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How X-ray Technology is Improving the Electronics Assembly Process
The document outlines how x-ray technology enhances electronic component inspection, focusing on real-time defect verification and various methods including computed tomography. It discusses challenges in manufacturing, such as counterfeit detection and component management, along with the importance of design for x-ray inspection. The document emphasizes the necessity of integrating x-ray inspection early in the PCB design process to improve efficiency and minimize defects.
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How X-ray Technology is Improving the Electronics Assembly Process
- 1. ©2018 Creative Electron,Inc. The X-Factor - How X-ray Technology is Improving the Electronics Assembly Industry Griffin Lemaster Creative Electron, Inc. +1 760.752.1192 glemaster@creativeelectron.com
- 2. Summary for today 1.Electronic component inspection. 2. Real-time defect verification. 3. Voids, bridging, and head-in-pillow failures in bottom terminated components (BTC). 4. Computed tomography (CT) techniques and how to differentiate between 2D, 2.5D, and 3D x-ray inspection. 5. Design for manufacturing (DFM) and design for x-ray inspection (DFXI). 6. Reverse engineering. 7. Counterfeit detection. 8. Component counting and material management. 9. Artificial Intelligence and x-ray inspection ©2018 Creative Electron, Inc.
- 3. Where Are DefectsIntroduced? Counterfeit Components
- 4. Defects associated withpaste application Excess solder Solder bridges Insufficient solder Solder Paste Application Defects
- 5. Component Placement Defects Defectsassociated with component placement Misalignment Polarity Missing component
- 6. Reflow Oven Defects Defectsassociated with the reflow profile Voiding Bridging Solder balls Excess solder Insufficient solder
- 7. Statistical Process Control Manufacturingprocess 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.
- 8. Principles of x-rayinspection 8
- 9. X-ray imaging 101:the bottom terminated component, side view BTC PCB Solder Balls Side View
- 10. PCB X-ray imaging 101:the BGA, top view Solder Balls BGA X-ray image of BGA
- 11. QFN assembly withexcess voiding
- 12. Detail of openpin in QFN package
- 13.
- 14. Solder voids inLED assembly
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- 20. Dual Energy High EnergyImage Low Energy Image Dual Energy Image PATENT PENDING
- 21. The best –and worse – BGA assembly 1. COPLANARITY 2. SHORT 3. HEAD IN PILLOW 4. OPEN 9. MISSING 8. SHAPE 7.VOIDS 6. SOLDER MASK 5. SPLATTER
- 22. 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
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- 25. So what’s 3DX-Ray Inspection (Computed Tomography)?
- 26. Principle of PlanarCT: 3D x-ray Large Area Detector Steer-able X-Ray Source Inspection Plane Multiple Transmission Images
- 27. Principle of PlanarCT 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
- 28.
- 29. Design for Inspection nThink carefully about component placement when designing PCB n 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
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- 32. Caps under QFNleads
- 33. Caps under BGAballs
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- 40. Heat sink removed:x-ray
- 41. Think 3D! n X-raysare a requirement when inspecting BTC n DFM + DFI: Easier to design for inspection n Some applications require 2.5D & 3D x-ray n Miniaturization major driver for high resolution, high magnification, x-ray inspection
- 42. 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
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- 44. Reasons for ReverseEngineering n Limited R&D budget n Part obsolescence n Poor or no documentation n Same product or concept must be recreated cheaper and/or better
- 45. Black Box CaseStudy Government product platform extended 10 years past original expectation and manufacturer of black box now out of business. Poor documentation leaves project in distress. Performing an x- ray CT on the device will show the full details of the product, including individual layers of the PCB.
- 46. Black Box CaseStudy 2D X-ray Scan CT X-ray Slice
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- 48. Surplus stock ofelectronic components dumped into the market further establishing the broker and grey markets Huge amounts of scrap electronics Components made obsolete Need for short delivery time Massive cost reduction pressures on OEM buyers for double digit price reductions Buying and selling via the internet became common practice The counterfeit electronics problem 48
- 49. Surplus stock ofelectronic components dumped into the market further establishing the broker and grey markets Huge amounts of scrap electronics Components made obsolete Need for short delivery time Massive cost reduction pressures on OEM buyers for double digit price reductions Buying and selling via the internet became common practice The counterfeit electronics problem 49
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- 51. Only expensive partsare counterfeited…
- 52. Anything wrong withthese caps?
- 53. What happens whenyou got the wrong cap?
- 56. Component Counting andMaterial Management
- 57. Material Management 101 nWhat 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?
- 58. 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
- 59. Inventory Accuracy Major reasonfor SMT line stoppage is that information in MRP does not match reality
- 60. Part Counting X-ray imagetaken of entire reel of components. Image is analyzed and component type, quantity, and defects can be reported back to operator.
- 61. X-ray Part CountingBenefits n Fast (15-30seconds per reel) n Accurate Countbacks (99%+) n Component Type Identification n Counterfeit Detection n Integration with MRP System
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- 63. 30-second intro toartificial intelligence (AI) X ? Y X Y 2 4 0 0 3 6 -5 -10 10 20 x2
- 64. ©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
- 65. ©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
- 66. ©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
- 67. ©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
- 68. ©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
- 69. ©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
- 70. www.creativeelectron.com Medical Devices MADE INUSA 19Confidential - Do not duplicate or distribute without written permission from Creative Electron Inc ©2018 Creative Electron, Inc.
- 71. ©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
- 72. Thanks for yourtime! +1 760.752.1192 info@creativeelectron.com www.creativeelectron.com