SENIOR DESIGNSENIOR DESIGNMEEG401 – FALL MEEG401 – FALL

20032003

The Automated The Automated Inspection Inspection

of Paste Coated of Paste Coated ElectrodesElectrodes

Janka Fazekas Chris Haynes

Sean Castorani Ryan Basch

Problem DefinitionProblem Definition

Dade Behring Consumables Dade Behring Consumables Manufacturing would like to automate the Manufacturing would like to automate the inspection of paste coatings on the inspection of paste coatings on the electrodes of ceramic circuit boards.electrodes of ceramic circuit boards.

Dimension® IMT Manufacturing(Current State)

MDS #1

Manual Inspection

(Microscope)

MDS #2

8-upPlates

IROven

Manual Inspection

(Microscope)

ConvectionOven

Manual Inspection

Vision (Camera)

CAM

Labeling(Imaje)

Packaging

Soniscan(Plate

Washer)

8-upPlates

Fluid Channel MemberWasher

FCM

Fluid Channel Member

Dryer

FCM

Housing

Housing / Fluid Channel Member

Assembly

Housing

S600S500

A

Fluid ChannelMember

CL UndercoatReference

CL OvercoatNaK

Batch Rack

Close-up of ChipClose-up of Chip

Mark

Paste-covered electrodes

Flow Chann

el

Close-up of Individual Close-up of Individual ElectrodeElectrode

Project GoalsProject Goals

Eliminate Erroneous, but Believable Eliminate Erroneous, but Believable defectsdefects

Improve Process ErgonomicsImprove Process Ergonomics Improve Production YieldImprove Production Yield Improve Product QualityImprove Product Quality Reduce Labor CostReduce Labor Cost

Wants, Metrics and Wants, Metrics and SpecificationsSpecifications

WantsWants MetricsMetrics Target ValuesTarget Values

PrecisionPrecisionStandard Deviation Standard Deviation

of Camera of Camera MeasurementMeasurement

0.001 in0.001 in

System ReliabilitySystem Reliability% Failed Chips % Failed Chips

PassedPassed0.000006 % ( 5 Std 0.000006 % ( 5 Std

Dev)Dev)

% Good Chips Failed% Good Chips Failed 0.3 % ( 3 Std Dev )0.3 % ( 3 Std Dev )

IntegrationIntegration # of independent # of independent systemssystems 11

Ease of UseEase of Use # of user operations# of user operations 22

Low Cost Low Cost PricePrice < $15,000< $15,000

AppearanceAppearance Surface finish Surface finish PolishedPolished

SimplicitySimplicity # of degrees of # of degrees of freedomfreedom 33

EfficiencyEfficiency Production rateProduction rate 212 sec per board212 sec per board

ConstraintsConstraints

SizeSize--Must be able to operate on a table (approx. 4 Must be able to operate on a table (approx. 4 ft. by 6 ft.)ft. by 6 ft.)

Safety ConcernsSafety Concerns--Must abide by safety rules set forth by Dade Must abide by safety rules set forth by Dade Behring and OSHABehring and OSHA

CleanClean operationoperation--Needs to operate in a clean environmentNeeds to operate in a clean environment

Possible ConceptsPossible Concepts

Concept 1Concept 1

Concept 2Concept 2

Concept 3Concept 3

Stationary CameraXY Table MovementXYZ Marker Movement

XY Camera MovementStationary TableXYZ Marker Movement

Stationary CameraXY Table MovementZ-Axis Marker Movement

Concept 3Concept 3 Lowest Cost Lowest Cost - - Least number of automated Least number of automated

componentscomponents

Simplest DesignSimplest Design - - Least number of degrees of freedomLeast number of degrees of freedom

Easiest to IntegrateEasiest to Integrate - - Least number of programmable Least number of programmable

componentscomponents

Load WaferStart

Process

X-Y MovementTo 1st Half Shot

Camera Analysisof !st Half

X-Y MovementTo Marker Position

Activate Pneumatic Cylinder

X-Y MovementTo 2nd Half

Shot

Camera AnalysisOf 2nd Half

X-Y MovementTo Marker Position

Next Chip

System Process FlowchartSystem Process Flowchart

Bad

Bad

Next Chip

Good

Good

X-Y MovementTo Marker Analysis position

Camera Analysisof Mark

X-Y MovementTo 1st Half

Shot

Camera Analysisof 1st Half

AdvantagesAdvantages

X-Y Table provides fast and X-Y Table provides fast and accurate point to point accurate point to point movementmovement

Camera provides precise and Camera provides precise and repeatable data acquisitionrepeatable data acquisition

Pen provides repeatable and low Pen provides repeatable and low cost marking systemcost marking system

PLC enables complete system PLC enables complete system integrating allowing for push - integrating allowing for push - button operationbutton operation

Camera Camera

Cognex Cognex In-Sight ® 1000CIn-Sight ® 1000C

640 x 480 Resolution640 x 480 Resolution Low-cost, self-contained vision sensor Low-cost, self-contained vision sensor Verifies and sorts parts based on their Verifies and sorts parts based on their

colorcolor Easily configured by PCEasily configured by PC Compatible with Ethernet displayCompatible with Ethernet display

