Lowering Rejection Rates with Delta's AI-Based Six-Sided Inspection Machine

With the advancement of technology, electronic products are becoming smaller and lighter with more comprehensive functions and better performance. The intricacy of their electronic components often require complex manufacturing processes. Delta's AI-based Six-sided Inspection Machine is a great solution for inspecting small passive components. Integrating an AOI machine and an AI system, it ensures the inspection for defects of passive components, ICs, LED components, and ceramic thermal pads.

The components with Low Temperature Co-fired Ceramic (LTCC) require the highest inspection technology among the small electronic components. It is difficult to inspect the appearance of this special material. The LTCC components are widely used in wireless communication manufacturing with strict product quality requirements. To meet the requirements, Delta implemented its Six-sided Inspection Machine on the production line of a Taiwanese wireless communication manufacturer. The machine successfully increased the inspection rate of the defective LTCC components.

Traditional manual LTCC component inspection doesn't fulfill the productivity and quality standards of low speed, accuracy and stability. Replacing human labor with Automated Optical Inspection (AOI) equipment, the inspection efficiency is enhanced, but the variability of the components is still hard to define. In addition to a high error rate, it also wastes much labor for parameter adjustment. Delta's AI-based Six-sided Inspection Machine inherits the AOI features with a new deep-learning function. The system is able to automatically categorize the good and non-good products after learning a certain quantity of defective images. It overcomes hard-to-inspect defects such as dark and micro cracks by AOI. With quicker and more accurate inspection, the error rate is greatly reduced.

The work flow of the AI-based Six-sided Inspection Machine is as follows. First, it feeds the materials into the built-in tray and conveys them to the glass tray. Next, the high-speed inspection turntable then conveys the materials into the color CCD inspection station for six-sided AOI: front, back, left, right, up, and down. There are two CCD inspection stations as back-ups to implement customized image algorithms for AOI. Via Delta's AI inspection system, the dark and micro cracks can be inspected. Finally, it conducts the sorting process to avoid mistakes in inspecting the non-goods.

The benefits of Delta's AI-based Six-sided Inspection Machine include:

• High inspection efficiency shortens cycle time
Delta's inspection system is high-speed and stable. With 8,000 pcs / min inspection, it greatly enhances efficiency. Delta offers customized inspection algorithms based on demands. The AI inspection system optimizes the production process, supports quick changeover, and strengthens the offline inspection and adjustment system. It also reduces labor costs and inconsistency of manual work.

• High inspection rate, low error rate
Delta's AI + AOI inspection system features white and compound light and AI algorithms. It is capable of inspecting components of various sizes and materials, even reflective objects or unique defects (micro and dark cracks). The minimum inspection size is 0.4 x 0.2 mm with 1um accuracy. The system effectively elevates the inspection rate and lowers the rejection rate.

• Statistical Analysis with MES
The machine supports a production data collection system for statistical control and chart output. It is connectable with the MES for real-time data upload as reference to future process improvement. In this way, unlike the traditional process, the production data can be collected and analyzed thoroughly.

Delta's AI-based Six-sided Inspection Machine inherits the AOI feature and integrates AI. It is applicable to inspecting passive components, ICs, LED components, and ceramic thermal pads, even reflective objects or unique defects (micro and dark cracks). The Six-sided Inspection Machine saves cycle time, elevates inspection rate and speed, and reduces error rates. It significantly lowers the rejection rate for the wireless communication manufacturing customer.