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InspectScan VPI (Virtual Product Inspection)

InspectScan VPI (Virtual Product Inspection). Agenda. INTRODUCTION TECHNOLOGY Product Philosophy Flatbed Scanners Hardware Configuration PRODUCTS Overview Pre Production – Set Up – Virtual Production Programming – Assembly Programs – Vision Files SUMMARY.

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InspectScan VPI (Virtual Product Inspection)

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  1. InspectScan VPI (Virtual Product Inspection)

  2. Agenda • INTRODUCTION • TECHNOLOGY • Product Philosophy • Flatbed Scanners • Hardware Configuration • PRODUCTS • Overview • Pre Production – Set Up – Virtual Production • Programming – Assembly Programs – Vision Files • SUMMARY

  3. InspectScan VPI (StencilScan Lite + Assembly Module + Component Module) Low Cost - Flexible System Avoid costly Rework Set up processes before production floor SPC sampling during production versus High Cost – Single Function System

  4. Introduction • ScanCAD Founded in 1990 • Global Sales & Support Network • Smart Sonic – OEM Partner since 2001 • Over 900 Customers in 46 Countries • First Systems Installed in 1987 • Vision Systems • PC- Based • Low Cost, Easy to Use, • Multi purpose

  5. InspectScan VPI Product Philosophy • Newest Technology • Consumer driven scanner hardware platform • Customer investment protected since 1987 – upgrade path • Applications • Board assembly and hybrid microcircuit production • Process control and setup for PCB’c, stencils, screens, artwork, printed & dispensed materials • Flexible • Many applications on one system • Process control, programming and inspection on one system • Low Cost • Best price/performance ratio in the industry • Many applications at much lower cost than most single function systems • Easy-to-use • Compare to CAD, Gerber or golden part in minutes • Scan and compare parts at all stages of production utilizing multiple layers

  6. Inspection vs.. Measurement Smart Sonic Inspection Systems Check 100% of Part – Ensure no bad parts ship Output is Pass/Fail vs. User Defined Tolerance Low Cost Overlay CAD and Image - Very Easy to Program Fast - Inspect parts with millions of features in minutes Multi-Purpose - Inspect multiple part types and create data Can also provide some measurement capability Complimentary to measurement systems - many customers have both. (Measurement systems not able to inspect 100% of part)

  7. Defects Found by Inspection 1 mil blockage Wafer Bump Stencil Over 350,000 Apertures – 100 um diameter

  8. Technology

  9. Flatbed Scanner Technology • Existing Vision Platform • Camera, lighting, motion control “all” in one unit • PC technology product cycle benefit • Worldwide availability and support • Excellent price/performance ratio • Low risk – not proprietary hardware • Very High Resolution • 200 – 12,800 dpi, Color or B&W • A3 size scan area – inspect up to 800 X 800 mm • Accurate • Calibrated system with glass plate • Software performs self diagnostic test • Robust Hardware • Small footprint • High MTBF “…a very smart package”

  10. Scanner Evolution (1990 – 2010) True Optical MpixelsTotal YearScannerResolution(DPI)per sq. in.MPixels 1990 Model F1 400 x 400 0.16 31 1998 Model E8 800 x 1600 1.28 247 2001 Model E16 1600 x 3200 5.12 988 2004 Model E24 2400 x 4800 11.50 2224 2004 Model E32 (A4) 3200 x 6400 20.50 2002 Model E24 Scanner equal to 440 5Mpixel Cameras

  11. Hardware Configuration • Desk & Scanner • InspectScan VPI & StencilScan Lite • Contact System • Scanner Faces Up • Part Faces Down • Dry parts or • 3D & wet parts with standoff • Lighting • Top or bottom • Calibrated System • Glass plate • Programming • CAD, Gerber or golden parts A3 size scanner

  12. Hardware Configuration • Scanner-Only • Contact System • Scanner Faces Up • Part Faces Down • Dry parts or • 3D & wet parts with standoff • Lighting • Bottom • Calibrated System • Glass plate • Programming • CAD, Gerber or golden parts (Assembly Module) • Golden parts (Component Module) A3 size (Assembly Module) A4 size (Component Module)

