Error Proofing Integrated Circuit Chips Loaded into Pocket Tape
Customer Requirements: Confirm presence and correct orientation of an integrated circuit chip
Solution: Q4X Laser Distance Sensor and iVu Vision System
Why Banner? Versatility –A Q4X can perform multiple functions at once, eliminating the need for additional sensors
Customer Benefits
Cost savings – Using fewer sensors to solve the application means less money spent on purchasing or replacing parts
Background
Integrated circuit (IC) chips are tested prior to installation onto a circuit board. After they pass quality tests they are placed into pocket tape and spooled onto a reel. The tape and reel make transport and storage for such small components easy and simplify the way that the product is fed into the assembly machines.
Challenges
Each IC chip is placed onto the pocket tape by a high-speed machine. Incorrectly oriented chips will result in improper installation onto a circuit board. There are three common failure modes with pocket tape: no chip in pocket, two chips in pocket, and one chip upside down in pocket. To prevent these errors from happening, each chip’s orientation needs to be confirmed before it is sealed in the pocket tape. Multiple sensors are often used to identify these failures. Supporting multiple sensors can drive up expenses and lead to increased downtime required for maintenance and installation.
Solution
The Q4X laser distance sensor from Banner Engineering can complete all the functions previously performed by multiple sensors. This versatile sensor can be taught to recognize items at a specific distance, meaning that it can tell the difference between no chip, one chip, or two chips, in each slot as the chip passes. If the distance is correct, one chip is placed into the pocket tape. If the distance is too short, a duplicate chip is on top. If nothing is sensed, or the distance is too long, then a chip is missing. Used in dual mode, the Q4X will detect differences in contrast to determine if a chip is right side up or right side down.
In some instances there may be writing present on the chips, such as logos or lot codes, and it may be preferred to have them all facing the same direction. An iVu vision sensor can be used to determine the correct orientation of the writing but utilizing the powerful match tool. If there is no match, an operator is notified of the fail.
Conclusion
In an industry where components are required to be tremendously small, errors and bad product can be hard to see. Banner Engineering offers solutions that fit the needs of such a demanding application. By using the Q4X and iVu vision sensor simultaneously, the manufacture is able to detect three different types of errors and confirm writing orientation on integrated circuit chips. By using fewer devices, companies are saving time and money by creating an easier to use solution.