What Are the Most Common Pick and Place Machine Problems — and How to Solve Them?

Introduction

In the modern electronics manufacturing industry, SMT machines are one of the core pieces of equipment in SMT production lines, performing the critical task of mounting components onto PCBs at high speed and with high precision. However, during daily operation, SMT machines encounter various faults or performance issues that affect production efficiency and product quality.

This article will systematically outline the major categories of issues commonly encountered during the use of SMT placement machines and provide practical solutions to help you quickly troubleshoot issues, optimize equipment performance, and enhance production line stability and yield rates. Whether you are an SMT engineer, equipment maintenance personnel, or a business manager, this “Ultimate Guide to Resolving Common Issues with SMT Placement Machines” will serve as a valuable reference resource.

 

I. Basic Workflow of SMT Placement Machines

  • Feeding System: Components are supplied to the placement head in sequence via feeders.
  • Image Recognition System: Cameras are used to locate and detect the angle of components.
  • Placement Head Movement: After the nozzle picks up the component, it is precisely placed at the program-set position.
  • X-Y Platform Movement: The PCB carrier precisely moves to the specified coordinates.
  • Placement Completion and Reflow Soldering: After placement is complete, the components enter the reflow oven for curing and soldering.

The efficient operation of a pick and place machine relies on the coordinated cooperation of multiple systems, including mechanical, optical, pneumatic, and electrical systems. Any issue in any of these systems can lead to placement failure or equipment downtime.

 

II. Common Issues with NeoDen pick and place machines and their solutions

Problems

Presumed causes

Countermeasure

Raspberry Pi can't enter system
  1. SD card loose connection
  2. SD card damaged
  1. Re-insert the SD card
  2. Use a backup SD card

Feeders feed abnormal
  1. The solenoid is damaged.
  2. Air leakage from air tubing
  3. Ventilation pin is damaged
  4. The feeding rate is not adjusted correctly
  5. Feeder is damaged
  6. Incorrectly installed the tape reel feeder and jammed reels resulting in abnormal feeds
  7. Feeders are not peeled
  1. If the abnormal situation of the feeders exchange when exchange the feeder solenoids, then replacement of the feeder solenoid valve
  2. Replace air tubing or re-insert
  3. Change another ventilation pin
  4. Adjust the feeding rate
  5. Change another good one
  6. Adjustment of the reel
  7. Reinstall the feeder

The components flip or stand when picking up
  1. Unreasonable setting of pick-up height
  2. Pick-up position deviation

1.Adjust the pick-up height

2.Re-calibrate pick-up position

Abnormal rotation of nozzle

20 Motor Abnormal

If exchanging the 20 motor, the phenomenon exchanges and replacing the 20 motor, then the 20 motor need to be replaced. Please contact our after-sales service.

Fiducial cameras (left and right) cannot take pictures
  1. PCB inside camera is damaged
  2. Poor contact with the camera's network cable

Need to provide relevant video for replacement.

Please contact our after-sales service.

Fly/IC Cameras cannot take pictures
  1. The cable is broken.
  2. Network not available
  3. The camera is broken.

Need to provide relevant video for replacement.

Please contact our after-sales service.

Insecure placement head, XY movement failure

1.Unsafe placement head condition
  1. Please contact our after-sales service and provide photos of the prompt box and current head status, etc.  
  2. Click Head Initialization and then XY Initialization on the Manual Test screen.

Indicates that the machine has not returned to zero or that the drive has been de-energized.
  1. Safety protection
  2. Driver error
  3. Emergency stops have been pushed
  1. Enter the manual test, XY interface, and check if there is a red background in the front and rear feeder protection and placement head safety status feedback.
  2. If the head can be pushed, check the error reported on the servo drive, re-plug the plugs on the drive, and then open it again when the emergency stop is pressed, the common errors reported are 21.0 (servo motor coding line related) and 16.0 (return to zero sensor related)
  3. Press and release the emergency stop, then click on the coordinates initialize.
  4. Please contact our after-sales service.

The nozzle can't suck and blow.

1.The solenoid is damaged.

