The Automated Inspection of Paste Coated Electrodes SENIOR

The Automated Inspection of Paste Coated Electrodes SENIOR DESIGN MEEG 401 – FALL 2003 Janka Fazekas Chris Haynes Sean Castorani Ryan Basch

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

Dimension IMT Manufacturing ® (Current State) CL Undercoat Reference IR Oven MDS #1 8 -up Plates MDS #2 CL Overcoat Na K Convection Oven Manual Inspection (Microscope) Soniscan Manual Inspection Vision (Camera) Batch Rack (Plate Washer) CAM 8 -up Plates Labeling (Imaje) Housing / Fluid Channel Member Assembly FCM Packaging Housing S 600 Fluid Channel Member Washer Fluid Channel Member Dryer Housing S 500 A Fluid Channel Member FCM

Close-up of Chip Mark Flow Channel Paste-covered electrodes

Close-up of Individual Electrode

Project Goals Eliminate Erroneous, but Believable defects n Improve Process Ergonomics n Improve Production Yield n Improve Product Quality n Reduce Labor Cost n

Wants, Metrics and Specifications Wants Metrics Target Values Precision Standard Deviation of Camera Measurement 0. 001 in % Failed Chips Passed 0. 000006 % ( 5 Std Dev) % Good Chips Failed 0. 3 % ( 3 Std Dev ) Integration # of independent systems 1 Ease of Use # of user operations 2 Low Cost Price < $15, 000 Appearance Surface finish Polished Simplicity # of degrees of freedom 3 Efficiency Production rate 212 sec per board System Reliability

Constraints n Size -Must be able to operate on a table (approx. 4 ft. by 6 ft. ) n Safety Concerns -Must abide by safety rules set forth by Dade Behring and OSHA n Clean operation -Needs to operate in a clean environment

Possible Concepts n n n Concept 1 Stationary Camera XY Table Movement XYZ Marker Movement Concept 2 XY Camera Movement Stationary Table XYZ Marker Movement Concept 3 Stationary Camera XY Table Movement Z-Axis Marker Movement

Concept 3 n Lowest Cost - Least number of automated components n Simplest Design - Least number of degrees of freedom n Easiest to Integrate - Least number of programmable components

System Process Flowchart Load Wafer Start Process Next Chip X-Y Next Chip Movement X-Y Movement To 1 st Half Shot To 1 st Half Camera Analysis of Mark Shot Camera Analysis of 1 st Half of !st Half Bad X-Y Movement To Marker Position Good X-Y Movement To 2 nd Half Shot Activate Pneumatic Cylinder Good Camera Analysis Of 2 nd Half Bad X-Y Movement To Marker Position X-Y Movement To Marker Analysis position

Advantages X-Y Table provides fast and accurate point to point movement n Camera provides precise and repeatable data acquisition n Pen provides repeatable and low cost marking system n PLC enables complete system integrating allowing for push - button operation n

Camera n n Cognex In-Sight ® 1000 C n n n 640 x 480 Resolution Low-cost, self-contained vision sensor Verifies and sorts parts based on their color Easily configured by PC Compatible with Ethernet display

Selection of Necessary Parts n n n n Parker X-Y Table with Animatics Servo-Motors SMC Pneumatic Cylinder In-Sight 1000 C Camera with 25 mm lens Allen Bradley PLC Cognex Expansion I/O Module Cognex White LED Ring Light Misc. Power Supplies Manufactured Parts (base plate; camera holder; marker holder)

Final Product Cognex In-Sight 1000 C Camera Allen Bradley PLC Wafer Tray Parker X-Y Table with Animatics Servo Motors SMC Pneumatic Cylinder and Marking Pen Cognex Expansion Module Total System Cost $18, 000

Validation n Stage 1: Properly measure electrode dimensions through camera Width = 0. 15 in Height = 0. 03 in

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

Validation n Stage 3: 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 Measurement • Data was collected from 25 trials • Plotted data vs. +/3 standard deviations

Demonstration

Metrics Comparison Wants Metrics Target Values Actual Values Precision Standard Deviation of Camera Measurement 0. 001 in 0. 0022 in % Failed Chips Passed 5 Std Dev % Good Chips Failed 3 Std Dev Integration # of independent systems 1 1 Ease of Use # of user operations 2 Low Cost Price < $15, 000 Appearance Surface finish Polished $13, 000 Polished Simplicity # of degrees of freedom 3 3 Efficiency Production rate 212 sec per board 165 sec per board System Reliability Achieved? 1 Fail Questionable Pass

Handoff Plan n Documentation Operating Manual and Troubleshooting Guide n Engineering/Wiring Drawings n Parts List n Safety Enclosure n Implementation by Dade Behring into Manufacturing Process n

Recommendations for Improvements (Outside Scope of Project) Verification of calibration at a routine interval n No inspection if vendor defect n System self check – verify using standard deviation n Automatic data collection n

Questions?

Cost Analysis Cognex Camera $ 6, 000 White Ring Light $ 1, 540 Expansion Module $ 500 Filters and Lenses $ 250 Parker X-Y Table $ 0 Animatics Servo-motors $ 0 Pneumatic Cylinder $ 200 Allen Bradley PLC $ 3, 000 Hoffman Enclosure $ 250 Misc. Electrical Supplies $ 250 80/20 Protective Enclosure$ 350 Marking Pen $ 2 Total $12, 342

Original Concept n n n Controller limited the functionality of the system Robocylinder overly complicated for easy application Changed XY-table software to ensure reliable movements