Introduction
NeoDen YY1, with its dual placement heads, high automation, and flexible feeding system, is an ideal choice for small-to-medium batch SMT production. However, many users encounter issues during operation: despite correct programs and normal feeder operation, placements frequently deviate, exhibit angle misalignment, or even result in component ejection.
The root cause of these issues often lies not in the program, but in misaligned coordination precision between the placement head, suction nozzle, and Up-looking Camera. Even a 0.1mm deviation among these three components can be significantly magnified on micro-components (such as 0201 or QFN), leading to placement failure.
This article provides an in-depth analysis of how to systematically calibrate the YY1's pick and place head, nozzles, and up-looking camera, elevating your placement accuracy from “acceptable” to “industrial-grade reliability.”
I. Analysis of the Three Core Modules for Precision Calibration
NeoDen YY1 placement accuracy relies on the precise coordination of three key modules.
- Pick and Place Head: Executes X/Y/Z-axis movements and rotations, determining physical positioning.
- Nozzle: Directly contacts components, its mounting perpendicularity and height directly impact pick and place stability.
- Up-looking Camera: Positioned beneath the workbench, it identifies the actual position and angle of components picked by the nozzle, serving as the core of visual feedback.
Interaction: The pick and place head moves the nozzle to preset coordinates → The nozzle picks up the component → The up-looking camera captures an image to identify the actual component center → The system automatically compensates for deviations → The component is placed onto the PCB.
Failure to calibrate any single component causes the compensation mechanism to fail.
II. Nozzle Calibration
1. Nozzle Selection and Installation Fundamentals
NeoDen YY1 supports 13 standard nozzles (CN030–CN750) and multiple specialty nozzles (YX series). Improper selection may cause:
- Insufficient suction force (nozzle too large).
- Component slippage or flipping (nozzle too small).
- Nozzle collision with component body (unmatched non-standard parts).
Recommendation: Refer to the “NeoDen YY1 User Manual”. Select CN040 for 0402, CN220 for SOP, YX03 for BGA, etc.
2. Critical Calibration Tool: “Imprint Method”
This is the NeoDen YY1's core nozzle positioning calibration method.
- Locate the imprint paper (or substitute with high-sensitivity pressure-sensitive paper) in the standard accessory kit.
- Navigate to [System Settings] → [Imprint] function.
- The system guides the placement head to press against the imprint paper at a fixed height, leaving an imprint.
- By comparing the theoretical center with the actual indent center, the system automatically calculates and saves X/Y offset values.
Note: Re-execute the trace calibration every time the nozzle model is changed or if nozzle loosening is suspected.
III. Up-looking Camera Calibration
The up-looking camera performs visual recognition and angle correction on components after pickup. If its coordinate system differs from the placement head, the system will misinterpret component positions.
1. Calibration Prerequisites
- Stable ambient lighting, avoid direct strong light on the camera lens (Manual emphasizes: Sunlight exposure prohibited, as it causes recognition failure).
- Camera lens must be clean, free of dust and fingerprints.
- Use a high-contrast, non-reflective calibration plate (or standard component).
2. Calibration Steps
- Navigate to 【System Settings】→【Camera Center】.
- The system guides the pick-and-place head with a standard calibration nozzle (e.g., CN100) to move to the center of the camera's field of view.
- Lower the nozzle to the preset height, and the camera captures an image.
- The user fine-tunes via the interface to ensure the nozzle tip perfectly aligns with the camera's crosshairs.
- Save the calibration data, and the system updates the camera coordinate system.
Advanced Tip: After calibration, enable Recognition Mode 4 (Large Chip Camera Recognition) for critical components (e.g., 0.5mm pitch QFP) in [Component Edit]. This expands the field of view and improves recognition success rates.
IV. Mechanical Precision Assurance for Placement Heads: Software-Hardware Synergy
1. Placement Head Positioning Calibration
- Nozzle Height Reference: Defines the Z-axis zero point where the nozzle contacts components.
- Acquisition Method: In [Manual Test], lower the nozzle to the component surface, record the value, and input it into the system as the reference.
- PCB Origin Calibration: Ensures the lower-left corner coordinates of the PCB align with the program to prevent overall offset.
2. Mechanical Structure Maintenance (Impact on Long-Term Accuracy)
- Belt Tension: Excessively loose X/Y-axis belts cause positioning lag; inspect regularly.
- Guide Rail Cleaning: Avoid contact with iron rails via hands or water to prevent rust and jamming.
- Pull Pin & Peeling Mechanism: Excessive peeling force may skew tape alignment, indirectly affecting pick-up accuracy.
V. Practical Calibration Workflow: Complete Path from Power-Up to High-Precision Placement
To facilitate rapid implementation, follow this standard calibration procedure:
| Step | Action | Description |
| 1 | Power on and preheat for 5 minutes | Allow mechanical system to stabilize |
| 2 | Execute “Trace Calibration” | Correct current nozzle X/Y offset |
| 3 | Execute “Camera Center Alignment” | Synchronize upper camera with placement head coordinate system |
| 4 | Set “Pick-up Nozzle Height Reference” | Obtain Z-axis reference via manual testing |
| 5 | Place test board (with fiducials) | Verify overall accuracy |
| 6 | Fine-tune component offset (if needed) | Use “Single Step + Fine-tune” function on the [Placement] page |
Note: For high-density boards, repeat steps 2–3 after each material or nozzle change.
VI. Common Accuracy Issues and Troubleshooting Guide
| Issue Symptom | Possible Cause | Solution |
| Component placement skewed (wrong angle) | Upper camera uncalibrated / Component reflection | Recalibrate camera, adjust threshold, rotate nozzle to avoid reflection |
| Persistent offset at same location | Uncorrected nozzle drift | Perform “Trace” calibration |
| Frequent component dropouts on small parts | Dirty nozzle / Insufficient vacuum | Clean nozzle, check vacuum module pressure |
| Overall Shift After Placement | PCB Origin Error / Fiducial Recognition Failure | Reset PCB origin, check fiducial contrast |
| Camera Fails to Recognize Component | Inappropriate Threshold / Light Interference | Adjust camera threshold in [System Settings], turn off top light |
Conclusion
In SMT production, precision is not a default attribute of equipment, but the result of calibration and maintenance. YY1 provides a complete calibration toolchain—from “marking” to “camera centering,” from nozzle selection to vacuum detection—but realizing its full potential depends on the operator's professional awareness.
Master the calibration methods described here, and you will no longer be troubled by “misplaced components.” Instead, you will truly unlock the value of YY1 as a high-precision placement machine.
Precise placement begins with calibration. Efficient production is achieved through attention to detail.
Quick facts about NeoDen
1) Established in 2010, 200 + employees, 27000+ Sq.m. factory.
2) NeoDen Products:Different Series PnP machines, NeoDen YY1, NeoDen4, NeoDen5, NeoDen K1830, NeoDen9, NeoDen N10P. Reflow Oven IN Series, as well as complete SMT Line includes all necessary SMT equipment.
3) Successful 10000+ customers across the globe.
4) 40+ Global Agents covered in Asia, Europe, America, Oceania and Africa.
5) R&D Center: 3 R&D departments with 25+ professional R&D engineers.
6) Listed with CE and got 70+ patents.
7) 30+ quality control and technical support engineers, 15+ senior international sales, for timely customer responding within 8 hours, and professional solutions providing within 24 hours.