Interchangeable the solenoids, if phenomenon interchangeable, then please contact the company after-sales replacement solenoid valve

Throwing material when mounting
  1. Failure to pick up material
  2. Wrong pickup position causes not picking up the material.
  3. Incorrect pickup height results in no pickup or pickup of vertical material.
  1. Adjusting the parameter information of feeder setting

Precision issues
  1. Recognition error, check for interference spots on the nozzle or head
  2. Fiducial camera position change
  3. Inaccurate nozzle center position
  1. Replace the nozzle and blacken the interference point
  2. Reference camera calibration
  3. Fine calibration of nozzles

Fiducial point not found, prompts Fiducial point auto-recognition failure
  1. Incorrect origin point setting
  2. Can't find the Fiducial spot. There's interference.
  1. Resetting the position of origin point 
  2. Setting Fiducial point parameters in the file edit PCB interface

Header movement does not correspond to actual coordinates
  1. XY magnetic grid data abnormality
  2. Abnormal magnetic grid ruler or magnetic grid reading head
  1. First XY initialization, initialization is normal, click on the factory settings, click on the XY grid initialization, after doing so, click on the configuration to save
  2. Manually test the XY interface, press the emergency stop button, and manually push the head to observe whether the XY axis coordinates are changing normally. If the data is abnormal, the corresponding magnetic grid reading head or magnetic grid ruler needs to be replaced

 

 

III. Daily Maintenance and Care Recommendations for Pick and Place Machines

To extend the service life of SMT machines and maintain their optimal performance, it is crucial to establish a scientific and reasonable maintenance plan. The following are the daily maintenance items we recommend:

Maintenance Cycle

Maintenance Content

Daily

Clean nozzles, check vacuum pressure, lubricate guide rails, and remove debris from workstations

Weekly

Check feeder status, clean cameras, and test pneumatic systems

Monthly

Perform comprehensive calibration (including Head, Board Mark, etc.), inspect servo motors

Quarterly

Replace filters, lubricate lead screws, inspect power supply and control box

Annually

Conduct in-depth maintenance, update software versions, and have professional engineers conduct inspections

Documentation Recommendations: Establish a complete maintenance record, documenting the time, content, and replaced parts of each maintenance session for traceability and analysis.

 

IV. How to prevent SMT machine failures?

In addition to promptly addressing existing issues, it is crucial to implement the following measures for proactive failure prevention:

1. Standardized operational procedures

Establish uniform operating guidelines and inspection standards to ensure all operators use the equipment consistently.

2. Employee training programs

Conduct regular training sessions on equipment operation, maintenance, and fault resolution to enhance overall technical proficiency.

3. Data-Driven Decision-Making

Utilize MES systems to collect equipment operation data, analyze trends to predict potential faults, and intervene proactively.

4. Implementing Intelligent Monitoring Systems

Deploy industrial internet of things (IIoT) devices to achieve equipment status visualization, automatic fault diagnosis, and remote assistance.

 

Conclusion

As the main equipment of the SMT production line, the operational status of SMT machines directly impacts the stability of the entire production process and product quality levels. In the face of continuously upgrading electronic component requirements and increasingly complex process demands, we must master strategies for addressing common issues with SMT machines.

In the future, with the development of smart manufacturing, SMT machines will also evolve toward smarter, more efficient, and more adaptive directions.

If you are seeking high-performance machines or related technical support services, please contact our professional team for customized SMT solutions.

Company Profile

Zhejiang NeoDen Technology Co., Ltd. has been manufacturing and exporting various small pick and place machines since 2010. Taking advantage of our own rich experienced R&D, well trained production, NeoDen wins great reputation from the world wide customers. 

In our global Ecosystem, we collaborate with our best partners to deliver a more closing sales service, high professional and efficient technical support.

We believe that great people and partners make NeoDen a great company and that our commitment to Innovation, Diversity and Sustainability ensures that SMT automation is accessible to every hobbyist everywhere.

2025-07-09 10:50
ꄘPageviews：0
ꂃPrevious： null
ꁹNext： null

WELCOME TO NEODEN

·

넳 넲