This guide walks you through setting up and completing your first placement job using the Getting Started Kit, included with the LumenPnP v3. Before going through this guide, make sure you’ve completed the Calibration guide to get your machine up and running.
It might be useful to refer to this guide again after you finish it the first time, since many of these steps will need to be performed for every new board and job you start. Take your time going through this the first time around and keep in mind that this process gets faster with experience.
What you’ll need
The “Getting Started Kit” with:
A FTP PCB
0603 Resistors and LEDs in 8mm tape
Universal Mounting Kit prints and hardware
Printed tray feeders
It’s highly recommend to take some time to read through the OpenPnP Wiki. The OpenPnP documentation is much more in depth that this guide, as this guide is meant to get you up and running quickly with a known board and configuration. As you set up your own jobs, the OpenPnP documentation should be your primary reference.
1 - Installing the Feeders
Getting the feeders ready for automatic picking
The FTP PCB has two different types of components that need to be placed: resistors and LEDs. Each will need its own feeder so that the LumenPnP can pick each type of component. For this guide, you’ll use printed tray feeders.
Use two M3x10 button head screws and two M3 wingnuts to secure the printed tray feeder through onto the staging plate using holes: C11 and E11.
For each component, cut a strip of component tape off the reel about 125mm long.
Slide the Resistors into the left-most tray feeder, and the LEDs the adjacent tray.
In OpenPnP, connect to your LumenPnP and home it.
Download the FTP board design. It’s in the LumenPnP_PCBs.zip artifact on the latest release.
Go to File > Save Job As and save your FTP job.
Navigate to the Job tab in the top right.
Click that “Add” Icon button to add a new board and select New Board. Save the board in the same directory as the job.
Click on the newly-created board in the list to select it.
Go to File > Import Board > KiCAD .pos
In the Import popup:
Select the ftp-top.pos file you downloaded earlier as the Top File
Enable the Assign Parts checkbox.
Enable the Create Missing Parts checkbox.
Navigate to the Feeders tab in the top-right pane.
Click on the “Add Feeder” icon button.
Select ReferenceTrayFeeder and click Accept.
In the lower-right panel, you’ll be in the Configuration tab. Change the Part to be R_0603_1608Metric-R_Small.
Set the YOffset to -4. This is the space between components on the tape.
Set the YTray Count to 30. This is the number of components available on the feeder before it needs to be manually moved forward.
Set the Pick location to: X=45, Y=175, Z=20 as a starting point.
Click on the “Position Camera” icon button to move the top camera roughly over the left feeder.
Position the center of the top camera feed over the center of the top-most slot holding a resistor in the tray. You can drag the reticle in the camera feed, or use the jog buttons.
Zoom in on the camera feed and precisely position the center of the reticle over the center of the slot holding the resistor. The resistor itself may not be perfectly centered, that is fine.
Click the “Capture Camera Location” icon button to save the XY position of the start of the feeder.
Click Apply to save the feeder settings
Click the Enable checkbox in the feeder list.
Do the same procedure again for the LED feeder. You’ll assign the part LED_0603_1608Metric-LED_Small to the new feeder.
Installing the N045 Nozzle
Grease the nozzle holder before installing the N045 nozzle.
In the lower-right pane, switch to the Nozzle Tips tab.
For row N045, check both the Compatible and Loaded checkboxes. If you haven’t set up automatic nozzle changing, you will receive a popup saying that you’re required to manually load the nozzle on the toolhead.
Go to the Packages tab in the top-right pane.
Select LED_0603_1608Metric from the list.
In the lower-right pane, you’ll be in the Nozzle Tips tab. Click the Compatible on the N045 row.
Similarly, select R_0603_1608Metric from the Package list.
And click the Compatible checkbox on the N045 row.
Under the bottom-left Machine Controls pane, select Nozzle: N1 - N045 (Head:H1) to enable the left toolhead.
Fine-tuning feeder height
Navigate to the Feeders tab in the top-right pane.
Click on the “Position Nozzle” icon button to bring the nozzle over the feeder.
Use the Jog controls to lower the Z axis until the nozzle is touching the surface of the plastic tape cover.
Click on the “Capture Nozzle” icon button to save the new Z height of the feeder.
Jog the XY gantry away from the feeder.
Remove the tape cover from the feeder.
Click the “Pick” icon button to pick a component from the feeder. If the component is picked up properly, your Z-height is correct. If not, you should:
Lower the Z height of the feeder by 0.1mm
Press Apply to save the change
Home the machine
Try picking a component from the feeder again.
After you’ve successfully picked a component, in the machine Machine Controls pane, switch to the Special Tab.
