1. SENIOR DESIGN MEEG401 – FALL 2003 The Automated Inspection of Paste Coated Electrodes Janka Fazekas Chris Haynes Sean Castorani Ryan Basch

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

3. Dimension ® IMT Manufacturing (Current State) MDS #1 Manual Inspection (Microscope) MDS #2 8-up Plates IR Oven Manual Inspection (Microscope) Convection Oven Manual Inspection Vision (Camera) CAM Labeling (Imaje) Packaging Soniscan (Plate Washer) 8-up Plates Fluid Channel Member Washer FCM Fluid Channel Member Dryer FCM Housing Housing / Fluid Channel Member Assembly Housing S600S500A Fluid Channel Member CL Undercoat Reference CL Overcoat Na K Batch Rack

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

5. Close-up of Individual Electrode

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

7. Wants, Metrics and Specifications WantsMetrics Target Values Precision Standard Deviation of Camera Measurement 0.001 in System Reliability % 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

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

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

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

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

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

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

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

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

16. Validation Stage 1: Properly measure electrode dimensions through camera Stage 1: Properly measure electrode dimensions through camera Width = 0.15 in Height = 0.03 in

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

18. Validation Stage 3: System Level Testing - 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

19. Variance In Camera Measurement Data was collected from 25 trials Plotted data vs. +/- 3 standard deviations

20. Demonstration

21. Metrics Comparison WantsMetrics Target Values Actual Values Achieved? Precision Standard Deviation of Camera Measurement 0.001 in System Reliability % Failed Chips Passed 5 Std Dev % Good Chips Failed % Good Chips Failed 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 Fail Questionable Pass $13,000 1 3 Std Dev 1 5 Std Dev Polished 3 165 sec per board 0.0022 in

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

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

24. Questions?

25. 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

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