Solid-state lighting has the potential to revolutionize the lighting industry. Light-emitting diodes (LEDs) — traditionally used in signs, signals and displays — are rapidly evolving to provide light sources for general illumination. This technology holds promise for lower energy consumption and reduced maintenance. Continued growth in LED technology and solid-state lighting has provided the electronics manufacturing industry with viable solutions for today’s electronic devices. As a result, companies in the surface mount technology (SMT) industry are expanding their manufacturing capabilities to meet this demand. The range of new and potential applications for LEDs in electronics is practically endless.

Count On Tools has realized this trend and worked to quickly develop a line of nozzle designs that allows customers to accurately and consistently place LEDs with existing SMT pick-and-place equipment. By working closely with LED component manufacturers such as CREE and Lumileds, Count On Tools guarantees secure picking of all fragile components and accurate placement on circuit boards.

We sat down with Jeff Lancaster, the Design Engineer behind the LED and custom nozzle program at Count On Tools, to discuss the growth of LED technology and how Count On Tools has overcome the issues that many contract manufacturers have faced with implementing this technology into their production capabilities.

Recent growth in LED technology and solid-state lighting have provided the electronics manufacturing industry with viable solutions for their use in today’s electronic devices. Have you seen an increase in demand for nozzle and tooling for LED components?
Yes, we have seen considerable growth for custom LED nozzles and tooling as well as high-volume repeat orders for tooling lines up for production. We constantly receive requests to build nozzles for the newest LEDs, some even before they hit the LED manufacturers’ customers.

We understand that the transition to high-power LED components, such as those offered by Cree and Phillips Lumileds, are more difficult to handle in the pick-and-place operations. What makes these LED components more difficult to handle than regular components?
As with all technology, everything has to get smaller yet more powerful — this holds true for LEDs as well. The die inside LEDs currently being made is staying close to the same size; however, the substrate is being cut closer to the die to reduce the footprint. This is done in order to increase LED population. The problem with the reduced substrate is that it makes the LED so lightweight that the tacky silicone dome literally sticks to the nozzle. This is where we have to get creative about how we approach picking the LEDs.

What problems do the stickiness or tackiness of the LED substrate cause for manufacturers attempting to place these components on boards?
Problems can start at presentation of the LED in the feeder. Because of the sticky silicone-based substrate, the dome of the LED can stick to the cover tape, causing the LED to flip on its side or even stay with the cover tape if the feeder is not set up properly. If the LED does get picked but does not release from the nozzle at placement, the machine could possibly start stacking the LEDs to each other and to the nozzle itself or start faulting out the machine with high reject counts.

How has Count On Tools been able to overcome these LED component problems for customers?
We have invested a tremendous amount into materials and nozzle designs to get the results that our customers need. We have tried ideas from wood nozzle tips to custom formulations of Teflon, and all have had varying levels of success. Our go-to material is urethane even though it is very difficult to machine to the fine details that are required for the smaller LEDs. Tip geometry places a huge toll also because what works great for one machine may not work at all for another. That is why we work with the customer to see which design will work best for their exact situation.

We also have recently seen a transition to smaller LED packages. How has Count On Tools been able to adjust its nozzle designs to accommodate these components?
The smaller LED packages have been a big challenge but we have stepped up with innovative designs. For example, we now can break the LED away from the nozzle tip after the vacuum has been turned off by building in vacuum leaks around the pick surface. This helps to stop the buildup of pressure that makes the silicone stick to the nozzle. Of course there are some things that the machine operator can do, such as minimize placement pressure and feeder, depending on their particular situations.

Count On Tools also works directly with LED component manufacturers on nozzle designs, specifically for new LED products coming to market. What does this mean to you to be able to stay on the forefront of this growing technology?
LED manufacturers come to us because they know they get quick turnaround and a lot of experience in the LED placement arena to get their customers up and running fast. We work closely with the manufacturers to get the best design that we then apply to other machine types and customer situations. It enables us to guarantee safe and reliable handling of the LED components for the pick-and-place operation.

