Electronics Assembly / SMT · Multi-Brand Device Data Acquisition & Correlation Analysis
For multi-brand, multi-protocol equipment on the SMT line, a protocol gateway connects printers, SPI, placement machines, reflow ovens and AOI data, while the G220 adds screen-level tuning and OCR verification — supporting SPC and yield improvement.
Core solution for this scenario
The SMT line is a tightly coupled process chain of "printer → pick-and-place machine → reflow oven → AOI", where a parameter drift at any single stage is amplified downstream. Solder-paste thickness from the printer, placement-coordinate accuracy from the pick-and-place machine, and the reflow oven temperature profile must be data-linked to locate the root cause of defects — collecting a single stage in isolation has limited value. This is precisely why SMT yield optimization must rely on "line-wide data acquisition + cross-device correlation" rather than single-machine monitoring.
I. Industry Pain Points
Typical challenges for Electronics Manufacturing / SMT Surface Mount in equipment O&M and data acquisition.
- SMT-line equipment brands are highly mixed (printers, SPI, placement machines, reflow ovens, AOI from different vendors) with disparate protocols, so data is naturally siloed and hard to correlate end-to-end.
- Key parameters such as reflow temperature profiles and placement offsets are scattered across equipment HMIs; manual aggregation is lagging and error-prone, so SPC is hard to truly implement.
- AOI defect results cannot be quickly correlated with upstream / downstream process parameters to locate root cause; quality traceability is difficult.
- Legacy equipment has no network port and exposes no protocol, becoming a blind spot in data acquisition.
II. Solution
Build a "screen layer + protocol layer" dual-source data closed loop with the AIXOT non-intrusive gateway combination.
- AIS-G160 Industrial Protocol Gateway uses its 500+ protocol library to unify access to printers, SPI, placement machines and reflow ovens, performing data cleaning and anomaly pre-screening at the edge, and reporting standard protocols to MES / SPC.
- APM-G220 Non-intrusive Smart Tuning Gateway non-intrusively takes over the IPC-controlled device screen for parameter review and OCR text records, bringing the “screen layer” judgement into the quality closed loop.
- Continuous variables — reflow temperature profile, placement coordinates, SPI solder-paste thickness — are correlated with AOI defect results on a timeline, supporting SPC and yield root-cause analysis.
- For legacy protocol-less devices, G220 + AIS-T100 Video OCR Data-Collection Gateway OCR provides fallback capture of key screen parameters, eliminating data blind spots.
III. Deployment Steps
An executable path from interface inventory to a standardised closed loop.
- Inventory each SMT-line equipment vendor / model and communication interface (Ethernet / RS485 / OPC UA)
- Configure the corresponding G160 protocol template and acquisition period; compute temperature / offset anomaly pre-screening at the edge
- The G220 takes over the AOI industrial PC, records a tuning script and adds OCR verification, bringing it into the quality closed loop
- Correlate device data on a timeline by board ID / batch; build an SPC dashboard and defect traceability chain
- Set threshold alarms for key processes; on anomaly, auto-correlate upstream / downstream parameters to locate root cause
IV. System Integration & Data Connectivity
Standardised connection points with MES / SCADA / PLC / quality systems.
- Connect to MES / SPC: device continuous variables reported via OPC UA / Modbus TCP
- Connect to the electronic batch record: board ID–parameter–defect correlation supports traceability
- Complement with AIS-T100 Video OCR Data-Collection Gateway OCR: fallback capture of protocol-less device screen parameters
V. Value & Quantified Metrics
Measurable benefits from the non-intrusive solution.
VI. Deployment Boundaries & Compliance Red Lines
Compliance & applicable boundaries
General electronics manufacturing in a non-sensitive industry may use the 4G public network for non-sensitive commissioning, but for customers involving core process parameters a private / intranet network is recommended. The G220 applies only to PC-controlled devices; pure controller protocol acquisition is handled by AIS-G160 Industrial Protocol Gateway.
VII. FAQ
High-frequency questions for the Electronics Manufacturing / SMT Surface Mount scenario.
What if different brands' equipment protocols are incompatible?
The G160 has a built-in 500+ industrial-protocol library covering mainstream printers, placement machines and reflow ovens; less common brands can be connected via a custom protocol / register mapping.
How to improve SMT yield?
G160 collects entire-line process parameters; reflow temperature profile, placement coordinates and SPI solder-paste thickness are correlated with defects on a timeline, supporting yield root-cause analysis via SPC dashboards.
How is the reflow temperature profile used for SPC?
The G160 continuously acquires oven temperature and belt speed, aligned on the board-ID timeline, and feeds the SPC dashboard for trend and breach analysis.
Can legacy devices without a network port be acquired?
