Browse Prior Art Database

Software controls for automated inspection device used to check interposer buttons for defects

IP.com Disclosure Number: IPCOM000011969D
Original Publication Date: 2003-Mar-27
Included in the Prior Art Database: 2003-Mar-27
Document File: 5 page(s) / 133K

Publishing Venue

IBM

Abstract

The Regatta H* Interposer Automated Inspection Device (RHIAID) is a machine developed to replace the manual visual inspection process on the MCM and L3 modules in the server systems. By using a smart sensor, intelligent actuator robot and PC, a process and machine were developed that significantly reduced labor cost associated with inspection. The software package to control this machinery consisted of three separate pieces that when linked together made for a powerful solution for this manufacturing process.

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  Software controls for automated inspection device used to check interposer buttons for defects

  During the process of manufacturing a server, some of the individual components in the machine need to be pre-tested before they are put into the final assembly. One common method of pre-testing these components is human visual inspection for defects. This process is costly, labor intensive, slow, and inconsistent.

  An instance of this type process (pertaining to this technical disclosure) is the visual inspection process used to inspect the interposer buttons (or contacts) of the Regatta H* server modules (named MCM and L3.)

  These two modules, both similar in concept, consist of a large heat sink through which multiple interconnect layers allow connection between the system boards and microprocessors. These connections are made through hundreds of miniature wire bundles coiled and set into small countersunk dimples on the interconnect surface (see the figure below).

  Thus during the manufacturing of these interconnect modules, it is often the case that the small wire bundles unravel from (or fall out altogether from) within the countersunk dimples in which they are placed. This occurs so frequently that a visual inspection test process to find the defect is needed to sort and fix the problem before modules advance to the next process steps.

    The Regatta H* Interposer Automated Inspection Device (RHIAID) is a machine developed to replace the visual inspection test process on the MCM and L3 modules in the Regatta H* server system with an automated one. By replacing the visual inspection process of the MCM and L3 modules in this system with an automated one, IBM* will realize a significant labor cost savings. An additional savings on top of the labor costs could be realized due to less defective component escapes (thus less service replacement costs on damaged components.) In addition to these cost savings, the test process will be faster and more consistent than the current one.

  The test system consists of a three axis robotic actuator that positions the module under a camera for inspection (see the figure below) .

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This disclosure is on the software that controls the actuator movement and camera inspection, acts as a user interface for the operator, and monitors and records all important data.

  The RHIAID software package consists of three separate pieces of software that handshake with each other in a triangle configuration. By developing the controls in this way, the process engineer ultimately will have control over the test equipment "process parameters" where the remainder of the machine controls will not have to be changed once completed. This makes process changes easier for the process engineer as the process is developed. The three pieces to the triangle include operator interface and data recording software, actuator control software, and test process criteria/...