Product Overview

The ZWD-AIT-502 Automatic Milling & Implanting Machine is a fully integrated, high-precision industrial system designed to perform the complete sequence of cavity milling and IC module implantation for standard ISO 7816 smart cards. Combining advanced mechanical engineering with intelligent process control, this machine transforms plastic card bodies into functional smart cards with exceptional speed, accuracy, and reliability. It is engineered for high-volume production environments where efficiency, yield, and consistent quality are paramount.

Core Process Integration

The system executes a seamless, fully automated workflow:

1. Card Feeding & Verification: A single high-capacity magazine holds up to 500 cards. Integrated electronic eyes and sensors perform multiple checks:

   • Card Presence & Positioning: Ensures each card is correctly loaded.

   • Double Card Detection: Prevents jams by detecting and stopping on multiple card feeds.

   • Orientation Detection: Verifies card direction; incorrect cards are automatically ejected, and continuous errors trigger an alarm.

2. High-Precision Milling: A key strength of the system.

   • Programmable Milling Parameters: Groove profile, depth, and level can be independently programmed via an intuitive software interface, offering unparalleled flexibility for different module types.

   • Superior Accuracy: Achieves exceptional milling precision (X, Y = ±0.015 mm, Z = ±0.01 mm) using a high-speed spindle (1000-25000 r/min) and a smooth, high-abrasion, fixed-fixture milling head that requires no manual plane adjustment.

   • Post-Milling Inspection: An integrated dust detection function ensures the milled cavity is clean before implantation, guaranteeing optimal bonding quality.

3. Intelligent Module Handling & Implantation:

   • Module Feed & Preparation: Automatically feeds module tape, applies adhesive, and punches individual modules.

   • Module Orientation: A 180-degree rotation mechanism accommodates modules from tapes supplied in different orientations.

   • Three-Stage Hot Implantation: Utilizes three independent hot implanting stations with a floating bottom board for automatic height adjustment, ensuring consistent pressure and temperature application for secure bonding.

   • Cooling Station: Stabilizes the implanted module and adhesive.

4. Quality Assurance & Testing:

   • Module Presence Detection: Alarms and stops if a card proceeds without a module.

   • ATR (Answer To Reset) Test Station: Performs a fundamental electrical functionality test on the completed card.

   • Automatic Sorting: Cards failing the ATR test are automatically picked out and segregated.

Key Features & Advantages

• All-in-One Efficiency: Integrates milling, cleaning, implanting, and testing into one compact machine, minimizing handling and maximizing throughput up to 3,500 Units Per Hour (UPH) with a 99.5% yield.

• Unmatched Milling Precision & Flexibility: Software-programmable milling paths and depths, combined with ultra-high mechanical accuracy, allow for perfect cavity creation for any ISO module.

• Robust Quality Control: Multiple in-process inspections (dust, module presence, orientation, ATR) ensure near-zero defect rates and prevent waste.

• User-Centric Design:

  • IPC + Servo Control: Ensures high precision and stable operation.

  • Multi-Point Operation: Three sets of control buttons on the left, right, and rear facilitate convenient access.

  • Secure Software: Password-protected access levels (Operator, Administrator) for parameter security.

• High Reliability & Safety: Built with CE-compliant circuitry, durable components, and comprehensive alarm systems for safe and dependable 24/7 operation.

• Compact Footprint: Efficient design (2000 x 800 x 2200 mm) saves valuable production floor space.

Technical Specifications

Applications

This machine is essential for manufacturers of:

• Financial Smart Cards: Credit, debit, and ATM cards.

• Identification Cards: National IDs, driver's licenses, corporate access badges.

• Telecom Cards: SIM cards.

• Healthcare Cards: Insurance and patient ID cards.

• Any application requiring high-volume, high-precision milling and implantation for contact-based smart cards.

Why Choose the ZWD-AIT-502?

For smart card manufacturers, precision in cavity milling directly translates to module retention strength and card longevity. The ZWD-AIT-502 excels by offering the most accurate and programmable milling solution on the market, coupled with a robust implantation process. Its high throughput, exceptional yield rate, and integrated quality gates make it a cost-effective and reliable powerhouse for any serious production line aiming for zero defects and maximum output.