Recycle the component you’ve successfully picked up
Copy the final Z height, select the other feeder, paste it for the other feeder, and press Apply
Test picking a component from the other feeder
2 - Setting up the FTP Board
Configuring and running the job
Securing the FTP Board
Note: it is not required that you mount your FTP board in the exact same location as described below. If you follow these steps you will have a slightly easier time setting the location of the board in OpenPnP, but if you need to set up a board somewhere else on the staging plates, that is totally fine, too.
Loosely screw in the universal mounting components in the following locations:
Static Board Mount positioned diagonally, screwed into B28
Dynamic Board Mount positioned vertically, screwed into D28
Dynamic Board Mount positioned horizontally, screwed into B30
Board Support placed in E31
Cut strips of double-sided tape and apply them to the top of the FTP board. Do not cover the fiducial markers, but make sure that each of the pads are covered by tape. The double-sided tape lets the components stick to the board so that you can do a “mock” run of a placement job without dealing with solder paste.
Place the FTP board in the holders and push them so that they’re snug against the sides of the board.
Tighten down the holders. You shouldn’t be able to move the board except by pressing on the tab holding it in place.
If you installed your holders in this location, the bottom left corner of your FTP board should be located around X328, Y94.
Finding the FTP Board Location
The next step is to set the physical location of the FTP board in OpenPNP. You’ll start by setting an approximate location and then fine tune the location using vision. Once the location is set, you can run the job to pick and place components. You’ll likely need to go through these steps a few times to tune the settings.
Navigate to the Job tab in the top-right pane.
In the bottom-right pane, you’ll see the Placements panel. Find the three elements with the IDs: FID1, FID2, and FID3. You can sort the list by Part to find them easily.
For each of the three elements, go to the Type column, select where it says Placement and switch it to Fiducial. This tells OpenPnP that these three elements on the board are not components to be picked and placed, but fiducials to be scanned.
Back in the top-right pane, double-click on the X and Y values of 0.000 and change them to X328 and Y94 respectively. This will be the rough location of the bottom-left corner of the FTP board.
Get the Z axis coordinate used when setting up the feeders, subtract 0.10 from it, and enter the result into the Z coordinate for the board. Setting the Z slightly lower than the actual board height allows the spring-loaded nozzle holder to lightly press components into the board to make them stick.
Click the “Position Camera on Board” icon button and check that the center of the camera feed is very roughly lined up with the bottom-left corner of the FTP board.
In the lower-right pane, select one of the fiducials to highlight it.
Click the “Position Camera” icon button to move the top camera over the fiducial location.
The alignment will probably not be perfect. To fix this, click on the digital readout in the bottom right corner to zero your current position.
Then, move the tool head with the Jog buttons until the fiducial is centered in the reticle.
Read the relative XY position you’ve moved your tool head, and add those values to the board’s X and Y positions. Do not change the position of the fiducial itself in the lower-right pane list as that will throw off the rest of the placements. Only adjust the location of the board itself, not the components relative to each other.
In the lower-right panel, select the other fiducial points in turn, and check their location with the “position camera” icon button.
If all the fiducials are close to the reticle center, you’re ready to run a fiducial scan to get the exact location of your FTP board. If only the first fiducial is centered, your board is probably rotated (ie the bottom edge is not parallel with the X axis). You can still move on to the fiducial scan, but you may need to manually readjust the board so that it is straighter.
Click on the “Fiducial Scan for Location” button. This will automatically move the camera to each of the fiducial locations and use the camera to try to identify the center of the fiducial. If it can find all three, it will automatically update the position and rotation of the board relative to the LumenPnP gantry.
If the fiducial check fails, here are some options for moving forward:
You might need to rotate the FTP board to be more square to the LumenPnP motion system.
If you’d prefer, you can also fall back on manually defining the board’s location using the “Multiple Placements” icon button.
To double-check the board’s location, you can repeat step 17. It is also useful to select some of the other placement locations and move the camera to them as well to check that the camera is centered between the metal pads. If the camera is not lining up correctly, see Troubleshooting for help getting things more tightly set up.
Make sure you’ve pulled back the protective tape cover on your feeders and that you have the correct nozzle installed.
It’s time to place your first component. Press the “Single job step” icon button repeatedly until OpenPnP moves to pick up an LED, check it’s orientation over the bottom camera, and then place it on the board.
If the component was not identified by the bottom camera correctly, you will likely need to adjust its vision pipeline.
If the component did not stick to the FTP board, you should lower the FTP board’s Z axis location (0.10mm increments are a good starting place).
If the component stuck to the FTP board but was not centered on placement location (on the metal pads), you will need to do some fine tuning. It is useful to place five or so components before attempting to diagnose exactly what’s wrong with your placements.
Continue to click the “Single Job Step” to place the additional components (or click the “Play” icon button and pause the operation when you’re ready.)
It is perfectly normal for your very first set of component placements to have some errors. There are several different sources of placement error that we can address, one at a time. It will take a little trial and error to get placements perfect. Go to the Troubleshooting page for easy instructions.