The world's environmental protection and energy conservation trends have spurred the emergence of the LED industry. LEDs are widely used in many fields, including streetlights, advertising signs, traffic signals, consumer electronic products, and transportation vehicles. Because of these burgeoning applications, suppliers are currently finding it extremely difficult to meet demand, and therefore seek faster LED production equipment that will maintain a high level of product quality. Because LED production requires numerous high-tech processes, the development of LED production equipment that meets manufacturers' needs while striking an optimal balance between performance, cost, and reliability is a great challenge. In particular, the LED die bonding process is the manufacturing step most dependent on close coordination between machine vision and multiple-axis motion control; this process requires the aggregation and processingof production condition data with millisecond precision.
Several years ago, when the LED industry was still at an early stage of development, ordinary LED equipment manufacturers used computer-based inspection systems which relied on image comparison, and pursued integration with motion control and digital signal monitoring PLC systems. However, maintaining synchronized real-time communications between these two subsystems ran into severe problems when customers attempted to increase their production rates; problems were chiefly due to skewed LED legs during the movement process and the resulting loss of system positioning precision. As a result, manufacturers encountered lower production yield rates. Accordingly, manufacturers have been searching for new system solutions with good cost-performance ratios and the following attributes:
- High-performance embedded industrial computers must employ Intel® processors,and integrate powerful image acquisition cards,cameras, and motion control cards able to accommodate up to 12 axes.
- The embedded industrial computers must provide a RAID 0, 1 storage array and redundant backup data storage.
- The embedded industrial computer must possess a 2-channel Gigabit Ethernet teaming function providing manufacturing execution system (MES) feedback.
- The embedded industrial computer must provide a dual-display interface, allowing the simultaneous display of control software and image inspection software.
- Must employ a high-accuracy, high-speed motion chip to dramatically improve bonding speed.
- Must use a PC-based image acquisition card to achieve even higher speeds and more precise machine vision and image acquisition.
- System volume must be optimized to enableembedding within equipment.
Advantech offers mid-level and introductory solutions aimed at the LED industry. The mid-level system combines multiple-axis servo motors and stepping motors to achieve high-speed production and the high-accuracy manufacture of high-quality LEDs. Advantech's IPC-7130
chassis + AIMB-781
embedded computer offers numerous interfaces, collects data feedback, and performs Raid 0,1 data storage. The introductory system is aimed specifically at integrated applications involving multiple-axis stepping motors; it can enable manufacturers tocompetitively produce large quantities of standard LEDs. Both systems contain Advantech's IPC-7130
IPC platform, and employ 1394b PCI interface cards linked to high-speed 1394b CCD cameras to perform image acquisition and quality analysis. Both systems also provide PCIe or PCI expansion slots able to accommodate image acquisition, motion control, analog data, and digital data cards. In addition, the AIMB-781
supports dual-display output, enabling the simultaneous monitoring of visual inspection software and test equipment control software. Both systems include PCI-1751U cards with digital I/O and 2-channel counters; these cards bear responsibility for digital data, status monitoring, and action counter feedback. Themid-level system contains three embedded 4-axis PCI-1240U motion control cards with high speed stability toperform synchronization and servomotor control duties. This system provides 2/3-axis linear, 2-axis annular, and continuous interpolation functions, and can control complex, precisemotions. The introductory system contains two embedded introductory-grade PCI-1245E 4-axis synchronization and servo motor control cards; this system offers 2-axis point-to-pointandlinear interpolation functions, and also has an embedded 4-axis PCI-1243U stepping motor control card to control basic transport functions, etc.
Advantech's embedded industrial computers provide all-round solutions for all types of industrial applications. Users can freely select different configurations of introductory ormid-level products,and can add appropriate control interface cards in order to strike an optimalbalance between performance and cost,and meet theirspecific microelectronic element assembly needs.
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- Desktop chassis, supports standard ATX motherboard
- Equipped with 7 expansion slots and anti-vibration optical drive bracket
- Can support one 5.25" and three 3.5" HDDs, where two 3.5" HDDs are hot swappable
- Smart system LED indicator lights allow monitoring of temperature, voltage,fan, and hard drives for abnormalities
- An audio alarm module beeps to provideearly warning of problems affecting system operating status
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- Uses hand-turned screws to greatly shorten systemassembly time
- ATX industrial motherboard, supports Intel® 2nd generation Core™ i processor
- Equipped with three PCIe Gen II slots and four PCI slots
- Supports up to 16GB DDR3-1333 memory, dual network interfaces, and two displays