Inspection systems are a vital part of maintaining quality, consistency, data collection and safety in manufacturing.
These systems used in common hardware platforms also provide shorter lead times as well as cost savings for vendors. Much like every other engineering process, inspection systems are gearing up to include artificial intelligence (AI) in systems. Modular systems are also becoming an emerging trend.
But how will this benefit these sectors? Andreas Tuerk, the product manager for inspection solutions at GOEPEL electronic GmbH, sat down with GlobalSpec to discuss inspection’s role in manufacturing and the benefits and challenges happening in the sector.
GlobalSpec: How do you envision the future of inspection on systems evolving with advancements in technology such as AI and modular systems?
Andreas Tuerk is the product manager of inspection solutions at GOEPEL electronic GmbH.Andreas Tuerk: Inspection systems designed on a common hardware platform are the key for hardware cost savings and shorter lead times. The goal is to keep common hardware components like axis system, PCB transport, electronic cabinet, PC and the metal frame with its metal parts the same to achieve cost savings. Only the camera module defines the final use of the inspection machine. If this common hardware design comes with the same software supported by AI, it is real cost saving for the end customer. By adding more and more AI features to the software, the costs for the test program generation will get lower and lower over time.
GlobalSpec: What specific manufacturing challenges does the Multi Line product family aim to address, and how does its modular design facilitate this?
Tuerk: The Multi Line platform is one common hardware and software platform with a perfect cost/benefit ratio that can be used for four different inspection tasks to ensure the quality in modern electronic manufacturing environments. The Multi Line SPI for 3D solder paste inspection at the very beginning of the SMT process.
The Multi Line AOI for THT assembly inspection and 3D THT solder joint inspection. And the Multi Line AOI for 3D SMD inspection as well as the Multi Line CCI for conformal coat inspection. The hardware platform can be equipped with camera modules from above and from below. With this approach a double side inspection at the same time is possible. By having the same software for all inspections tasks training costs can be saved and programmers can work with maximum efficiency.
GlobalSpec: What advantages does the Multi Line Assist offer for THT placement stations compared to traditional inspection methods?
Tuerk: The Multi Line Assist is the perfect complement to the Multi Line platform. The Multi Line Assist is an integration module for THT placement stations that comes with a high class 47-megapixel camera and a projector. The camera unit comes in three different lens options and resolutions. It performs a live inspection after each assembled part or a final inspection after all parts were mounted. The inspection ensures that the correct part was placed at the correct position of the PCB. An optional projection unit marks the placement position directly on the PCB and gives additional hints about the parts to be placed directly on the placement station table. With this the placement effectiveness is increased and the quality is ensured.
GlobalSpec: How does AI and digital twin technologies improve the efficiency and accuracy of the manufacturing process?
Tuerk: The test program generation software has already AI integrated as a very important feature to speed up the test program generation to save time and costs. The test program generation is quick by the help of the GOEPEL magic click software that allows a fully automated generation and optimization of test programs. Also, AI models (for example, polarity check) are used to make the polarity mark detection more efficient. The latest software version supports the generation of a digital twin of the PCB with all components and solder joints. This digital twin is used to create a test program without having the PCB available in real life. This is efficient because the first assembled and soldered PCB can already be inspected by the test program that was generated using the digital twin.
GlobalSpec: Can you elaborate on the importance of resolution variants in the Multi Line Assist and how they cater to different manufacturing needs?
Tuerk: The better the resolution the more details can be inspected and the better is the inspection quality. This can be important when characters on components must be read or if small polarity marks must be inspected. Therefore, three resolution variants are available (81 µm for 660 mm x 450 mm, 58 µm for 475 mm x 320 mm, 37 µm for 300 mm x 200 mm) for the Multi Line Assist integration module that also end in three different inspection areas.
For some inspection tasks like OCR or polarity it is important to have a higher resolution to make differences visible. Source: GOEPEL
GlobalSpec: What role does conformal coating inspection (CCI) play in the overall quality assurance of the manufacturing process, and how is it integrated within the Multi Line platform?
Tuerk: Conformal coatings are always required when electronic assemblies are used in products that perform safety-relevant tasks or are used in harsh environments. For example, in automotive applications, defense technology, aerospace, marine, lighting and industrial applications as well as in the green energy sector. The fluorescent coating, which is applied by spraying or dipping, protects against environmental influence. Due to miniaturization, components are moving ever closer together and packing density is increasing. Here, the insulating effect of the protective lacquer helps to reduce the distance between the conductor tracks. The automatic optical inspection of the conformal coating (Conformal Coat Inspection (CCI)) helps to ensure the quality of painted assemblies. According to the specifications of a coating plan, the presence of the coating is checked for as well as for too much coating — in places where it should not be present.
The Multi Line CCI has a high-resolution color camera with telecentric optics for razor-sharp images. In combination with UV illumination from above and from the side, high-contrast images are produced. The UV lighting causes the ultraviolet fluorescent particles in the coat to glow. This reveals defects such as scratches and bubbles. Above all, however, it also reveals whether there is too much or too little coat on the assembly.
The Multi Line CCI can inspect protective coatings either from above or from below. Simultaneous inspection from both sides is also possible. In addition, product carriers can be fed back under the system.
Electronica 2024 takes place this week in Munich, Germany.
