correct positioning of components and connectors
Polarity & colour
Labelling (OCR)
Position and defect detection
Completeness check

Reduced stress for your employees

Easier work when changing products
Shorter assembly times
Process reliability with THT AOI
Find errors in real time

statistical analysis

documented result data

Transfer to MES systems

Step-by-step worker guidance
Assemble complex products without prior knowledge
Large number of variants becomes manageable
More productive and flexible deployment of employees

Overcome language barriers among employees
Find errors in real time
Avoid rework and need for 8D reports
Ensure reproducible quality

Multiple lighting options – no flashing! MagicLight features top and side lighting with different light coding. Depending on the inspection task, side lighting, top lighting or a combination of both can be used to create the ideal contrast for inspection features:

Embossed characters
Polarity and registration marks
Small components located in gaps between tall components
and much more

Switching between lighting modes does not cause any flashing. The workplace lighting always remains the same for the worker.

Assembly assistance system for THT manufacturing

consistent test results

Assembly assistance system for THT manufacturing

consistent

Illumination at the workplace

Assembly assistance system for THT manufacturing

dimmed assembly

Assembly assistance system for THT manufacturing

Ideal working conditions in production!

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Grip the handle to see the benefits of MagicLight on left side relay

Component with pole mark — Standard lighting: Reflections prevent inspection of the component's pole marks

Component with visible pole mark — Illumination with MagicLight: Pole mark on component can be checked without reflection

Capacitors with bright illumination from the side — Standard illumination: Reflections prevent inspection of the pole marks on the capacitor

Capacitors with dark illumination from above — Illumination with MagicLight: Pole mark on capacitor can be checked without reflection

Section of a board with DMC — Standard illumination: Data Matrix code not visible

Section of a board with visible DMC — Illumination with MagicLight: Data Matrix code verifiable

Complete solution of Multi Line Assist with assembly desk — Fully pre-assembled and calibrated Multi Line Assist with height-adjustable assembly table

Complete solution Multi Line Assist with tabletop frame — Fully pre-assembled and calibrated Multi Line Assist with a tabletop frame on an existing assembly table.

Integration solution Multi Line Assist — Existing assembly tables can be expanded with the Multi Line Assist. The basic module is supplied with add-on options.

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PC
Windows 11	i7, 32GB RAM, 512GB SSD integrated in standard module
Camera
	47 Megapixel, Colour
Illumination
Position	LED top and side lighting
Technology	MagicLight
Light colour	4.000 Kelvin (neutral white)
Illuminance on work surface	ca. 2.500 Lux
Field of view and recognition accuracy
Focal length	Field of view	Resolution	Recognition accuracy
35 mm	660 mm x 450 mm	81 μm/Pixel	0,7 mm
50 mm	475 mm x 320 mm	58 μm/Pixel	0,6 mm
75 mm	300 mm x 200 mm	37 μm/Pixel	0,5 mm
Recognition accuracy refers to empirical values from practical experience (e.g. inspection of small features such as lettering, pole marks, data matrix codes). Recognition accuracy improves under optimal conditions.
Projector		Monitor
Full HD DLP laser projection unit		24‘‘ or 32‘‘
Integration
Self-integration	Integration at existing table
Table solutions	Complete solution with height-adjustable table
Tabletop solution	Tabletop frame for existing table
Working distance from the test object	1310 mm

Is the software for test program generation identical to that used in other GÖPEL inspection systems?
Yes. All GÖPEL electronic AOI (THT, SMD), SPI and CCI systems use identical software for test program generation. CAD data import, verification station software, statistics software and MES plug-ins are also identical.
Can CAD data be used for test program generation?
Yes. Gerber + placement data, ODB++ and OPM formats are supported.
Can a component library be used?
Yes. Inspections are generated based on item numbers. If the same item number appears on other PCBA, it can be reused.
How are multiple uses handled?
Any number of multiple uses can be conveniently generated thanks to a use editor.
What are the disadvantages of entocentricity?
The image capturing is performed using a central perspective. Depending on the distance from the camera's optical axis, this results in areas of varying sizes that may be obscured by tall components.
What influence does extraneous light have on the inspection?
MagicLight technology reduces interference from extraneous light by up to 50%. However, strong extraneous light can still affect the reproducibility of inspection results. The calibration of multiple systems with each other can be impaired by locally varying extraneous light influences. Consistent hall lighting and the avoidance of direct sunlight are recommended. If necessary, measures to prevent extraneous light influences (e.g. enclosures) may be required.
How can the influence of extraneous light be reduced?
Keep the ambient conditions as constant as possible, e.g. leave the ceiling light on at all times. Avoid placing the Multi Line Assist directly next to large windows. If necessary, use Plexiglas or Makrolon panels to block out extraneous light from the sides and rear.
Can colour rings be detected on resistors?
Inspection of colour rings on resistors with Multi Line Assist is not recommended. However, the software does provide a colour ring inspection function. Practical experience has shown that the colour values of resistors vary too greatly between batches.
How long does training for Multi Line Assist take?
For new customers with no experience of our PILOT software, we recommend the two-day basic seminar. For existing customers with prior knowledge, we recommend the one-day advanced seminar.
Can the system be rented?
Yes. Please speak to our sales staff about this.

Inspection Solutions
Sales AOI · X ray · SPI
+49-3641-6896-702 Phone
inspection.sales@goepel.com