Overview
According to Moore's Law, the number of transistors doubles on integrated circuits every 18 months. This shows that the electronic components become smaller and more complex as technology improves. For SMT/PCB board, same story applies. More components are needed to be implemented and the gaps between pins are narrower. Therefore, it is inevitable to have an accurate and fast dispenser for mass production. With Advantech's automation solution, the PC-based operating system can cope with the technology growth and future trend.
Printed Circuit Boards are used in virtually every electronic device today, from cellular phones and personal computers to industrial and medical machinery. One of the most integral steps in assembling Circuit Boards is the solder placement. Our customer was having issues in the creation of their Circuit Boards with misplaced and weak solderjoints. Furthermore, they were using 2 separate machines for 2D solder inspection. To save costs, increase reliability, and speed up the inspection process, the customer wanted only 1 machine that could handle machine vision and control with 3D solder inspection capabilities.
By using the same system configuration, it can be fulfill following segmentation's machineries.
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Solder Paste Inspection |
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SMT/DIP Mounter |
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PCB Separator |
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Dispenser |
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Reflower |
Application
Project Requirements
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Our customer was using an outdated system that required 2 expensive machines, one for machine vision and one for machine control. Furthermore, this system was only capable of 2D solder inspection, which is not good at judging the corners/angles of the placement and can cause weak connections, leading to faulty boards and potential short-circuits. |
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They desired to have an entirely new system, with the following requirements: |
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They wanted 1 machine that could handle both machine vision and control |
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The system needed to have 3D solder inspection capabilities |
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They wanted a higher-performance PC-based system |
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The system needed to have high inspection accuracy with high-speed motion control |
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They wanted a system thatrequired lessmanagement |
Solution Description
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The system is comprised of an Optical Inspection machine which examines the surface of the PCB board. In the machine architecture, there are 2 subsystems, one for moving the PCB board and the other for visual quality inspection. These systems work independently within the machine providing a combined solution. |
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In this application, the motion "trajectories" are sent from the host to the drives. The drives interpret the trajectories and drive the servo motors accordingly. The drives also run supervisory monitoring programs and can execute a programmed script that is stored in flash memory. |
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Advantech's PCI-1240U was applied for the highspeed motion control, giving the added performance from motors. For the I/O card architecture, Advantech's PCI-1751 DI/O card is applied, helping the moving motor control different lighting forvisual judgment, which helps make the inspection clear and reliable. |
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Having two subsystems running independently (automatic soldering application and automatic visual inspection) with the ability to interact with each other for coordinated motion, allowed the overall machine to provide 20% more throughput. This coupled with a quicker changeover process, provided greater machine utilization when smaller production runs dictated machine usage. |
Conclusion
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By combining Advantech's PCI-1240U and PCI-1751 cards, a high-performance, |
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highly reliable, and cost-effective solution was found. The customer now had 1 machinethat controlled machinevision and motioncontrol, with 3D solder inspection capabilities. Furthermore, the system provided the following benefits:
- 3D solder paste printing inspection machine
- Ultra simple and highly precise in-line PCB inspection system
- Ultra high-speed inspection
- Real-time judgments of failed patterns
- High-speed and easy Human Machine Interface
- SPC (Statistical Process Control) System providing Online fault Pareto listing
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The main purpose of an SPC (Statistical Process Control) System is to collect quality- |
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related data during production process for further statistical analysis, and to discover any abnormality in theproduction process. |
Advantech provides One-stop Shopping service and provides the dedicated driver terminal module for popular motors/drivers to get rid of wiring riskfor engineers. We also have dedicated and experienced AEsupport teamtoshorten ourcustomers development time.
Features
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Centralized motion controlarchitecture |
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One-stop shop form computing platform to motion control interface |
Advantages
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Dedicated driver terminal module for popular motors/drivers |
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Most stability and field proven isolation hardware designed |
Benefits
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Ease to integrate different brandmotors/drivers |
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Save wiring and maintenanceeffort |
Product
HMI S/W
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Microsoft Visual C++ |
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Microsoft Visual C++
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Control Drivers
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Device Driver and Utilities |
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Advantech DLL driver
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Serial Communication Cards
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PCI-1611U |
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4-port RS-422/485 Universal PCI Communication Card with Isolation & EFT Surge Protection
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Machine Vision
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Machine VisIon Controller |
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Standalone Machine Vision Controller
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Data Acquisition Card
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PCI-1711 |
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PCI-1758UDIO |
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100 kS/s, 12-bit, 16-ch SE Input PCI Multifunction Card
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128-ch Isolated Digital I/O Universal PCI Card
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PCI-1724U |
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14-bit, 32-ch Isolated Analog Output Universal PCI Card
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OS
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Windows XP
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Embedded Automation Computers (UNO)
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UNO-3072 |
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Intel® Pentium® M UNO w/2 x PCI slot, 1 x PC Card
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Industrial Monitors
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FPM-3120G |
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FPM-3150G |
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12.1" SVGA Industrial Monitor with Resistive Touchscreen and Direct-VGA Port
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15" XGA IndustrialMonitor with Resistive Touchscreen, Direct-VGA and DVI Port
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