Selection of Necessary Selection of Necessary PartsParts

Parker X-Y Table with Animatics Servo-Parker X-Y Table with Animatics Servo-MotorsMotors

SMC Pneumatic CylinderSMC Pneumatic Cylinder In-Sight 1000C Camera with 25mm lensIn-Sight 1000C Camera with 25mm lens Allen Bradley PLCAllen Bradley PLC Cognex Expansion I/O ModuleCognex Expansion I/O Module Cognex White LED Ring LightCognex White LED Ring Light Misc. Power SuppliesMisc. Power Supplies Manufactured Parts (base plate; camera Manufactured Parts (base plate; camera

holder; marker holder)holder; marker holder)

Final ProductFinal Product

Cognex In-SightCognex In-Sight 1000C Camera1000C Camera

SMC PneumaticSMC Pneumatic Cylinder and Cylinder and Marking PenMarking Pen

Wafer Tray

Parker X-Y Table with Parker X-Y Table with Animatics Servo MotorsAnimatics Servo Motors

Cognex Expansion Module

Allen Bradley PLC

Total System Cost $18,000

ValidationValidation

Stage 1Stage 1: Properly measure electrode : Properly measure electrode dimensions through cameradimensions through camera

Width = 0.15 in

Height = 0.03 in

ValidationValidation

Stage 2Stage 2: : Functionality Functionality Testing – PLC Testing – PLC used to force I/O used to force I/O ensuring all major ensuring all major subsystems subsystems function function independentlyindependently

ValidationValidation

Stage 3Stage 3: System Level Testing - : System Level Testing - Test machine with wafers that contain known defects ensuring entire system functions together properly – Collect and analyze data

Inspected Wafer with defective chips marked

Variance In Camera Variance In Camera MeasurementMeasurement

•Data was collected from 25 trials

•Plotted data vs. +/- 3 standard deviations

Variation in Camera Measurement for 5 Inspections per Analysis

5

5.5

6

6.5

7

7.5

8

0 5 10 15 20 25 30

Trial #

Me

as

ure

me

nt

(th

ou

sa

nd

ths

of

an

in

ch

)

Left Overlap

AverageMeasurementUpper Limit (+ 3*sigma)Lower Limit (- 3*sigma)

DemonstrationDemonstration

Metrics ComparisonMetrics ComparisonWantsWants MetricsMetrics Target Target

ValuesValuesActual Actual ValuesValues Achieved?Achieved?

PrecisionPrecision

Standard Standard Deviation of Deviation of

Camera Camera MeasurementMeasurement

0.001 in0.001 in

System System ReliabilityReliability

% Failed % Failed Chips PassedChips Passed 5 Std Dev5 Std Dev

% Good % Good Chips FailedChips Failed 3 Std Dev 3 Std Dev

IntegrationIntegration# of # of

independent independent systemssystems

11

Ease of UseEase of Use # of user # of user operationsoperations 22

Low Cost Low Cost PricePrice < $15,000< $15,000

AppearanceAppearance Surface finish Surface finish PolishedPolished

SimplicitySimplicity # of degrees # of degrees of freedomof freedom 33

EfficiencyEfficiency Production Production raterate

212 sec per 212 sec per boardboard Fail Questionable

Pass

$13,000

1

3 Std Dev

1

5 Std Dev

Polished

3

165 sec per board

0.0022 in

Handoff PlanHandoff Plan

DocumentationDocumentation Operating Manual and Troubleshooting Operating Manual and Troubleshooting

GuideGuide Engineering/Wiring DrawingsEngineering/Wiring Drawings Parts ListParts List

Safety EnclosureSafety Enclosure Implementation by Dade Behring Implementation by Dade Behring

into Manufacturing Process into Manufacturing Process

Recommendations for Recommendations for ImprovementsImprovements

(Outside Scope of Project)(Outside Scope of Project) Verification of calibration at a Verification of calibration at a

routine intervalroutine interval No inspection if vendor defectNo inspection if vendor defect System self check – verify using System self check – verify using

standard deviationstandard deviation Automatic data collectionAutomatic data collection

Questions?Questions?

Cost AnalysisCost Analysis

Cognex Camera $ 6,000 White Ring Light $ 1,540 Expansion Module $ 500 Filters and Lenses $ 250Parker X-Y Table $ 0Animatics Servo-motors $ 0Pneumatic Cylinder $ 200Allen Bradley PLC $ 3,000Hoffman Enclosure $ 250Misc. Electrical Supplies $ 25080/20 Protective Enclosure $ 350Marking Pen $ 2

Total $12,342

Original ConceptOriginal Concept

Controller limited Controller limited the functionality the functionality of the systemof the system

Robocylinder Robocylinder overly overly complicated for complicated for easy applicationeasy application

Changed XY-table Changed XY-table software to software to ensure reliable ensure reliable movementsmovements