Advantech Ultra Compact IPC for Defect Inspection Solution for Passive Component Testing Machine

Background

Demand for consumer electronics products that are light, thin,short, and small has been increasing rapidly over the past few years. As a result, there is an insufficient supply of passive components on the global market — resulting in a constant increase in prices. Manufacturers of passive components need to improve both their throughput and quality in order to keep up. In this environment, high-precision and high performance appearance testing equipment for passive components has been primarily monopolized by Japanese corporations. Chinese domestic equipment suppliers still lag behind their Japanese competitors.The throughput of testing equipment for passive components from international leaders can reach 12000 pieces per minute. Domestic equipment, on the other hand, generally renders a throughput below 3000. How can Chinese domestics break the monopoly? Brand new solutions from Advantech and partners are here to help!

System Requirements

Products that may be machine tested primarily include patch resistance, capacitance, inductance, and certain ICs and LEDs. Machines are mainly used for component appearance testing. The test consists of one to six aspects with primary emphasis placed on the inspection of damage, scratches, unfilled corners, pits, bulges,and burr. Products are divided into categories: “good”, “defective,”“self-defined,” and “redo” based on the test results.Depending on testing demands, 1 to 12 industrial cameras may beset up. Each camera works at a sampling rate of 50-200 frames and a maximum precision of up to 3 um. The camera captures images by taking photos at a flying speed. A GigE Vision camera is primarily utilized (sometimes it will be a USB Vision camera). The cameras are located at angles above and beneath the DD motor-controlled optic glass rotary disc respectively in order to detect defects at different levels and of different types.At present, most of the domestic component testing equipment is controlled by the PLC, with a minimal throughput below 500 pieces per minute. Some equipment is controlled by the motion control card + IO, with a throughput of around 2000 pieces per minute. In this case, the customer required the new unit to reach 10000 pieces per minute. The throughput was close to that of international leading equipment — 12000 pieces per minute. Approximate performance measures, more flexible localized service, and better prices help secure a larger market share.

System Description

Advantech PCI-1274-12AE 4-axis motion control card is known for its precise acceleration/deceleration rate and soft motion computing core that precisely controls the position of the DD motor. Moreover,it has a 12CH position latch that can document precise position information provided by the encoder in real time when materials pass through the sensor to offer precise coordinates for reference in subsequent camera photo-taking and material classification. Plus,12 channels for comparative positions and comparison triggering that can be customized according to the actual demands of each customer in order to satisfy demand for flying capture of up to12 cameras with high-speed comparison control at four splitting positions.On the other hand, PCIE-1674E involves one to four pieces and is meant to expand the GigE Vision camera (for some models USB Vision cameras are utilized). While PCI-1756 has a 32-channel DI and a 32-channel DO for controlling the three-color indicator, the emergency stop button, the solenoid valve, the cylinder, and other sensors of the unit.As for system,IPC-240 system has 1 PCIE*16, 1 PCIE*4, 2 PCI, and I7-6700 CPU with an internal memory of 16 G, 128G SSD+1T hard drive. Offering expandability, high performance, and reliable quality, it serves as the visual processing and motion control logic computing control platform for the customer’s overall system.

Why Advantech?

In this case, precise acceleration and deceleration, in combination with soft motion computing, made precision position control possible.Along with the DSP and FPGA designs, customization of specific features was now made easy. The new unit had more cameras and the splitting positions could be controlled. Customized features satisfied a range of customer demands: with the PCI-1274 motion control card at its core, Advantech met the customer’s specific requirements for the passive component testing equipment.The PCIE-1674E, 4-port GigE Vision PoE interface card features with INTEL I350 server grade performance, allowed the multi-channel GigE Vision camera to perform high-speed image acquisition with dedicated 1.0 Gbps/port while the direct power supply through Ethernet reduces wiring for the customer. The IPC-610 has the largest sales of any IPC in the world based on its reputation for steady, safe, and reliable operation. In terms of the motion control algorithm and application experience, powerful R&D and professional technical support teams are available to help the customer with preliminary functional assessment, sample research and development, user-end field debugging, and to provide professional technical support.