Molex Wireless Technology (Shanghai) SMT Reflow Oven Intelligent Error-Proofing and Quality Traceability

Centered on RockPlus PVT's Reflow process error-proofing scenario, Hegong Software coordinated PCB barcode identification, Recipe verification, network I/O control, and the KIC temperature profiling system, upgrading "detecting abnormalities" to "automatic interception on abnormality, release only after correctness is confirmed".

1. Automatic board-arrival sensing and barcode acquisition, establishing the furnace-entry identification gateway

A board-arrival sensing signal is set at the reflow oven entrance. When a PCB reaches the designated position, the RockPlus iBox reads the sensor state and triggers a fixed barcode scanner head to read the code automatically. The pass-station control program receives the scan result and handles duplicate reads and abnormal characters, reducing the interference of repeated triggers and invalid data with pass-station judgment.

For PCBs whose valid barcode is not successfully read, the system keeps the rail locked and raises an alarm per on-site error-proofing rules, preventing unconfirmed products from entering the oven directly.

2. Automatic Recipe identification for intelligent PCB-to-production-program verification

The system monitors changeover files and current production program information on the KIC side, and automatically updates the Recipe used for verification after product switching.

For the differences between actual product codes and program names in production, the system supports configurable barcode comparison rules and maintains the "product—program" mapping. After a PCB is scanned, its product identity is automatically checked against the current Recipe:

• Check passed: the rail lock is released, allowing the PCB to enter the reflow soldering process.
• Check failed: the rail remains locked, and the alarm light plus on-site abnormality prompt are triggered, awaiting re-verification and handling.
• No valid barcode read: interception per rules, preventing missed-scan products from entering the oven directly.

Through automatic reading of changeover information and real-time comparison, wrong-board prevention is moved forward to the reflow oven entrance.

3. RockPlus iBox with rail interlocking, forming an equipment-level error-proofing mechanism

The project uses the RockPlus iBox network I/O acquisition box to connect on-site sensors, barcode scanner heads, alarm lights, and rail blocking devices, communicating over the network with the pass-station control program on the industrial PC.

The system converts RockPlus PVT's verification results into on-site control actions: lock the rail and light the alarm when identification is abnormal; release the lock after the check passes so PCBs flow normally. Compared with merely showing errors on a software interface, rail interlocking implements error-proofing at the physical release stage, reducing risks caused by human oversight.

4. Interfacing with KIC ProBot to correlate barcode with profiling data and link abnormalities

For PCBs that pass the check, the system sends their barcodes to the KIC ProBot automatic temperature profiling system via communication interface, and the KIC side establishes the association between board code and profiling records, providing a basis for later verification of reflow soldering process conditions by board number.

Meanwhile, the pass-station control program receives the PWI exceedance alarm signal output by KIC. When a profiling abnormality is detected, the system links rail locking, alarm light, and on-site prompting to prevent subsequent PCBs from continuing into the reflow oven; when the alarm signal recovers, the associated interlocks are released per on-site control rules.

This achieves coordinated control from furnace-entry identity verification to profiling-abnormality intervention.

5. Abnormality handling and operation logs, supporting on-site analysis

The system provides on-site operational capabilities including abnormality prompts, manual debugging, and manual release after abnormality verification, helping production and equipment personnel handle scanning, communication, and pass-station issues.

At the same time, classified operation logs are generated for key events such as barcode acquisition, check results, equipment control, and alarms. Combined with the profiling data retained on the KIC side, quality personnel can analyze around PCB barcode, production program, and abnormality occurrence time, improving the operability of problem localization.

On-site business closed loop:

PCB in position → automatic scan → Recipe verification → release on match / lock rail and alarm on abnormality → board code sent to KIC → PWI abnormality linkage → event recording and abnormality handling