Upload
others
View
3
Download
0
Embed Size (px)
Citation preview
©2018 Creative Electron, Inc.
The X-Factor - How X-ray Technology is Improving the Electronics Assembly Industry
Dr. Bill CardosoCreative Electron, Inc.
+1 760.752.1192 [email protected]
Summary for today
1. Electronic component inspection and failure analysis.2. Component counting and material management.3. Reverse engineering.4. Counterfeit detection.5. Real-time defect verification.6. Computed tomography (CT) techniques and how to differentiate between 2D, 2.5D,
and 3D x-ray inspection.7. Design for manufacturing (DFM) and design for x-ray inspection (DFXI).8. Voids, bridging, and head-in-pillow failures in bottom terminated components (BTC).9. Artificial Intelligence and x-ray inspection
©2018 Creative Electron, Inc.
Where Are Defects Introduced?
Counterfeit Components
Defects associated with paste applicationExcess solderSolder bridgesInsufficient solder
Solder Paste Application Defects
Component Placement Defects
Defects associated with component placementMisalignmentPolarityMissing component
Reflow Oven Defects
Defects associated with the reflow profileVoidingBridgingSolder ballsExcess solderInsufficient solder
Statistical Process Control
Manufacturing process quality assurance.Solder joint measurement data, collected during x-ray test, can be statistically analyzed to identify manufacturing drifts, trends and other relevant process quality issues.
Principles of x-ray inspection
8
X-ray imaging 101: the bottom terminated component, side view
BTC
PCB
Solder Balls Side View
PCB
X-ray imaging 101: the BGA, top view
Solder Balls
BGA
X-ray image of BGA
QFN assembly with excess voiding
Detail of open pin in QFN package
Void Measurement
Solder voids in LED assembly
BGA Inspector
Dual EnergyHigh Energy Image Low Energy Image
Dual Energy Image
PATENT PENDING
The best – and worse – BGA assembly1. COPLANARITY
2. SHORT
3. HEAD IN PILLOW
4. OPEN
9. MISSING
8. SHAPE
7. VOIDS
6. SOLDER MASK 5. SPLATTER
Design For Inspection: Think 3D!n Components on both sides of board align in such a way it’s difficult
to assess defects¨ Overlapping BTC ¨ Caps under QFN and BGA¨ Heat sinks
n How to avoid it¨ ($) Design for Inspection¨ ($$) 2.5 or ($$$$) 3D x-ray inspection
BGA 2D x-ray
BGA 2.5D x-ray
So what’s 3D X-Ray Inspection (Computed Tomography)?
Principle of Planar CT: 3D x-ray
Large AreaDetector
Steer-ableX-Ray Source
Inspection Plane
Multiple Transmission Images
Principle of Planar CT
Use multiple off-axis x-ray images to separate top/bottom overlapping or obscured solder connections
QFP
ResistorPCB
Top Side
Bottom Side
Cross Section x-ray provides the capability to generate un-obscured views of top and bottom side components
2D
2.5D
3D
Design for Inspection
n Think carefully about component placement when designing PCBn Place parts so 2.5 and 3D x-ray are not needed. n Goal is to have the whole board inspected with 2D x-ray
¨ Faster¨ Better quality¨ Cheaper
Power components under BGA
Caps under BGA
Caps under QFN leads
Caps under BGA balls
Sample
Voiding
Complex construction
Caps and QFN
QFN overlap
Heat sink
Heat sink: x-ray
Heat sink removed: x-ray
Think 3D!
n X-rays are a requirement when inspecting BTCn DFM + DFI: Easier to design for inspection n Some applications require 2.5D & 3D x-rayn Miniaturization major driver for high resolution, high
magnification, x-ray inspection
Design for Inspection – DFI
n The right time to think about x-ray inspection is during PCB layout
n After board is assembled is too late to improve x-ray inspection ability
Counterfeit Electronics
Surplus stock of electronic components dumped into the market further establishing the broker and grey marketsHuge amounts of scrap electronicsComponents made obsolete Need for short delivery timeMassive cost reduction pressures on OEM buyers for double digit price reductionsBuying and selling via the internet became common practice
The counterfeit electronics problem
44
Component Harvesting
45
Only expensive parts are counterfeited…
Anything wrong with these caps?
What happens when you got the wrong cap?
Component Counting and Material Management
©2018 Creative Electron, Inc.
Material Management 101
n What does a factory do?¨ Moving, Storing, Transforming
n What materials need to be purchased?n Who will supply these materials?n When do these materials need to be purchased?n How much of these materials need to be purchased?
©2018 Creative Electron, Inc.
Just-In-Time Inventory vs. Reality
n Too little inventory¨ Results in costly production line stoppages
n Too much inventory¨ Wasted cash sitting on the shelves
n To achieve best balance, real time data counts must be accurate
©2018 Creative Electron, Inc.
Part Counting
X-ray image taken of entire reel of components. Image is analyzed and component type, quantity, and defects can be reported back to operator.
©2018 Creative Electron, Inc.
X-ray Part Counting Benefits
n Fast (15-30seconds per reel)n Accurate Countbacks (99%+)n Component Type Identificationn Counterfeit Detectionn Integration with MRP System
©2018 Creative Electron, Inc.
Artificial Intelligence
30-second intro to artificial intelligence (AI)
X ? YX Y2 40 03 6-5 -1010 20
x2
©2018 Creative Electron, Inc. www.creativeelectron.com
Automatic Phone Inspection
MADE IN USA
12Confidential - Do not duplicate or distribute without written permission from Creative Electron Inc
©2018 Creative Electron, Inc. www.creativeelectron.com
Automatic Phone Inspection
MADE IN USA
13Confidential - Do not duplicate or distribute without written permission from Creative Electron Inc
©2018 Creative Electron, Inc. www.creativeelectron.com
Automatic Phone Inspection
MADE IN USA
10Confidential - Do not duplicate or distribute without written permission from Creative Electron Inc
©2018 Creative Electron, Inc. www.creativeelectron.com
Automatic Phone Inspection
MADE IN USA
11Confidential - Do not duplicate or distribute without written permission from Creative Electron Inc
©2018 Creative Electron, Inc. www.creativeelectron.com
Automatic Phone Inspection
MADE IN USA
14Confidential - Do not duplicate or distribute without written permission from Creative Electron Inc
©2018 Creative Electron, Inc. www.creativeelectron.com
Automatic Phone Inspection
MADE IN USA
15Confidential - Do not duplicate or distribute without written permission from Creative Electron Inc
www.creativeelectron.com
Medical Devices
MADE IN USA
19Confidential - Do not duplicate or distribute without written permission from Creative Electron Inc©2018 Creative Electron, Inc.
©2018 Creative Electron, Inc. www.creativeelectron.com
Medical Devices
MADE IN USA
20Confidential - Do not duplicate or distribute without written permission from Creative Electron Inc
Thanks for your time!+1 [email protected]
www.creativeelectron.com