Tray packing equipment plays a crucial role in SMT production lines, improving throughput and protecting delicate components. However, long-term operation can lead to wear and tear, affecting productivity and quality. This article highlights common issues, their causes, inspection tips, and preventive measures to help engineers reduce downtime.

1. Conveyor Belt and Pulley Wear

Symptoms: Unstable conveyance, vibration, misalignment, or slipping.

Causes

• Belt aging or cracking.
• Worn pulley bearings or shaft misalignment.
• Incorrect tension or foreign object obstruction.

Inspection & Prevention

1. Visually inspect belts every 3-6 months, replace if cracked.
2. Check pulley bearings and correct balance during maintenance.
3. Install guards and debris guides to prevent foreign object interference.

Maintenance Checklist (Collapsible)

• Check belt tension and record weekly.
• Lubricate bearings as recommended by manufacturer.
• Replace worn belts and document replacement.

2. Nozzle & Feeding Module Wear

Symptoms: Failed pick-up, misplacement, or tape jams.

Causes

• Worn or clogged nozzles.
• Vacuum leaks reducing suction power.
• Feed module misalignment or contaminated guide rails.

Inspection & Prevention

1. Establish nozzle cleaning cycle (weekly or after 100k picks).
2. Monitor vacuum pressure and set alert thresholds.
3. Keep guide rails clean, lubricated, and check for wear.

3. Positioning Accuracy Degradation

Symptoms: Placement errors leading to rework.

Causes

• Sensor drift or encoder errors.
• Mechanical backlash or guide rail wear.
• Thermal deformation or loose fasteners.

Inspection & Prevention

1. Calibrate sensors and encoders regularly, keep records.
2. Tighten key bolts and base fasteners to avoid shifts.
3. Perform quick accuracy check after shifts or high load operations.

4. Electrical & Control System Issues

Symptoms: Intermittent freezing, communication errors, or false I/O triggers.

Causes

• Poor power quality damaging electronic components.
• Improper grounding causing interference.
• Controller firmware/configuration errors or aging.

Inspection & Prevention

1. Install surge protection and voltage stabilizers, check outputs regularly.
2. Ensure proper grounding, separate critical sensor wiring.
3. Backup firmware and configuration for recovery.

5. Pneumatic & Hydraulic System Wear

Symptoms: Slow movement, insufficient force, leakage, or cylinder sticking.

Causes

• Aged seals or contaminated air/oil.
• Clogged filters causing pressure fluctuations.

Inspection & Prevention

1. Regularly replace seals and filters, record cycles.
2. Use clean, dry air source with oil/water separators and pressure regulators.

Maintenance Strategy & Troubleshooting

Establish a multi-level maintenance system: L1 – operator daily checks, L2 – shop-level maintenance, L3 – engineer-level maintenance. Use SOPs for common failures.

Sample Workflow

1. Receive alert → Operator logs and photos the issue.
2. Perform L1 checks (power, air, visual) and upload results.
3. If unresolved, notify L2 with logs/screenshots.
4. L2 inspects/replaces parts, escalate to L3 if needed.

Tip: Digital dashboards (MES + CMMS) structure fault data, reducing repeat failures long-term.

Conclusion

Tray packing equipment can accumulate wear over time, reducing productivity and quality. Regular inspections, calibration, electrical/air system management, and digital maintenance records help reduce failures and extend equipment life.

Contact SMT PACK LAB to schedule equipment health checks or maintenance plans.

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Last updated: October 31, 2025 · Suitable for SMT production line engineers and maintenance personnel.