Programming is one of the most essential elements in acquiring the inspection and measurement data needed to ensure that your manufacturing process produces defect-free circuit boards and devices. Whether you are inspecting a golden board or need an algorithm-based system to delve into more complex assembly situations, the programming capabilities of the software and its ease-of-use influence the:
- manufacturing process and down time
- training, personnel, and time resources
- ability to detect defects
- efficiency and cost-of-operation
Saki's Auto Programming Software significantly reduces library creation time. Optimal inspection libraries are automatically assigned and created by utilizing Gerber and CAD data. Saki's 3D AOI series uses pad shape information to provide automatic inspection based on IPC standards. Reliable threshold settings are determined from statistical information and model images are provided in the offline debug feature, installed as standard on every machine. This greatly improves the reliability of inspection performance and results, regardless of user skill level.
A complete step-by-step explanation of how Saki's programming wizard can determine the attributes of your component and prepare a recipe, even if you don't have the actual component, is below.
Programming begins by having accurate data. Inspection data for performing automatic inspection should be prepared prior to production start-up. When inspection data is generated, part shape and pad layout information are combined to define inspection locations. Usually, part shape information is acquired by converting CAD and component placement data. Pad layout information can be obtained from the substrate design or print stencil production data. Then, inspection content and procedures need to be defined for each component.
Inspection data can be generated using an existing inspection method or a method that includes lighting, brightness, color, and/or height information. A wizard is available as a guide (see below). Inspection data can be registered into the library database and then used as a reference for another substrate design. Once inline production is started, the inspection program should be fine-tuned and optimized, either on the inspection machine or off-line, using component shape or solder volume data previously acquired and already in the library database. In case multiple lines are in operation, the global library function can be used to share data between machines.
New intuitive software and programming wizard
Saki's new software makes it easy to program the inspection of a component, even if you don't have the actual component or you don't have a particular component in your shape library because it's an odd-shaped component. Using Saki's extensive global component data library, you can define the component using the shape and then the recipe library.
To begin, first use the shape library which shows the shape of the package. Shape can be chosen from a global library in the system that has more than 900 preprogrammed packages. You can select the component shape manually or use the assistance wizard. Select the type of package and the system finds the best fit from the shape library for your component, including variants. Saki's resource library guides you through the geometry of the package. It starts by asking for the shape and body size. For the shape, it analyzes the image and height information and suggests the body size. After the body size is found, you are directed to follow the next step.
Now the program looks for orientation of the component. How much area does it take and what is going on around the component? By seeing the spacing around the component, the software can identify and amplify how many leads there are on every side and the pitch of the leads. Once the leads are identified, the program can determine the type of component. Then the only thing you have to set is the edge of the lead or edge of the pitch. That's it. The software then provides the recipe.
Preparing a new recipe
The geometry is already determined by the shape in the first step. In the recipe resource there is a list of the templates that can be used for automatic generation of the recipe i.e. the inspection steps. You can generate the body, lead, and bridge elements, and for every element you can deploy steps for each stage. For the body, it checks for 3 things: position, presence or absence, including coplanarity, and planarity. For leads, it checks soldering, and for bridging, it will check the bridge.
History menu — create the program
Start to program the first inspection step, which is defining the specifications of the body. The height map is displayed and you can see the surface by its color. When you find the height, it checks to see if the body is positioned without interference. For coplanarity, use an algorithm for the plane which measures the area and measures the area between the PCB level and the component surface. It doesn't just look at the height, but also the angle between the PCB and the component. For the planarity, you can decide whether you want a 2D or 3D approach.
After you define specifications for the body, define the elements for the leads. This involves designing the expected position and maximum and minimum height.
Bridging can be defined using 2D or 3D. 2D can be beneficial because it can detect very high bridges.
All the steps are then finalized to prepare the library for the component: position, average height, and polarity. At the same time, you have the inspection of the leads, including the height measurement and program classification of the leads. Finally, there is the bridging inspection.
Watch this video to see how easy Saki's BF-3Di 3D AOI systems are to program.