Yes. Screen-class parameters are covered by G220 + AIS-T100 Video OCR Data-Collection Gateway OCR fallback; devices with a serial port are acquired by the G160 via RS485.
In the 'Electronics Manufacturing / SMT Surface Mount' scenario, which CNC, PLC and injection-molding brands can G160 connect to?
AIS-G160 ships a 500+ industrial-protocol driver library, verified for CNC systems from FANUC, Siemens, Mitsubishi, SYNTEC; PLCs from Siemens, Mitsubishi, OMRON, Delta, Inovance; and injection machines from Techmation, Keqiang, Mediatek, Chen Hsong. See the 'Device Compatibility' list on this page for specific models; some legacy devices require on-site confirmation of network/extension-module conditions.
Related Scenarios & Products
Robot / Automation
Multi-brand communication-protocol acquisition and interlocking monitoring
→ View ScenarioCNC Machine Tools Brands & Models Supported by G160
AIS-G160 ships a 500+ industrial-protocol driver library with native brand support for dedicated controllers (CNC, injection molding, robots) that generic gateways struggle to connect. Below are mainstream brands and models verified for data acquisition (some models require on-site confirmation of interface conditions).
| Brand | Supported Models / Comms |
|---|---|
| FANUC | All systems with an Ethernet port can communicate; for systems without an Ethernet port, on-site confirmation is required to determine whether an expansion module can be added |
| SYNTEC | System version 10.116.16X or later |
| Mitsubishi | E70, M70, M700, E80, M80, M800 |
| BROTHER | Systems with an Ethernet port |
| SIEMENS | 828D, 828DSL, 840DSL, 808D/808DSL (Ethernet-capable) |
| Haas | Full Ethernet series / full serial-port series |
| KND | Systems with an Ethernet port |
| GSK | All Ethernet-capable systems; 988 series, 25imc, etc. |
| Other Ethernet-capable brands | HNC, Mazak, HEIDENHAIN, Huazhong CNC, etc. can also be connected via the edge gateway |
PLC (Programmable Logic Controller) Brands & Models Supported by G160
AIS-G160 ships a 500+ industrial-protocol driver library with native brand support for dedicated controllers (CNC, injection molding, robots) that generic gateways struggle to connect. Below are mainstream brands and models verified for data acquisition (some models require on-site confirmation of interface conditions).
| Manufacturer / Brand | Typical Series & Models | Comms | Protocol / Driver |
|---|---|---|---|
| Siemens | S7-200 (PPI), S7-300/400 (MPI), S7-200 Smart, S7-1200, S7-1500, LOGO! | Serial / Ethernet | S7 PPI, MPI, S7comm, Modbus TCP |
| Mitsubishi | FX0/FX1/FX2, FX3U/3G, Q series (Q00J/Q00/Q02/Q02H/Q06H/Q12H/Q25H, QnU Q00U~Q26U, QnA/A series), FX3U-ENET, FX5U, QJ71E71 | Serial / Ethernet | Mitsubishi MC, MELSEC, SLMP |
| Rockwell AB | Micro800 | Ethernet | EtherNet/IP |
| LS | XGT, XGB, XBC-DN32U | Serial / Ethernet | Proprietary protocol |
| Modbus | Standard Modbus devices | Serial / Ethernet | Modbus RTU / ASCII / TCP / RTU over TCP |
| Schneider | Full range | Serial / Ethernet | Modbus RTU / TCP |
| Power utility protocols | Power utility terminals | Serial / Ethernet | IEC 60870-5-101, DNP3.0, IEC 60870-5-104 |
| HollySys | LE/LK220, LK210 | Serial / Ethernet | Modbus RTU |
| THINGET | XD/XL, XC | Serial / Ethernet | Modbus TCP |
| Inovance | H1U/H2U, H3U, H5U | Serial / Ethernet | Modbus |
| OMRON | CJ/CS, CV, CP | Serial / Ethernet | OMRON FINS, Ethernet TCP |
| FATEK | Full range | Serial / Ethernet | Proprietary protocol |
| Delta | DVP, AS228T | Serial / Ethernet | Modbus RTU / TCP |
| Panasonic | FPX, FP | Serial / Ethernet | MEWTOCOL_COM |
| Haiwell | Full range | Serial | Modbus RTU / ASCII |
| Kewei | LP series | Serial | Modbus RTU / proprietary protocol |
| Meters / Environmental / Building Automation | Smart meters, environmental monitoring, building-automation devices | Serial / Ethernet | CJ/T188, DL/T645 (2007/1997), HJ212, BACnet MS/TP, BACnet IP |
| OPC UA | Software/devices supporting OPC UA | Ethernet | OPC UA |