Application requirements
I/O density, cycle time, motion or process requirements, field distances and maintenance needs are assessed together. This defines the requirements of the working system, not just individual products.
Samkoon · Machine automation
High-speed control for LED sorting machines
This machine automation application uses HMI, high-speed PLC and pulse outputs to address field control, reliable communication and maintainable commissioning.
Solution architecture
The proposed architecture combines HMI, high-speed PLC and pulse outputs with the machine’s existing control infrastructure and communication protocols. Final product and module selection depends on site requirements.
How can ProControl help?
ProControl can adapt the solution to local project requirements in Türkiye, from site assessment, I/O planning and protocol selection to panel layout, commissioning and after-sales support.
Official application content
Technical details, tables and application images
The technical workflow and visual information from the manufacturer are presented below.
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.
This content is based on the manufacturer’s published High-speed control for LED sorting machines application, adapted by ProControl while preserving its technical scope. View the official manufacturer source.