Is there any other information you can give customers regarding handling LED components in the pick-and-place operation, especially first timers?
Do your research on the LEDs you are placing because most manufacturers have comprehensive documentation on their websites regarding information from machine setup to temperature and humidity levels, which play a significant role in how tacky the silicone can be. You can always call us and we will do our best to solve whatever issue you may run into.

Conclusion
Count On Tools’ LED nozzle technology was developed to provide a consistent and reliable platform for the placement of solid-state LED lighting components in the SMT assembly process. The company’s technology is based on an exclusive urethane material coupled with its precision machining capabilities, which has allowed it to manufacture tooling that not only overcomes the tackiness of the LED substrate but also offers better handling of the sensitive shapes and profiles of the many different LED designs. Count On Tools’ LED nozzles and tooling is available for all brands of SMT pick-and-place equipment. Additionally, Count On Tools generally can provide a finished nozzle within 1-2 weeks while saving customers up to 50 percent or more over OEM designs for custom nozzles. Volume discounts are available for orders of more than 50 nozzles. There are no design fees and Count On Tools provides free quotes based on the equipment and type of LED being placed.

Count On Tools, Inc. (COT), a leading provider of precision components and SMT spare parts, will display its new QWIKTRAY system in the AdoptSMT Booth, Hall A3 Booth 181, at the productronica International Trade Fair, scheduled to take place Nov. 10-13, 2015 at the Messe München exhibition center in Munich, Germany. The QWIKTRAY platform allows surface mount components to be picked up in a repeatable method when tape-and-reel is not available and standard JEDEC trays do not exists. As a result, customers no longer have to place these components by hand.

Utilizing the latest in machining and additive manufacturing technologies, QWIKTRAY will develop a custom pocket design matched to your component specifications and machine it into a finished matrix tray. QWIKTRAYs can be designed for almost any component, including QFP, BGA, hybrid, assemblies, sockets, pins, connectors, LEDs, switches, buttons, transformers and more.

Each QWIKTRAY is CNC machined to the specific configuration for your component and ships ready to load and install in the equipment. Each QWIKTRAY includes CAD drawings, containing pocket dimensions, first part location, spacing, and other programing details. QWIKTRAYs come standard in non-ESD black acrylic (ESD-safe and other materials are optional). For more information, please visit www.qwiktray.com.

Count On Tools, Inc. (COT), a leading provider of precision components and SMT spare parts, is pleased to announce the launch of the new QWIKTRAY system, developed to provide low-cost, custom matrix trays for many types of electronic components. The QWIKTRAY platform allows surface mount components to be picked up in a repeatable method when tape-and-reel is not available and standard JEDEC trays do not exists. Customers no longer have to place these components by hand.

Utilizing the latest in machining and additive manufacturing technologies, QWIKTRAY will develop a custom pocket design matched to your component specifications and machine it into a finished matrix tray. QWIKTRAYs can be designed for almost any component, including QFP, BGA, hybrid, assemblies, sockets, pins, connectors, LEDs, switches, buttons, transformers and more.

Each QWIKTRAY is CNC machined to the specific configuration for your component and ships ready to load and install in the equipment. Each QWIKTRAY includes CAD drawings, containing pocket dimensions, first part location, spacing, and other programing details. QWIKTRAYs come standard in non-ESD black acrylic (ESD-safe and other materials are optional).

According to Zach Shook, Operations Director of Count On Tools, Inc., “Our company understands that in order for our customers to remain competitive in today’s market, they must be able to cut costs while maximizing the capabilities of their existing SMT assembly equipment to prevent costly investments in new equipment or increased labor from hand placements of electronic components. The QWIKTRAY platform provides customers with a fast and easy way to get components back into the machines. This could be from loose components with no standard packaging, such as tape reel or JEDEC trays, or from recovered components that were miss-picked or dropped during previous production runs.”

