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Use the Functional Test Placement PCB to learn how to run a job

What you’ll learn

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

  • A LumenPnP
  • 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.

Attach Feeders

  1. 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.

    Install the feeder to the staging plate

  2. For each component, cut a strip of component tape off the reel about 125mm long.

  3. Slide the Resistors into the left-most tray feeder, and the LEDs the adjacent tray.

  4. In OpenPnP, connect to your LumenPnP and home it.

    Connect to your LumenPnP and home it

Import Board

  1. Download the FTP board design. It’s in the artifact on the latest release.

  2. Go to File > Save Job As and save your FTP job.

    Save Job As

  3. Navigate to the Job tab in the top right.

    Job Tab

  4. Click that “Add” Icon button to add a new board and select New Board. Save the board in the same directory as the job.

    Add a new board to the job

  5. Click on the newly-created board in the list to select it.

    Select the board to import the design

  6. Go to File > Import Board > KiCAD .pos

    Start importing the board

  7. In the Import popup:

    1. Select the ftp-top.pos file you downloaded earlier as the Top File
    2. Enable the Assign Parts checkbox.
    3. Enable the Create Missing Parts checkbox.
    4. Click Import
      Fill out the board import dialog

Add Feeders

  1. Navigate to the Feeders tab in the top-right pane.

    Switch to the feeders list

  2. Click on the “Add Feeder” icon button.

    Start adding a new feeder

  3. Select ReferenceTrayFeeder and click Accept.

    Select and add a new reference tray feeder

  4. In the lower-right panel, you’ll be in the Configuration tab. Change the Part to be R_0603_1608Metric-R_Small.

    Assign the resistor to the tray feeder

  5. Set the Y Offset to -4. This is the space between components on the tape.

    Set feeder offset

  6. Set the Y Tray Count to 30. This is the number of components available on the feeder before it needs to be manually moved forward.

    Set the feeder tray count

  7. Set the Pick location to: X=45, Y=175, Z=20 as a starting point.

    Set the starting location for the left feeder

  8. Click on the “Position Camera” icon button to move the top camera roughly over the left feeder.

    Move the top camera over the left feeder's approximate location

  9. 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.

    Manually move closer to the correct feeder location

  10. 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.

    Manually move closer to the correct feeder location

  11. Click the “Capture Camera Location” icon button to save the XY position of the start of the feeder.

    Save the current camera position as the start place for the feeder

  12. Click Apply to save the feeder settings

    Save feeder settings

  13. Click the Enable checkbox in the feeder list.

    Enable the feeder so that it is used

  14. 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

  1. Grease the nozzle holder before installing the N045 nozzle.

    Grease the nozzle holder before installing the N045 nozzle

  2. Install your N045 nozzle onto the nozzle holder.

    Install the N045 nozzle

  3. Wipe off any excess grease.

    Wipe excess grease from the nozzle holder

  4. Go to the Machine Setup tab in OpenPnP.

    Switch to the Machine Setup Tab

  5. Navigate to Heads > ReferenceHead H1 > Nozzles > ReferenceNozzle N1.

    Select Nozzle N1

  6. In the lower-right pane, switch to the Nozzle Tips tab.

    Switch to the nozzle tips tab

  7. 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.

    Load Nozzle N045

  8. Go to the Packages tab in the top-right pane.

    Switch to the Packages Tab

  9. Select LED_0603_1608Metric from the list.

    Select the LED package

  10. In the lower-right pane, you’ll be in the Nozzle Tips tab. Click the Compatible on the N045 row.

    Mark compatible with N045 nozzle

  11. Similarly, select R_0603_1608Metric from the Package list.

    Select the resistor package

  12. And click the Compatible checkbox on the N045 row.

    Mark compatible with N045 nozzle

  13. Under the bottom-left Machine Controls pane, select Nozzle: N1 - N045 (Head:H1) to enable the left toolhead.

    Select Nozzle N1

Fine-tuning feeder height

  1. Navigate to the Feeders tab in the top-right pane.

    Switch to the feeders list

  2. Click on the “Position Nozzle” icon button to bring the nozzle over the feeder.

    Position the nozzle over the feeder

  3. Use the Jog controls to lower the Z axis until the nozzle is touching the surface of the plastic tape cover.

    Use the jog controls to position the nozzle over the feeder
    Position the nozzle over the feeder
    Position the nozzle over the feeder

  4. Click on the “Capture Nozzle” icon button to save the new Z height of the feeder.

    Save the nozzle position

  5. Jog the XY gantry away from the feeder.

    Move the Tool Head away from the feeder

  6. Remove the tape cover from the feeder.

  7. 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:

    Pick from the feeder

    1. Lower the Z height of the feeder by 0.1mm
    2. Press Apply to save the change
    3. Home the machine
    4. Try picking a component from the feeder again.
  8. After you’ve successfully picked a component, in the machine Machine Controls pane, switch to the Special Tab.

    Switch to the special tab

  9. Recycle the component you’ve successfully picked up

    Recycle the component you've picked up

  10. Copy the final Z height, select the other feeder, paste it for the other feeder, and press Apply

    Apply the z height from the first feeder to the second one

  11. Test picking a component from the other feeder

    Pick from the 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.

  1. Loosely screw in the universal mounting components in the following locations:

    1. Static Board Mount positioned diagonally, screwed into B28
    2. Dynamic Board Mount positioned vertically, screwed into D28
    3. Dynamic Board Mount positioned horizontally, screwed into B30
    4. Board Support placed in E31
      Install the board mounting hardware
  2. 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.

    Apply double-sided tape to the board

  3. Place the FTP board in the holders and push them so that they’re snug against the sides of the board.

    Insert the FTP board

  4. Tighten down the holders. You shouldn’t be able to move the board except by pressing on the tab holding it in place.

  5. 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.

  1. Navigate to the Job tab in the top-right pane.

    Switch to the Job Tab

  2. 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.

    Find each of the board fiducial markers

  3. 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.

    Switch each fiducial component to fiducial type

  4. 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.

    Set the XY coordinates of your board

  5. 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.

    Set the Z coordinates of your board

  6. 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.

    Move the top camera to the board

  7. In the lower-right pane, select one of the fiducials to highlight it.

    Highlight one fiducial

  8. Click the “Position Camera” icon button to move the top camera over the fiducial location.

    Move the top camera to one fiducial to check its location

  9. 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.

    Switch the digital readout to relative mode

  10. Then, move the tool head with the Jog buttons until the fiducial is centered in the reticle.

    Use the Jog buttons to position the camera directly above the fiducial

  11. 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.

    Get the reading on the digital readout and apply it to the board position

  12. In the lower-right panel, select the other fiducial points in turn, and check their location with the “position camera” icon button.

    Move the top camera to one fiducial to check its location

  13. 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.

  14. 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.

    Automatically set board location

  15. If the fiducial check fails, here are some options for moving forward:

    1. You might need to rotate the FTP board to be more square to the LumenPnP motion system.
    2. You may need to adjust your vision pipeline.
    3. If you’d prefer, you can also fall back on manually defining the board’s location using the “Multiple Placements” icon button.
      Use the board location from multiple placements button to manually set the board location and rotation
  16. 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.

Placing Components

  1. Make sure you’ve pulled back the protective tape cover on your feeders and that you have the correct nozzle installed.

  2. 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.

    Start placing components

  3. If the component was not picked up correctly, you will need to adjust your feeder location or height.

  4. If the component was not identified by the bottom camera correctly, you will likely need to adjust its vision pipeline.

  5. 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).

  6. 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.

  7. 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.