Project Background & System Requirements
LED semiconductor manufacturing demands extreme precision and ultra-low latency during the packaging and testing phase. The spectroscopic sorting machine operates as a high-speed automation system that tests and classifies SMD LEDs based on complex photometric parameters. To achieve a throughput of 80,000 UPH (Units Per Hour) with a cycle time of just 45 ms per component, the control infrastructure must execute near-instantaneous logic processing. This system requires a dedicated hardware configuration capable of managing continuous vibration plate feeding, high-speed indexing table synchronization, and multi-channel analog inputs without data degradation or micro-kernel crashes.
Hardware Architecture
- System Configuration
| Hardware Category | Implemented Model | Specific Role within the Architecture |
| Logic & Motion Layer | Samkoon PLC FAs-64MT-AC + FAs-16T (10-channel high-speed pulse output) | Features a compiled instruction architecture. Executes real-time execution logic loops with a 0.3 ms scan time to drive 10-channel high-speed pulse outputs (up to 200kHz). |
| Operator Interface Layer | Samkoon SK-070QE HMI | 7-inch single serial port interface operating on a non-OS micro-kernel. Manages multi-level access security, recipe logs, and localized telemetry storage. |
| Expansion Interface | Dedicated Serial Port | Provides direct physical wiring for external industrial label printers and barcode scanners to ensure lot traceability. |
Core Control Logic & Hardware Implementation
- 0.3 ms Scan Time Logic Loop: Leveraging our compiled instruction architecture, the PLC executes logical determinations over faster than traditional interpretive PLCs, supporting a deterministic 80,000 UPH throughput with zero timing lag.
- 256-Channel BIN Categorization: The control matrix seamlessly parses photometric feedback to route individual components into up to 256 physical sorting BIN profiles via high-speed counter triggers.
- Cost-Effective Alternative to Legacy Hardware: Designed to directly replace expensive imported controllers, this setup maintains continuous, non-stop high-throughput sorting while slashing total hardware procurement costs and delivery lead times.
- High-Frequency Multi-Segment Counting: The system native inputs track high-frequency encoders and sensor responses up to 200kHz, preserving signal integrity under intense electromagnetic fields common in semiconductor factory environments.
Field Telemetry & Screen Interface Compilation
Actual SATOOL/SKTOOL software configuration layouts compiled for semi-conductor manufacturing floors. Screens illustrate localized BIN counter metrics, manual JOG adjustments, feeding pneumatic timers, and complete physical I/O register status monitoring.