The QWIKTRAY program provides rapid turnaround on the design and production of any quantity of custom matrix trays. Standard lead time is 7-10 days with optional expedited service in as little as 24-48 hours (additional charges may apply). The system is designed for any application requirements, from prototype to high-volume processes. With the QWIKTRAY platform, there is one flat fee per tray with no minimum orders and no additional charges for design, programing, molds, setup, etc. Volume discounts also are available.

Mr. Shook continued, “Our company is based on engineering solutions for the entire SMT operation, from component handling and presentation to pick-and-place to final processing. The QWIKTRAY system is just another way that customers can move costly manual labor back into their production equipment. The design and manufacturing process has been streamlined to make the turnarounds fast while maintaining our high quality standards. Our QWIKTRAYs are designed for precision, stability and protection during the pick-and-place process.”

Count On Tools, Inc. (COT), a leading provider of precision components and SMT spare parts, has released a new accessory – the Transition Rail – for its award-winning line of StripFeeder products. Each StripFeeder Transition Rail features machined tracks for both paper and emboss tape on the same rail for a seamless transition.

The StripFeeder Transition Rail allows customers to take full advantage of the StripFeeder platform when running both paper and emboss tape, simultaneously, without the loss of a component lane. The rail will be sold individually or in StripFeeder .mod and Mini kits. StripFeeder Transition kits are set up to run three lanes of paper tape and three lanes of emboss tape in 0.25" (6mm), 0.50" (12mm), and 0.75" (19mm) pocket depths. Additional rails can be added to these kits to increase the amount of component lanes, up to 10 per tray for 8mm tape.

All StripFeeder .mod and Mini systems feature removable rails that can be mounted to accommodate a wide array of tape sizes in the same feeder. Unlike fixed width feeders, the StripFeeder Mini can be adjusted by removing the rails and re-positioning them on the base plate at the desired width (4mm pitched pattern). The rails align with precision pin locaters and lock down tightly with magnets to guarantee a stable, repeatable application. All StripFeeder rails also feature a mechanical lock-spring to hold the tape in place by the sprocket hole for part registration and repeatable pick-and-place applications. This means the user only has to teach the pick-up location one time and consistently reload the unit with the same parts over and over for longer runs.

This innovative rail design holds the components securely in the machined tracks to prevent parts from being miss-picked, flipped in the pocket or lost. Customers also can remove rails to accommodate larger components up to 120mm tape width. The StripFeeder system is compatible with most types of SMT equipment. The StripFeeder systems are a cost-effective way to load many components, including odd-form and custom components, without having to purchase expensive feeders. The quick-to-assemble, easy-to-install modules are designed for rapid loading of tape-and-reel components on existing SMT pick-and-place equipment. Additionally, the trays enable fast changeover between product runs without unloading from the machine.

Count On Tools, Inc. (COT), a leading provider of precision components and SMT spare parts, recently expanded its manufacturing operations at its Gainesville, Georgia headquarters. The latest expansion is in response to the growing market for custom engineered SMT nozzles and consumables.

According to company representative, Zach Shook, Count On Tools recently installed a Langun American Turnmaster Manual Lathe to increase production capabilities and lower product lead times on custom engineered nozzles and tooling for the SMT industry. Count On Tools also recently expanded its production and assembly staff in this division to further speed up delivery times on custom engineered SMT nozzles and consumables.

The industries Count On Tools serves count on accuracy of part specifications and on-time delivery of their orders. The new equipment will enable Count On Tools to achieve both. Additionally, the new equipment handles more complex jobs faster by providing Count On Tools with increased production speeds, automation of production and faster processing power. "This new equipment produces tight tolerance, precision components reliably," said Shook. "As a result, we can now respond to changing customer needs quickly and at highly competitive costs."

Count On Tools Inc., a leading provider of precision components and SMT spare parts, today announced they will display an array of products in the Adopt SMT booth, Hall 7-100, at SMT Hybrid Packaging, scheduled to take place May 5-7, 2015 in Nuremberg, Germany.

On display at the show will be the full range of Count On Tools’ SMT Nozzles (standard & custom) , as well as the original StripFeeder and all new Stripfeeder Mini, which features the same award-winning design of the StripFeeder in a smaller package (134mm x 152mm).

