This article introduces Stepper Technology's innovative chip inserter solution, detailing its comprehensive solution utilizing the CANopen bus system for multi-axis control and high-performance linear servo motors, and elucidating its system architecture and performance characteristics. 1 System Overview Chip inserting is a crucial step in the packaging of electronic components such as crystal oscillators. A rotary nozzle picks up bulk quartz wafers, and a vision processing system automatically corrects their position and angle, then neatly places them into a uniform coating tray according to a specified orientation for the next process. Traditional chip inserters use rotary motors to drive the spindle and employ a single-pickup method, limiting the inserting speed to a maximum of 0.67 wafers/second. Stepper Technology's new design, through creative modifications to the spindle and pick-up method, uses a linear servo motor as the spindle and a unique 4-head circulating pick-up method, significantly improving speed and accuracy. The design speed reaches 1.25 wafers/second, with a pick-up and drop accuracy of 0.01mm. Meanwhile, the system adopts multi-axis control based on CANopen bus, realizing the control of 10 axes by a single PLC. The high-efficiency communication speed not only realizes the synchronization of motors, but also reduces the complexity of system installation and maintenance. 2 Working Principle (as shown in Figure 1) Main processes of the chip inserter: (1) Identify bulk materials: Move the camera and bulk material tray, find the position of the bulk materials on the tray through the vision system, and move the suction nozzle according to the identified position; (2) Pick up materials: The four suction heads sequentially pick up the bulk materials and move them to the material release position along the main shaft; (3) Adjust position and direction: The position of the individual bulk materials is identified again during the main shaft transmission process; (4) Material tray feeding: The coating tray moves along the shaft to the material suction and release position; (5) Place it into the tray: According to the identification of the individual position, the angle is adjusted to a uniform direction and then the coating tray is placed in [IMG=chip inserter transmission principle diagram]/uploadpic/THESIS/2007/11/2007111616231265349L.jpg[/IMG] Figure 1 Chip inserter transmission principle diagram 3 Scheme framework diagram As shown in Figure 2, in the ten-axis chip inserter servo control system, the main controller is Beckhoff PLC BX9000, The BX9000 Ethernet port connects to a high-speed digital image inspection instrument (Keyence CV2100), and the CANopen communication port connects to 10 different Kinco intelligent servo drives to complete closed-loop control. The Kinco ECOVARIO high-performance servo drive is used to control the linear servo motor of the spindle to achieve the motion requirements of fast speed, high acceleration, and high positioning accuracy. One Kinco ED200 servo drive and eight Kinco ED100 servo drives control the bulk material tray movement motor, coating tray movement motor, camera movement motor, four-way suction head rotation motor, and coating tray in/out lifting motor, respectively, to complete the feeding of the bulk material tray, camera movement, suction head rotation and positioning, and coating tray feeding and lifting actions. The system is also equipped with an eView 5.7” color TFT touchscreen (MT5300T), which communicates with the BX9000 via Ethernet to control the equipment and monitor operating data. The system communicates via CANopen fieldbus at a rate of 1Mbps, which well meets the real-time requirements. [IMG=Insertion Machine Electrical Scheme Schematic Diagram]/uploadpic/THESIS/2007/11/2007111616240641037Z.jpg[/IMG] Figure 2 Insertion Machine Electrical Scheme Schematic Diagram 4 Configuration Table (as shown in Table 1) Control Characteristics Controller: Beckhoff PLC completes logic control, position closed-loop, Ethernet and CANopen communication. The system is stable and reliable, and programming is simple. [IMG=Configuration Table]/uploadpic/THESIS/2007/11/2007111616272185340R.jpg[/IMG] Table 1 The BX9000 series PLC is a mid-range PLC from Beckhoff, featuring multiple communication methods and powerful processing capabilities. Through its CANopen port, it connects to a CANopen fieldbus network composed of ECOVARIO and ED series drivers, enabling a multi-axis, high-speed communication system. The BX9000's Ethernet port connects to the Keyence CV2100 high-speed digital image inspection instrument and MT5300, significantly improving the communication and display speed of the system's position control loop. The spindle motor is a Kinco SLM-025-244-000 linear motor. Unlike traditional rotary servo motors, linear motors eliminate the need for a transmission structure between the motor and the load, thus avoiding the mechanical inertia associated with transmission parts. This results in high speed (large acceleration and deceleration within a specified stroke), high efficiency, and suitability for frequent starts and stops. In this system, with a spindle speed set to 1.5 m/s, the acceleration can reach 107 m/s², with no motor jitter during acceleration/deceleration, achieving a positioning accuracy of 5 μm. Fieldbus communication utilizes a CANopen bus with a communication rate up to 1 Mbps, based on CAN... The BUS application layer protocol boasts advantages such as strong anti-interference capability, high speed, and real-time performance. Through communication objects like PDO, SDO, and NMT, bus management and application are very convenient. Kinco's ECOVARIO and ED series drives offer models supporting CANopen communication. CANopen supports up to 127 slave nodes, fully meeting the control requirements of this system's 10 motors. The system's unique design of four suction heads is also based on the multi-node support of the CANopen bus. Traditional designs use pulse control for each motor, with ordinary PLCs supporting 2 to 4 pulse outputs. For multi-axis systems with more than 4 outputs, additional pulse modules or multiple PLCs connected in series via RS232/485 are necessary. Using multiple PLCs increases system design complexity, and the communication speed between PLCs affects system response. Furthermore, pulse control is susceptible to interference; the presence of large interference sources such as high-power frequency converters around the equipment can affect system communication and cause pulse loss. 5. Conclusion High-performance linear servo motors eliminate the need for mechanical transmission components, significantly improving acceleration and deceleration. Utilizing the CANopen bus system for multi-axis control not only enhances equipment production capacity but also increases system configuration flexibility. The system achieves high performance, convenient maintenance, and cost-effectiveness. With the continuous improvement of the performance of new chip inserters, the design scheme combining linear motors with the CANopen fieldbus will be more widely and deeply applied in the electronic component packaging industry. (Proceedings of the 2nd and 3rd Servo and Motion Control Forums)