Automatic Machinery Asia

Project Introduction: As part of the global green-energy initiative, energy saving LEDs are being increasingly applied worldwide in lighting, traffic, and consumer electronic applications. These applications are creating a high demand for automatic LED manufacturing machines that meet balance of performance, cost and reliability. The quality of LED die bonding relies on excellent collaboration between machinery vision and motion control with microsecond precision that demands for high computing capability.

System Requirements:

Our customer is an LED die-bonding manufacturer that is gaining an increasing market share in China. Many years ago they adopted a PC-based video inspection system with a set of PLCs for motion control and signal monitoring. However, challenges remained for the twofold system to achieve synchronized communication; and the skewed motion resulted in inaccurate placement and high defective rates. Therefore, they were looking to build a new system that:

• Incorporates high-resolution video inspection and 10-12 axes motion control
• Is a PC-based dual core system with high performance
• Enables greater precision and speed of die attachment
• Ensures faster, more precise and reliable machinery vision
• Dual DVI-I Display for control software and image inspection software
• 2 x IEEE-1394-B port FireWire high speed image input interface
• Raid 0,1 for inspection data recording
• 2-ch Gigabit Ethernet teaming function for MES feedback

Project Implementation:

System Diagram:

System Description:
This solution is comprised of two systems working together. A mid-range system designed to create quality LEDs for high-end applications driven by servo and stepping motors, which allows for data feedback and greater precision, and a low-tech system designed to create standard LEDs driven only by stepping motors. Each system is built with Advantech’s dual-core UNO-3084 as the IPC platform, with two onboard IEEE 1394 ports for controlling CCD image data acquisition and also allowing PCIe or PCI cards installation for pick & place motion, Analog I/O and Digital I/O.

Both systems also adopt the PCI-1751U, a digital input/output and 2-ch counter module which is in charge of digitizing data, status monitoring and motion counter feedback. For the mid-range system they adopted three PCI-1240U’s, a 4-axis stepping and servo motor control card, having 2/3-axis linear, 2-axis circular and continuous interpolation functions to handle complicated and precise motion control. The low-tech case adopts two PCI-1244U’s, entry-level 4-axis stepping and servo motor control cards with 2-axis linear interoperation. It also includes the PCI-1243U, a 4-axis stepping motor control card for process in and process out control for simpler motion control applications.

UNO-3084 embedded automation computer has an excellent integration which can add several expansion cards into one platform and also has two onboard IEEE-1394-B ports which allow one or two CCD cameras to capture images and carry out synchronized signal digitalization for machine vision inspections. The project also includes one 15” TFT LCD monitor with touchscreen for each system as the human-machine interface to show the status of the LED die bonding machine.

Conclusion:
Advantech is able to provide products that can be selectively combined into low-to-mid end or high end solutions that meet the best balance between performance and cost and can be used in various forms of micro-electronic component assembly. Advantech also boasts a unique capability in providing costume-tailored total solutions for our customers. For LED die-bonders we provide packaged solutions, including IPCs, PCI cards, motors, monitors, video cameras and associated software that have been fully tested before delivery.