This full Auto Contactless Card Inlay Sheet Production Line realizes the whole automation process  of contactless card Inlay sheet production. No manual interventions are needed, the operator is only for loading and unloading the materials when required.

This machine reduces labor costs and error rates, with a significant improvement in efficiency. No green tape or glue consumables are required in the process. All the inlay making process are done by one pass, which could ensure the machine accuracy.

The compact machine design saves space and cost. It runs safely and stably, improving production efficiency and product quality.

Ø Realize inlay production: chips pick and placer, wire embedding, chip welding, inlay test, pre-lam sheets collating are all in one process automatically.

Ø The collating sheets could be directly sent to laminator for lamination, after lamination, the Prelam sheets are finished.

Ø Chips pick and placer, wire embedding, chip welding processes are in one pass could ensure the chips position accuracy, which could improve the contactless cards good rates.

Features:

1. The feeding station enables convenient sheets feeding via a loading cart. The feeding mechanism is liftable, equipped with an air-blowing separation design to prevent double sheets, and the feeding height is precisely controlled by a motor and sensors.

2. The sheets transfer module precisely conveys sheets via a module after sucking them with suction cups, effectively feeding and prevent double sheets feeding.

3. The pre-positioning station achieves deviation correction via air cylinders system, which could ensure the sheet feeding position is accurate on the working tables. And this station is with a fiber optic detection function, and can accurately identify double sheets then alarm.

4. The correction station achieves precise correction via air cylinders system.

5. The chip pick and place station realizes precise positioning and feeding of chips via a vision system with a flexible vibration tray. Below are details:

a) The servo system handles the picking and alignment processes, and through the coordinated movement of servo modules, the chips are rapidly and accurately placed into the designated positions.

b) Chips transfer is driven by a servo system, and the air nozzle is controlled by an air cylinder to perform pick-and-place process. The air nozzle includes a vacuum detection function, which monitors the chip pick and place status in real time, and the placement position parameters of each chip module can be adjusted independently.

c) Each chip’s position on the vacuum plate is equipped with an independent hard material block to prevent damage to the vacuum plate caused by chip welding

6. The antenna embedding station adopts ultrasonic generators for wire embedding. The vacuum sheet suction could ensure flat and reliable wire embedding. This station is equipped with wire breakage detection function, which could monitor wire break anomalies in real time and trigger alarms and stop the machine when necessary.

7. The wire embedding software supports automatic import of customer-defined graphics such as CAD file for wire embedding. The speed of each line or arch segment can be set independently, and the wire jumper height can be adjusted flexibly.

8. The welding station adopts inverter resistance welding technology. The servo system controls the precise movement of the welding tips, ensuring welding accuracy and consistency. The machine is equipped with an automatic cleaning function for welding tips; the tips can be automatically polished by steel brushes and sandpaper, reducing manual polishing cost.

9. The auto Inlay Test station could automatically identify the NG contactless cards. Defective products are automatically marked and separated into NG collection station, while qualified sheets transfer into the next process.

10. The sheet collating and spot welding station achieves positioning correction via air cylinders and with high-efficiency ultrasonic welding for accurate, efficient welding process. The collating sequence, sheets picking quantity, and welding quantity are all configurable. Thickness detection device is with instant abnormal alarm prevents stacking errors, ensuring the sheets are OK for Pre-lam sheets.

11. The X axis, Y-axis sheets transfer units enables automatic sheets collection. When the sheets are full in the collection station, the operator could use the unloading cart to move them to next lamination process.

12. The machine is managed by professional PC+PLC control system, ensuring coordinated cooperation between stations, automatic cyclic work switching. Product transitions between stations: no downtime required. Meanwhile, all production line links support personalized customization and upgrading to flexibly adapt to different production needs.

Parameters

Q1: What is the main function of this machine?
A1: This fully automated line produces contactless card inlay sheets from start to finish. It handles sheet feeding, vision-based chip placement, antenna embedding, chip welding, inlay testing, and pre-lam sheet collating without manual intervention.

Q2: What is the production capacity?
A2: Standard capacity is 2,000 chips per hour. Actual speed varies based on chip layout and parameter settings.

Q3: How many operators are required?
A3: Only 1 operator is needed for loading/unloading materials. The entire process is automated.

Q4: Does it require consumables like glue or tape?
A4: No. The machine uses ultrasonic welding and precise embedding, eliminating the need for green tape or glue, reducing costs and waste.

Q5: How is positioning accuracy ensured?
A5: A vision system aligns chips precisely. The servo-driven placement and single-pass welding ensure high accuracy and a high yield rate.

Q6: Can it handle custom antenna designs?
A6: Yes. The software supports importing CAD files for custom antenna patterns. Line speeds and jumper heights are adjustable.

Q7: How does the machine detect defects?
A7: An automatic inlay test station identifies NG cards. Defective products are marked and separated into an NG station, while good sheets proceed.

Q8: Is the welding tip maintenance difficult?
A8: No. The machine features an automatic cleaning function with steel brushes and sandpaper, reducing manual polishing costs.

Q9: What is the machine footprint?
A9: Dimensions: L4850mm × W340mm × H225mm. The compact design saves floor space.

Q10: What are the power requirements?
A10: Input: AC380V, 50Hz. Power: 20KW. Compressed air: 0.6MPa, 400L/min.