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FIGURE 25.6 Fiducial target.
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FIGURE 25.7 Multiple entries exposing all layers.
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It is also recommended that this pattern be repeated around the circuitry in four places around the corners to enable the most flexible selection of analysis algorithms as described in the discussion of analysis later in this section. With thick boards, all of the layers may not be visible with one countersink hole. The conical part of the drill bit is the only part where layers are exposed. The tip of the drill does not expose the layer adjacent due to alcohol residue during the cleaning process. Repeat entries at progressive depths expose all of the internal layers, as shown in Fig. 25.7. After the conical holes are drilled, an automatic alcohol sprayer is activated to clean debris caused by the drilling process. The camera then activates its autofocus/autozoom mode to close in on the subject area. Figure 25.8 shows the image created by the camera on the first conical hole. You can see the copper layers and some of the movement in the innerlayers.
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being displayed
Drilled hole is being viewed prior to having gained the offset information.
FIGURE 25.8 Camera-generated conical hole image.
The operator sets the area in which the analysis software should attempt to locate the edges of the traces (see Fig. 25.9). These bounding boxes are mouse-controlled and should be wide enough to enclose all traces. Gray circles represent the layer for the system to search. The area inside a boundary where the gray circle crosses a trace is searched for trace edges. The analysis software then locates the trace edges and indicates them with hash marks (see Fig. 25.10). If any of these are incorrect, the operator can easily move the marks with the mouse.
PRINTED CIRCUITS HANDBOOK
FIGURE 25.9 Selecting the inspection areas.
FIGURE 25.10 Trace edges located.
PRECISION INTERCONNECT DRILLING
Correction for Registration Alignment (Direct or X-Ray) After the data have been recorded by the x-ray or direct image system, the operator can select from several algorithms to perform several functions. If there were only two corner fiducials inspected, the software can perform the following function: Two-point offset and rotation Two alignment fiducials are inspected (see Fig. 25.11) to calculate the offset and rotation values. The pattern is rotated to a point located about halfway between the two fiducials. The offset is calculated based on the average distance of the fiducials from their programmed location after the rotation is applied. If three or four cornered fiducials are inspected, the analysis software can perform the following: Three- or four-point offset, rotation, and scaling Three or four alignment fiducials are inspected (see Fig. 25.12) to calculate the vision corrections. If only three alignment points are used, they may be located on any three corners. The offset is calculated based on the average distance of the fiducials from their programmed location after the rotation is applied. Three- or four-point best-fit This function is the same as the three- or four-point offset, rotation, and scaling algorithm, except scaling is not applied (see Fig. 25.13). Three- or four-point alignment The pattern is linearly adjusted in both axes to match the alignment fiducials. This generally transforms the pattern into a trapezoidal shape. Four-point alignment is used to adjust the pattern to match the visible landmarks precisely.
FIGURE 25.11 Two-point offset and rotation.
FIGURE 25.12 Three- or fourpoint offset rotation and scaling.
When the selected algorithm is applied, the operator has some choices. One is to elect to go ahead and drill the board on the same machine if it happens also to be an x-ray drilling machine or the Intelli-Drill, since such machines are also high-precision single spindle drillers with a 180,000 rpm spindle. This is the best choice because it does not require the operator to remove the panel from its tooling and all FIGURE 25.13 Four-point best-fit. reference points are still aligned. The operator can, however, elect to remove the panel and output the modified drill program for drilling on another machine, thereby freeing the Intelli-Drill or x-ray system to inspect another panel. A third option is for the operator to inspect a number of panels and have the algorithms averaged to produce the best-fit program for the entire lot.
Saving Data The data that are generated can also be stored in an optional database that allows searches to determine, by board type or part number, what is changing over time so that predrill processes can be modified to eliminate error as much as possible. Material types and vendors can also be tracked to verify performance. A utility for basic searches is included with the database option. For more detailed searches, any standard database acquisition program may be used.
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