The StripFeeder Mini is better equipped to handle shorter strips of components, such as 2-4" of tape. It offers increased lane capacity with the ability to run two StripFeeder Minis in the same space as one original StripFeeder. The Mini is a lower cost option than OEM feeders, both standard and custom, for small strips of components. Additionally, it is designed for both prototyping and low-volume, high-mix applications.

Other product lines that will be displayed at the show include: ezLOAD PCB Supports and the all new ezCLIPs, as well as Mydata Agilis Feeder Repair, which is now available as a service directly from AdoptSMT in Europe.

All COT products and services are designed to optimize SMT equipment for faster production and lower build costs. The company supplies a full range of SMT tooling, odd-form component tooling and design services, and other SMT consumables for the electronics manufacturing industry.

Count On Tools, Inc. (COT), a leading provider of precision components and SMT spare parts, today announced that it has authorized AdoptSMT Group, its distributor in Europe, to offer repair services for MYDATA Agilis Feeders. This program will be available for the 3.7, 4.0, 4.7, and 5.4 Agilis feeders. This is the only repair option for these feeders on the market and provides significant costs savings over purchasing replacement feeders.

All repair components (tape plows and feeder springs) are precision machined replacements for the original parts using high quality materials and industry leading coatings. COT and AdoptSMT guarantee the functionality of the equipment and the ability to extend the life cycle of worn or damaged feeders.

Count On Tools Inc. (COT) announces that it has been awarded a 2015 Circuits Assembly Service Excellence Award for its outstanding customer ratings, as judged by its own customers. Count On Tools was selected for the Automation and Handling Equipment category.

Circuits Assembly Editor-in-Chief, Mike Buetow presented the award to Curt Couch, COT’s President, during a Tuesday, Feb. 24, 2015 ceremony that took place at the San Diego Convention Center during the IPC APEX EXPO. Mr. Couch commented about the award, “As with last years’ service excellence award I am always humbled by recognition of this caliber based solely on customer response. It is not by chance, our dedicated caring and responsive team always places the customers’ needs first. Service isn’t a product that can be created; it’s a culture and attitude towards others. We treat customers as we would like to be treated ourselves.”

Sponsored by Circuits Assembly, the Service Excellence Awards (SEAs) for Electronics Manufacturing Services (EMS) providers and electronics assembly suppliers honor companies excelling in the crucial area of customer service. The program, now in its 23rd year, functions as a way for participants to see how they compare to peers in customer satisfaction. 

Count On Tools is a leading provider of precision components and SMT spare parts. The company has won numerous awards for its quality products and service. 

Count On Tools Inc. (COT), a leading provider of precision components and SMT spare parts, is launching an innovative program designed to give EMS companies on-demand access to high quality SMT nozzles, tooling and consumables for more than 20 of the top pick-and-place equipment vendors. The INSTOCK Consignment Program has been developed to give EMS companies and contract manufacturers immediate access to project critical products with no up-front inventory costs or risk of overstock.

Customers can benefit from guaranteed on-hand supply of products at their facilities, which eliminates emergencies and machine downtime while reducing product overstocking and waiting for purchase order approvals. This low-cost solution means NO additional service fees, NO upfront costs and NO monthly-minimums. COT welcomes the opportunity to help EMS companies gain vital product access with minimal risk.

With the INSTOCK program, participants can take advantage of program and volume discounts of up to 25 percent on all consignment purchases. Customers also receive enhanced customer service by working directly with specialized Account Managers for up-to-date customer support, product pricing and availability, and more!

Additionally, the INSTOCK Consignment Program is available for the full COT product catalog, including all OEM’s standard products, custom nozzles, StripFeeders, ezLOAD and more. All SMT nozzles and consumables are guaranteed to function properly with the original equipment. Every product manufactured by Count On Tools comes standard with a 100 percent satisfaction guarantee. If any customer is not completely satisfied with the performance or quality of a product, Count On Tools will replace it or offer a full refund.