  13. InspectScan VPI

  14. Pre-Production Process Control PCB Assembly • InspectScan VPI • Virtual Product Inspection With a single system check: (StencilScan Lite) • Design - holes, slots, real estate, manufacturability… • Components - multi vendor, shape, color, size… • Bare Boards - FR4, Ceramic, Flex (multi vendor, variables…) • Wet Boards - paste, adhesive, coatings, etc. • Stencils/screens - stretch, missing, blocked or damaged apertures All variables come together in VIRTUAL system before Production First article inspection and SPC during production And in addition, same system can: (Assembly Module) • Create assembly programs from CAD, Gerber data or scanned images • First article inspection of loaded boards - SMT, Through hole, Connectors, etc. • Create stencil Gerber data • Create component vision files for SMT placement machines (Component Module)

  15. Pre-Production Process Control PCB Assembly InspectScan VPI PCB’s with Paste or Adhesives Bare PCB’s Flex Circuits Components Stencils Loaded PCB’s

  16. Pre-Production Process Control Hybrid Microcircuits InspectScan VPI Substrates with Paste or Adhesives LTCC or Thick Film Print Holes in Substrates Artwork Loaded Substrates Screens

  17. Process Control and Inspection Functions

  18. Input Gerber Overlay and Inspect Scan PCB in Color Convert to Raster Process Control & Set Up Store Images of All Assembly Steps and Gerber/CAD in Layers to Easily Find Issues before Production! • Compare PCB to Gerber • Find PCB Problems before Production • Compare to PCB or Stencil Gerber

  19. Input Stencil Gerber Overlay and Inspect Scan Stencil in Color Convert to Raster Process Control & Setup • Compare Stencil to Gerber • Find incoming stencil problems • Compare to original or modified Gerber cut file • Find blocked apertures or stretch after cleaning

  20. Overlay and Inspect Scan PCB in Color Convert PCB to Raster Scan Stencil Process Control & Setup • Compare PCB to Stencil • Avoid production problems • Similar method to compare new PCB to PCB in production

  21. Step through Remaining Components Scan PopulatedPCB in Color Input and Overlay CAD Step to First Component Process Control & Setup • First Article Component Placement Inspection • Existing method such as assembly drawings or overlays highly prone to operator error and overlays add cost • Overlay CAD on board image for operator verification • Eliminate errors - Zoom in or out, CAD info available on status line

  22. Process Control & Setup • First Article Component Placement Inspection • View of full screen including status line with CAD data

  23. Process Control & Setup • Other Capabilities: • Inspect Artwork or Emulsion Screens vs.. Gerber data or Golden Part • Compare Components from Different Suppliers • Inspect Wet Material versus Gerber or Golden Part

  24. Inspection Process In seven quick and easy steps! • Import Gerber file • Scan stencil or screen at appropriate dpi • Super-impose scanned image and Gerber • Fine align scanned image and Gerber • Inspect automatically • Review errors • Print certification report

  25. 1. Import Gerber File The imported Gerber is displayed in green

  26. 2. Scan The PCB, stencil, paste, etc is scanned at the appropriate dpi and displayed in blue

  27. 3. Overlay Scanned Image and Gerber The scanned image and Gerber image are super-imposed at a common point

  28. 4. Fine Align Any remaining skew between the two images is corrected using the “Fine Alignment” function

  29. 5. Inspect The automatic inspection process offers a variety of inspection levels and options to verify aperture position, shape and size

  30. 6. Review Errors Errors are highlighted in red and sequentially numbered for easy viewing

  31. 7. Print Certification Report Add the report to any letterhead or certificate

  32. Programming Functions

  33. Board Programming Generate programs off-line for automated assembly machines using bareboards, artwork, Gerber or ASCII CAD. • Create assembly programs from scanned images of PCB’s, artwork or stencils when no CAD or Gerber exists • Create assembly programs from Gerber data • Supports surface mount, through hole, test and AOI equipment • Stand-alone or compliments installed CIM packages

  34. Programming Process In three quick and easy steps! • Input data • Process data • Output program files

  35. Film Gerber / CAD Stencil / Screen Bareboard 1. Input Data • Scan: • Boards • Stencil / Screens • Film • Import Gerber and /or CAD data

  36. 2. Process Data • Automatic centroid extraction • Merge BOM • Part # • Package # • Reference ID • Etc.

