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Inspecting LCD Displays
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One key application in mobile electronics is display inspection. Display pixels fail for a variety of reasons. Problems range from solder shorts, in which excess solder paste bridges connector leads, to firmware bugs, in which case the software governing display behavior generates the wrong output. Whatever the root cause, to remain competitive, electronics manufacturers need to find these defects long before the customer does, and early enough in the manufacturing process before more value is added to the device being produced.
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The most advanced vision systems accomplish display inspection by applying a virtual “probe” to each pixel on a display, enabling the system to determine whether the display is good or defective despite inconsistent lighting or creases that have formed in the transparent lens tape. The same vision systems that inspect pixels can be used to measure the alignment of a display within the housing. They can measure the consistency of back-lighting, verify the print quality of keypads, and check the color of logos.
As today’s consumer electronics devices continue to increase in functionality and drive greater capability in their displays, more manufacturers are turning to machine vision technology for consistent and reliable inspection.
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Accurate Alignment Improves Equipment Performance
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Machine vision alignment is a key application at Wecon Automation in Taiwan where improving LED yields requires precise pattern alignment. In LED back-end machines, inconsistent LED patterns make it very difficult to set up process tools for smooth operation. This OEM capital equipment manufacturer improved equipment performance using Cognex FG 85 frame grabber with VisionPro® machine vision software and a SONY camera kit in their Chip Mapping Sorters, Probers, Die Bonders and Wire Bonders to provide accurate alignment of LED devices under the most challenging manufacturing conditions. Wecon also uses VisionPro color segmentation tools for Automated Optical Inspection (AOI). The result isimproved yields, minimized manufacturing variability, improved quality, and extended useful life of SSL components. Learn more about Cognex vision software by downloading the VisionPro Software Product Guide
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Tracking Wafers
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Automated semiconductor manufacturing processes rely on vision-based wafer readers to automatically track wafers through each step of the fabrication process, from bare wafer manufacturing to final test. Whether reading OCR and bar code scribes on the topside of wafers, or bottom-side 2D codes, wafer readers play a critical role in a number of essential functions: - Tracking work-in-process,
- Wafer mapping, and
- Verifying that process and parameter steps for each wafer are correct.
Many LED manufacturers mark individual wafers directly with 2D codes for part traceability to document the genealogy of each wafer and track it through production. In-Sight® 1720 Series wafer readers provide reliable traceability with unmatched performance. Lighting fixture manufacturers do the same with the components, parts and sub-assemblies that make up a finished product. Because luminaires are highly application specific, many manufacturers use DataMan® ID readers to track optical, electronic and mechanical components to ensure the right parts are assembled into their fixture designs. By implementing wafer and part tracking, manufacturers achieve higher levels of process control, and in turn, improved yield.
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Detecting Errors Saves Time and Money
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Perhaps the most important benefit machine vision technology offers is the ability to detect errors early in the manufacturing process. This enables operators to take care of problems on the spot and make modifications to the process before more value is added to a product.
Manufacturers estimate that identifying a defect on a device at the board level, before final assembly, can save up to 90 minutes of a technician’s time per defect in the troubleshooting/repair loop. This includes debugging, disassembling, reassembling, re-testing, process logging, and reinsertion of the device on the assembly line. Many small electronics housings were not meant to be re-closed after opening. Therefore, the housings and any other associated parts (e.g., gaskets, rivets, shock pads) become 100% scrap.
By helping to improve quality and productivity while lowering production costs, machine vision technology is proving essential for highly competitive industries that want to profit within tight margins.
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