Measurement Sensors for the Electronics Systems Industry

The electronics industry’s massive development since the invention of the transistor shrunk many components in size while increasing their effectiveness. This gave birth to several new branches with the word “micro” in their name, including micro components in various electronic systems.

These components are incredibly small (some smaller than a poppy seed), and in the electronics industry, they’re mostly handled and inspected by robots. These robots rely on numerous sensors to ensure every component is in the right spot. Such components are usually placed onto boards by pick-and-place robots that arrange and align them onto pads at fantastic speeds, often multiple at a time.

After placing components, machines use precision measurement sensors to check for possible misalignments. This takes place before the components go to soldering and ensures that everything is positioned correctly.

Correct position and orientation of components and defective component detection are crucial, as they ensure the quality of the electronic system and increase the effectiveness of the entire process by eliminating human operators, who are more prone to error.

3D snapshot sensors for electronic industry applications help with quality control and productivity. Especially as printed circuit boards (PCBs) are getting smaller and their development cycles become increasingly shorter, inspection devices such as 3D laser snapshot sensors enable manufacturers to inspect these boards for defects and irregularities so electronics on the board can fulfill performance requirements.

3D snapshot sensors can easily integrate with robots for different automation needs. Instead of relying on human labor or inefficient traditional systems, industrial snapshot sensors provide fast and efficient solutions. These sensors are a key type of measurement sensors that help ensure quality control in modern manufacturing environments.

As a laser-based system, 3D snapshot sensors offer advantages similar to vision systems but with an added dimension of depth, increasing the accuracy of surface inspections.

In PCB quality control, the sensors are mounted in such a way that they can measure the boards from above. Their ability to measure different materials, including plastic and metals, also makes them usable for the inspections of integrated components.

Bigger components, such as ICs and various chips with SON and TSOP footprints, might get misaligned during pickup and placement. In order to avoid product failure due to misalignment, the electronics industry frequently relies on 2D laser profilers such as the LJ-X8000 Series to detect misalignment and trigger a warning or other appropriate automated action.

Once the components are positioned and checked for alignment, they are transferred to the reflow oven, where the solder is melted. This crucial step requires that all components on the electronic system board are precisely aligned.

After the solder finishes melting, component alignment and the quality of the solder joints are checked using 2D/3D laser profilers once again. Their single-digit µm accuracy allows them to detect misaligned components or cracks in solder joints, which are most likely to expand and lose connection once the electronic system heats up during operation.

This type of inspection typically relies on sensors like the aforementioned LJ-X8000 Series laser profiler paired with a data logger. This allows for accurate measurement and data storage, resulting in more effective quality control.

As previously explained, the electronics industry relies on several different measurement sensors. Measurement sensors are used to inspect component placement and solder quality, with defect detection at an enviable µm scale. Laser displacement sensors are particularly useful in automated assemblies as they also ensure precise component placement.

• Connector Pin Position Inspection and Measurement

If you want to learn more about precision measurement in electronics or how to increase the effectiveness of your manufacturing process while simultaneously cutting down on various costs associated with revisions and downtime, ask KEYENCE. Our trained and professional staff will respond to any inquiries you might have.

Use any of KEYENCE’s snapshot sensor products in the LJ-S8000 Series for advanced in-line application needs. The LJ-S8000 Series has a first-of-its-kind motor-driven scanning detection design. Its built-in scanning mechanism coupled with an internal laser lighting source means zero need for lensing, external lighting, a moving stage, or an encoder.

By just installing the product, manufacturers can perform dimension, appearance, shape, and other types of inspections. An image capturing speed of 0.2 seconds and repeatability of 0.3 µm means high inspection speeds and precision measurements.

For more information about our laser snapshot sensors for the electronic systems industry, contact us today.