  37. Sample Machine Output 3. Output Program Files • Placement files for 50+ machines • Component vision files • Stencil files (Gerber-274X) • Test Data (Drill files) • Depanel Data (Route files) • Documentation: • DXF • HPGL • BMP • TIFF • PCX

  38. AmiStar ASCII Assembléon Asymtek CAM/A LOT Contact Systems Control Automation CR Technology Creative Automation DEK Dynapert Europlacer Four-PI (HP) Fuji Generic Hitachi Juki KME LPKF MVT Mydata Panasonic/Panasert Philips Tyco/Quad InspectScan VPI Supports: Board Programming Outputs Robotic Process Sys. Royonics Sanyo Siemens SMTech Sony TDK Tenyru Universal Vi Technology Yamaha Zevatech

  39. Barco/Gerber All machines (plotters & AOI) CAMTEK CAM/350 & ECAM-ACT CIMBridge FabMaster GenCAD GraphiCode GC-Place & GC-CAM LPKF Laser Stencil Cutting Lavanier Lumonics Mitron PanaPRO SIPLACE PRO Technomatix Unicam/Fujicam Unicraft - Japan WYSE Software Many others… InspectScan VPI CIM Supports: Board Programming

  40. Component Programming Scan components and generate measurement data automatically for component libraries--No more calipers. • Stand-alone workstation to create component vision files • Quick • Easy • Accurate

  41. Component Programming Build Component Libraries • Supports SMD, IMD, Odd form, etc. • Scan the component in color • Fill in the requested fields • Output the component data • Component image and data stored for future use

  42. Component Programming Output Component Data Sheets

  43. SMT Magazine Article • GOOD NEWS:  ScanINSPECT VPI  ROI ARTICLE: • “Using Stencil Design to Reduce SMT Defects” - SMT Magazine, April 2006 • www.electroiq.com/index/display/smt-article-display/252912/articles/smt/volume-20/issue-4/features/features/using-stencil-design-to-reduce-smt-defects.html • Case Study of benefits of making a STENCIL that matches the PCB • 125,000 units over three weeks to obtain the data • Board measurements made using CMM at 6 reference points • Modify Gerber data to match board • Stencil made to PCB instead of Gerber • 43% solder paste defect reduction…..!!! Click Here

  44. Figure 5.Pad positional deviation measurements (mils) between a stencil and PCB prior to scaling. Relative to the original Gerber data, some pads were off by as much as 0.005”-0.006”. Figure 6.The same X, Y pad aperture deviation after scaling the stencil to the PCB. SMT Magazine Article - continued

  45. Summary

  46. InspectScan VPI • Catch problems BEFORE production floor – “Virtual problem” • Catch problems DURING production – “Sampling for SPC” • Eliminate REWORK • Environmentally friendly • Quick program set up and change over • Reduce operator, engineer & management stress • Focus on SOLUTIONS versus problems Eliminate SURPRISES…!!!

  47. Smart Sonic Systems • Proven - 900+ Systems Installed in 46 Countries • Economical - Low Cost Systems - Quick ROI • Easy to use - User Friendly, PC Based • Off-line - Small Footprint Desk or Desktop • In-line - Small Footprint Conveyor • Accurate - Calibrated System • Flexible - Many Inputs / Outputs • Multi-purpose - All Software on Same Platform • Powerful - 50 micron (2mil) Features • Upgradeable - Annual Releases Since 1990 • Environment - Minimize Scrap and Rework

  48. SMART SONIC CORPORATION837 E. 79 Street · Cleveland, Ohio 44103 · U.S.A.TEL: +1-818-610-7900 · FAX: +1-216-881-8950E-mail: smt@SmartSonic.com · Web Site: www.SmartSonic.com

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