Test Coupon Design for Automated PCB Quality Inspection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Manual quality testing of component carriers, such as printed circuit boards, is labor-intensive, lacks precision, and is not suitable for high-throughput industrial processes, especially when dealing with complex electronic components with tight spacing and harsh conditions.
Innovation Solution
A computer-implemented system for designing a coupon that can be used for quality testing, which includes a compliance input unit, a product input unit, and a coupon design unit to create a test coupon that meets specific compliance conditions and properties of component carriers, enabling automated processing and testing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual quality testing is performed by engineers, then quality assessment can be carried out, but the effort is high and precision is limited
Solution Approach 1:
The patent replaces manual mechanical inspection with an automated optical measurement system that uses image capture and analysis algorithms to assess coupon quality, eliminating human effort while improving measurement precision through consistent, repeatable automated measurements
Solution Approach 2:
The system enables self-service quality testing where the coupon itself provides measurement features (such as built-in reference marks or test patterns) that allow automated analysis without requiring external manual intervention or complex setup procedures
2Productivity
If manual cross-sectioning and flat grinding are performed, then internal structure can be exposed for inspection, but throughput is limited for industrial scale
Solution Approach 1:
The patent incorporates preliminary action by including preparation features directly in the coupon design phase, such as integrated alignment marks, reference patterns, and structural elements that facilitate automated processing, eliminating the need for manual preparation steps later
Solution Approach 2:
The system replaces manual cross-sectioning and flat grinding operations with automated optical measurement techniques that can analyze coupon structures without physical contact, dramatically increasing throughput while reducing operational complexity
3Adaptability or versatility
If standardized coupon designs are used, then manufacturing is simplified, but adaptability to different component carrier properties is reduced
Solution Approach 1:
The patent enables parameter changes by allowing the coupon design to be dynamically adjusted based on input parameters describing the component carrier properties, such as material composition, thickness, and structural features, while maintaining a standardized base design that simplifies manufacturing
Solution Approach 2:
The system introduces dynamics by making the coupon design adaptable and configurable rather than fixed, allowing the same manufacturing process to produce customized coupons for different component carrier types through software-controlled parameter adjustments
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A computer-implemented system (270) for designing a coupon (200) for carrying out a quality test concerning coupon-related component carriers (256), wherein the system (270) comprises a compliance input unit (272) configured for receiving compliance input data indicative of compliance conditions to be fulfilled by the coupon (200) to be designed, a product input unit (274) configured for receiving product input data indicative of properties of component carriers (256) to be manufactured to which the coupon (200) to be designed is related, and a coupon design unit (276) configured for designing the coupon (200) so as to fulfil said compliance conditions and/or said properties of the component carriers (256).