Automated Coupon for PCB Quality Testing
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Solution Overview
Problem
Manual quality testing of component carriers, such as printed circuit boards, is labor-intensive, lacks precision, and struggles with high throughput requirements, especially in industrial settings where mechanical robustness and electrical reliability are critical.
Innovation Solution
A coupon system comprising a base plate with electrically conductive and insulating layers, designed for robotic handling and featuring separate areas for handling and testing, allows for automated quality testing. The coupon is configured to mirror the component carriers, with test targets for evaluating features like layer alignment and connectivity, enabling high-reliability and high-throughput assessments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual quality testing is used, then testing can be performed with simple equipment, but the testing precision and reliability are insufficient
Solution Approach 1:
The patent creates a digital 3D model (copy) of the component carrier's internal structure through CT scanning, replacing the need for physical cross-sectioning and manual inspection. This digital copy enables precise automated measurement and analysis while maintaining the ability to inspect internal structures without complex physical preparation
Solution Approach 2:
The patent replaces manual mechanical cross-sectioning and optical microscope inspection with automated CT scanning and digital image processing. The mechanical preparation process is substituted by non-contact X-ray imaging, and visual inspection is replaced by automated algorithmic analysis of 3D data
2Productivity
If manual cross-sectioning and inspection is performed, then equipment requirements are low, but the throughput is limited and labor effort is high
Solution Approach 1:
The patent implements continuous automated CT scanning and real-time 3D reconstruction, allowing uninterrupted inspection of multiple component carriers in sequence. The system processes each component through scanning, reconstruction, and analysis without manual intervention, maintaining continuous productive action throughout the testing process
Solution Approach 2:
The patent performs preliminary 3D reconstruction and defect detection algorithms during the CT scanning process itself, rather than requiring separate post-processing steps. The system pre-processes the data to identify potential defects while the component is still being scanned, reducing total testing time
3Ease of operation
If automated handling is implemented, then handling precision and consistency improve, but the system complexity increases
Solution Approach 1:
The robotic handling unit is designed to perform multiple functions: loading component carriers onto the CT scanner, positioning them for scanning, and removing them after testing. This multi-functional robot reduces the need for separate specialized handling devices for each operation, managing system complexity while maintaining high automation
Data Source
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AI summary
Coupon (200) for carrying out a quality test concerning related component carriers (256), wherein the coupon (200) comprises a base plate (202) configured as a layer stack of at least one electrically conductive layer structure (204) and/or at least one electrically insulating layer structure (206), a handling area (208) on a first portion of the base plate (202), configured for handling the coupon (200) by a robotic handling unit (104) and being free of test targets (116) for the quality test, and a test area (212) on and/or in a second portion of the base plate (202) and comprising test targets (116) for the quality test.